All-Inclusive Factory Service Technical manual for Hitachi Wheel Excavators Models Zaxis 140W-5B.
This manuals will assist you in diagnosing, repairing, troubleshooting, repairing engine, operating, and other for your wheel excavator.
You can use a Windows, Mac, or Android device to view this manuals. You only need to have a PDF reader installed.
Covered Models:
Zaxis 140W-5B
The manual comprises 8 documents, including the Workshop Manual, Troubleshooting Manual, Engine Technical Manual, Operational Principle Manual, two Operators Manuals, Wiring Diagram, and Aditional Service Information
1. Workshop Manual (WLAA-EN-00(20160219))
Format: PDF, 762 pages
Language: English
Table of Contents:
GENERAL
Precautions for Disassembling and Assembling
Tightening
Painting
Bleeding Air
Pressure Release Procedure
Preparation
MAINTENANCE STANDARD
Upperstructure
Under carriage
Front Attachment
UPPERSTRUCTURE
Cab
Counterweight
Main Frame
Engine
Pump Device
Control Valve
Swing Device
Pilot Valve
Solenoid Valve
Signal Control Valve
Shockless Valve
Muffler Filter
Electric Lever
Steering Valve
Brake Valve
Accumulator Charging Valve
Accumulator Manifold
UNDERCARRIAGE
Swing Bearing
Travel Motor
Center Joint
Transmission
Axle
Axle Lock Cylinder
Operate Check Valve
Solenoid Valve
Propeller Shaft
Cylinder
FRONT ATTACHMENT
Front Attachment
Cylinder
Hose Rupture Valve
2. Troubleshooting Manual (TTLAA-EN-00(20150123))
Format: PDF, 626 pages
Language: English
Table of Contents:
OPERATIONAL PERFORMANCE TEST
Introduction
Standard
Engine Test
Machine Performance Test
Component Test
Adjustment
TROUBLESHOOTING
Diagnosing Procedure
Monitor
e-Service
Component Layout
Troubleshooting A
Troubleshooting B
Air Conditioner
3. Engine Technical Manual (EDBE-EN-01)
Format: PDF, 1004 pages
Language: English
Table of Contents:
EDBE-EN-01
FOREWORD
0 Introduction (All)
Introduction
14A Service Information Guide (All)
Contents included in service information
Plastic gauge
Recommended liquid gasket
Thread locking adhesive agent
Term
Abbreviations
Standard bolts
15B Maintenance Information (4JJ1)
Maintenance precautions
Primary specifications
Function,Structure,Operation
Introduction to the trouble diagnosis
15C Functional Inspection (4JJ1)
Engine compression pressure inspection
Fuel system check
Lubrication system check
Air intake system check
Exhaust system check
DPD control system check
EGR control system check
Starting system check
Glow control system check
OBD system check
Inspection of the diagnostic light warning light illumination circuit system
Inspection of the diagnostic light warning light blinking circuit system
Inspection of the starter circuit system
15D Symptom (4JJ1)
Engine start failure
Engine stalling
Engine hunching,rough idling
Excessive white smoke in the exhaust gas
Excessive black smoke in the exhaust gas
Abnormal noise
Large fuel consumption
Large oil consumption
Insufficient engine output
DPD system manual regeneration frequently
DPD system regeneration long time
15E DTC Information (4JJ1)
DTC P0016 (Flash Code 16) Crankshaft Position -Camshaft Position Correlation
DTC P0045 (Flash Code 33) Turbocharger Boost Control Solenoid Circuit
DTC P0087 (Flash Code 225) Fuel Rail/System Pressure -Too Low
DTC P0088 (Flash Code 118) Fuel Rail/System Pressure -Too High
DTC P0089 (Flash Code 151) Fuel Pressure Regulator Performance
DTC P0091 (Flash Code 247) Fuel Pressure Regulator Control Circuit Low
DTC P0092 (Flash Code 247) Fuel Pressure Regulator Control Circuit High
DTC P0093 (Flash Code 227) Fuel System Leak Detected
DTC P0102 (Flash Code 91) Mass Air Flow Circuit Low Input
DTC P0103 (Flash Code 91) Mass Air Flow Circuit High Input
DTC P0112 (Flash Code 22) Intake Air Temperature Sensor Circuit Low
DTC P0113 (Flash Code 22) Intake Air Temperature Sensor Circuit High
DTC P0117 (Flash Code 23) Engine Coolant Temperature Sensor Circuit Low
DTC P0118 (Flash Code 23) Engine Coolant Temperature Sensor Circuit High
DTC P0122 (Flash Code 43) Throttle Position Sensor Circuit Low
DTC P0123 (Flash Code 43) Throttle Position Sensor Circuit High
DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low
DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High
DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low
DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High
DTC P0201 (Flash Code 271) Injector Circuit -Cylinder 1
DTC P0202 (Flash Code 272) Injector Circuit -Cylinder 2
DTC P0203 (Flash Code 273) Injector Circuit -Cylinder 3
DTC P0204 (Flash Code 274) Injector Circuit -Cylinder 4
DTC P0217 (Flash Code 542) Engine Coolant Over Temperature Condition
DTC P0219 (Flash Code 543) Engine Overspeed Condition
DTC P0234 (Flash Code 42) Turbocharger Overboost Condition
DTC P0237 (Flash Code 32) Turbocharger Boost Sensor Circuit Low
DTC P0238 (Flash Code 32) Turbocharger Boost Sensor Circuit High
DTC P0299 (Flash Code 65) Turbocharger Underboost
DTC P0335 (Flash Code 15) Crankshaft Position Sensor Circuit
DTC P0336 (Flash Code 15) Crankshaft Position Sensor Circuit Range/Performance
DTC P0340 (Flash Code 14) Camshaft Position Sensor Circuit
DTC P0404 (Flash Code 45) Exhaust Gas Recirculation 1 Control Circuit Range/Performance
DTC P0409 (Flash Code 44) Exhaust Gas Recirculation 1 Sensor Circuit
DTC P041C (Flash Code 27) Intake Manifold Temperature Sensor Circuit High
DTC P041D (Flash Code 27) Intake Manifold Temperature Sensor Circuit Low
DTC P0426 (Flash Code 143) Catalyst Temperature Sensor Circuit Range/Performance Sensor 1
DTC P0427 (Flash Code 48) Catalyst Temperature Sensor Circuit Low Sensor 1
DTC P0428 (Flash Code 48) Catalyst Temperature Sensor Circuit High Sensor 1
DTC P042B (Flash Code 145) Catalyst Temperature Sensor Circuit Range/Performance Sensor 2
DTC P042C (Flash Code 49) Catalyst Temperature Sensor Circuit Low Sensor 2
DTC P042D (Flash Code 49) Catalyst Temperature Sensor Circuit High Sensor 2
DTC P0522 (Flash Code 294) Oil Pressure Sensor Circuit Low
DTC P0523 (Flash Code 294) Oil Pressure Sensor Circuit High
DTC P0560 (Flash Code 155) System Voltage
DTC P0563 (Flash Code 35) System Voltage High
DTC P0601 (Flash Code 53) Internal Control Module Memory Check Sum Error
DTC P0602 (Flash Code 154) Control Module Programming Error
DTC P0604 (Flash Code 153) Internal Control Module Random Access Memory (RAM)Error
DTC P0606 (Flash Code 51) ECM/PCM Processor
DTC P060B (Flash Code 36) Internal Control Module A/D Processing Performance
DTC P0638 (Flash Code 61) Throttle Actuator Control Range/Performance
DTC P0641 (Flash Code 55) Sensor Reference Voltage 1 Circuit
DTC P0650 (Flash Code 77) Malfunction Indicator Lamp (MIL)Control Circuit
DTC P0651 (Flash Code 56) Sensor Reference Voltage 2 Circuit
DTC P0685 (Flash Code 416) ECM/PCM Power Relay Control Circuit/Open
DTC P0687 (Flash Code 416) ECM/PCM Power Relay Control Circuit High
DTC P0697 (Flash Code 57) Sensor Reference Voltage 3 Circuit
DTC P1093 (Flash Code 227) Fuel Rail Pressure (FRP)Too Low
DTC P1112 (Flash Code 295) Boost Temperature Sensor Circuit Low
DTC P1113 (Flash Code 295) Boost Temperature Sensor Circuit High
DTC P1261 (Flash Code 34) Injector Positive Voltage Control Circuit Group 1
DTC P1262 (Flash Code 34) Injector Positive Voltage Control Circuit Group 2
DTC P1293 (Flash Code 221) Fuel Filter Pressure Sensor Circuit Low
DTC P1294 (Flash Code 221) Fuel Filter Pressure Sensor Circuit High
DTC P1404 (Flash Code 45) Exhaust Gas Recirculation 1 Closed Position Performance
DTC P1455 (Flash Code 132) PM Over Accumulation
DTC P1471 (Flash Code 149) DPD Insufficient Regeneration
DTC P1621 (Flash Code 54) Control Module Long Term Memory Performance
DTC P1655 (Flash Code 59) Sensor Reference Voltage 4 Circuit
DTC P1669 (Flash Code 75) DPD Lamp Control Circuit
DTC P2122 (Flash Code 121) Pedal Position Sensor 1 Circuit Low Input
DTC P2123 (Flash Code 121) Pedal Position Sensor 1 Circuit High Input
DTC P2127 (Flash Code 122) Pedal Position Sensor 2 Circuit Low Input
DTC P2128 (Flash Code 122) Pedal Position Sensor 2 Circuit High Input
DTC P2138 (Flash Code 124) Pedal Position Sensor 1 -2 Voltage Correlation
DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply Voltage Circuit
DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply Voltage Circuit
DTC P2228 (Flash Code 71) Barometric Pressure Circuit Low
DTC P2229 (Flash Code 71) Barometric Pressure Circuit High
DTC P242F (Flash Code 131) DPD Restriction
DTC P2452 (Flash Code 142) DPD Differential Pressure Sensor Circuit
DTC P2453 (Flash Code 141) DPD Differential Pressure Sensor Circuit Range/Performance
DTC P2454 (Flash Code 47) DPD Differential Pressure Sensor Circuit Low
DTC P2455 (Flash Code 47) DPD Differential Pressure Sensor Circuit High
DTC P2456 (Flash Code 47) DPD Differential Pressure Sensor Learned Position
DTC P2458 (Flash Code 139) DPD Regeneration Duration
DTC P2527 (Flash Code 233) Vacuum Pressure Sensor Circuit Low
DTC P2528 (Flash Code 233) Vacuum Pressure Sensor Circuit High
DTC U0001 (Flash Code 84) CAN-Bus Malfunction (ISO-CAN)
DTC U0073 (Flash Code 84) CAN-Bus Malfunction (J1939)
DTC U0101 (Flash Code 85) Lost Communication with TCM
DTC mapping table
1A Engine Control (4JJ1)
DTC P0016 (Flash Code 16) Crankshaft Position -Camshaft Position Correlation
DTC P0045 (Flash Code 33) Turbocharger Boost Control Solenoid Circuit
DTC P0087 (Flash Code 225) Fuel Rail/System Pressure -Too Low
DTC P0088 (Flash Code 118) Fuel Rail/System Pressure -Too High
DTC P0089 (Flash Code 151) Fuel Pressure Regulator Performance
DTC P0091 (Flash Code 247) Fuel Pressure Regulator Control Circuit Low
DTC P0092 (Flash Code 247) Fuel Pressure Regulator Control Circuit High
DTC P0093 (Flash Code 227) Fuel System Leak Detected
DTC P0102 (Flash Code 91) Mass Air Flow Circuit Low Input
DTC P0103 (Flash Code 91) Mass Air Flow Circuit High Input
DTC P0112 (Flash Code 22) Intake Air Temperature Sensor Circuit Low
DTC P0113 (Flash Code 22) Intake Air Temperature Sensor Circuit High
DTC P0117 (Flash Code 23) Engine Coolant Temperature Sensor Circuit Low
DTC P0118 (Flash Code 23) Engine Coolant Temperature Sensor Circuit High
DTC P0122 (Flash Code 43) Throttle Position Sensor Circuit Low
DTC P0123 (Flash Code 43) Throttle Position Sensor Circuit High
DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low
DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High
DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low
DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High
DTC P0201 (Flash Code 271) Injector Circuit -Cylinder 1
DTC P0202 (Flash Code 272) Injector Circuit -Cylinder 2
DTC P0203 (Flash Code 273) Injector Circuit -Cylinder 3
DTC P0204 (Flash Code 274) Injector Circuit -Cylinder 4
DTC P0217 (Flash Code 542) Engine Coolant Over Temperature Condition
DTC P0219 (Flash Code 543) Engine Overspeed Condition
DTC P0234 (Flash Code 42) Turbocharger Overboost Condition
DTC P0237 (Flash Code 32) Turbocharger Boost Sensor Circuit Low
DTC P0238 (Flash Code 32) Turbocharger Boost Sensor Circuit High
DTC P0299 (Flash Code 65) Turbocharger Underboost
DTC P0335 (Flash Code 15) Crankshaft Position Sensor Circuit
DTC P0336 (Flash Code 15) Crankshaft Position Sensor Circuit Range/Performance
DTC P0340 (Flash Code 14) Camshaft Position Sensor Circuit
DTC P0404 (Flash Code 45) Exhaust Gas Recirculation 1 Control Circuit Range/Performance
DTC P0409 (Flash Code 44) Exhaust Gas Recirculation 1 Sensor Circuit
DTC P041C (Flash Code 27) Intake Manifold Temperature Sensor Circuit High
DTC P041D (Flash Code 27) Intake Manifold Temperature Sensor Circuit Low
DTC P0426 (Flash Code 143) Catalyst Temperature Sensor Circuit Range/Performance Sensor 1
DTC P0427 (Flash Code 48) Catalyst Temperature Sensor Circuit Low Sensor 1
DTC P0428 (Flash Code 48) Catalyst Temperature Sensor Circuit High Sensor 1
DTC P042B (Flash Code 145) Catalyst Temperature Sensor Circuit Range/Performance Sensor 2
DTC P042C (Flash Code 49) Catalyst Temperature Sensor Circuit Low Sensor 2
DTC P042D (Flash Code 49) Catalyst Temperature Sensor Circuit High Sensor 2
DTC P0522 (Flash Code 295) Oil Pressure Sensor Circuit Low
DTC P0523 (Flash Code 295) Oil Pressure Sensor Circuit High
DTC P0560 (Flash Code 155) System Voltage
DTC P0563 (Flash Code 35) System Voltage High
DTC P0601 (Flash Code 53) Internal Control Module Memory Check Sum Error
DTC P0602 (Flash Code 154) Control Module Programming Error
DTC P0604 (Flash Code 153) Internal Control Module Random Access Memory (RAM)Error
DTC P0606 (Flash Code 51) ECM/PCM Processor
DTC P060B (Flash Code 36) Internal Control Module A/D Processing Performance
DTC P0638 (Flash Code 61) Throttle Actuator Control Range/Performance
DTC P0641 (Flash Code 55) Sensor Reference Voltage 1 Circuit
DTC P0650 (Flash Code 77) Malfunction Indicator Lamp (MIL)Control Circuit
DTC P0651 (Flash Code 56) Sensor Reference Voltage 2 Circuit
DTC P0685 (Flash Code 416) ECM/PCM Power Relay Control Circuit/Open
DTC P0687 (Flash Code 416) ECM/PCM Power Relay Control Circuit High
DTC P0697 (Flash Code 57) Sensor Reference Voltage 3 Circuit
DTC P1093 (Flash Code 227) Fuel Rail Pressure (FRP)Too Low
DTC P1112 (Flash Code 295) Boost Temperature Sensor Circuit Low
DTC P1113 (Flash Code 295) Boost Temperature Sensor Circuit High
DTC P1261 (Flash Code 34) Injector Positive Voltage Control Circuit Group 1
DTC P1262 (Flash Code 34) Injector Positive Voltage Control Circuit Group 2
DTC P1293 (Flash Code 221) Fuel Filter Pressure Sensor Circuit Low
DTC P1294 (Flash Code 221) Fuel Filter Pressure Sensor Circuit High
DTC P1404 (Flash Code 45) Exhaust Gas Recirculation 1 Closed Position Performance
DTC P1455 (Flash Code 132) PM Over Accumulation
DTC P1471 (Flash Code 149) DPD Insufficient Regeneration
DTC P1621 (Flash Code 54) Control Module Long Term Memory Performance
DTC P1655 (Flash Code 59) Sensor Reference Voltage 4 Circuit
DTC P1669 (Flash Code 75) DPD Lamp Control Circuit
DTC P2122 (Flash Code 121) Pedal Position Sensor 1 Circuit Low Input
DTC P2123 (Flash Code 121) Pedal Position Sensor 1 Circuit High Input
DTC P2127 (Flash Code 122) Pedal Position Sensor 2 Circuit Low Input
DTC P2128 (Flash Code 122) Pedal Position Sensor 2 Circuit High Input
DTC P2138 (Flash Code 124) Pedal Position Sensor 1 -2 Voltage Correlation
DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply Voltage Circuit
DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply Voltage Circuit
DTC P2228 (Flash Code 71) Barometric Pressure Circuit Low
DTC P2229 (Flash Code 71) Barometric Pressure Circuit High
DTC P242F (Flash Code 131) DPD Restriction
DTC P2452 (Flash Code 142) DPD Differential Pressure Sensor Circuit
DTC P2453 (Flash Code 141) DPD Differential Pressure Sensor Circuit Range/Performance
DTC P2454 (Flash Code 47) DPD Differential Pressure Sensor Circuit Low
DTC P2455 (Flash Code 47) DPD Differential Pressure Sensor Circuit High
DTC P2456 (Flash Code 47) DPD Differential Pressure Sensor Learned Position
DTC P2458 (Flash Code 139) DPD Regeneration Duration
DTC P2527 (Flash Code 233) Vacuum Pressure Sensor Circuit Low
DTC P2528 (Flash Code 233) Vacuum Pressure Sensor Circuit High
DTC U0001 (Flash Code 84) CAN-Bus Malfunction (ISO-CAN)
DTC U0073 (Flash Code 84) CAN-Bus Malfunction (J1939)
DTC U0101 (Flash Code 85) Lost Communication with TCM
1B Mechanical (4JJ1)
Cylinder head cover
Cylinder head assembly
Cylinder block
Exhaust manifold
Crankshaft
Camshaft
Flywheel
Crankshaft front oil seal
Crankshaft rear oil seal
Timing chain
Timing gear train
CMP sensor
Intake throttle valve
CKP sensor
Timing gear case
Inlet manifold
Rocker arm shaft assembly
Piston and connecting rod
Valve stem oil seal and valve spring
Supplementary Information
1C Fuel System (4JJ1)
Common rail assembly
Injector
Suction control valve
Fuel filter
Fuel temperature sensor
Pressure limiter
Fuel pressure sensor
Fuel filter pressure sensor
Fuel supply pump
Supplementary Information
1D Cooling (4JJ1)
Thermostat
Cooling fan belt
Radiator
Overheat switch
Coolant
Water pump assembly
Engine coolant temperature sensor
Supplementary Information
1E Lubrication (4JJ1)
Oil pump assembly
Engine oil
Oil cooler assembly
Oil filter element
Oil pressure sensor
Oil pan and crank case
Supplementary Information
1F Induction (4JJ1)
Turbocharger assembly
Turbocharger control solenoid
Boost sensor
Intercooler
Air cleaner element
IMT sensor
Vacuum sensor
Boost temperature sensor
Supplementary Information
1G Exhaust (4JJ1)
DPD assembly
Exhaust differential pressure sensor
Exhaust gas temperature sensor
Supplementary Information
1H Aux.Emission Control Devices (4JJ1)
EGR valve
EGR cooler
Supplementary Information
1J Electrical (4JJ1)
Glow plug
Generator
ECM
Starter motor
Supplementary Information
Wiring Diagram
Using the Wiring Diagram
Engine
Location Diagram
Connector List
Terminal Name
SERVICE MANUAL REVISION REQUEST FORM
4. Operational Principle Manual (TOLAA-EN-01(20141224))
Format: PDF, 608 pages
Language: English
Table of Contents:
GENERAL
Specifications
Component Layout
Component Specifications
SYSTEM
Controller
Control System
ECM System
Hydraulic System
Electrical System
COMPONENT OPERATION
Pump Device
Swing Device
Control Valve
Pilot Valve
Electric Lever
Transmission
Axle
Travel Motor
Signal Control Valve
Steering Valve
Brake Valve
Others (Upperstructure)
Others (Undercarriage)
5. Operators Manual (ENMLBA-LC1-1)
Format: PDF, 132 pages
Language: English
Table of Contents:
LIFTING CAPACITIES
ZX140W-5B (Mono block boom)
ZX140W-5B (2-piece boom)
ZX170W-5B (Mono block boom)
ZX170W-5B (2-piece boom)
ZX190W-5B (Mono block boom)
ZX190W-5B (2-piece boom)
ZX220W-5B (Mono block boom)
ZX220W-5B (2-piece boom)
6. Operators Manual (ENMLBA-EN1-1)
Format: PDF, 512 pages
Language: English
7. Wiring Diagram (TTLAA-EN-00_curcuit)
Format: PDF, 44 pages
Language: English
Table of Contents:
ELECTRICAL CIRCUIT DIAGRAM
CONNECTORS
CAB HARNESS
MAIN HARNESS
FLOOR HARNESS
LEFT CONSOLE HARNESS
RIGHT CONSOLE HARNESS
LEFT CONTROL LEVER HARNESS
RIGHT CONTROL LEVER HARNESS
PUMP HARNESS
CHASSIS HARNESS
KEY SWITCH HARNESS
PILOT SHUT-OFF SWITCH HARNESS
MONITOR HARNESS
GSM (MOBILE COMMUNICATION TERMINAL) HARNESS
MUFFLER FILTER SWITCH HARNESS
REARVIEW CAMERA HARNESS
BLADE/OUTRIGGER HARNESS
POSITIONING SOLENOID VALVE SUB HARNESS
POSITIONING PRESSURE SENSOR SUB HARNESS
AUXILIARY SOLENOID VALVE SUBHARNESS
AUXILIARY SUB HARNESS
AUXILIARY PRESSURE SENSOR HARNESS
BREAKER HARNESS
BREAKER SUB HARNESS
FUEL SOLENOID PUMP HARNESS
FUEL SOLENOID PUMP SWITCH HARNESS
ASSIST PRESSURE SENSOR SUB HARNESS
ASSIST SOLENOID VALVE SUB HARNESS
ADDITIONAL PUMP PRESSURE SENSOR HARNESS
BOOM BOTTOM PRESSURE SENSOR HARNESS
FRONT HEADLIGHT(CAB)HARNESS
WORK LIGHT(CAB FRONT 1)HARNESS
WORK LIGHT(CAB FRONT 2)HARNESS
WORK LIGHT(CAB REAR)HARNESS
WORK LIGHT SWITCH(CAB REAR)HARNESS
BEACON LIGHT SWITCH HARNESS
BEACON LIGHT(CAB)HARNESS
BEACON LIGHT(COUNTERWEIGHT)HARNESS
LICENSE PLATE LIGHT HARNESS
HYDRAULIC CIRCUIT DIAGRAM (2-PIECE BOOM, FULLY OPTIONAL)
HYDRAULIC CIRCUIT DIAGRAM (MONOBLOCK BOOM, FULLY OPTIONAL)
AIR CONDITIONER CIRCUIT DIAGRAM
AIR CONDITIONER HARNESS
8. Aditional Service Information (ZX140W-5B-add)
Language: English
This manuals will assist you in diagnosing, repairing, troubleshooting, repairing engine, operating, and other for your wheel excavator.
You can use a Windows, Mac, or Android device to view this manuals. You only need to have a PDF reader installed.
Covered Models:
Zaxis 140W-5B
The manual comprises 8 documents, including the Workshop Manual, Troubleshooting Manual, Engine Technical Manual, Operational Principle Manual, two Operators Manuals, Wiring Diagram, and Aditional Service Information
1. Workshop Manual (WLAA-EN-00(20160219))
Format: PDF, 762 pages
Language: English
Table of Contents:
GENERAL
Precautions for Disassembling and Assembling
Tightening
Painting
Bleeding Air
Pressure Release Procedure
Preparation
MAINTENANCE STANDARD
Upperstructure
Under carriage
Front Attachment
UPPERSTRUCTURE
Cab
Counterweight
Main Frame
Engine
Pump Device
Control Valve
Swing Device
Pilot Valve
Solenoid Valve
Signal Control Valve
Shockless Valve
Muffler Filter
Electric Lever
Steering Valve
Brake Valve
Accumulator Charging Valve
Accumulator Manifold
UNDERCARRIAGE
Swing Bearing
Travel Motor
Center Joint
Transmission
Axle
Axle Lock Cylinder
Operate Check Valve
Solenoid Valve
Propeller Shaft
Cylinder
FRONT ATTACHMENT
Front Attachment
Cylinder
Hose Rupture Valve
2. Troubleshooting Manual (TTLAA-EN-00(20150123))
Format: PDF, 626 pages
Language: English
Table of Contents:
OPERATIONAL PERFORMANCE TEST
Introduction
Standard
Engine Test
Machine Performance Test
Component Test
Adjustment
TROUBLESHOOTING
Diagnosing Procedure
Monitor
e-Service
Component Layout
Troubleshooting A
Troubleshooting B
Air Conditioner
3. Engine Technical Manual (EDBE-EN-01)
Format: PDF, 1004 pages
Language: English
Table of Contents:
EDBE-EN-01
FOREWORD
0 Introduction (All)
Introduction
14A Service Information Guide (All)
Contents included in service information
Plastic gauge
Recommended liquid gasket
Thread locking adhesive agent
Term
Abbreviations
Standard bolts
15B Maintenance Information (4JJ1)
Maintenance precautions
Primary specifications
Function,Structure,Operation
Introduction to the trouble diagnosis
15C Functional Inspection (4JJ1)
Engine compression pressure inspection
Fuel system check
Lubrication system check
Air intake system check
Exhaust system check
DPD control system check
EGR control system check
Starting system check
Glow control system check
OBD system check
Inspection of the diagnostic light warning light illumination circuit system
Inspection of the diagnostic light warning light blinking circuit system
Inspection of the starter circuit system
15D Symptom (4JJ1)
Engine start failure
Engine stalling
Engine hunching,rough idling
Excessive white smoke in the exhaust gas
Excessive black smoke in the exhaust gas
Abnormal noise
Large fuel consumption
Large oil consumption
Insufficient engine output
DPD system manual regeneration frequently
DPD system regeneration long time
15E DTC Information (4JJ1)
DTC P0016 (Flash Code 16) Crankshaft Position -Camshaft Position Correlation
DTC P0045 (Flash Code 33) Turbocharger Boost Control Solenoid Circuit
DTC P0087 (Flash Code 225) Fuel Rail/System Pressure -Too Low
DTC P0088 (Flash Code 118) Fuel Rail/System Pressure -Too High
DTC P0089 (Flash Code 151) Fuel Pressure Regulator Performance
DTC P0091 (Flash Code 247) Fuel Pressure Regulator Control Circuit Low
DTC P0092 (Flash Code 247) Fuel Pressure Regulator Control Circuit High
DTC P0093 (Flash Code 227) Fuel System Leak Detected
DTC P0102 (Flash Code 91) Mass Air Flow Circuit Low Input
DTC P0103 (Flash Code 91) Mass Air Flow Circuit High Input
DTC P0112 (Flash Code 22) Intake Air Temperature Sensor Circuit Low
DTC P0113 (Flash Code 22) Intake Air Temperature Sensor Circuit High
DTC P0117 (Flash Code 23) Engine Coolant Temperature Sensor Circuit Low
DTC P0118 (Flash Code 23) Engine Coolant Temperature Sensor Circuit High
DTC P0122 (Flash Code 43) Throttle Position Sensor Circuit Low
DTC P0123 (Flash Code 43) Throttle Position Sensor Circuit High
DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low
DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High
DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low
DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High
DTC P0201 (Flash Code 271) Injector Circuit -Cylinder 1
DTC P0202 (Flash Code 272) Injector Circuit -Cylinder 2
DTC P0203 (Flash Code 273) Injector Circuit -Cylinder 3
DTC P0204 (Flash Code 274) Injector Circuit -Cylinder 4
DTC P0217 (Flash Code 542) Engine Coolant Over Temperature Condition
DTC P0219 (Flash Code 543) Engine Overspeed Condition
DTC P0234 (Flash Code 42) Turbocharger Overboost Condition
DTC P0237 (Flash Code 32) Turbocharger Boost Sensor Circuit Low
DTC P0238 (Flash Code 32) Turbocharger Boost Sensor Circuit High
DTC P0299 (Flash Code 65) Turbocharger Underboost
DTC P0335 (Flash Code 15) Crankshaft Position Sensor Circuit
DTC P0336 (Flash Code 15) Crankshaft Position Sensor Circuit Range/Performance
DTC P0340 (Flash Code 14) Camshaft Position Sensor Circuit
DTC P0404 (Flash Code 45) Exhaust Gas Recirculation 1 Control Circuit Range/Performance
DTC P0409 (Flash Code 44) Exhaust Gas Recirculation 1 Sensor Circuit
DTC P041C (Flash Code 27) Intake Manifold Temperature Sensor Circuit High
DTC P041D (Flash Code 27) Intake Manifold Temperature Sensor Circuit Low
DTC P0426 (Flash Code 143) Catalyst Temperature Sensor Circuit Range/Performance Sensor 1
DTC P0427 (Flash Code 48) Catalyst Temperature Sensor Circuit Low Sensor 1
DTC P0428 (Flash Code 48) Catalyst Temperature Sensor Circuit High Sensor 1
DTC P042B (Flash Code 145) Catalyst Temperature Sensor Circuit Range/Performance Sensor 2
DTC P042C (Flash Code 49) Catalyst Temperature Sensor Circuit Low Sensor 2
DTC P042D (Flash Code 49) Catalyst Temperature Sensor Circuit High Sensor 2
DTC P0522 (Flash Code 294) Oil Pressure Sensor Circuit Low
DTC P0523 (Flash Code 294) Oil Pressure Sensor Circuit High
DTC P0560 (Flash Code 155) System Voltage
DTC P0563 (Flash Code 35) System Voltage High
DTC P0601 (Flash Code 53) Internal Control Module Memory Check Sum Error
DTC P0602 (Flash Code 154) Control Module Programming Error
DTC P0604 (Flash Code 153) Internal Control Module Random Access Memory (RAM)Error
DTC P0606 (Flash Code 51) ECM/PCM Processor
DTC P060B (Flash Code 36) Internal Control Module A/D Processing Performance
DTC P0638 (Flash Code 61) Throttle Actuator Control Range/Performance
DTC P0641 (Flash Code 55) Sensor Reference Voltage 1 Circuit
DTC P0650 (Flash Code 77) Malfunction Indicator Lamp (MIL)Control Circuit
DTC P0651 (Flash Code 56) Sensor Reference Voltage 2 Circuit
DTC P0685 (Flash Code 416) ECM/PCM Power Relay Control Circuit/Open
DTC P0687 (Flash Code 416) ECM/PCM Power Relay Control Circuit High
DTC P0697 (Flash Code 57) Sensor Reference Voltage 3 Circuit
DTC P1093 (Flash Code 227) Fuel Rail Pressure (FRP)Too Low
DTC P1112 (Flash Code 295) Boost Temperature Sensor Circuit Low
DTC P1113 (Flash Code 295) Boost Temperature Sensor Circuit High
DTC P1261 (Flash Code 34) Injector Positive Voltage Control Circuit Group 1
DTC P1262 (Flash Code 34) Injector Positive Voltage Control Circuit Group 2
DTC P1293 (Flash Code 221) Fuel Filter Pressure Sensor Circuit Low
DTC P1294 (Flash Code 221) Fuel Filter Pressure Sensor Circuit High
DTC P1404 (Flash Code 45) Exhaust Gas Recirculation 1 Closed Position Performance
DTC P1455 (Flash Code 132) PM Over Accumulation
DTC P1471 (Flash Code 149) DPD Insufficient Regeneration
DTC P1621 (Flash Code 54) Control Module Long Term Memory Performance
DTC P1655 (Flash Code 59) Sensor Reference Voltage 4 Circuit
DTC P1669 (Flash Code 75) DPD Lamp Control Circuit
DTC P2122 (Flash Code 121) Pedal Position Sensor 1 Circuit Low Input
DTC P2123 (Flash Code 121) Pedal Position Sensor 1 Circuit High Input
DTC P2127 (Flash Code 122) Pedal Position Sensor 2 Circuit Low Input
DTC P2128 (Flash Code 122) Pedal Position Sensor 2 Circuit High Input
DTC P2138 (Flash Code 124) Pedal Position Sensor 1 -2 Voltage Correlation
DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply Voltage Circuit
DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply Voltage Circuit
DTC P2228 (Flash Code 71) Barometric Pressure Circuit Low
DTC P2229 (Flash Code 71) Barometric Pressure Circuit High
DTC P242F (Flash Code 131) DPD Restriction
DTC P2452 (Flash Code 142) DPD Differential Pressure Sensor Circuit
DTC P2453 (Flash Code 141) DPD Differential Pressure Sensor Circuit Range/Performance
DTC P2454 (Flash Code 47) DPD Differential Pressure Sensor Circuit Low
DTC P2455 (Flash Code 47) DPD Differential Pressure Sensor Circuit High
DTC P2456 (Flash Code 47) DPD Differential Pressure Sensor Learned Position
DTC P2458 (Flash Code 139) DPD Regeneration Duration
DTC P2527 (Flash Code 233) Vacuum Pressure Sensor Circuit Low
DTC P2528 (Flash Code 233) Vacuum Pressure Sensor Circuit High
DTC U0001 (Flash Code 84) CAN-Bus Malfunction (ISO-CAN)
DTC U0073 (Flash Code 84) CAN-Bus Malfunction (J1939)
DTC U0101 (Flash Code 85) Lost Communication with TCM
DTC mapping table
1A Engine Control (4JJ1)
DTC P0016 (Flash Code 16) Crankshaft Position -Camshaft Position Correlation
DTC P0045 (Flash Code 33) Turbocharger Boost Control Solenoid Circuit
DTC P0087 (Flash Code 225) Fuel Rail/System Pressure -Too Low
DTC P0088 (Flash Code 118) Fuel Rail/System Pressure -Too High
DTC P0089 (Flash Code 151) Fuel Pressure Regulator Performance
DTC P0091 (Flash Code 247) Fuel Pressure Regulator Control Circuit Low
DTC P0092 (Flash Code 247) Fuel Pressure Regulator Control Circuit High
DTC P0093 (Flash Code 227) Fuel System Leak Detected
DTC P0102 (Flash Code 91) Mass Air Flow Circuit Low Input
DTC P0103 (Flash Code 91) Mass Air Flow Circuit High Input
DTC P0112 (Flash Code 22) Intake Air Temperature Sensor Circuit Low
DTC P0113 (Flash Code 22) Intake Air Temperature Sensor Circuit High
DTC P0117 (Flash Code 23) Engine Coolant Temperature Sensor Circuit Low
DTC P0118 (Flash Code 23) Engine Coolant Temperature Sensor Circuit High
DTC P0122 (Flash Code 43) Throttle Position Sensor Circuit Low
DTC P0123 (Flash Code 43) Throttle Position Sensor Circuit High
DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low
DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High
DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low
DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High
DTC P0201 (Flash Code 271) Injector Circuit -Cylinder 1
DTC P0202 (Flash Code 272) Injector Circuit -Cylinder 2
DTC P0203 (Flash Code 273) Injector Circuit -Cylinder 3
DTC P0204 (Flash Code 274) Injector Circuit -Cylinder 4
DTC P0217 (Flash Code 542) Engine Coolant Over Temperature Condition
DTC P0219 (Flash Code 543) Engine Overspeed Condition
DTC P0234 (Flash Code 42) Turbocharger Overboost Condition
DTC P0237 (Flash Code 32) Turbocharger Boost Sensor Circuit Low
DTC P0238 (Flash Code 32) Turbocharger Boost Sensor Circuit High
DTC P0299 (Flash Code 65) Turbocharger Underboost
DTC P0335 (Flash Code 15) Crankshaft Position Sensor Circuit
DTC P0336 (Flash Code 15) Crankshaft Position Sensor Circuit Range/Performance
DTC P0340 (Flash Code 14) Camshaft Position Sensor Circuit
DTC P0404 (Flash Code 45) Exhaust Gas Recirculation 1 Control Circuit Range/Performance
DTC P0409 (Flash Code 44) Exhaust Gas Recirculation 1 Sensor Circuit
DTC P041C (Flash Code 27) Intake Manifold Temperature Sensor Circuit High
DTC P041D (Flash Code 27) Intake Manifold Temperature Sensor Circuit Low
DTC P0426 (Flash Code 143) Catalyst Temperature Sensor Circuit Range/Performance Sensor 1
DTC P0427 (Flash Code 48) Catalyst Temperature Sensor Circuit Low Sensor 1
DTC P0428 (Flash Code 48) Catalyst Temperature Sensor Circuit High Sensor 1
DTC P042B (Flash Code 145) Catalyst Temperature Sensor Circuit Range/Performance Sensor 2
DTC P042C (Flash Code 49) Catalyst Temperature Sensor Circuit Low Sensor 2
DTC P042D (Flash Code 49) Catalyst Temperature Sensor Circuit High Sensor 2
DTC P0522 (Flash Code 295) Oil Pressure Sensor Circuit Low
DTC P0523 (Flash Code 295) Oil Pressure Sensor Circuit High
DTC P0560 (Flash Code 155) System Voltage
DTC P0563 (Flash Code 35) System Voltage High
DTC P0601 (Flash Code 53) Internal Control Module Memory Check Sum Error
DTC P0602 (Flash Code 154) Control Module Programming Error
DTC P0604 (Flash Code 153) Internal Control Module Random Access Memory (RAM)Error
DTC P0606 (Flash Code 51) ECM/PCM Processor
DTC P060B (Flash Code 36) Internal Control Module A/D Processing Performance
DTC P0638 (Flash Code 61) Throttle Actuator Control Range/Performance
DTC P0641 (Flash Code 55) Sensor Reference Voltage 1 Circuit
DTC P0650 (Flash Code 77) Malfunction Indicator Lamp (MIL)Control Circuit
DTC P0651 (Flash Code 56) Sensor Reference Voltage 2 Circuit
DTC P0685 (Flash Code 416) ECM/PCM Power Relay Control Circuit/Open
DTC P0687 (Flash Code 416) ECM/PCM Power Relay Control Circuit High
DTC P0697 (Flash Code 57) Sensor Reference Voltage 3 Circuit
DTC P1093 (Flash Code 227) Fuel Rail Pressure (FRP)Too Low
DTC P1112 (Flash Code 295) Boost Temperature Sensor Circuit Low
DTC P1113 (Flash Code 295) Boost Temperature Sensor Circuit High
DTC P1261 (Flash Code 34) Injector Positive Voltage Control Circuit Group 1
DTC P1262 (Flash Code 34) Injector Positive Voltage Control Circuit Group 2
DTC P1293 (Flash Code 221) Fuel Filter Pressure Sensor Circuit Low
DTC P1294 (Flash Code 221) Fuel Filter Pressure Sensor Circuit High
DTC P1404 (Flash Code 45) Exhaust Gas Recirculation 1 Closed Position Performance
DTC P1455 (Flash Code 132) PM Over Accumulation
DTC P1471 (Flash Code 149) DPD Insufficient Regeneration
DTC P1621 (Flash Code 54) Control Module Long Term Memory Performance
DTC P1655 (Flash Code 59) Sensor Reference Voltage 4 Circuit
DTC P1669 (Flash Code 75) DPD Lamp Control Circuit
DTC P2122 (Flash Code 121) Pedal Position Sensor 1 Circuit Low Input
DTC P2123 (Flash Code 121) Pedal Position Sensor 1 Circuit High Input
DTC P2127 (Flash Code 122) Pedal Position Sensor 2 Circuit Low Input
DTC P2128 (Flash Code 122) Pedal Position Sensor 2 Circuit High Input
DTC P2138 (Flash Code 124) Pedal Position Sensor 1 -2 Voltage Correlation
DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply Voltage Circuit
DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply Voltage Circuit
DTC P2228 (Flash Code 71) Barometric Pressure Circuit Low
DTC P2229 (Flash Code 71) Barometric Pressure Circuit High
DTC P242F (Flash Code 131) DPD Restriction
DTC P2452 (Flash Code 142) DPD Differential Pressure Sensor Circuit
DTC P2453 (Flash Code 141) DPD Differential Pressure Sensor Circuit Range/Performance
DTC P2454 (Flash Code 47) DPD Differential Pressure Sensor Circuit Low
DTC P2455 (Flash Code 47) DPD Differential Pressure Sensor Circuit High
DTC P2456 (Flash Code 47) DPD Differential Pressure Sensor Learned Position
DTC P2458 (Flash Code 139) DPD Regeneration Duration
DTC P2527 (Flash Code 233) Vacuum Pressure Sensor Circuit Low
DTC P2528 (Flash Code 233) Vacuum Pressure Sensor Circuit High
DTC U0001 (Flash Code 84) CAN-Bus Malfunction (ISO-CAN)
DTC U0073 (Flash Code 84) CAN-Bus Malfunction (J1939)
DTC U0101 (Flash Code 85) Lost Communication with TCM
1B Mechanical (4JJ1)
Cylinder head cover
Cylinder head assembly
Cylinder block
Exhaust manifold
Crankshaft
Camshaft
Flywheel
Crankshaft front oil seal
Crankshaft rear oil seal
Timing chain
Timing gear train
CMP sensor
Intake throttle valve
CKP sensor
Timing gear case
Inlet manifold
Rocker arm shaft assembly
Piston and connecting rod
Valve stem oil seal and valve spring
Supplementary Information
1C Fuel System (4JJ1)
Common rail assembly
Injector
Suction control valve
Fuel filter
Fuel temperature sensor
Pressure limiter
Fuel pressure sensor
Fuel filter pressure sensor
Fuel supply pump
Supplementary Information
1D Cooling (4JJ1)
Thermostat
Cooling fan belt
Radiator
Overheat switch
Coolant
Water pump assembly
Engine coolant temperature sensor
Supplementary Information
1E Lubrication (4JJ1)
Oil pump assembly
Engine oil
Oil cooler assembly
Oil filter element
Oil pressure sensor
Oil pan and crank case
Supplementary Information
1F Induction (4JJ1)
Turbocharger assembly
Turbocharger control solenoid
Boost sensor
Intercooler
Air cleaner element
IMT sensor
Vacuum sensor
Boost temperature sensor
Supplementary Information
1G Exhaust (4JJ1)
DPD assembly
Exhaust differential pressure sensor
Exhaust gas temperature sensor
Supplementary Information
1H Aux.Emission Control Devices (4JJ1)
EGR valve
EGR cooler
Supplementary Information
1J Electrical (4JJ1)
Glow plug
Generator
ECM
Starter motor
Supplementary Information
Wiring Diagram
Using the Wiring Diagram
Engine
Location Diagram
Connector List
Terminal Name
SERVICE MANUAL REVISION REQUEST FORM
4. Operational Principle Manual (TOLAA-EN-01(20141224))
Format: PDF, 608 pages
Language: English
Table of Contents:
GENERAL
Specifications
Component Layout
Component Specifications
SYSTEM
Controller
Control System
ECM System
Hydraulic System
Electrical System
COMPONENT OPERATION
Pump Device
Swing Device
Control Valve
Pilot Valve
Electric Lever
Transmission
Axle
Travel Motor
Signal Control Valve
Steering Valve
Brake Valve
Others (Upperstructure)
Others (Undercarriage)
5. Operators Manual (ENMLBA-LC1-1)
Format: PDF, 132 pages
Language: English
Table of Contents:
LIFTING CAPACITIES
ZX140W-5B (Mono block boom)
ZX140W-5B (2-piece boom)
ZX170W-5B (Mono block boom)
ZX170W-5B (2-piece boom)
ZX190W-5B (Mono block boom)
ZX190W-5B (2-piece boom)
ZX220W-5B (Mono block boom)
ZX220W-5B (2-piece boom)
6. Operators Manual (ENMLBA-EN1-1)
Format: PDF, 512 pages
Language: English
7. Wiring Diagram (TTLAA-EN-00_curcuit)
Format: PDF, 44 pages
Language: English
Table of Contents:
ELECTRICAL CIRCUIT DIAGRAM
CONNECTORS
CAB HARNESS
MAIN HARNESS
FLOOR HARNESS
LEFT CONSOLE HARNESS
RIGHT CONSOLE HARNESS
LEFT CONTROL LEVER HARNESS
RIGHT CONTROL LEVER HARNESS
PUMP HARNESS
CHASSIS HARNESS
KEY SWITCH HARNESS
PILOT SHUT-OFF SWITCH HARNESS
MONITOR HARNESS
GSM (MOBILE COMMUNICATION TERMINAL) HARNESS
MUFFLER FILTER SWITCH HARNESS
REARVIEW CAMERA HARNESS
BLADE/OUTRIGGER HARNESS
POSITIONING SOLENOID VALVE SUB HARNESS
POSITIONING PRESSURE SENSOR SUB HARNESS
AUXILIARY SOLENOID VALVE SUBHARNESS
AUXILIARY SUB HARNESS
AUXILIARY PRESSURE SENSOR HARNESS
BREAKER HARNESS
BREAKER SUB HARNESS
FUEL SOLENOID PUMP HARNESS
FUEL SOLENOID PUMP SWITCH HARNESS
ASSIST PRESSURE SENSOR SUB HARNESS
ASSIST SOLENOID VALVE SUB HARNESS
ADDITIONAL PUMP PRESSURE SENSOR HARNESS
BOOM BOTTOM PRESSURE SENSOR HARNESS
FRONT HEADLIGHT(CAB)HARNESS
WORK LIGHT(CAB FRONT 1)HARNESS
WORK LIGHT(CAB FRONT 2)HARNESS
WORK LIGHT(CAB REAR)HARNESS
WORK LIGHT SWITCH(CAB REAR)HARNESS
BEACON LIGHT SWITCH HARNESS
BEACON LIGHT(CAB)HARNESS
BEACON LIGHT(COUNTERWEIGHT)HARNESS
LICENSE PLATE LIGHT HARNESS
HYDRAULIC CIRCUIT DIAGRAM (2-PIECE BOOM, FULLY OPTIONAL)
HYDRAULIC CIRCUIT DIAGRAM (MONOBLOCK BOOM, FULLY OPTIONAL)
AIR CONDITIONER CIRCUIT DIAGRAM
AIR CONDITIONER HARNESS
8. Aditional Service Information (ZX140W-5B-add)
Language: English
Included in the package | |
Workshop Manual | 1 |
Troubleshooting Manual | 1 |
Engine Technical Manual | 1 |
Operational Principle Manual | 1 |
Operators Manual | 2 |
Wiring Diagram | 1 |
Aditional Service Information | 1 |
Covered | |
Model Class | ZAXIS 140 |
Generation | 5B |
Truck Type | Wheel Excavator |
Truck Models | ZAXIS 140W-5B |
Hitachi Zaxis 140W-5B Wheel Excavator set of Service Manuals
- Brands Hitachi
- Product Code:Hitachi::ZX140W-5B
- Availability:Ready to instant download
-
$23.00
Tags: Zaxis 140W-5B