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Information included in the Hitachi ZW220 & ZW250 Wheel Loader Technical Manual (Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures.
TABLE OF CONTENTS :
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Wheel Loader Test
Group 5 Component Test
Group 6 Adjustment
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Group 2 Dr-ZX
Group 3 e-Wheel
Group 4 Component Layout
Group 5 Troubleshooting A
Group 6 Troubleshooting B
Group 7 Troubleshooting C
Group 8 Electrical System Inspection
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Part No. : TT4GB-E-00
Total Pages : 597
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ZW220/250_TT4GB-E-00
INTRODUCTION
SECTION AND GROUP CONTENTS
SAFETY
RECOGNIZE SAFETY INFORMATION
UNDERSTAND SIGNAL WORDS
FOLLOW SAFETY INSTRUCTIONS
PREPARE FOR EMERGENCIES
WEAR PROTECTIVE CLOTHING
PROTECT AGAINST NOISE
NSPECT MACHINE
GENERAL PRECAUTIONS FOR CAB
USE HANDHOLDS AND STEPS
ADJUST THE OPERATOR'S SEAT
ENSURE SAFETY BEFORE RISING FROMOR LEAVING OPERATOR’S SEAT
FASTEN YOUR SEAT BELT
MOVE AND OPERATE MACHINE SAFELY
HANDLE STARTING AIDS SAFELY
OPERATE ONLY FROM OPERATOR'SSEAT
JUMP STARTING
INVESTIGATE JOB SITE BEFOREHAND
EQUIPMENT OF HEAD GUARD, ROPS,FOPS
PROVIDE SIGNALS FOR JOBS INVOLVINGMULTIPLE NUMBERS OF 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 UPAND TURNING
AVOID POSITIONING BUCKET OVERANYONE
AVOID TIPPING
NEVER UNDERCUT A HIGH BANK
DIG WITH CAUTION
PERFORM TRUCK LOADING SAFELY
AVOID POWER LINES
PRECAUTIONS FOR OPERATION
PRECAUTIONS FOR LIGHTENING
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
PREVENT FIRES
EVACUATING IN CASE OF FIRE
BEWARE OF EXHAUST FUMES
PRECAUTIONS FOR WELDING ANDGRINDING
AVOID HEATING NEAR PRESSURIZEDFLUID LINES
AVOID APPLYING HEAT TO LINES CONTAININGFLAMMABLE FLUIDS
REMOVE PAINT BEFORE WELDING ORHEATING
BEWARE OF ASBESTOS DUST
PREVENT BATTERY EXPLOSIONS
SERVICE AIR CONDITIONING SYSTEMSAFELY
HANDLE CHEMICAL PRODUCTS SAFELY
DISPOSE OF WASTE PROPERLY
BEFORE RETURNING THE MACHINE TOTHE CUSTOMER
SECTION 4OPERATIONALPERFORMANCE TEST
Group 1 Introduction
Operational Performance Tests
Preparation for Performance Tests
Group 2 Standard
Operational PerformanceStandard Table
Main Pump P-Q Curve
Sensor Activating Range
Group 3 Engine Test
Engine Speed
Engine Compression Pressure
Valve Clearance Adjustment
Lubricant Consumption
Group 4 Wheel Loader Test
Travel Speed
Service Brake Function Check
Service Brake Wear Amount
Parking Brake Function Check
Bucket and Bell Crank StopperClearances
Hydraulic Cylinder Cycle Time
Cylinder Drift Check
Bucket Levelness
Control Lever Operating Force
Control Lever Stroke
Group 5 Component Test
Primary Pilot Pressure
Secondary Pilot Pressure
Solenoid Valve Set Pressure
Main Pump Delivery Pressure
Main Relief Valve Set Pressure
Steering Relief Pressure
Overload Relief Valve Set Pressure
Main Pump Flow Rate
Regulator Adjustment
Service Brake Pressure (Front and Rear)
Parking Brake Pressure
Brake Accumulated Pressure
Brake Warning Set Pressure (Decrease)
Brake Warning Set Pressure (Increase)
Transmission Clutch Pressure
Torque Converter Pressure(Inlet and Outlet)
Group 6 Adjustment
Transmission Learning
Lift Arm Angle SensorLearning (Optional)
Drive Belt Tension Adjustment
SECTION 5TROUBLESHOOTING
Group 1 Diagnosing Procedure
Introduction
Diagnosing Procedure
How to Operate Service Made ofMonitor
Display List of Monitor Service Mode
Group 2 Dr.ZX
Outline
Operation
Self-Diagnosing Result
Select Controller
Main Controller
Main Menu Monitor Display (MainController)
Setting (Main Controller)
Record Data Display (Main Controller)
Password Change (Main Controller)
Engine Controller
Monitor Display (Engine Controller)
Recorded Data Display (EngineController)
Password Change (Engine Controller)ICF Controller
ICF Various Setup (ICF Controller)
Save Data Check (ICF Controller)
Password Change (ICF Controller)
Monitor Unit
Monitoring (Monitor Unit)
Various Settings (Monitor Unit)
Internal Hour Meter Synchronization
Password Change (Monitor Unit)
TCU Controller
Monitor Display (TCU Controller)
Recorded Data Display (TCU Controller)
Password Change (TCU Controller)
Group 3 e-Wheel
Outline
List of Daily Report Data
List of Frequency Distribution Data
List of Total Operationg Hours
List of Alarm
List of failure
How to Download and Upload Data ofICF
Various Setup if ICF and SatelliteCommunication Terminal by UsingDr.ZX
List of ICF Fault Code
List of Fault Code of SattelliteCommunication Terminal
Group 4 Component Layout
Main Component Layout (Overview)
Main Component Layout (Upper-structure)
Main Component Layout (TravelSystem)
Electric Component Layout (Overview)
Electrical System (Cab)
Engine and Fan Pump
Pump Device, Drive Unit
Control Valve
Ride Control Valve ,Charging Block,Fan Motor, Parking Brake SolenoidValve
Steering Valve, EmergencySteering Pump
Components in Control Valve
Components in Steering Valve
Components in Charging Block
Components in Ride Control Valve
Side View of Transmission
Front View of Transmission
Pressure Sensor Ports ofTransmission
Cross-Sectional Drawing ofTransmission
Cross-Sectional Drawing of TorqueConverter
Cross-Sectional Drawing ofTransmission Control Valve
Circuit of Drive Unit
Group 5 Troubleshooting A
Troubleshooting A Procedure
MC Fault Code List
ECM Fault Code List
TCU Fault Code List
ICF Fault Code List
Satellite Terminal Fault Code List
Monitor Unit Fault Code List
Controller Hardware FailureMC Fault Codes 11000 to 11002
MC Fault Code 11003
MC Fault Code 11004
CAN Harness Check
Engine FailureMC Fault Code 11103
Pump FailureMC Fault Code 11204
MC Fault Code 11209
Pilot FailureMC Fault Code 11313
Proportional Solenoid Valve FailureMC Fault Code 11412
MC Fault Code 11413
CAN Data Reception FailureMC Fault Codes 11910, 11920
CAN Harness Check(MC Fault Codes 11910, 11920)
MC Fault Code 11914
CAN Harness Check(MC Fault Code 11914)
MC Fault Codes 11912, 11913,11916, 11917
CAN Harness Check(MC Fault Codes 11912, 11913,11916, 11917)
Other FailuresMC Fault Code 11901
Proportional Solenoid Valve TrubleCheck
ECM, Sensor SystemECM Fault Codes 100, 102, 105, 108,110, 157, 172
ECM Fault Codes 174, 636, 723,10001
ECM, External Device SystemECM Fault Codes 651, 652, 653, 654,655, 656, 1347, 10002
ECM, Fuel SystemECM Fault Codes 157, 633, 1239,1240
ECM, Engine ProtectionECM Fault Codes 110, 190
ECM, External Circuit SystemECM Fault Codes 987, 1485
ECM, Internal Circuit SystemECM Fault Codes 628, 1077, 1079,1080, 10003, 10004, 10005
ECM Fault Codes 10006, 10007,10008, 10009, 10010, 10011, 10013
ECM, Communication SystemECM Fault Codes 639
Role and Connection of EachTerminal in TCU
ICF, Satellite Terminal Fault Codes14000 to 14003
ICF, Satellite Terminal Fault Codes14006, 14008, 14100 to 14106
Monitor Unit Fault Codes 13306,13308
Monitor Unit Fault Code 13312
Monitor Unit Fault Code 13314
Group 6 Troubleshooting B
Troubleshooting B Procedure
Relationship between Machine TroubleSymptoms and Related Parts
Correlation between TroubleSymptoms and Part Failures
Engine System Troubleshooting
Front Attachment SystemTroubleshooting
Travel System Troubleshooting
Brake System Troubleshooting
Steering System Troubleshooting
Other System Troubleshooting
Exchange Inspection
Bleeding Air from Brake (Axle)
One Part of Data, “Daily ReportData”, “Distribution Data”, “TotalOperationg Hours” and “Alarm” isNot Recorded
Group 7 Troubleshooting C
Troubleshooting C (Trouble Shootingfor Monitor) Procedure
Malfunction of Indicator Light CheckSystem
Malfunction of Buzzer in Monitor
Malfunction of Coolant TemperatureGauge
Malfunction of Transmission OilTemperature Gauge
Malfunction of Fuel Gauge
Malfunction of Turn Signal Indicators(Left and Right)
Malfunction of Hazard Light Indicator
Malfunction of High Beam Indicator
Malfunction of Working Light Indicator
Malfunction of Forward/ReverseSwitch Indicator
Malfunction of Maintenance Indicator
Malfunction of Preheat Indicator
Malfunction of Transmission OilTemperature
Malfunction of Hydraulic OilTemperature Indicator
Malfunction of Transmission WarningIndicator
Malfunction of Air Filter RestrictionIndicator
Malfunction of Engine Oil PressureIndicator
Malfunction of Overheat Indicator
Malfunction of Engine WarningIndicator
Malfunction of Stop Indicator
Malfunction of Service Indicator
Malfunction of Parking Brake Indicator
Malfunction of Clearance LightIndicator
Malfunction of Brake Low Oil PressureIndicator
Malfunction of Brake Low Oil LevelIndicator
Malfunction of Emergency SteeringIndicator (Optional)
Malfunction of Low Steering OilPressure Indicator (Optional)
Malfunction of Discharge WarningIndicator
Malfunction of Monitor Display
Malfunction of Ride Control Indicator
Malfunction of Engine CoolantTemperature Display
Group 8 Electrical System Inspection
Precautions for Inspection andMaintenance
Instructions for DisconnectingConnectors
Fuse Inspection
Fusible Link Inspection
Battery Voltage Check
Alternator Check
Continuity Check
Voltage and Current Measurement
Check by False Signal
SERVICE MANUAL REVISION REQUEST FORM
THE ATTACHED DIAGRAM LIST
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