Technical Manual Hitachi ZW120-5B Wheel Loader | TTNCC-EN-00 (2017.02.06)

Technical Manual Hitachi ZW120-5B Wheel Loader TTNCC-EN-00 (2017.02.06) (Preview)

TTNCC-EN-00
INTRODUCTION
SYMBOL AND ABBREVIATION
SAFETY
SECTION AND GROUP CONTENTS
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction
Operational Performance Tests
Preparation for Performance Tests
Group 2 Standard
Operational Performance Standard Table
Sensor Activating Range
Group 3 Engine Test
Engine Speed
Lubricant Consumption
Group 4 Machine Performance Test
Travel Speed
Service Brake Function Check
Service Brake Wear Amount
Parking Brake Function Check
Bucket Stopper and Bell Crank Stopper Clearance
Hydraulic Cylinder Cycle Time
Dig Function Drift Check
Bucket Levelness
Control Lever Operating Force
Control Lever Stroke
Group 5 Component Test
Main Pump Delivery Pressure
HST Pump Delivery Pressure
HST Charging Pump Delivery Pressure(HST Charging Pump Relief Pressure)
Brake/ Transmission Pump Delivery Pressure
Main Relief Set Pressure
HST Pump Relief Pressure
Steering Relief Pressure
Overload Relief Valve Set Pressure
HST Pump Displacement Angle Control Pressure
HST Motor Displacement Angle Control Pressure
Transmission Clutch Pressure
Primary Pilot Pressure (Hydraulic Operated Type: Optional)
Secondary Pilot Pressure (Hydraulic Operated Type: Optional)
Accumulator Gas Pressure
Gas Pressure Adjustment Procedure of Accumulator (Ride Control Circuit (OPT))
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Introduction
Diagnosis Procedure
Electric System Inspection
Precautions for Inspection and Maintenance
Instructions for Disconnecting Connectors
Fuse Inspection
Fusible Link Inspection
Battery Voltage Check
Alternator Check
Continuity Check
Voltage and Current Measurement
Check by False Signal
Test Harness
Group 2 Monitor
Outline
Operating Procedures of Service Menu
Coolant Temperature Gauge and HST Oil Temperature Gauge
Fuel Gauge
Group 3 e-Service
Outline
List of Operation Data
Communication System
Group 4 Component Layout
Main Component (Upperstructure)
Main Component (Travel System)
Electrical System (Overview)
Electrical System (Components Related with Relays)
Electrical System (Components Related with Engine)
Electrical System (Cab)
Engine
Pump Device
Transmission/ HST Motor
Control Valve
Priority Valve
Ride Control Valve (Optional)
Emergency Steering Block (Optional)
Emergency Steering Pump (Optional)
Pilot Shut-Off Solenoid Valve (Hydraulic Operated Type: Optional)
Group 5 Troubleshooting A
Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure
MC Fault Code List
ICF Fault Code List
Monitor Controller Fault Code List
Air Conditioner Controller Fault Code List
Communication Terminal Fault Code List
ECM Fault Code List
MC Fault Codes 111004, 111910, 111914
CAN1 Harness Check
MC Fault Code 111103
MC Fault Code 111217
MC Fault Codes 111330, 111331
MC Fault Code 111332
MC Fault Code 111422
MC Fault Code 111430
MC Fault Code 111434
MC Fault Codes 111450, 111451
MC Fault Code 111455
MC Fault Code 111457
MC Fault Code 111622
MC Fault Code 111801
MC Fault Code 111904
MC Fault Code 111908
MC Fault Code 111922
Monitor Controller Fault Code 115000
CAN1 Harness Check
Monitor Controller Fault Code 115001
Monitor Controller Fault Code 115011
Monitor Controller Fault Code 115014
Monitor Controller Fault Code 115015
Monitor Controller Fault Codes 120500 to 120502
Monitor Controller Fault Codes 120506, 120507, 120510, 120512, 120515, 120518
Air Conditioner Controller Fault Codes E11 to E22
Air Conditioner Controller Fault Codes E43 to E92
Group 6 Troubleshooting B
Troubleshooting B (Machine Diagnosis by Using Troubleshooting Symptom) Procedure
Relationship between Machine Trouble Symptoms and Related Parts
Correlation between Trouble Symptoms and Part Failures
Engine System Troubleshooting
Front Attachment System Troubleshooting
Steering System Troubleshooting
Travel System Troubleshooting
Brake System Troubleshooting
Other System Troubleshooting
Transporting Wheel Loader (Urgent Situation)
How to Release Parking Brake in Case of Emergency and When Engine Stops
Recovery After Parking Brake Release
Group 7 Troubleshooting C
Troubleshooting C (Monitor Diagnosis) Procedure
Malfunction of Monitor Buzzer
Malfunction of Coolant Temperature Gauge
Malfunction of Fuel Gauge
Malfunction of HST Oil Temperature Gauge
Malfunction of Monitor Display
Malfunction of Light Bulb Check Ststem
Malfunction of Left And Right Turn Signal Light Indicators
Malfunction of Hazard Light Indicator
Malfunction of High Beam Indicator
Malfunction of Work Light Indicator
Malfunction of Maintenance Light
Malfunction of Preheat Indicator
Malfunction of HST Oil Temperature Indicator
Malfunction of HST Warning Indicator
Malfunction of Engine Oil Pressure Indicator
Malfunction of Overheat Indicator
Malfunction of Engine Warning Indicator
Malfunction of Service Indicator
Malfunction of Parking Brake Indicator
Malfunction of Clearance Light Indicator
Malfunction of Emergency Steering Indicator (OPT)
Malfunction of Low Steering Oil Pressure Indicator (OPT)
Malfunction of Alternator Indicator
Malfunction of Control Lever Lock Indicator (Optional)
Malfunction of Power Mode Indicator
Malfunction of Seat Belt Indicator (Optional)
Group 8 Air Conditioner
Outline
Functions of Main Parts
Troubleshooting
Air Conditioner Controller Fault Code List
Air Conditioner Controller Fault Codes E11 to E22
Air Conditioner Controller Fault Codes E43 to E92
Work after Replacing Components
Refill Compressor Oil
Charge Air Conditioner with Refrigerant
Hose and Pipe Tightening Torque
SERVICE MANUAL REVISION REQUEST FORM
The Attached Diagram List