Hitachi ZW180 Wheel Loader Troubleshooting Technical Manual (TT4GD-E-00)
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Hitachi ZW180 Wheel Loader Troubleshooting Technical Manual (TT4GD-E-00)
- Manual Language:English
- Pages: 558
- Size: 10.6 MB
- Downloadable:Yes
- Format:PDF
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Description:
Hitachi ZW180 Wheel Loader Troubleshooting Technical Manual (TT4GD-E-00)
TO THE READER
• This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
• 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 materials listed below in addition to this manual.
• The Operator’s Manual
• The Parts Catalog
• The Engine Manual
• Parts Catalog of the Engine
• Hitachi Training Material
MANUAL COMPOSITION
• This manual consists of three portions: the Technical Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual.
• Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems.
• Information included in the Technical Manual (Troubleshooting): technical information needed for 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.
Table Of Contents:
Hitachi ZW180 Wheel Loader Troubleshooting Technical Manual (TT4GD-E-00)
ZW180_TT4GD-E-00............................................................................................................ 1 INTRODUCTION................................................................................................................ 3 SAFETY...................................................................................................................... 5 SECTION AND GROUP CONTENTS.................................................................................................. 35 SECTION 4 OPERATIONAL PERFORMANCE TEST...................................................................................... 37 Group 1 Introduction.................................................................................................... 39 Operational Performance Tests....................................................................................... 39 Preparation for Performance Tests................................................................................... 40 Group 2 Standard........................................................................................................ 41 Operational Performance Standard Table.............................................................................. 41 Main Pump P-Q Curve................................................................................................. 47 Sensor Activating Range............................................................................................. 49 Group 3 Engine Test..................................................................................................... 51 Engine Speed........................................................................................................ 51 Lubricant Consumption............................................................................................... 53 Group 4 Wheel Loader Test............................................................................................... 55 Travel Speed........................................................................................................ 55 Service Brake Function Check........................................................................................ 56 Service Brake Wear Amount........................................................................................... 57 Parking Brake Function Check........................................................................................ 58 Bucket Stopper and Bell Crank Stopper Clearance..................................................................... 60 Hydraulic Cylinder Cycle Time....................................................................................... 62 Cylinder Drift Check................................................................................................ 64 Bucket Levelness.................................................................................................... 65 Control Lever Operating Force....................................................................................... 66 Control Lever Stroke................................................................................................ 67 Group 5 Component Test.................................................................................................. 69 Primary Pilot Pressure.............................................................................................. 69 Secondary Pilot Pressure............................................................................................ 71 Solenoid Valve Set Pressure......................................................................................... 72 Main Pump Delivery Pressure......................................................................................... 74 Main Relief Pressure................................................................................................ 76 Steering Relief Pressure............................................................................................ 78 Overload Relief Pressure............................................................................................ 80 Main Pump Flow Rate................................................................................................. 82 Regulator Adjustment................................................................................................ 86 Service Brake Pressure (Front and Rear)............................................................................. 88 Parking Brake Pressure.............................................................................................. 90 Brake Accumulated Pressure.......................................................................................... 92 Service Brake Warning Set Pressure (Decrease)....................................................................... 94 Service Brake Warning Set Pressure (Increase)....................................................................... 96 Transmission Clutch Pressure........................................................................................ 98 Torque Converter Pressure (Inlet and Outlet)........................................................................ 99 Group 6 Adjustment......................................................................................................101 Transmission Learning...............................................................................................101 Lift Arm Angle Sensor Learning (Optional)...........................................................................106 Drive Belt Tension Adjustment.......................................................................................108 SECTION 5 TROUBLESHOOTING...................................................................................................111 Group 1 Diagnosing Procedure............................................................................................115 Introduction........................................................................................................115 Diagnosing Procedure................................................................................................116 How to Operate Service Mode of Monitor..............................................................................120 Display List of Monitor Service Mode................................................................................121 Group 2 Dr.ZX...........................................................................................................123 Outline.............................................................................................................123 Operation...........................................................................................................124 Self-Diagnostic Result..............................................................................................126 Select Controller...................................................................................................128 Main Controller.....................................................................................................129 Main Menu Monitor Display...........................................................................................130 Setting.............................................................................................................134 Record Data Display.................................................................................................141 Password Change.....................................................................................................142 Engine Controller...................................................................................................143 Monitor Display.....................................................................................................144 Recorded Data Display...............................................................................................148 Password Change.....................................................................................................149 ICF Controller......................................................................................................151 Information C/U Various Setup.......................................................................................152 Save Data Check.....................................................................................................162 Password Change.....................................................................................................163 Monitor Unit........................................................................................................165 Monitoring..........................................................................................................166 Various Settings....................................................................................................168 Internal Hour Meter Synchronization.................................................................................169 Password Change.....................................................................................................170 Group 3 e-Wheel.........................................................................................................171 Outline.............................................................................................................171 List of Daily Report Data...........................................................................................172 List of Frequency Distribution Data.................................................................................173 List of Total Operationg Hours......................................................................................174 List of Alarm.......................................................................................................175 List of failure.....................................................................................................176 How to Download and Upload Data of ICF..............................................................................177 Various Setup of ICF and Satellite Communication Terminal by Using Dr.ZX............................................180 List of ICF Fault Code..............................................................................................192 List of Fault Code of Sattellite Communication Terminal.............................................................193 Group 4 Component Layout................................................................................................197 Main Component (Overview)...........................................................................................197 Main Component (Upperstructure).....................................................................................198 Main Component (Travel System)......................................................................................199 Electric System (Overview)..........................................................................................200 Electrical System (Cab).............................................................................................201 Engine and Fan Pump.................................................................................................206 Pump Device.........................................................................................................207 Drive Unit..........................................................................................................207 Control Valve.......................................................................................................208 Ride Control Valve..................................................................................................209 Charging Block......................................................................................................209 Fan Motor...........................................................................................................209 Steering Valve......................................................................................................210 Emergency Steering Pump (Optional)..................................................................................210 Components in Control Valve.........................................................................................212 Components in Steering Valve........................................................................................218 Components in Charging Block........................................................................................222 Components in Ride Control Valve....................................................................................228 Front View of Transmission..........................................................................................232 Side View of Transmission...........................................................................................233 Rear View of Transmission...........................................................................................234 Cross-Sectional Drawing of Torque Converter.........................................................................235 Cross-Sectional Drawing of Transmission.............................................................................236 Cross-Sectional Drawing of Clutch Shaft.............................................................................237 Cross-Sectional Drawing of Transmission Regulator Valve.............................................................238 Cross-Sectional Drawing of Transmission Control Valve...............................................................239 Group 5 Troubleshooting A...............................................................................................241 Troubleshooting A Procedure.........................................................................................241 MC Fault Code List..................................................................................................242 ECM Fault Code List.................................................................................................262 ICF Fault Code List.................................................................................................278 Satellite Terminal Fault Code List..................................................................................280 Monitor Unit Fault Code List........................................................................................282 Controller Hardware Failure MC Fault Codes 11000 to 11002...........................................................283 MC Fault Code 11003.................................................................................................284 MC Fault Code 11004.................................................................................................285 CAN Harness Check...................................................................................................286 Engine Failure MC Fault Code 11103..................................................................................306 MC Fault Code 11105.................................................................................................307 Pump Failure MC Fault Code 11204....................................................................................308 Pilot Failure MC Fault Code 11312...................................................................................309 MC Fault Code 11313.................................................................................................310 Proportional Solenoid Valve Failure MC Fault Code 11412.............................................................311 MC Fault Code 11413.................................................................................................312 MC Fault Code 11414, 11415, 11416, 11417, 11418, 11419..............................................................313 Transmission Failure MC Fault Code 11600............................................................................316 MC Fault Code 11601.................................................................................................317 MC Fault Code 11602.................................................................................................318 MC Fault Code 11904.................................................................................................319 MC Fault Code 11905.................................................................................................320 CAN Data Reception Failure MC Fault Codes 11910, 11920..............................................................321 CAN Harness Check (MC Fault Codes 11910, 11920).....................................................................322 MC Fault Code 11914.................................................................................................325 CAN Harness Check Fault Code 11914..................................................................................326 Other Failures MC Fault Code 11901..................................................................................329 Proportional Solenoid Valve Truble Check............................................................................330 ECM, Fault Code Contrast List.......................................................................................333 ICF, Satellite Terminal Fault Codes 14000to14003....................................................................349 ICF, Satellite Terminal Fault Codes 14006, 14008, 14100 to 14106....................................................353 Monitor Unit Fault Codes 13306, 13308...............................................................................355 Monitor Unit Fault Code 13312.......................................................................................356 Monitor Unit Fault Code 13314.......................................................................................357 Group 6 Troubleshooting B...............................................................................................359 Troubleshooting B Procedure.........................................................................................359 Relationship between Machine Trouble Symptoms and Related Parts.....................................................360 Correlation between Trouble Symptoms and Part Failures..............................................................376 Engine System Troubleshooting.......................................................................................390 Front Attachment System Troubleshooting.............................................................................399 Travel System Troubleshooting.......................................................................................418 Brake System Troubleshooting........................................................................................434 Steering System Troubleshooting.....................................................................................442 Other System Troubleshooting........................................................................................445 Exchange Inspection.................................................................................................467 Bleeding Air from Brake (Axle)......................................................................................469 One Part of Data, “Daily Report Data”, “Distribution Data”, “Total Operationg Hours” and “Alarm” is Not Recorded....470 Group 7 Troubleshooting C...............................................................................................485 Troubleshooting C (Trouble Shooting for Monitor) Procedure..........................................................485 Malfunction of Indicator Light Check System.........................................................................486 Malfunction of Buzzer in Monitor....................................................................................488 Malfunction of Coolant Temperature Gauge............................................................................490 Malfunction of Transmission Oil Temperature Gauge...................................................................492 Malfunction of Fuel Gauge...........................................................................................494 Malfunction of Turn Signal Indicators (Left and Right)..............................................................496 Malfunction of Hazard Light Indicator...............................................................................497 Malfunction of High Beam Indicator..................................................................................498 Malfunction of Working Light Indicator..............................................................................500 Malfunction of FNR Switch Indicator.................................................................................502 Malfunction of Maintenance Indicator................................................................................504 Malfunction of Preheat Indicator....................................................................................505 Malfunction of Transmission Oil Temperature Indicator...............................................................506 Malfunction of Hydraulic Oil Temperature Indicator..................................................................508 Malfunction of Transmission Warning Indicator.......................................................................510 Malfunction of Air Filter Restriction Indicator.....................................................................512 Malfunction of Engine Oil Pressure Indicator........................................................................514 Faulty Overheat Indicator...........................................................................................516 Malfunction of Engine Warning Indicator.............................................................................518 Malfunction of Stop Indicator.......................................................................................519 Malfunction of Service Indicator....................................................................................520 Malfunction of Parking Brake Indicator..............................................................................522 Malfunction of Clearance Light Indicator............................................................................524 Malfunction of Brake Low Oil Pressure Indicator.....................................................................525 Malfunction of Brake Low Oil Level Indicator........................................................................526 Malfunction of Emergency Steering Indicator (Optional)..............................................................528 Malfunction of Low Steering Oil Pressure Indicator (Optional).......................................................530 Malfunction of Discharge Warning Indicator..........................................................................532 Malfunction of Monitor Display......................................................................................534 Malfunction of Ride Control Indicator...............................................................................535 Malfunction of Engine Coolant Temperature Display...................................................................536 Group 8 Electrical System Inspection....................................................................................537 Precautions for Inspection and Maintenance..........................................................................537 Instructions for Disconnecting Connectors...........................................................................539 Fuse Inspection.....................................................................................................542 Fusible Link Inspection.............................................................................................544 Battery Voltage Check...............................................................................................545 Alternator Check....................................................................................................546 Continuity Check....................................................................................................548 Voltage and Current Measurement.....................................................................................550 Check by False Signal...............................................................................................553 SERVICE MANUAL REVISION REQUEST FORM........................................................................................557 THE ATTACHED DIAGRAM LIST...................................................................................................558
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