Technical Manual Hitachi ZW120-6 Wheel Loader | TTNSA60-EN-00

Technical Manual Hitachi ZW120-6 Wheel Loader TTNSA60-EN-00 (Preview)

TTNSA60-EN-00
CONTENTS
INTRODUCTION
To The Reader
Additional References
Manual Composition
Page Number
Trademark
Safety Alert Symbol and Headline Notations
Units Used
SYMBOL AND ABBREVIATION
Symbol and Abbreviation
SAFETY
Recognize Safety Information
Understand Signal Words
Follow Safety Instructions
Prepare for Emergencies
Wear Protective Clothing
Protect Against Noise
Inspect Machine
General Precautions for the Cab
Use Handrails and Steps
Never Ride Attachment
Adjust Operator’s Seat
Ensure Safety Before Rising from or Leaving Operator’s Seat
Fasten Your Seat Belt
Move and Operate Machine Safely
Handle Starting Aids Safely
Operate Only from Operator’s Seat
Jump Starting
Investigate Job Site Beforehand
Equipment of Head Guard, ROPS, FOPS
Provide Signals for Jobs Involving Multiple Machines
Keep Riders Off Machine
Drive Safely
Drive Machine Safely (Work Site)
Drive Safely with Bucket Loaded
Drive on Snow Safely
Travel on Public Roads Safely
Avoid Injury from Rollaway Accidents
Avoid Accidents from Backing Up and Turning
Avoid Positioning Bucket or Attachment Over Anyone
Avoid Tipping
Never Undercut a High Bank
Dig with Caution
Perform Truck Loading Safely
Avoid Power Lines
Precautions for Operation
Precautions for Lightning
Object Handling
Protect Against Flying Debris
Park Machine Safely
Store Attachments Safely
Transport Safely
Handle Fluids Safely−Avoid Fires
Practice Safe Maintenance
Warn Others of Service Work
Support Machine Properly
Stay Clear of Moving Parts
Support Maintenance Properly
Prevent Parts from Flying
Prevent Burns
Replace Rubber Hoses Periodically
Avoid High-Pressure Fluids
Prevent Fires
Evacuating in Case of Fire
Beware of Exhaust Fumes
Precautions for Welding and Grinding
Avoid Heating Near Pressurized Fluid Lines
Avoid Applying Heat to Lines Containing Flammable Fluids
Precautions for Handling Accumulator and Gas Damper
Remove Paint Before Welding or Heating
Beware of Asbestos and Silica Dust and Other Contamination
Prevent Battery Explosions
Service Air Conditioning System Safely
Handle Chemical Products Safely
Dispose of Waste Properly
Notes on Aftertreatment Device
Precautions for Communication Terminal
Precaution for Communication Terminal Equipment
Before Returning the Machine to the Customer
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
Primary Pilot Pressure
Secondary Pilot Pressure
HST Pump Delivery Pressure
HST Pump Relief Pressure
HST Charge Pump Delivery Pressure
HST Pump Displacement Angle Control Pressure
Main Relief Set Pressure
Steering Relief Pressure
Brake/Transmission Pump Delivery Pressure
Transmission Clutch Pressure
HST Motor Displacement Angle Control Pressure
Accumulator Gas Pressure (Ride Control Circuit)
Accumulator Gas Pressure Adjustment Procedure (Ride Control Circuit)
Group 6 Adjustment
REWRITE OF AFTERTREATMENT DEVICE SERIAL NO.
HOW TO CLEAR FAULT CODE
AIR BLEEDING FROM THE DEF DEFROSTING PIPING
REMEDY AT ENGINE OIL CHANGE REQUEST
REMEDY AT DEF PRESSURE DECREASE
REMEDY AT DEF ABNORMAL QUALITY
CLEAN DEF TANK
REMEDY WHEN MIXING OIL IN DEF TANK
AFTERTREATMENT DEVICE FORCIBLE MANUAL REGENERATION PROCEDURE
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
INTRODUCTION
DIAGNOSIS PROCEDURE
ELECTRICAL SYSTEM INSPECTION
PRECAUTIONS FOR INSPECTION AND MAINTENANCE
INSTRUCTIONS FOR DISCONNECTING CONNECTORS
FUSE INSPECTION
FUSE AND FUSIBLE LINK INSPECTION
BATTERY VOLTAGE CHECK
HOW TO CHECK ALTERNATOR
CONTINUITY CHECK
VOLTAGE AND CURRENT MEASUREMENT
CHECK BY FALSE SIGNAL
Test Wire Harness
Group 2 Monitor
OPERATING PROCEDURES OF SERVICE MENU
COOLANT TEMPERATURE GAUGE AND HST OIL TEMPERATURE GAUGE
FUEL GAUGE AND DEF GAUGE
Group 3 e-Service
OVERVIEW
LIST OF OPERATION DATA
SNAPSHOT DATA
COMMUNICATION SYSTEM
Group 4 Component Layout
MAIN COMPONENT (OVERVIEW)
MAIN COMPONENT
ELECTRICAL SYSTEM (OVERVIEW)
AIR CLEANER, RADIATOR, AND SURROUNDINGS
BATTERY BOX
FRAME: REAR RIGHT INSIDE
HYDRAULIC OIL TANK
FUEL TANK
CAB
FRONT CONSOLE
RIGHT CONSOLE
REAR CONSOLE
CONROL UNIT
ENGINE
AFTERTREATMENT DEVICE
TRANSMISSION/HST MOTOR
PUMP DEVICE
CONTROL VALVE
PILOT SHUTOFF SOLENOID VALVE
RIDE CONTROL VALVE
DEF TANK
DEF SUPPLY MODULE
Group 5 Troubleshooting A
TROUBLESHOOTING A (BASE MACHINE DIAGNOSIS BY USING FAULT CODES) Procedure
MC FAULT CODE LIST
HST CONTROLLER FAULT CODE LIST
INFORMATION CONTROLLER FAULT CODE LIST
COLUMN DISPLAY CONTROLLER FAULT CODE LIST
AIR CONDITIONER CONTROLLER FAULT CODE LIST
COMMUNICATION TERMINAL FAULT CODE LIST
MC FAULT CODES 111000 to 111002
MC FAULT CODE 111003
MC FAULT CODES 111006, 111007, 111030
CAN1 HARNESS CHECK
MC FAULT CODES 111008, 111014, 111025
CAN2 HARNESS CHECK
MC FAULT CODES 111103, 111106, 111107
MC FAULT CODE 111217
MC FAULT CODE 111313
MC FAULT CODE 111422
MC FAULT CODE 111908
MC FAULT CODE 111909
HST CONTROLLER FAULT CODES 111027, 111028
HST CONTROLLER FAULT CODE 111332
HST CONTROLLER FAULT CODES 111330, 111331
HST CONTROLLER FAULT CODES 111430, 111434, 111455
HST CONTROLLER FAULT CODE 111457
HST CONTROLLER FAULT CODES 111450, 111451
HST CONTROLLER FAULT CODE 111622
HST CONTROLLER FAULT CODE 111904
HST CONTROLLER FAULT CODE 111905
INFORMATION MONITOR CONTROLLER FAULT CODE 115001
COLUMN DISPLAY CONTROLLER FAULT CODE 115011
COLUMN DISPLAY CONTROLLER FAULT CODES 120500 TO 120505
COLUMN DISPLAY CONTROLLER FAULT CODES 120507, 120510, 120511, 120515, 120519
Group 6 Troubleshooting B
TROUBLESHOOTING B (MACHINE DIAGNOSIS BY USING TROUBLE SYMPTOM) Procedure
RELATIONSHIP BETWEEN MACHINE TROUBLE SYMPTOM AND RELATED PARTS
CORRELATION BETWEEN TROUBLE SYMPTOMS AND PART FAILURES
ENGINE SYSTEM TROUBLESHOOTING
ALL ACTUATOR SYSTEM TROUBLESHOOTING
FRONT ATTACHMENT SYSTEM TROUBLESHOOTING
STEERING SYSTEM TROUBLESHOOTING
TRAVEL SYSTEM TROUBLESHOOTING
BRAKE SYSTEM TROUBLESHOOTING
OTHER SYSTEM TROUBLESHOOTING
BLEEDING AIR FROM BRAKE CIRCUIT
MACHINE MOVEMENT (IN EMERGENCY)
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 TROUBLESHOOTING) PROCEDURE
Faulty Buzzer
Faulty Coolant Temperature Gauge
Faulty Fuel Gauge
Faulty HST Oil Temperature Gauge
Faulty Monitor Display
Insufficient Burnt Bulb Check
Faulty Turn Signal Light Indicators (Right and Left)
Faulty Hazard Light
Faulty High Beam Indicator
Faulty Work Light Indicator
Faulty Maintenance Light
Faulty Glow Signal
Faulty Inspection/Maintenance Indicator
Faulty Alternator Indicator
Faulty Engine Warning Indicator
Faulty Engine Oil Pressure Indicator
Faulty Overheat Indicator
Faulty HST Warning Indicator
Faulty HST Oil Temperature Indicator
Faulty Brake Oil Level Indicator
Faulty Control Lever Lock Indicator
Faulty Power Mode Indicator
Forward/Reverse Selector Switch Indicator
Faulty Parking Brake Indicator
Faulty Clearance Light Indicator
Faulty Seat Belt Indicator
Group 8 Air Conditioner
Outline
Functions of Main Parts
Troubleshooting
Air Conditioner Controller Fault Code List
Air Conditioner Controller Fault Codes 11 to 22
Air Conditioner Controller Fault Codes 43 to 92
Work after Replacing Components
Refill Compressor Oil
Charge Air Conditioner with Refrigerant
Hose and Pipe Tightening Torque