Technical Manual Hitachi ZW140-5B, ZW140PL-5B Wheel Loader | TTNDF90-EN-00

Technical Manual Hitachi ZW140-5B, ZW140PL-5B Wheel Loader TTNDF90-EN-00 (Preview)

TTNDF90-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
Primary Pilot Pressure (Including Brake Circuit)
Secondary Pilot Pressure
Combined Delivery Pressure of Main Pump and Steering Pump
HST Pump Delivery Pressure
HST Charging Pump Delivery Pressure
Transmission Charge Pump Delivery Pressure
Main Relief Set Pressure
HST Pump Relief Pressure
Steering Relief Pressure
Overload Relief Valve Set Pressure
Service Brake Pressure (Front and Rear)
Parking Brake Pressure
Service Brake Accumulator Pressure
Brake Warning Pressure (Pressure-Decreasing)
Brake Warning Pressure (Pressure-Increasing)
Transmission Clutch Pressure
Accumulator Gas Pressure
Gas Pressure Adjustment Procedure of Accumulator (Service Brake Circuit, Steering Circuit)
Gas Pressure Adjustment Procedure of Accumulator (Ride Control Circuit (OPT))
Group 6 Adjustment
Measuring Method of No-Load-Max Differential Pressure
Zero-Point Calibration (Correction)
Rewrite of Muffler Filter Serial No.
Maintenance of Muffler Filter
Clutch Learning
Brake Pedal Angle Learning
Lift Arm Angle Sensor Learning
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
Snapshot Data
Communication System
Group 4 Component Layout
Main Component Layout (Overview)
Main Component Layout (Upperstructure)
Main Component Layout (Travel System)
Electrical System (Overview)
Electrical System (Cab)
Engine
Muffler Filter
HST Pump, 4-Gear Pump Unit
Transmission, HST Motor
Manifold Valve
Fan Valve
Ride Control Valve (Optional)
Emergency Steering Block (Optional)
Solenoid Valve (In Front Frame)
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
ECM Fault Code List
MC Fault Codes 111000 to 111002
MC Fault Code 111003
MC Fault Codes 111006, 111007, 111030
CAN1 Harness Check
CAN3 (Engine) Harness Check
MC Fault Codes 111008, 111014, 111025
CAN2 Harness Check
MC Fault Code 111103
MC Fault Codes 111205, 111207
MC Fault Codes 111217
MC Fault Codes 111206
MC Fault Code 111208
MC Fault Codes 111311
MC Fault Code 111406
MC Fault Code 111411
MC Fault Code 111412
MC Fault Code 111422
MC Fault Code 111908
MC Fault Code 111909
MC Fault Codes 120003, 120004, 120014
HST Controller Fault Codes 111027, 111028
HST Controller Fault Code 111332
HST Controller Fault Codes 111330, 111331, 111333
HST Controller Fault Code 111334
HST Controller Fault Codes 111430, 111431, 111432
HST Controller Fault Code 111433
HST Controller Fault Code 111457
HST Controller Fault Codes 111450, 111451
HST Controller Fault Codes 111620, 111621
HST Controller Fault Code 111622
HST Controller Fault Code 111904
HST Controller Fault Code 111905
Column Display Controller Fault Code 115001
Column Display Controller Fault Code 115011
Column Display Controller Fault Code 115015
Column Display Controller (Information) Fault Codes 120500 to 120505
Column Display Controller Fault Codes 120506, 120507, 120510 to 120513, 120515, 120517, 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
All Actuator System Troubleshooting
Front Attachment System Troubleshooting
Steering System Troubleshooting
Travel System Troubleshooting
Brake System Troubleshooting
Other System Troubleshooting
Exchange Inspection
Air Bleeding Procedures for Brake (Axle)
Transporting Wheel Loader (Urgent Situation)
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 Air Filter Restriction Indicator
Malfunction of Fuel Filter Restriction Indicator
Malfunction of Brake Oil Low Pressure Indicator
Malfunction of Hydraulic Oil Level Indicator
Malfunction of Muffler Filter Indicator
Malfunction of Muffler Filter Regeneration Inhibit Indicator
Malfunction of Water Separator Indicator (OPT)
Malfunction of Muffler Filter Regeneration Inhibit Indicator
Malfunction of Control Lever Lock Indicator
Malfunction of Power Mode Indicator
Malfunction of Fan Reverse Rotation Indicator(OPT)
Malfunction of Seat Belt Indicator
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