Technical Manual Hitachi ZW310-5A Wheel Loader | TTNFC-EN-00 (2018.01.26)

Technical Manual Hitachi ZW310-5A Wheel Loader TTNFC-EN-00 (2018.01.26) (Preview)

TTNFC-EN-00
INTRODUCTION
To The Reader
Additional References
Manual Composition
Page Number
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 Cab
Use Handrails and Steps
Never Ride Attachment
Adjust Operator’s Seat
Ensure Safety Before Rising from or LeavingOperator’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 MultipleMachines
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 OverAnyone
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 ContainingFlammable Fluids
Precautions for Handling Accumulator and GasDamper
Remove Paint Before Welding or Heating
Beware of Asbestos and Silicon Dust and OtherContamination
Prevent Battery Explosions
Service Air Conditioning System Safely
Handle Chemical Products Safely
Dispose of Waste Properly
Notes for Muffler Filter
Precautions for Communication Terminal
Precaution for Communication TerminalEquipment
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
Main Pump P-Q Diagram
Sensor Activating Range
Group 3 Engine Test
Engine Speed
Group 4 Machine Performance Test
Travel Speed
Service Brake Function Check
Service Brake Wear Amount
Parking Brake Function Check
Bucket Stopper Clearance, Lever (Bell Crank)Stopper Clearance
Hydraulic Cylinder Cycle Time
Cylinder Drift Check
Bucket Levelness
Control Lever Operating Force
Control Lever Stroke
Group 5 Component Test
Hydraulic Circuit
Loading Pilot Circuit
Primary Pilot Pressure (Including BrakeCircuit)
Secondary Pilot Pressure
Secondary Pilot Pressure Adjustment Procedure
Main Pump Delivery Pressure
Loading Circuit Main Relief Set Pressure
Loading Main Relief Pressure Adjustment
Steering Circuit Main Relief Set Pressure
Steering Main Relief Pressure Adjustment
Overload Relief Valve Set Pressure
Overload Relief Valve Pressure Adjustment
Main Pump Flow Rate Measurement
Regulator Adjustment
Service Brake Pressure (Front and Rear)
Parking Brake Pressure
Brake Accumulator Pressure
Brake Warning Pressure (Pressure-Decreasing)
Brake Warning Pressure (Pressure-Increasing)
Transmission Clutch Pressure
Torque Converter Pressure
Group 6 Adjustment
Transmission Learning
Lift Arm Angle Sensor Learning
Digging Position Adjustment
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Introduction
Diagnosis Procedure
Electric System Inspection
Precautions for Inspection and Maintenance
Instructions for Disconnecting Connectors
Fuse Inspection
Fuse Box A
Fuse Box B
Fusible Link Inspection
Battery Voltage Check
Alternator Check
Continuity Check
Voltage and Current Measurement
24-Volt Circuit
5-Volt Circuit
Check by False Signal
Test Harness
Group 2 Monitor
Outline
Monitor Panel
Monitor Display
Vehicle Information Display (6)
Operating Procedures of Service Menu
How to display service menu
Engine Speed (Figure A)
Coolant Temperature (Figure B)
Transmission Oil Temperature (Figure C)
Hydraulic Oil Temperature (Figure D)
Fault Code (Figure E)
Fuel Consumption (Figure F)/Average Fuel Consumption (Figure G)
List of Service Menu Display
Coolant Temperature Gauge andTransmission Oil Temperature Gauge
Fuel Gauge
Group 3 e-Service
Outline
List of Operation Data
List of Daily Report Data
List of Frequency Distribution Data
List of Total Operating Hours
Snapshot Data
Communication System
Group 4 Component Layout
Main Component (Overview)
Main Component (Travel System)
Electric Component Layout (Overview)
Electrical System (Cab)
Controller and Relays
Right Console
Monitor and Switches
Monitor Panel
Electrical System (Relays)
Engine/Fan Pump
Transmission and Torque Converter Assembly
Hydraulic Pump Device
Control Valve
Charging Block
Front Axle
Steering Valve
Brake Valve
Fan Motor
Pilot Valve
Ride Control Group (Option)
Emergency Steering Group (Option)
Emergency Steering Pump (Option)
Group 5 Troubleshooting A
Troubleshooting A (Base Machine DiagnosisBy Using Fault Codes) Procedure
MPDr. Fault Code Reference Table
MC Fault Code List
Controller Hardware Failure
CAN Data Reception Failure
Engine Failure
Pump Failure
Pilot Failure
Proportional Solenoid Valve Failure
Revolution Sensor Failure
Learning Failure
Switch Failure
Temperature Sensor Failure
Other Sensor Failures
Alarms on Monitor
Monitor Controller (Monitor) Fault Code List
Monitor Controller (Information) Fault CodeList
Column Display Controller Fault Code List
Communication Terminal Fault Code List
Air Conditioner Controller Fault Code List
ECM Fault Code List
MC Fault Codes 111000 to 111002
MC Fault Code 111003
MC Fault Codes 111006, 111007, 111014,111025
Monitor Controller (Monitor) Fault Codes113002, 113003, 113005, 113007
Monitor Controller (Information) Fault Codes114010, 114011, 114015
CAN1 Harness Check
MC Fault Codes 111103, 111105
MC Fault Code 111200
MC Fault Codes 111205, 111207
MC Fault Codes 111217, 111312
MC Fault Code 111204
MC Fault Code 111206
MC Fault Code 111208
MC Fault Codes 111311, 111313
MC Fault Code 111411
MC Fault Code 111412
MC Fault Code 111413
MC Fault Codes 111414 to 111419
MC Fault Code 111422
MC Fault Codes 111600, 111601, 111602
MC Fault Code 111900
Torque Converter Oil Temperature SensorSpecification
MC Fault Code 111901
Hydraulic Oil Temperature Sensor Specification
MC Fault Code 111902
Axle Oil Temperature Sensor Specification
MC Fault Codes 111700 to 111705
MC Fault Codes 120000 to 120005
MC Fault Code 120014
Column Display Controller Fault Code115001
Column Display Controller Fault Code115011
Fuel Level Sensor Specifications
Monitor Controller (Monitor) Fault Code 120300
Column Display Controller (Information) Fault Codes 120500 to 120503
Column Display Controller (Information) Fault Codes 120505 to 120507
Air Conditioner Controller Fault Codes 11 to22
Air Conditioner Controller Fault Codes 43 to92
Group 6 Troubleshooting B
Troubleshooting B (Machine Diagnosis byUsing Troubleshooting Symptom) Procedure
Relationship between Machine TroubleSymptoms and Related Parts
Correlation between Trouble Symptoms andPart Failures
Engine System Troubleshooting
All Actuator System Troubleshooting
Front Attachment System Troubleshooting
Steering System Troubleshooting
Travel System Troubleshooting
Brake System Troubleshooting
Other System Troubleshooting
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)
Group 7 Air Conditioner
Outline
Component Layout
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
Faulty cooling (1)
Faulty heating (1)
Others
Cooling circuit check by using manifold gauge
Work after Replacing Components
Refill Compressor Oil
Charge Air Conditioner with Refrigerant
Hose and Pipe Tightening Torque
SERVICE MANUAL REVISION REQUEST FORM