Hitachi ZW310 Performance Check & Troubleshooting Training Text Manual (TTLA-0669-ZW)
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Hitachi ZW310 Performance Check & Troubleshooting Training Text Manual (TTLA-0669-ZW)
- Manual Language:English
- Pages: 533
- Size: 8.66 MB
- Downloadable:Yes
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Description:
Hitachi ZW310 Performance Check & Troubleshooting Training Text Manual (TTLA-0669-ZW)
Use operational performance test procedure to quantitatively check all system and functions on the machine.
Purpose of Performance Tests
1. To comprehensively evaluate each operational function by comparing the performance test data with the standard values.
2. According to the evaluation results, repair, adjust, or replace parts or components as necessary to restore the machine’s performance to the desired standard.
3. To economically operate the machine under optimal conditions.
Kinds of Tests
1. Base machine performance test is to check the operational performance of each system such as engine, travel, swing, and hydraulic cylinders.
2. Hydraulic component unit test is to check the operational performance of each component such as hydraulic pump, motor, and various kinds of valves.
Performance Standards
“Performance Standard” is shown in tables to evaluate the performance test data.
Precautions for Evaluation of Test Data
1. To evaluate not only that the test data are correct, but also in what range the test data are.
2. Be sure to evaluate the test data based on the machine operation hours, kinds and state of work loads, and machine maintenance conditions.
The machine performance does not always deteriorate as the working hours increase. However, the machine performance is normally considered to reduce in proportion to the increase of the operation hours. Accordingly, restoring the machine performance by repair, adjustment, or replacement shall consider the number of the machine’s working hours.
Definition of “Performance Standard”
1. Operation speed values and dimensions of the new machine.
2. Operational performance of new components adjusted to specifications. Allowable errors will be indicated as necessary
Table Of Contents:
Hitachi ZW310 Performance Check & Troubleshooting Training Text Manual (TTLA-0669-ZW)
MATERIALS TOP............................................................................................................. 0 PERFORMANCE TEST&TROUBLESHOOTING.......................................................................................... 1 SECTION 4 OPERATIONALPERFORMANCE TEST..................................................................................... 2 Group 1 Introduction.................................................................................................. 4 Operational Performance Tests..................................................................................... 4 Preparation for Performance Tests................................................................................. 5 Group 2 Standard...................................................................................................... 6 Operational Performance Standard Table............................................................................ 6 Main Pump P-Q Curve............................................................................................... 16 Sensor Activating Range........................................................................................... 18 Group 3 Engine Test................................................................................................... 20 Engine Speed...................................................................................................... 20 Engine Compression Pressure ...................................................................................... 23 Valve Clearance................................................................................................... 25 Lubricant Consumption ............................................................................................ 27 Group 4 Wheel Loader Test............................................................................................. 28 Travel Speed...................................................................................................... 28 Service Brake Function Check...................................................................................... 29 Service Brake Wear Amount ........................................................................................ 30 Parking Brake Function Check...................................................................................... 31 Bucket Stopper and Bell CrankClearances .......................................................................... 33 Hydraulic Cylinder Cycle Time..................................................................................... 35 Cylinder Drift Check.............................................................................................. 37 Bucket Levelness.................................................................................................. 38 Control Lever Operating Force..................................................................................... 39 Control Lever Stroke.............................................................................................. 40 Group 5 Component Test................................................................................................ 42 Primary Pilot Pressure............................................................................................ 42 Secondary Pilot Pressure.......................................................................................... 44 Solenoid Valve Set Pressure....................................................................................... 45 Main Pump Delivery Pressure....................................................................................... 47 Main Relief Pressure.............................................................................................. 49 Steering Relief Pressure.......................................................................................... 51 Overload Relief Valve Set Pressure................................................................................ 53 Main Pump Flow Rate............................................................................................... 55 Regulator Adjustment.............................................................................................. 59 Service Brake Pressure (Front and Rear)........................................................................... 61 Parking Brake Pressure............................................................................................ 63 Brake Accumulated Pressure........................................................................................ 65 Brake Warning Set Pressure (Decrease)............................................................................. 67 Brake Warning Set Pressure (Increase)............................................................................. 69 Transmission Clutch Pressure...................................................................................... 71 Torque Converter Pressure(Inlet and Outlet)....................................................................... 72 Group 6 Adjustment.................................................................................................... 74 Transmission Learning............................................................................................. 74 Lift Arm Angle SensorLearning (Optional).......................................................................... 79 Unit Injector Setting............................................................................................. 81 SECTION 5 TROUBLESHOOTING................................................................................................. 86 Group 1 Diagnosing Procedure.......................................................................................... 92 Introduction...................................................................................................... 92 Diagnosing Procedure.............................................................................................. 93 How to Operate Service Made ofMonitor............................................................................. 97 Display List of Monitor Service Mode.............................................................................. 98 Group 2 Dr.ZX.........................................................................................................100 Outline...........................................................................................................100 Operation.........................................................................................................101 Self-Diagnosing Result............................................................................................103 Select Controller.................................................................................................105 Main Controller...................................................................................................106 Main Menu Monitor Display (MainController) .......................................................................107 Setting (Main Controller).........................................................................................111 Record Data Display (Main Controller).............................................................................118 Password Change (Main Controller).................................................................................119 Engine Controller.................................................................................................120 Monitor Display (Engine Controller)...............................................................................121 Recorded Data Display (EngineController) .........................................................................125 Password Change (Engine Controller)...............................................................................126 ICF Controller ...................................................................................................128 ICF Various Setup (ICF Controller)................................................................................129 Save Data Check (ICF Controller)..................................................................................139 Password Change (ICF Controller)..................................................................................140 Monitor Unit .....................................................................................................142 Monitoring (Monitor Unit).........................................................................................143 Various Settings (Monitor Unit)...................................................................................145 Internal Hour Meter Synchronization...............................................................................146 Password Change (Monitor Unit)....................................................................................147 Group 3 e-Wheel.......................................................................................................148 Outline...........................................................................................................148 List of Daily Report Data.........................................................................................149 List of Frequency Distribution Data...............................................................................150 List of Total Operationg Hours....................................................................................151 List of Alarm.....................................................................................................152 List of failure...................................................................................................153 How to Download and Upload Data ofICF.............................................................................154 Various Setup if ICF and SatelliteCommunication Terminal by UsingDr.ZX............................................157 List of ICF Fault Code............................................................................................169 List of Fault Code of SattelliteCommunication Terminal............................................................170 Group 4 Component Layout..............................................................................................174 Main Component Layout (Overview)..................................................................................174 Main Component Layout (Upper-structure) ..........................................................................175 Main Component Layout (TravelSystem)..............................................................................176 Electric Component Layout (Overview)..............................................................................177 Electrical System (Cab) ..........................................................................................178 Engine and Fan Pump...............................................................................................183 Pump Device, Drive Unit ..........................................................................................184 Control Valve ....................................................................................................185 Ride Control Valve ,Charging Block,Fan Motor .....................................................................186 Steering Valve, EmergencySteering Pump (Optional).................................................................187 Components in Control Valve.......................................................................................189 Components in Steering Valve......................................................................................195 Components in Charging Block......................................................................................199 Components in Ride Control Valve..................................................................................205 Front View of Transmission........................................................................................209 Side View of Transmission.........................................................................................210 Rear View of Transmission.........................................................................................211 Cross-Sectional Drawing ofTorque Converter........................................................................212 Cross-Sectional Drawing ofTransmission ...........................................................................213 Cross-Sectional Drawing ofClutch Shaft............................................................................214 Cross-Sectional Drawing ofTransmission Regulator Valve............................................................215 Cross-Sectional Drawing ofTransmission Control Valve..............................................................216 Group 5 Troubleshooting A.............................................................................................218 Troubleshooting A Procedure.......................................................................................218 MC Fault Code List................................................................................................219 ECM1 & ECM2 Fault Code List.......................................................................................239 ICF Fault Code List...............................................................................................263 Satellite Terminal Fault Code List................................................................................265 Monitor Unit Fault Code List......................................................................................267 Controller Hardware FailureMC Fault Codes 11000 to 11002..........................................................268 MC Fault Code 11003...............................................................................................269 MC Fault Code 11004...............................................................................................270 CAN Harness Check ................................................................................................271 Engine FailureMC Fault Code 11103 ................................................................................292 MC Fault Code 11105...............................................................................................293 Pump FailureMC Fault Code 11204...................................................................................294 MC Fault Code 11209...............................................................................................295 Pilot FailureMC Fault Code 11312..................................................................................296 MC Fault Code 11313...............................................................................................297 Proportional Solenoid Valve FailureMC Fault Code 11412............................................................298 MC Fault Code 11413...............................................................................................299 MC Fault Code 11414, 11415, 11416,11417, 11418, 11419 ............................................................300 Transmission FailureMC Fault Code 11600...........................................................................303 MC Fault Code 11601...............................................................................................304 MC Fault Code 11602...............................................................................................305 MC Fault Code 11904...............................................................................................306 MC Fault Code 11905...............................................................................................307 CAN Data Reception FailureMC Fault Codes 11910, 11920.............................................................308 CAN Harness Check(MC Fault Codes 11910, 11920)....................................................................309 MC Fault Code 11914...............................................................................................312 CAN Harness Check(MC Fault Code 11914)............................................................................313 Other FailuresMC Fault Code 11901.................................................................................316 Proportional Solenoid Valve TrubleCheck ..........................................................................317 Each Connector Terminal Rolein ECM1...............................................................................320 Each Connector Terminal Rolein ECM2...............................................................................323 ICF, Satellite Terminal Fault Codes14000 to 14003.................................................................326 ICF, Satellite Terminal Fault Codes14006, 14008, 14100 to 14106 ..................................................330 Monitor Unit Fault Codes 13306,13308..............................................................................332 Monitor Unit Fault Code 13312.....................................................................................333 Monitor Unit Fault Code 13314.....................................................................................334 Monitor Unit Fault Code 13334.....................................................................................335 Group 6 Troubleshooting B.............................................................................................336 Troubleshooting B Procedure.......................................................................................336 Relationship between Machine TroubleSymptoms and Related Parts....................................................337 Correlation between TroubleSymptoms and Part Failures ............................................................353 Engine System Troubleshooting.....................................................................................367 Front Attachment SystemTroubleshooting............................................................................376 Travel System Troubleshooting ....................................................................................395 Brake System Troubleshooting......................................................................................411 Steering System Troubleshooting...................................................................................419 Other System Troubleshooting......................................................................................422 Exchange Inspection...............................................................................................444 Bleeding Air from Brake (Axle)....................................................................................446 One Part of Data, “Daily ReportData”, “Distribution Data”, “TotalOperationg Hours” and “Alarm” isNot Recorded ....447 Group 7 Troubleshooting C.............................................................................................462 Troubleshooting C (Trouble Shootingfor Monitor) Procedure.........................................................462 Malfunction of Indicator Light CheckSystem........................................................................463 Malfunction of Buzzer in Monitor..................................................................................465 Malfunction of Coolant TemperatureGauge ..........................................................................467 Malfunction of Transmission OilTemperature Gauge..................................................................469 Malfunction of Fuel Gauge.........................................................................................471 Malfunction of Turn Signal Indicators(Left and Right).............................................................473 Malfunction of Hazard Light Indicator.............................................................................474 Malfunction of High Beam Indicator................................................................................475 Malfunction of Working Light Indicator............................................................................477 Malfunction of Forward/ReverseSwitch Indicator ...................................................................479 Malfunction of Maintenance Indicator..............................................................................481 Malfunction of Preheat Indicator..................................................................................482 Malfunction of Transmission OilTemperature........................................................................483 Malfunction of Hydraulic OilTemperature Indicator.................................................................485 Malfunction of Transmission WarningIndicator......................................................................487 Malfunction of Air Filter RestrictionIndicator....................................................................489 Malfunction of Engine Oil PressureIndicator.......................................................................491 Malfunction of Overheat Indicator.................................................................................493 Malfunction of Engine WarningIndicator............................................................................495 Malfunction of Stop Indicator.....................................................................................496 Malfunction of Service Indicator..................................................................................497 Malfunction of Parking Brake Indicator............................................................................499 Malfunction of Clearance LightIndicator...........................................................................501 Malfunction of Brake Low Oil PressureIndicator....................................................................502 Malfunction of Brake Low Oil LevelIndicator.......................................................................503 Malfunction of Emergency SteeringIndicator (Optional) ............................................................505 Malfunction of Low Steering OilPressure Indicator (Optional)......................................................507 Malfunction of Discharge WarningIndicator.........................................................................509 Malfunction of Monitor Display....................................................................................511 Malfunction of Ride Control Indicator.............................................................................512 Malfunction of Engine CoolantTemperature Display..................................................................513 Group 8 Electrical System Inspection..................................................................................514 Precautions for Inspection andMaintenance ........................................................................514 Instructions for DisconnectingConnectors .........................................................................516 Fuse Inspection...................................................................................................519 Fusible Link Inspection...........................................................................................521 Battery Voltage Check.............................................................................................522 Alternator Check..................................................................................................523 Continuity Check..................................................................................................525 Voltage and Current Measurement...................................................................................527 Check by False Signal.............................................................................................530
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