Hitachi ZW180-6 Wheel Loader Troubleshooting Technical Manual (TTPD850-EN-00)
File Details:
Hitachi ZW180-6 Wheel Loader Troubleshooting Technical Manual (TTPD850-EN-00)
- Manual Language:English
- Pages: 498
- Size: 6.48 MB
- Downloadable:Yes
- Format:PDF
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Description:
Hitachi ZW180-6 Wheel Loader Troubleshooting Technical Manual (TTPD850-EN-00)
To The Reader
This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
The machine specification and description according to destination may be explained on this manual.
Be sure to thoroughly read this manual for correct product information and service procedures.
If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual.
Additional References
Please refer to the other materials (operator’s manual, parts catalog, engine technical material and Hitachi training material etc.) in addition to this manual.
Manual Composition
This manual consists the Technical Manual, the Workshop Manual and the Engine Manual.
Information included in the Technical Manual: Technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.
Information included in the Workshop Manual: Technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and assemble / disassemble procedures.
Information included in the Engine Manual: Technical information needed for redelivery and delivery and maintenance and repair of the machine, operation and activation of all devices and systems, troubleshooting and assemble / disassemble procedures.
Table Of Contents:
Hitachi ZW180-6 Wheel Loader Troubleshooting Technical Manual (TTPD850-EN-00)
TTPD850-EN-00........................................................................ 1 CONTENTS............................................................................. 3 INTRODUCTION......................................................................... 7 SYMBOL AND ABBREVIATION.............................................................. 9 SAFETY............................................................................... 11 SECTION AND GROUP CONTENTS........................................................... 49 SECTION 4OPERATIONAL PERFORMANCE TEST................................................ 51 Group 1 Introduction............................................................. 53 Operational Performance Tests................................................ 53 Preparation for Performance Tests............................................ 54 Group 2 Standard................................................................. 55 Operational Performance Standard Table....................................... 55 Main Pump P-Q Diagram........................................................ 64 Sensor Activating Range...................................................... 66 Group 3 Engine Test.............................................................. 67 Engine Speed................................................................. 67 Lubricant Consumption........................................................ 69 Group 4 Machine Performance Test................................................. 71 Travel Speed................................................................. 71 Service Brake Function Check................................................. 74 Service Brake Wear Amount.................................................... 76 Parking Brake Function Check................................................. 77 Bucket Stopper and Bell Crank Stopper Clearance.............................. 78 Hydraulic Cylinder Cycle Time................................................ 80 Dig Function Drift Check..................................................... 82 Bucket Levelness............................................................. 83 Control Lever Operating Force................................................ 84 Control Lever Stroke......................................................... 86 Group 5 Component Test........................................................... 87 Primary Pilot Pressure (Including Brake Circuit)............................. 87 Secondary Pilot Pressure..................................................... 90 Main Pump Delivery Pressure.................................................. 92 Main Relief Set Pressure..................................................... 94 Steering Relief Pressure..................................................... 98 Overload Relief Valve Set Pressure...........................................100 Main Pump Flow Rate Measurement..............................................102 Service Brake Pressure (Front and Rear)......................................110 Parking Brake Release Pressure...............................................112 Brake Accumulator Pressure...................................................114 Brake Warning Pressure (Pressure-Decreasing).................................116 Brake Warning Pressure (Pressure-Increasing).................................118 Transmission Clutch Pressure.................................................120 Torque Converter Pressure (Inlet)............................................122 Group 6 Adjustment...............................................................125 Rewrite of Aftertreatment Device Serial No...................................125 Clean DEF Tank...............................................................126 Transmission Learning........................................................127 Lift Arm Angle Sensor Learning...............................................131 Digging Position Adjustment..................................................133 SECTION 5 TROUBLESHOOTING............................................................137 Group 1 Diagnosing Procedure.....................................................139 Introduction.................................................................139 Diagnosis Procedure..........................................................140 Electrical System Inspection.................................................143 Precautions for Inspection and Maintenance...................................144 Instructions for Disconnecting Connectors....................................146 Fuse Inspection..............................................................148 Fusible Link Inspection......................................................151 Battery Voltage Check........................................................152 Alternator Check.............................................................153 Continuity Check.............................................................154 Voltage and Current Measurement..............................................156 Check by False Signal........................................................163 Test Wire Harness............................................................164 Group 2 Monitor..................................................................167 Outline......................................................................167 Operating Procedures of Service Menu.........................................168 Engine Tachometer............................................................203 Transmission Oil Temperature Gauge and DEF / AdBlue Level Gauge..............204 Coolant Temperature Gauge....................................................205 Group 3 e-Service................................................................207 Outline......................................................................207 List of Operation Data.......................................................208 Snapshot Data................................................................212 Communication System.........................................................213 Group 4 Component Layout.........................................................215 Main Component (Overview)....................................................215 Main Component...............................................................217 Electrical System (Overview).................................................219 Air Cleaner and Radiator Assembly............................................220 Battery Box..................................................................222 Hydraulic Oil Tank...........................................................223 Fuel Tank....................................................................224 Drive Unit...................................................................225 Front Axle...................................................................226 Cab..........................................................................227 Engine.......................................................................233 Aftertreatment Device........................................................234 Fan Valve (Optional).........................................................235 Priority Valve...............................................................235 Pump Device..................................................................236 Control Valve................................................................236 Manifold Valve...............................................................237 Parking Brake Solenoid Valve Block...........................................237 Brake Charge Valve...........................................................237 Ride Control Valve (Optional)................................................238 Emergency Steering Block (Optional)..........................................239 Emergency Steering Pump (Optional)...........................................239 Flow Regulator Valve.........................................................239 DEF Tank.....................................................................240 DEF Supply Module............................................................240 Group 5 Troubleshooting A........................................................241 Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure....241 MC Fault Code List...........................................................243 Monitor Controller (Monitor) Fault Code List.................................255 Monitor Controller (Information) Fault Code List.............................256 Column Display Controller Fault Code List....................................259 Air Conditioner Controller Fault Code List...................................261 ECM Fault Code List..........................................................263 TCU Fault Code List..........................................................293 MC Fault Codes 111000 to 111002..............................................313 MC Fault Code 111003.........................................................314 MC Fault Codes 111006, 111007, 111009, 111011................................317 Monitor Controller (Monitor) Fault Codes 113002, 113003, 113005, 113012......317 CAN1 Harness Check...........................................................318 CAN3 (Engine) Harness Check..................................................322 MC Fault Codes 111008, 111010, 111014, 111025................................325 Monitor Controller (Monitor) Fault Codes 113004, 113006, 113007..............325 CAN2 Harness Check...........................................................326 MC Fault Code 111100.........................................................329 MC Fault Code 111103.........................................................330 MC Fault Codes 111205, 111207................................................331 MC Fault Codes 111200........................................................332 MC Fault Codes 111217, 111312................................................333 MC Fault Codes 111204, 111206................................................334 MC Fault Code 111208.........................................................335 MC Fault Codes 111311, 111313................................................336 MC Fault Code 111411.........................................................339 MC Fault Code 111412.........................................................340 MC Fault Code 111413.........................................................341 MC Fault Code 111422.........................................................342 MC Fault Codes 111901, 111902................................................343 MC Fault Codes 120000, 120002 to 120005......................................344 MC Fault Code 120014.........................................................345 Monitor Controller Fault Code 115001.........................................347 Monitor Controller (Information) Fault Code 113311...........................348 Monitor Controller (Information) Fault Code 120300...........................349 Monitor Controller (Monitor) Fault Codes 120400, 120401......................350 Column Display Controller Fault Codes 120500 to 120505.......................351 Group 6 Troubleshooting B........................................................353 Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure.....353 Relationship between Machine Trouble Symptoms and Related Parts..............355 Correlation between Trouble Symptoms and Part Failures.......................378 Engine System Troubleshooting................................................398 All Actuator System Troubleshooting..........................................404 Front Attachment System Troubleshooting......................................409 Steering System Troubleshooting..............................................418 Travel System Troubleshooting................................................422 Brake System Troubleshooting.................................................431 Other System Troubleshooting.................................................434 Exchange Inspection..........................................................448 Air Bleeding Procedures for Brake (Axle).....................................450 Group 7 Air Conditioner..........................................................451 Outline......................................................................451 Functions of Main Parts......................................................454 Troubleshooting..............................................................459 Air Conditioner Controller Fault Code List...................................460 Air Conditioner Controller Fault Codes 11 to 22..............................461 Air Conditioner Controller Fault Codes 43 to 92..............................462 Work after Replacing Components..............................................484 Refill Compressor Oil........................................................485 Charge Air Conditioner with Refrigerant......................................486 Hose and Pipe Tightening Torque..............................................494 SERVICE MANUAL REVISION REQUEST FORM.................................................497 The Attached Diagram List............................................................498
Please Note:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]
Lance Lawrence –
Great site, too easy.