Hitachi ZW220, ZW250, ZW310 Wheel Loaders Repair Service Manuals + Operator's Manuals
Complete service repair manual with Electrical Wiring Diagrams for Hitachi ZW220, ZW250, ZW310 Wheel Loaders, with all the shop information to maintain, diagnose, and repair.
Hitachi ZW220, ZW250, ZW310 Wheel Loaders workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 3,033 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English
TT4GB-E-00 - Hitachi ZW220, ZW250 Wheel Loader Technical Manual (Troubleshooting).pdf
TT4HA-E-00 - Hitachi ZW310 Wheel Loader Technical Manual (Troubleshooting).pdf
W4GC-E-00 - Hitachi ZW220, ZW250 Wheel Loader (Standard Specification) Workshop Manual.pdf
W4HA-E-00 - Hitachi ZW310 Wheel Loader Workshop Manual.pdf
WCLA-0595-ZW - Hitachi ZW220, ZW250, ZW310 Transmission Control (TCM Transmission).pdf
WCLA-0596-ZW - Hitachi ZW310 Hydraulic Circuit Diagram (EU Standard).pdf
EM4GF-EN2-1 - Hitachi ZW180, ZW220, ZW250, ZW310 Wheel Loader Operator's Manual.pdf
TO4HA-E-00 - Hitachi ZW310 Wheel Loader Technical Manual (Operational Principle).pdf
EM4GFEN21 - Hitachi ZW180, ZW220, ZW250, ZW310 Wheel Loader Operator' Manual...2
TO4HAE00 - Hitachi ZW310 Wheel Loader Technical Manual (Operational Principle)...336
Operational Principle...336
INTRODUCTION...338
SECTION AND GROUP...340
SECTION 1...342
Group 1 Specifications...344
Specifications...344
Group 2 Component Layout...346
Main Component Layout...346
Electrical Component Layout...349
Electrical System (Cab)...350
Electrical System...351
Electrical System (Right Console)...352
Electrical System (Monitor and Switchs)...353
Monitor Panel...354
Engine and Fan Pump...355
Pump Device and Drive Unit...356
Control Valve...357
Ride Control Valve,Charging Block ...358
Steering Valve and Emergency Steering ...359
Group 3 Component Specifications...360
Engine...360
Engine Accessories...364
Hydraulic Component...365
Electrical Component...369
SECTION 2...374
Group 1 Control System...376
Outline...376
Engine Control...381
Pump Control...390
Transmission Control...395
Other Controls...416
Control by Electric and Hydraulic ...426
Group 2 ECM System...440
Outline...440
Fuel Injection Control...441
Group 3 Hydraulic System...446
Outline...446
Main Circuit...447
Pilot Circuit...458
Steering Circuit...471
Hydraulic Drive Fan Circuit...477
Group 4 Electrical System...480
Outline...480
Main Circuit...481
Electric Power Circuit...482
Indicator Light Check Circuit...483
Accessory Circuit...484
Preheat Circuit...485
Starting Circuit...487
Charging Circuit...491
Serge Voltage Prevention Circuit...493
Engine Stop Circuit...495
Lamplight Circait...496
Head Light Circuit...497
Turn Signal Circuit...501
Brake Light Circuit...502
Hazard Light Circuit...503
Horn Circuit...504
Reverse Light/Buzzer Circuit...505
Parking Brake Circuit...507
Emergency Steering Check ...509
SECTION 3...514
Group 1 Pump Device...516
Outline...516
Main Pump...517
Regulator...519
Priority Valve...533
Pilot Pump,Pump Delivery ...534
Steering Main Relief Valve...535
Group 2 Control Valve...536
Outline...536
Hydraulic Circuit...543
Main Relief Valve...547
Overload Relief Valve...549
Restriction Valve...552
Negative Control Valve...553
Flow Rate Control Valve...555
Group 3 Hydraulic Fan Motor...558
Outline...558
Operation...561
Flow Control Valve...563
Reverse Control Valve...565
Fun Pump...567
Group 4 Pilot Valve...568
Outline...568
Construction...569
Operation...570
Group 5 Steering Valve...574
Outline...574
Operation...577
Steering Overload Relief Valve...581
Group 6 Pilot Valve...584
Outline (Two Lever Type Pilot Valve for ...584
Operation...585
Electromagnetic Detent...589
Outline (Joystick Type Pilot Valve for ...590
Operation...591
Electromagnetic Detent...595
Outline (Lever Type Pilot Valve for ...596
Operation...597
Outline (Joystick Type Pilot Valve for ...600
Operation...601
Group 7 Charging Block...608
Outline...608
Priority Valve...613
Pilot Relief Valve...614
Pump Torque Control Proportional ...615
Service Brake Accumulator, ...616
Parking Brake Solenoid Valve...617
Service Brake Pressure Sensor...619
Parking Brake Pressure Sensor...619
Group 8 Ride Control Valve...620
Outline...620
Operation...623
Charge Cut Spool...625
Over Load Relief Valve...627
Ride Control Accumlator...629
Drain Plug...630
Group 9 Drive Unit...632
Outline...632
Torque Converter...633
Transmission...635
Transmisson Regulator Valve...657
Transmission Control Valve...659
Manual Spool (Emergency Travel ...667
Proportional Solenoid Valve...669
Group 10 Axle...670
Outline...670
Differential...671
Torque Proportioning Differential (TPD)...675
Limited Slip Differential (LSD)...677
Service Brake...679
Final Drivel Axle Shaft...681
Group 11 Brake Valve...682
Outline...682
Operation...685
Group 12 Others...688
Pilot Shutoff Valve...688
Propeller Shaft...689
Emergency Steering Check Block...690
Emergency Steering Pump (Optional)...691
TT4GBE00 - Hitachi ZW220, ZW250 Wheel Loader Technical Manual (Troubleshooting)...696
ZW220/250_TT4GB-E-00...696
INTRODUCTION...697
SAFETY...699
RECOGNIZE SAFETY INFORMATION...699
UNDERSTAND SIGNAL WORDS...699
FOLLOW SAFETY INSTRUCTIONS...700
PREPARE FOR EMERGENCIES...700
WEAR PROTECTIVE CLOTHING...701
PROTECT AGAINST NOISE...701
NSPECT MACHINE...701
GENERAL PRECAUTIONS FOR CAB...702
USE HANDHOLDS AND STEPS...703
ADJUST THE OPERATOR' SEAT...703
ENSURE SAFETY BEFORE RISING FROMOR LEAVING OPERATOR’S SEAT...703
FASTEN YOUR SEAT BELT...704
MOVE AND OPERATE MACHINE SAFELY...704
HANDLE STARTING AIDS SAFELY...704
OPERATE ONLY FROM OPERATOR'SEAT...705
JUMP STARTING...705
INVESTIGATE JOB SITE BEFOREHAND...706
EQUIPMENT OF HEAD GUARD, ROPS,FOPS...707
PROVIDE SIGNALS FOR JOBS INVOLVINGMULTIPLE NUMBERS OF MACHINES...707
KEEP RIDERS OFF MACHINE...708
DRIVE SAFELY...708
DRIVE MACHINE SAFELY (WORK SITE)...708
DRIVE SAFELY WITH BUCKET LOADED...709
DRIVE ON SNOW SAFELY...709
TRAVEL ON PUBLIC ROADS SAFELY...709
AVOID INJURY FROM ROLLAWAY ACCIDENTS...710
AVOID ACCIDENTS FROM BACKING UPAND TURNING...711
AVOID POSITIONING BUCKET OVERANYONE...712
AVOID TIPPING...712
NEVER UNDERCUT A HIGH BANK...713
DIG WITH CAUTION...713
PERFORM TRUCK LOADING SAFELY...713
AVOID POWER LINES...714
PRECAUTIONS FOR OPERATION...714
PRECAUTIONS FOR LIGHTENING...714
OBJECT HANDLING...714
PROTECT AGAINST FLYING DEBRIS...715
PARK MACHINE SAFELY...715
STORE ATTACHMENTS SAFELY...716
TRANSPORT SAFELY...716
HANDLE FLUIDS SAFELY-AVOID FIRES...717
PRACTICE SAFE MAINTENANCE...718
WARN OTHERS OF SERVICE WORK...719
SUPPORT MACHINE PROPERLY...719
STAY CLEAR OF MOVING PARTS...719
SUPPORT MAINTENANCE PROPERLY...720
PREVENT PARTS FROM FLYING...720
PREVENT BURNS...721
REPLACE RUBBER HOSES PERIODICALLY...721
PREVENT FIRES...723
EVACUATING IN CASE OF FIRE...724
BEWARE OF EXHAUST FUMES...724
PRECAUTIONS FOR WELDING ANDGRINDING...724
AVOID HEATING NEAR PRESSURIZEDFLUID LINES...725
AVOID APPLYING HEAT TO LINES CONTAININGFLAMMABLE FLUIDS...725
REMOVE PAINT BEFORE WELDING ORHEATING...725
BEWARE OF ASBESTOS DUST...726
PREVENT BATTERY EXPLOSIONS...726
SERVICE AIR CONDITIONING SYSTEMSAFELY...726
HANDLE CHEMICAL PRODUCTS SAFELY...727
DISPOSE OF WASTE PROPERLY...727
BEFORE RETURNING THE MACHINE TOTHE CUSTOMER...728
SECTION AND GROUPCONTENTS...729
SECTION 4 OPERATIONALPERFORMANCE TEST...731
Group 1 Introduction...733
Operational Performance Tests...733
Preparation for Performance Tests...734
Group 2 Standard...735
Operational PerformanceStandard Table ...735
Main Pump P-Q Curve...745
Sensor Activating Range...747
Group 3 Engine Test...749
Engine Speed...749
Engine Compression Pressure...751
Valve Clearance Adjustment...752
Lubricant Consumption...755
Group 4 Wheel Loader Test...757
Travel Speed...757
Service Brake Function Check...758
Service Brake Wear Amount...759
Parking Brake Function Check...760
Bucket and Bell Crank StopperClearances ...762
Hydraulic Cylinder Cycle Time...764
Cylinder Drift Check...766
Bucket Levelness...767
Control Lever Operating Force...768
Control Lever Stroke...769
Group 5 Component Test...771
Primary Pilot Pressure...771
Secondary Pilot Pressure...773
Solenoid Valve Set Pressure...774
Main Pump Delivery Pressure...776
Main Relief Valve Set Pressure...778
Steering Relief Pressure...782
Overload Relief Valve Set Pressure...784
Main Pump Flow Rate...786
Regulator Adjustment...790
Service Brake Pressure (Front and Rear)...792
Parking Brake Pressure...794
Brake Accumulated Pressure...796
Brake Warning Set Pressure (Decrease)...798
Brake Warning Set Pressure (Increase)...800
Transmission Clutch Pressure...802
Torque Converter Pressure(Inlet and Outlet)...804
Group 6 Adjustment...807
Transmission Learning...807
Lift Arm Angle SensorLearning (Optional)...812
Drive Belt Tension Adjustment...814
SECTION 5 TROUBLESHOOTING...817
Group 1 Diagnosing Procedure...821
Introduction...821
Diagnosing Procedure...822
How to Operate Service Made ofMonitor ...826
Display List of Monitor Service Mode...827
Group 2 Dr.ZX...829
Outline...829
Operation...830
Self-Diagnosing Result...832
Select Controller...834
Main Controller...835
Main Menu Monitor Display (MainController) ...836
Setting (Main Controller)...840
Record Data Display (Main Controller)...847
Password Change (Main Controller)...848
Engine Controller...849
Monitor Display (Engine Controller)...850
Recorded Data Display (EngineController) ...854
Password Change (Engine Controller)ICF Controller ...855
ICF Various Setup (ICF Controller)...857
Save Data Check (ICF Controller)...868
Password Change (ICF Controller)...869
Monitor Unit...871
Monitoring (Monitor Unit)...872
Various Settings (Monitor Unit)...874
Internal Hour Meter Synchronization...875
Password Change (Monitor Unit)...876
TCU Controller...877
Monitor Display (TCU Controller)...878
Recorded Data Display (TCU Controller)...882
Password Change (TCU Controller)...883
Group 3 e-Wheel...885
Outline...885
List of Daily Report Data...886
List of Frequency Distribution Data...887
List of Total Operationg Hours...888
List of Alarm...889
List of failure ...890
How to Download and Upload Data ofICF...891
Various Setup if ICF and SatelliteCommunication Terminal by UsingDr.ZX ...894
List of ICF Fault Code ...906
List of Fault Code of SattelliteCommunication Terminal...907
Group 4 Component Layout...911
Main Component Layout (Overview)...911
Main Component Layout (Upper-...912
Main Component Layout (TravelSystem) ...913
Electric Component Layout (Overview)...914
Electrical System (Cab)...915
Engine and Fan Pump...920
Pump Device, Drive Unit...921
Control Valve...922
Ride Control Valve ,Charging Block,Fan Motor, Parking Brake SolenoidValve...923
Steering Valve, EmergencySteering Pump...924
Components in Control Valve...926
Components in Steering Valve...938
Components in Charging Block...942
Components in Ride Control Valve...948
Side View of Transmission...952
Front View of Transmission...953
Pressure Sensor Ports ofTransmission ...954
Cross-Sectional Drawing ofTransmission ...955
Cross-Sectional Drawing of TorqueConverter ...956
Cross-Sectional Drawing ofTransmission Control Valve ...957
Circuit of Drive Unit ...958
Group 5 Troubleshooting A...959
Troubleshooting A Procedure...959
MC Fault Code List...960
ECM Fault Code List...974
TCU Fault Code List...998
ICF Fault Code List...1016
Satellite Terminal Fault Code List...1018
Monitor Unit Fault Code List...1020
Controller Hardware FailureMC Fault Codes 11000 to 11002...1021
MC Fault Code 11003...1022
MC Fault Code 11004...1023
CAN Harness Check...1024
Engine FailureMC Fault Code 11103...1049
Pump FailureMC Fault Code 11204...1050
MC Fault Code 11209...1051
Pilot FailureMC Fault Code 11313...1052
Proportional Solenoid Valve FailureMC Fault Code 11412...1053
MC Fault Code 11413...1054
CAN Data Reception FailureMC Fault Codes 11910, 11920...1055
CAN Harness Check(MC Fault Codes 11910, 11920)...1056
MC Fault Code 11914...1059
CAN Harness Check(MC Fault Code 11914)...1060
MC Fault Codes 11912, 11913,11916, 11917 ...1063
CAN Harness Check(MC Fault Codes 11912, 11913,11916, 11917)...1064
Other FailuresMC Fault Code 11901...1067
Proportional Solenoid Valve TrubleCheck ...1068
ECM, Sensor SystemECM Fault Codes 100, 102, 105, 108,110, 157, 172 ...1071
ECM Fault Codes 174, 636, 723,10001...1072
ECM, External Device SystemECM Fault Codes 651, 652, 653, 654,655, 656, 1347, 10002 ...1073
ECM, Fuel SystemECM Fault Codes 157, 633, 1239,1240...1074
ECM, Engine ProtectionECM Fault Codes 110, 190 ...1075
ECM, External Circuit SystemECM Fault Codes 987, 1485...1076
ECM, Internal Circuit SystemECM Fault Codes 628, 1077, 1079,1080, 10003, 10004, 10005 ...1077
ECM Fault Codes 10006, 10007,10008, 10009, 10010, 10011, 10013...1078
ECM, Communication SystemECM Fault Codes 639...1079
Role and Connection of EachTerminal in TCU ...1080
ICF, Satellite Terminal Fault Codes14000 to 14003 ...1083
ICF, Satellite Terminal Fault Codes14006, 14008, 14100 to 14106...1087
Monitor Unit Fault Codes 13306,13308 ...1089
Monitor Unit Fault Code 13312...1090
Monitor Unit Fault Code 13314...1091
Group 6 Troubleshooting B...1093
Troubleshooting B Procedure...1093
Relationship between Machine TroubleSymptoms and Related Parts ...1094
Correlation between TroubleSymptoms and Part Failures ...1110
Engine System Troubleshooting...1124
Front Attachment SystemTroubleshooting ...1133
Travel System Troubleshooting...1152
Brake System Troubleshooting...1168
Steering System Troubleshooting...1176
Other System Troubleshooting...1179
Exchange Inspection...1201
Bleeding Air from Brake (Axle)...1203
One Part of Data, “Daily ReportData”, “Distribution Data”, “TotalOperationg Hours” and “Alarm” isNot Recorded ...1204
Group 7 Troubleshooting C...1219
Troubleshooting C (Trouble Shootingfor Monitor) Procedure...1219
Malfunction of Indicator Light CheckSystem ...1220
Malfunction of Buzzer in Monitor...1222
Malfunction of Coolant TemperatureGauge ...1224
Malfunction of Transmission OilTemperature Gauge...1226
Malfunction of Fuel Gauge...1228
Malfunction of Turn Signal Indicators(Left and Right)...1230
Malfunction of Hazard Light Indicator...1231
Malfunction of High Beam Indicator...1232
Malfunction of Working Light Indicator...1234
Malfunction of Forward/ReverseSwitch Indicator ...1236
Malfunction of Maintenance Indicator...1238
Malfunction of Preheat Indicator...1239
Malfunction of Transmission OilTemperature...1240
Malfunction of Hydraulic OilTemperature Indicator ...1242
Malfunction of Transmission WarningIndicator...1244
Malfunction of Air Filter RestrictionIndicator...1246
Malfunction of Engine Oil PressureIndicator...1248
Malfunction of Overheat Indicator...1250
Malfunction of Engine WarningIndicator...1252
Malfunction of Stop Indicator...1253
Malfunction of Service Indicator...1254
Malfunction of Parking Brake Indicator...1256
Malfunction of Clearance LightIndicator...1258
Malfunction of Brake Low Oil PressureIndicator...1259
Malfunction of Brake Low Oil LevelIndicator...1260
Malfunction of Emergency SteeringIndicator (Optional) ...1262
Malfunction of Low Steering OilPressure Indicator (Optional) ...1264
Malfunction of Discharge WarningIndicator...1266
Malfunction of Monitor Display...1268
Malfunction of Ride Control Indicator...1269
Malfunction of Engine CoolantTemperature Display ...1270
Group 8 Electrical System Inspection...1271
Precautions for Inspection andMaintenance ...1271
Instructions for DisconnectingConnectors ...1273
Fuse Inspection...1276
Fusible Link Inspection...1278
Battery Voltage Check...1279
Alternator Check...1280
Continuity Check...1282
Voltage and Current Measurement...1284
Check by False Signal...1287
SERVICE MANUAL REVISION REQUEST FORM...1291
THE ATTACHED DIAGRAM LIST...1292
TT4HAE00 - Hitachi ZW310 Wheel Loader Technical Manual (Troubleshooting)...1293
ZW310_TT4HA-E-00...1293
INTRODUCTION...1294
SAFETY...1296
RECOGNIZE SAFETY INFORMATION...1296
UNDERSTAND SIGNAL WORDS...1296
FOLLOW SAFETY INSTRUCTIONS...1297
PREPARE FOR EMERGENCIES...1297
WEAR PROTECTIVE CLOTHING...1298
PROTECT AGAINST NOISE...1298
NSPECT MACHINE...1298
GENERAL PRECAUTIONS FOR CAB...1299
USE HANDHOLDS AND STEPS...1300
ADJUST THE OPERATOR' SEAT...1300
ENSURE SAFETY BEFORE RISING FROMOR LEAVING OPERATOR’S SEAT...1300
FASTEN YOUR SEAT BELT...1301
MOVE AND OPERATE MACHINE SAFELY...1301
HANDLE STARTING AIDS SAFELY...1301
OPERATE ONLY FROM OPERATOR'SEAT...1302
JUMP STARTING...1302
INVESTIGATE JOB SITE BEFOREHAND...1303
EQUIPMENT OF HEAD GUARD, ROPS,FOPS...1304
PROVIDE SIGNALS FOR JOBS INVOLVING...1304
KEEP RIDERS OFF MACHINE...1305
DRIVE SAFELY...1305
DRIVE MACHINE SAFELY (WORK SITE)...1305
DRIVE SAFELY WITH BUCKET LOADED...1306
DRIVE ON SNOW SAFELY...1306
TRAVEL ON PUBLIC ROADS SAFELY...1306
AVOID INJURY FROM ROLLAWAY ACCIDENTS...1307
AVOID ACCIDENTS FROM BACKING UPAND TURNING...1308
AVOID POSITIONING BUCKET OVERANYONE...1309
AVOID TIPPING...1309
NEVER UNDERCUT A HIGH BANK...1310
DIG WITH CAUTION...1310
PERFORM TRUCK LOADING SAFELY...1310
AVOID POWER LINES...1311
PRECAUTIONS FOR OPERATION...1311
PRECAUTIONS FOR LIGHTENING...1311
OBJECT HANDLING...1311
PROTECT AGAINST FLYING DEBRIS...1312
PARK MACHINE SAFELY...1312
STORE ATTACHMENTS SAFELY...1313
TRANSPORT SAFELY...1313
HANDLE FLUIDS SAFELY-AVOID FIRES...1314
PRACTICE SAFE MAINTENANCE...1315
WARN OTHERS OF SERVICE WORK...1316
SUPPORT MACHINE PROPERLY...1316
STAY CLEAR OF MOVING PARTS...1316
SUPPORT MAINTENANCE PROPERLY...1317
PREVENT PARTS FROM FLYING...1317
PREVENT BURNS...1318
REPLACE RUBBER HOSES PERIODICALLY...1318
PREVENT FIRES...1320
EVACUATING IN CASE OF FIRE...1321
BEWARE OF EXHAUST FUMES...1321
PRECAUTIONS FOR WELDING ANDGRINDING...1321
AVOID HEATING NEAR PRESSURIZEDFLUID LINES...1322
AVOID APPLYING HEAT TO LINES CONTAINING...1322
REMOVE PAINT BEFORE WELDING ORHEATING...1322
BEWARE OF ASBESTOS DUST...1323
PREVENT BATTERY EXPLOSIONS...1323
SERVICE AIR CONDITIONING SYSTEMSAFELY...1323
HANDLE CHEMICAL PRODUCTS SAFELY...1324
DISPOSE OF WASTE PROPERLY...1324
BEFORE RETURNING THE MACHINE TOTHE CUSTOMER...1325
SECTION AND GROUP...1326
SECTION 4 OPERATIONALPERFORMANCE TEST...1328
Group 1 Introduction...1330
Operational Performance Tests...1330
Preparation for Performance Tests...1331
Group 2 Standard...1332
Operational Performance Standard Table...1332
Main Pump P-Q Curve...1342
Sensor Activating Range...1344
Group 3 Engine Test...1346
Engine Speed...1346
Engine Compression Pressure ...1349
Valve Clearance...1351
Lubricant Consumption ...1353
Group 4 Wheel Loader Test...1354
Travel Speed...1354
Service Brake Function Check...1355
Service Brake Wear Amount ...1356
Parking Brake Function Check...1357
Bucket Stopper and Bell CrankClearances ...1359
Hydraulic Cylinder Cycle Time...1361
Cylinder Drift Check...1363
Bucket Levelness...1364
Control Lever Operating Force...1365
Control Lever Stroke...1366
Group 5 Component Test...1368
Primary Pilot Pressure...1368
Secondary Pilot Pressure...1370
Solenoid Valve Set Pressure...1371
Main Pump Delivery Pressure...1373
Main Relief Pressure...1375
Steering Relief Pressure...1377
Overload Relief Valve Set Pressure...1379
Main Pump Flow Rate...1381
Regulator Adjustment...1385
Service Brake Pressure (Front and Rear)...1387
Parking Brake Pressure...1389
Brake Accumulated Pressure...1391
Brake Warning Set Pressure (Decrease)...1393
Brake Warning Set Pressure (Increase)...1395
Transmission Clutch Pressure...1397
Torque Converter Pressure(Inlet and Outlet)...1398
Group 6 Adjustment...1400
Transmission Learning...1400
Lift Arm Angle SensorLearning (Optional)...1405
Unit Injector Setting...1407
SECTION 5 TROUBLESHOOTING...1412
Group 1 Diagnosing Procedure...1418
Introduction...1418
Diagnosing Procedure...1419
How to Operate Service Made ofMonitor...1423
Display List of Monitor Service Mode...1424
Group 2 Dr.ZX...1426
Outline...1426
Operation...1427
Self-Diagnosing Result...1429
Select Controller...1431
Main Controller...1432
Main Menu Monitor Display (MainController) ...1433
Setting (Main Controller)...1437
Record Data Display (Main Controller)...1444
Password Change (Main Controller)...1445
Engine Controller...1446
Monitor Display (Engine Controller)...1447
Recorded Data Display (EngineController) ...1451
Password Change (Engine Controller)...1452
ICF Controller ...1454
ICF Various Setup (ICF Controller)...1455
Save Data Check (ICF Controller)...1465
Password Change (ICF Controller)...1466
Monitor Unit ...1468
Monitoring (Monitor Unit)...1469
Various Settings (Monitor Unit)...1471
Internal Hour Meter Synchronization...1472
Password Change (Monitor Unit)...1473
Group 3 e-Wheel...1474
Outline...1474
List of Daily Report Data...1475
List of Frequency Distribution Data...1476
List of Total Operationg Hours...1477
List of Alarm...1478
List of failure...1479
How to Download and Upload Data ofICF...1480
Various Setup if ICF and SatelliteCommunication Terminal by UsingDr.ZX...1483
List of ICF Fault Code...1495
List of Fault Code of SattelliteCommunication Terminal...1496
Group 4 Component Layout...1500
Main Component Layout (Overview)...1500
Main Component Layout (Upper-structure) ...1501
Main Component Layout (TravelSystem)...1502
Electric Component Layout (Overview)...1503
Electrical System (Cab) ...1504
Engine and Fan Pump...1509
Pump Device, Drive Unit ...1510
Control Valve ...1511
Ride Control Valve ,Charging Block,Fan Motor ...1512
Steering Valve, EmergencySteering Pump (Optional)...1513
Components in Control Valve...1515
Components in Steering Valve...1521
Components in Charging Block...1525
Components in Ride Control Valve...1531
Front View of Transmission...1535
Side View of Transmission...1536
Rear View of Transmission...1537
Cross-Sectional Drawing ofTorque Converter...1538
Cross-Sectional Drawing ofTransmission ...1539
Cross-Sectional Drawing ofClutch Shaft...1540
Cross-Sectional Drawing ofTransmission Regulator Valve...1541
Cross-Sectional Drawing ofTransmission Control Valve...1542
Group 5 Troubleshooting A...1544
Troubleshooting A Procedure...1544
MC Fault Code List...1545
ECM1 & ECM2 Fault Code List...1565
ICF Fault Code List...1589
Satellite Terminal Fault Code List...1591
Monitor Unit Fault Code List...1593
Controller Hardware FailureMC Fault Codes 11000 to 11002...1594
MC Fault Code 11003...1595
MC Fault Code 11004...1596
CAN Harness Check ...1597
Engine FailureMC Fault Code 11103 ...1618
MC Fault Code 11105...1619
Pump FailureMC Fault Code 11204...1620
MC Fault Code 11209...1621
Pilot FailureMC Fault Code 11312...1622
MC Fault Code 11313...1623
Proportional Solenoid Valve FailureMC Fault Code 11412...1624
MC Fault Code 11413...1625
MC Fault Code 11414, 11415, 11416,11417, 11418, 11419 ...1626
Transmission FailureMC Fault Code 11600...1629
MC Fault Code 11601...1630
MC Fault Code 11602...1631
MC Fault Code 11904...1632
MC Fault Code 11905...1633
CAN Data Reception FailureMC Fault Codes 11910, 11920...1634
CAN Harness Check(MC Fault Codes 11910, 11920)...1635
MC Fault Code 11914...1638
CAN Harness Check(MC Fault Code 11914)...1639
Other FailuresMC Fault Code 11901...1642
Proportional Solenoid Valve TrubleCheck ...1643
Each Connector Terminal Rolein ECM1...1646
Each Connector Terminal Rolein ECM2...1649
ICF, Satellite Terminal Fault Codes14000 to 14003...1652
ICF, Satellite Terminal Fault Codes14006, 14008, 14100 to 14106 ...1656
Monitor Unit Fault Codes 13306,13308...1658
Monitor Unit Fault Code 13312...1659
Monitor Unit Fault Code 13314...1660
Monitor Unit Fault Code 13334...1661
Group 6 Troubleshooting B...1662
Troubleshooting B Procedure...1662
Relationship between Machine TroubleSymptoms and Related Parts...1663
Correlation between TroubleSymptoms and Part Failures ...1679
Engine System Troubleshooting...1693
Front Attachment SystemTroubleshooting...1702
Travel System Troubleshooting ...1721
Brake System Troubleshooting...1737
Steering System Troubleshooting...1745
Other System Troubleshooting...1748
Exchange Inspection...1770
Bleeding Air from Brake (Axle)...1772
One Part of Data, “Daily ReportData”, “Distribution Data”, “TotalOperationg Hours” and “Alarm” isNot Recorded ...1773
Group 7 Troubleshooting C...1788
Troubleshooting C (Trouble Shootingfor Monitor) Procedure...1788
Malfunction of Indicator Light CheckSystem...1789
Malfunction of Buzzer in Monitor...1791
Malfunction of Coolant TemperatureGauge ...1793
Malfunction of Transmission OilTemperature Gauge...1795
Malfunction of Fuel Gauge...1797
Malfunction of Turn Signal Indicators(Left and Right)...1799
Malfunction of Hazard Light Indicator...1800
Malfunction of High Beam Indicator...1801
Malfunction of Working Light Indicator...1803
Malfunction of Forward/ReverseSwitch Indicator ...1805
Malfunction of Maintenance Indicator...1807
Malfunction of Preheat Indicator...1808
Malfunction of Transmission OilTemperature...1809
Malfunction of Hydraulic OilTemperature Indicator...1811
Malfunction of Transmission WarningIndicator...1813
Malfunction of Air Filter RestrictionIndicator...1815
Malfunction of Engine Oil PressureIndicator...1817
Malfunction of Overheat Indicator...1819
Malfunction of Engine WarningIndicator...1821
Malfunction of Stop Indicator...1822
Malfunction of Service Indicator...1823
Malfunction of Parking Brake Indicator...1825
Malfunction of Clearance LightIndicator...1827
Malfunction of Brake Low Oil PressureIndicator...1828
Malfunction of Brake Low Oil LevelIndicator...1829
Malfunction of Emergency SteeringIndicator (Optional) ...1831
Malfunction of Low Steering OilPressure Indicator (Optional)...1833
Malfunction of Discharge WarningIndicator...1835
Malfunction of Monitor Display...1837
Malfunction of Ride Control Indicator...1838
Malfunction of Engine CoolantTemperature Display...1839
Group 8 Electrical System Inspection...1840
Precautions for Inspection andMaintenance ...1840
Instructions for DisconnectingConnectors ...1842
Fuse Inspection...1845
Fusible Link Inspection...1847
Battery Voltage Check...1848
Alternator Check...1849
Continuity Check...1851
Voltage and Current Measurement...1853
Check by False Signal...1856
SERVICE MANUAL REVISION REQUEST FORM...1860
THE ATTACHED DIAGRAM LIST...1861
W4GCE00 - Hitachi ZW220, ZW250 Wheel Loader (Standard Specification) Workshop Manual...1862
ZW220/250_W4GC-E-00...1862
INTRODUCTION...1864
SAFETY...1866
SECTION AND GROUP CONTENTS...1896
SECTIO...1898
Group 1 Precautions for Disassembling and Assembling...1900
Precautions for Disassembling and Assembling...1900
Maintenance Standard Terminology...1906
Group 2 Tightening...1908
Tightening Torque Specifications...1908
Torque Chart...1909
Piping Joint...1912
Periodic Replacement of Parts...1916
Group 3 Painting...1918
Painting...1918
Group 4 Bleeding Air from Hydraulic Oil Tank...1920
Bleeding Air from Hydraulic Oil Tank...1920
SECTION 2 BODY (UPPERSTRUCTURE)...1924
Group 1 Cab...1926
Remove and Install Cab...1926
Group 2 Counterweight...1938
Remove and Install Counterweight...1938
Group 3 Center Hinge...1940
Disassemble Center Hinge...1940
Assemble Center Hinge...1945
Group 4 Hood...1950
Removal and Installation of Hood...1950
Group 5 Hydraulic Oil Tank...1952
Removal and Installation of Hydraulic Oil Tank...1952
Group 6 Pump Device...1960
Removal and Installation of Pump Device...1960
Removal and Installation of Pilot Pump and Regulator...1967
Disassembly of Main Pump...1971
Assembly of Main Pump...1973
Disassembly of Regulator...1979
Assembly of Regulator...1981
Disassembly of Priority Valve...1983
Assembly of Priority Valve...1985
Structure of Pilot Pump...1987
Maintenance Standard...1989
Group 7 Control Valve...1990
Removal and Installation of Control Valve (ZW220)...1990
Removal and Installation of Control Valve (ZW250)...1995
Disassembly of Control Valve (ZW220)...2001
Assembly of Control Valve (ZW220)...2005
Disassembly of Control Valve (ZW250)...2011
Assembly of Control Valve (ZW250)...2015
Group 8 Pilot Valve...2022
Removal and Installation of Pilot Valve...2022
Disassembly of Standard Pilot Valve for Front Attachment...2025
Assembly of Standard Pilot Valve for Front Attachment...2033
Maintenance Standard...2041
Disassembly of Joy-Stick Type Pilot Valve for Additional Circuit (Optional)...2043
Assembly of Joy-Stick Type Pilot Valve for Additional Circuit (Optional)...2047
Disassembly of 2-Way Lever Type Pilot Valve for Additional Circuit (Optional)...2051
Assembly of 2-Way Lever Type Pilot Valve for Additional Circuit...2053
Group 9 Pilot Shut-Off Valve...2056
Removal and Installation of Pilot Shut-Off Valve...2056
Disassembly of Pilot Shut-Off Valve...2059
Assembly of Pilot Shut-Off Valve...2061
Group 10 Hydraulic Fan Pump and Motor...2064
Removal and Installation of Hydraulic Fan Pump...2064
Removal and Installation of Hydraulic Fan Motor...2066
Disassembly of Fan Pump...2071
Assembly of Fan Pump...2073
Fan Motor Standard...2077
SECTION 3 BODY (TRAVEL SYSTEM)...2082
Group 1 Tire...2084
Removal and Installation of Tire...2084
Group 2 Drive Unit...2086
Removal and Installation of Drive Unit...2086
Disassembly of Drive Unit...2101
Disassembly of Torque Converter Wheel...2135
Assembly of Torque Converter Wheel...2145
Disassembly of Clutch Shaft (Forward Clutch, Reverse Clutch)...2153
Assembly of Clutch Shaft (Forward Clutch, Reverse Clutch)...2157
Disassembly of Clutch Shaft (1-Speed to 2-Speed Clutch, 3-Speed to 4-Speed Clutch)...2163
Assembly of Clutch Shaft (1-Speed to 2-Speed Clutch, 3-Speed to 4-Speed Clutch)...2165
Disassembly of Idler Shaft...2167
Assembly of Idler Shaft...2169
Disassembly of Control Valve...2171
Assembly of Control Valve...2175
Disassembly of Regulator Valve...2183
Assembly of Regulator...2185
Assembly of Drive Unit...2187
Group 3 Axle...2224
Removal and Installation of Axle...2224
Disassembly of Axle...2236
Assembly of Axle...2256
Group 4 Propeller Shaft...2288
Removal and Installation of Propeller Shaft...2288
Group 5 Brake Valve...2298
Removal and Installation of Brake Valve...2298
Disassembly of Brake Valve...2301
Assembly of Brake Valve...2307
Maintenance Standard...2317
Group 6 Charging Block...2318
Removal and Installation of Charging Block...2318
Disassembly of Charging Block...2321
Assembly of Charging Block...2326
Group 7 Steering Pilot Valve...2334
Removal and Installation of Steering Pilot Valve...2334
Disassembly of Steering Pilot Valve...2337
Assembly of Steering Pilot Valve...2341
Group 8 Steering Valve...2348
Removal and Installation of Steering Valve...2348
Disassembly of Steering Valve...2349
Assembly of Steering Valve...2351
Group 9 Steering Cylinder...2354
Removal and Installation ofSteering Cylinder...2354
Disassembly of Steering Cylinder...2359
Assembly of Steering Cylinder...2367
SECTION 4FRONT ATTACHMENT...2382
Group 1 Front Attachment...2384
Removal and Installation of Front Attachment...2384
Group 2 Cylinder...2394
Removal and Installation of Cylinder (Lift Cylinder)...2394
Removal and Installation of Cylinder (Bucket Cylinder)...2399
Disassembly of Bucket Cylinder...2403
Assembly of Bucket Cylinder...2411
Disassembly of Lift Cylinder...2421
Assembly of Lift Cylinder...2429
SERVICE MANUAL REVISION REQUEST FORM...2442
W4HAE00 - Hitachi ZW310 Wheel Loader Workshop Manual...2444
ZW310_W4HA-E-00...2444
INTRODUCTION...2446
SAFETY...2448
SECTION AND GROUP CONTENTS...2478
SECTION 1 GENERAL...2480
Group 1 Precautions for Disassembling and Assembling...2482
Precautions for Disassembling and Assembling...2482
Maintenance Standard Terminology...2488
Group 2 Tightening...2490
Tightening Torque Specifications...2490
Torque Chart...2491
Piping Joint...2494
Periodic Replacement Parts...2498
Group 3 Painting...2500
Painting...2500
Group 4 Bleed Air from Hydraulic Oil Tank...2502
Bleed Air from Hydraulic Oil Tank...2502
SECTION 2 BODY (UPPERSTRUCTURE)...2506
Group 1 Cab...2508
Removal and Installation of Cab...2508
Group 2 Counterweight...2520
Removal and Installation of Counterweight...2520
Group 3 Center Hinge...2522
Disassembly of Center Hinge...2522
Assembly of Center Hinge...2527
Group 4 Hood...2532
Removal and Installation of Hood...2532
Group 5 Hydraulic Oil Tank...2534
Removal and Installation of Hydraulic Oil Tank...2534
Group 6 Pump Device...2542
Removal and Installation of Pump Device...2542
Removal and Installation of Pilot Pump and Regulator...2549
Disassembly of Main Pump...2553
Assembly of Main Pump...2555
Disassembly of Regulator...2561
Assembly of Regulator...2563
Disassembly of Priority Valve...2565
Assembly of Priority Valve...2567
Structure of Pilot Pump...2569
Maintenance Standard...2571
Group 7 Control Valve...2572
Removal and Installation of Control Valve...2572
Disassembly of Control Valve...2579
Assembly of Control Valve...2583
Group 8 Pilot Valve...2590
Removal and Installation of Pilot Valve...2590
Disassembly of Standard Pilot Valve for Front Attachment...2593
Assembly of Standard Pilot Valve for Front Attachment...2601
Maintenance Standard...2609
Disassembly of Joy-Stick Type Pilot Valve for Additional Circuit (Optional)...2611
Assembly of Joy-Stick Type Pilot Valve for Additional Circuit (Optional)...2615
Disassembly of 2-Way Lever Type Pilot Valve for Additional Circuit (Optional)...2619
Assembly of 2-Way Lever Type Pilot Valve for Additional Circuit...2621
Group 9 Pilot Shut-Off Valve...2624
Removal and Installation of Pilot Shut-Off Valve...2624
Disassembly of Pilot Shut-Off Valve...2627
Assembly of Pilot Shut-Off Valve...2629
Group 10 Hydraulic Fan Pump and Motor...2632
Removal and Installation of Hydraulic Fan Pump...2632
Removal and Installation of Hydraulic Fan Motor...2634
Disassembly of Hydraulic Fan Pump...2639
Assembly of Hydraulic Fan Pump...2641
Hydraulic Fan Motor Standard...2645
SECTION 3 BODY (TRAVEL SYSTEM)...2650
Group 1 Tire...2652
Removal and Installation of Tire...2652
Group 2 Drive Unit...2654
Removal and Installation of Drive Unit...2654
Disassembly of Drive Unit...2673
Disassembly of Torque Converter Wheel...2707
Assembly of Torque Converter Wheel...2717
Disassembly of Clutch Shaft (Forward Clutch, Reverse Clutch)...2725
Assembly of Clutch Shaft (Forward Clutch, Reverse Clutch)...2729
Disassembly of Clutch Shaft (1-Speed to 2-Speed Clutch, 3-Speed to 4-Speed Clutch)...2735
Assembly of Clutch Shaft (1-Speed to 2-Speed Clutch, 3-Speed to 4-Speed Clutch)...2737
Disassembly of Idler Shaft...2739
Assembly of Idler Shaft...2741
Disassembly of Control Valve...2743
Assembly of Control Valve...2747
Disassembly of Regulator Valve...2755
Assembly of Regulator...2757
Assembly of Drive Unit...2759
Group 3 Axle...2796
Removal and Installation of Axle...2796
Disassembly of Axle...2808
Assembly of Axle...2828
Group 4 Propeller Shaft...2860
Removal and Installation of Propeller Shaft...2860
Group 5 Brake Valve...2870
Removal and Installation of Brake Valve...2870
Disassembly of Brake Valve...2873
Assembly of Brake Valve...2879
Maintenance Standard...2889
Group 6 Charging Block...2890
Removal and Installation of Charging Block...2890
Disassembly of Charging Block...2893
Assembly of Charging Block...2898
Group 7 Steering Pilot Valve...2906
Removal and Installation of Steering Pilot Valve...2906
Disassembly of Steering Pilot Valve...2909
Assembly of Steering Pilot Valve...2913
Group 8 Steering Valve...2920
Removal and Installation of Steering Valve...2920
Disassembly of Steering Valve...2921
Assembly of Steering Valve...2923
Group 9 Steering Cylinder...2926
Removal and Installation of Steering Cylinder...2926
Disassembly of Steering Cylinder...2931
Assembly of Steering Cylinder...2939
SECTION 4 FRONT ATTACHMENT...2954
Group 1 Front Attachment...2956
Removal and Installation of Front Attachment...2956
Group 2 Cylinder...2966
Removal and Installation of Cylinder (Lift Cylinder)...2966
Removal and Installation of Cylinder (Bucket Cylinder)...2971
Disassembly of Bucket Cylinder...2975
Assembly of Bucket Cylinder...2983
Disassembly of Lift Cylinder...2993
Assembly of Lift Cylinder...3001
SERVICE MANUAL REVISION REQUEST FORM...3014
WCLA0595ZW - Hitachi ZW220, ZW250, ZW310 Transmission Control (TCM Transmission)...3016
WCLA0596ZW - Hitachi ZW310 Hydraulic Circuit Diagram (EU Standard)...3017
Hitachi ZW220, ZW250, ZW310 Wheel Loaders Repair Service Manuals + Operator's Manuals
