Technical Manual Hitachi ZW40-5B, ZW50-5B Wheel Loader | TTNBC-EN-00

Technical Manual Hitachi ZW40-5B, ZW50-5B Wheel Loader TTNBC-EN-00 (Preview)

TTNBC-EN-00
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
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
Group 3 Engine Test
Engine Speed
Group 4 Machine Performance Test
Travel Speed
Service Brake Function Check
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 Charge Pump Delivery Pressure (HST Charge Pump Relief Pressure)
Main Relief Set Pressure
HST Pump Relief Pressure
Steering Relief Pressure
Overload Relief Valve Set Pressure
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Introduction
Diagnosis Procedure
Electrical System Inspection
Precautions for Inspection and Maintenance
Instructions for Disconnecting Connectors
Fuse Inspection
Fusible Link Inspection
Battery Voltage Check
Alternator Check
Continuity Check
Voltage Check Method
Group 2 Monitor
Outline
Operating Procedures of Service Menu
Coolant Temperature Gauge and Fuel Gauge
Engine Tachometer
List of Alarm
Group 3 Troubleshooting A
Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure
ECM Fault Code List
Monitor Controller Fault Code List
Monitor Controller Fault Code 115002
CAN2 Harness Check
Monitor Controller Fault Code 115001
Monitor Controller Fault Code 115011
Group 4 Troubleshooting B
Troubleshooting B (Machine Diagnosis by Using Trouble 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
Machine transport (in emergency)
The Attached Diagram List
SERVICE MANUAL REVISION REQUEST FORM