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: 490
- Size: 9.32 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 SECTION 5 TROUBLESHOOTING............................................................129 Group 1 Diagnosing Procedure.....................................................131 Introduction.................................................................131 Diagnosis Procedure..........................................................132 Electrical System Inspection.................................................135 Precautions for Inspection and Maintenance...................................136 Instructions for Disconnecting Connectors....................................138 Fuse Inspection..............................................................140 Fusible Link Inspection......................................................143 Battery Voltage Check........................................................144 Alternator Check.............................................................145 Continuity Check.............................................................146 Voltage and Current Measurement..............................................148 Check by False Signal........................................................155 Test Wire Harness............................................................156 Group 2 Monitor..................................................................159 Outline......................................................................159 Operating Procedures of Service Menu.........................................160 Engine Tachometer............................................................195 Transmission Oil Temperature Gauge and DEF / AdBlue Level Gauge..............196 Coolant Temperature Gauge....................................................197 Group 3 e-Service................................................................199 Outline......................................................................199 List of Operation Data.......................................................200 Snapshot Data................................................................204 Communication System.........................................................205 Group 4 Component Layout.........................................................207 Main Component (Overview)....................................................207 Main Component...............................................................209 Electrical System (Overview).................................................211 Air Cleaner and Radiator Assembly............................................212 Battery Box..................................................................214 Hydraulic Oil Tank...........................................................215 Fuel Tank....................................................................216 Drive Unit...................................................................217 Front Axle...................................................................218 Cab..........................................................................219 Engine.......................................................................225 Aftertreatment Device........................................................226 Fan Valve (Optional).........................................................227 Priority Valve...............................................................227 Pump Device..................................................................228 Control Valve................................................................228 Manifold Valve...............................................................229 Parking Brake Solenoid Valve Block...........................................229 Brake Charge Valve...........................................................229 Ride Control Valve (Optional)................................................230 Emergency Steering Block (Optional)..........................................231 Emergency Steering Pump (Optional)...........................................231 Flow Regulator Valve.........................................................231 DEF Tank.....................................................................232 DEF Supply Module............................................................232 Group 5 Troubleshooting A........................................................233 Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure....233 MC Fault Code List...........................................................235 Monitor Controller (Monitor) Fault Code List.................................247 Monitor Controller (Information) Fault Code List.............................248 Column Display Controller Fault Code List....................................251 Air Conditioner Controller Fault Code List...................................253 ECM Fault Code List..........................................................255 TCU Fault Code List..........................................................285 MC Fault Codes 111000 to 111002..............................................305 MC Fault Code 111003.........................................................306 MC Fault Codes 111006, 111007, 111009, 111011................................309 Monitor Controller (Monitor) Fault Codes 113002, 113003, 113005, 113012......309 CAN1 Harness Check...........................................................310 CAN3 (Engine) Harness Check..................................................314 MC Fault Codes 111008, 111010, 111014, 111025................................317 Monitor Controller (Monitor) Fault Codes 113004, 113006, 113007..............317 CAN2 Harness Check...........................................................318 MC Fault Code 111100.........................................................321 MC Fault Code 111103.........................................................322 MC Fault Codes 111205, 111207................................................323 MC Fault Codes 111200........................................................324 MC Fault Codes 111217, 111312................................................325 MC Fault Codes 111204, 111206................................................326 MC Fault Code 111208.........................................................327 MC Fault Codes 111311, 111313................................................328 MC Fault Code 111411.........................................................331 MC Fault Code 111412.........................................................332 MC Fault Code 111413.........................................................333 MC Fault Code 111422.........................................................334 MC Fault Codes 111901, 111902................................................335 MC Fault Codes 120000, 120002 to 120005......................................336 MC Fault Code 120014.........................................................337 Monitor Controller Fault Code 115001.........................................339 Monitor Controller (Information) Fault Code 113311...........................340 Monitor Controller (Information) Fault Code 120300...........................341 Monitor Controller (Monitor) Fault Codes 120400, 120401......................342 Column Display Controller Fault Codes 120500 to 120505.......................343 Group 6 Troubleshooting B........................................................345 Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure.....345 Relationship between Machine Trouble Symptoms and Related Parts..............347 Correlation between Trouble Symptoms and Part Failures.......................370 Engine System Troubleshooting................................................390 All Actuator System Troubleshooting..........................................396 Front Attachment System Troubleshooting......................................401 Steering System Troubleshooting..............................................410 Travel System Troubleshooting................................................414 Brake System Troubleshooting.................................................423 Other System Troubleshooting.................................................426 Exchange Inspection..........................................................440 Air Bleeding Procedures for Brake (Axle).....................................442 Group 7 Air Conditioner..........................................................443 Outline......................................................................443 Functions of Main Parts......................................................446 Troubleshooting..............................................................451 Air Conditioner Controller Fault Code List...................................452 Air Conditioner Controller Fault Codes 11 to 22..............................453 Air Conditioner Controller Fault Codes 43 to 92..............................454 Work after Replacing Components..............................................476 Refill Compressor Oil........................................................477 Charge Air Conditioner with Refrigerant......................................478 Hose and Pipe Tightening Torque..............................................486 SERVICE MANUAL REVISION REQUEST FORM.................................................489 The Attached Diagram List............................................................490
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]