Technical Manual Hitachi ZW550-6 Wheel Loader | TTNHK40-EN-00 (2017.05.10)

Technical Manual Hitachi ZW550-6 Wheel Loader TTNHK40-EN-00 (2017.05.10) (Preview)

TTNHK40-EN-00
CONTENTS
SECTION 4 OPERATIONAL PERFORMANCE TEST
SECTION 5 TROUBLESHOOTING
INTRODUCTION
To The Reader
Additional References
Manual Composition
Page Number
Trademark
Safety Alert Symbol and Headline Notations
Units Used
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
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
Primary Pilot Pressure (Unloader Valve Setting Pressure)
Secondary Pilot Pressure
Solenoid Valve Set Pressure
Main Pump Delivery Pressure
Loading Circuit Main Relief Set Pressure
Steering Circuit Main Relief Set Pressure
Steering Circuit Pilot Pressure
Loading/Steering Overload Relief Valve Set Pressure
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
Rewrite of Aftertreatment Device Serial No.
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
Surge Voltage and Surge Suppression Diodes
Group 2 Monitor
Outline
Operating Procedures of Service Menu
Troubleshooting
Monitoring
Controller Version
Issued Warning Record
Communication Terminal Status
Machine Setting
Engine Setting
Aftertreatment Device No.
Engine Output Restriction Suspend
Engine Tachometer
Transmission Oil Temperature Gauge and DEF Level Gauge
Coolant Temperature Gauge
Group 3 e-Service
Outline
List of Operation Data
Snapshot Data
Communication System
Group 4 Component Layout
Main Component (Overview)
Main Component
Main Component
Electric Component Layout (Front Chassis)
Electric Component Layout (Rear Grill)
Electrical System (Cab)
Electrical System (Around Battery Box)
Electrical System (Around Hydraulic Tank)
Electrical System (Around Fuel Tank)
Electrical System (Rear Chassis Center Frame)
Engine
Aftertreatment Device
Hydraulic Pump
Transmission and Torque Converter Assembly
Multiple Control Valve
Unloader Valve (Brake Charge Valve) and Combination Valve (Brake Manifold Valve)
Steering Valve
Flow Regulator Valve
Ride Control Valve (Option)
Emergency Steering Pump (Option)
Group 5 Troubleshooting A
Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure
MPDr. Fault Code List
MC Fault Code List
SC Fault Code List
Monitor Controller (Monitor) Fault Code List
Monitor Controller (Information) Fault Code List
Column Display Controller Fault Code List
JCU Fault Code List
Air Conditioner Controller Fault Code List
ECM Fault Code List
DCU Fault Code List
MC Fault Codes 111000 to 111002
SC Fault Codes 111000 to 111002
MC Fault Code 111003
SC Fault Code 111003
MC Fault Codes 111006, 111007, 111009, 111012
SC Fault Codes 111015, 111017, 111019, 111024
Monitor Controller (Monitor) Fault Codes 113002, 113003, 113005, 113010
Preparation
CAN1 Harness Check
MC Fault Codes 111008, 111010, 111013, 111014, 111025
SC Fault Codes 111016, 111018, 111020, 111021, 111026
Monitor Controller (Monitor) Fault Codes 113004, 113006, 113007, 113011
Preparation
CAN2 Harness Check
MC Fault Codes 111103, 111105, 111106
CAN3 Harness Check
CAN4 Harness Check
SC Fault Codes 111205, 111207
SC Fault Codes 111200, 111202, 111203
MC Fault Codes 111204, 111312
SC Fault Codes 111206, 111217
SC Fault Code 111208
MC Fault Code 111313
MC Fault Codes 111600 to 111602
MC Fault Codes 111210 to 111212
MC Fault Codes 111214, 111215
SC Fault Codes 111309, 111310
SC Fault Code 111407
SC Fault Code 111410
SC Fault Code 111411
SC Fault Code 111412
MC Fault Code 111413
MC Fault Code 111414 to 111421
MC Fault Code 111408
SC Fault Code 111422
SC Fault Code 111423
MC Fault Codes 111502 to 111504, 111506, 111507
MC Fault Codes 111700 to 111704
SC Fault Code 111900
SC Fault Code 111901
MC Fault Code 111903
MC Fault Code 111906, 111907
MC Fault Codes 120014, 120101 to 120104, 120106
SC Fault Codes 120000 to 120005
Column Display Controller Fault Code 115001
Monitor Controller (Monitor) Fault Code 120300
Monitor Controller (Information) Fault Code 113311
Column Display Controller Fault Codes 120500 to 120507
Air Conditioner Controller Fault Codes 11 to 22
Air Conditioner Controller Fault Codes 43 to 92
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)
Group 7 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
Group 8 Joystick Steering System
JCU Fault Code List
JCU Fault Codes 116003, 116004
JCU Fault Codes 116006, 116007, 116008
JCU Fault Code 116118
JCU Fault Code 116119
Component Layout
Component Specifications
JSS Control System (Option)
JSS: Joystick Steering Control
Joystick Steering Lever Control
Forward/Reverse Switch Control
Alarm Control
JSS Hydraulic System (Option)
JSS Electrical System (Optional)
Outline
SERVICE MANUAL REVISION REQUEST FORM
The Attached Diagram List