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Hitachi ZW180-5A Wheel Loader Troubleshooting Technical Manual (TTNDJ-EN-00) – PDF Download
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- Hitachi ZW180-5A Wheel Loader Troubleshooting Technical Manual
- Part No:TTNDJ-EN-00
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Description
Hitachi ZW180-5A Wheel Loader Troubleshooting Technical Manual (TTNDJ-EN-00)
File Details:
Hitachi ZW180-5A Wheel Loader Troubleshooting Technical Manual (TTNDJ-EN-00)
- Manual Language:English
- Pages: 436
- Size:4.77 MB
- Downloadable:Yes
- Format:PDF
HITACHI ZW180-5A WHEEL LOADER TROUBLESHOOTING TECHNICAL MANUAL (TTNDJ-EN-00) – PDF DOWNLOAD:
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Description:
Hitachi ZW180-5A Wheel Loader Troubleshooting Technical Manual (TTNDJ-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 ZW180-5A Wheel Loader Troubleshooting Technical Manual (TTNDJ-EN-00)
TTNDJ-EN-00............................................................................................... 1 INTRODUCTION.............................................................................................. 3 SYMBOL AND ABBREVIATION................................................................................... 5 SAFETY.................................................................................................... 7 SECTION AND GROUP CONTENTS................................................................................ 47 SECTION 4 OPERATIONAL PERFORMANCE TEST.................................................................... 49 Group 1 Introduction.................................................................................. 51 Operational Performance Tests..................................................................... 51 Preparation for Performance Tests................................................................. 52 Group 2 Standa........................................................................................ 53 Operational Performance Standard Table............................................................ 53 Main Pump P-Q Diagram............................................................................. 62 Sensor Activating Range........................................................................... 64 Group 3 Engine Test................................................................................... 65 Engine Speed...................................................................................... 65 Lubricant Consumption............................................................................. 67 Group 4 Machine Performance Test...................................................................... 69 Travel Speed...................................................................................... 69 Service Brake Function Check...................................................................... 72 Service Brake Wear Amount......................................................................... 74 Parking Brake Function Check...................................................................... 75 Bucket Stopper and Bell Crank Stopper Clearance................................................... 76 Hydraulic Cylinder Cycle Time..................................................................... 78 Dig Function Drift Check.......................................................................... 80 Bucket Levelness.................................................................................. 81 Control Lever Operating Force..................................................................... 82 Control Lever Stroke.............................................................................. 84 Group 5 Component Test................................................................................ 85 Primary Pilot Pressure (Including Brake Circuit).................................................. 85 Secondary Pilot Pressure.......................................................................... 88 Main Pump Delivery Pressure....................................................................... 90 Main Relief Set Pressure.......................................................................... 92 Steering Relief Pressure.......................................................................... 96 Overload Relief Valve Set Pressure................................................................ 98 Main Pump Flow Rate Measurement...................................................................100 Service Brake Pressure (Front and Rear)...........................................................108 Parking Brake Pressure............................................................................110 Brake Accumulator Pressure........................................................................112 Brake Warning Pressure (Pressure-Decreasing)......................................................114 Brake Warning Pressure (Pressure-Increasing)......................................................116 Transmission Clutch Pressure......................................................................118 Torque Converter Pressure (Inlet).................................................................120 Group 6 Adjustment....................................................................................123 Transmission Learning.............................................................................123 Lift Arm Angle Sensor Learning....................................................................127 Digging Position Adjustment.......................................................................129 SECTION 5 TROUBLESHOOTING.................................................................................133 Group 1 Diagnosing Procedure..........................................................................135 Introduction......................................................................................135 Diagnosis Procedure...............................................................................136 Electric System Inspection........................................................................139 Precautions for Inspection and Maintenance........................................................140 Instructions for Disconnecting Connectors.........................................................142 Fuse Inspection...................................................................................144 Fusible Link Inspection...........................................................................147 Battery Voltage Check.............................................................................148 Alternator Check..................................................................................149 Continuity Check..................................................................................150 Voltage and Current Measurement...................................................................152 Check by False Signal.............................................................................159 Test Harness......................................................................................160 Group 2 Monitor.......................................................................................163 Outline...........................................................................................163 Operating Procedures of Service Menu..............................................................165 Coolant Temperature Gauge and Transmission Oil Temperature Gauge..................................169 Fuel Gauge........................................................................................170 Group 3 e-Service.....................................................................................171 Outline...........................................................................................171 List of Operation Data............................................................................172 Snapshot Data.....................................................................................176 Communication System..............................................................................177 Group 4 Component Layout..............................................................................179 Main Component (Overview).........................................................................179 Main Component....................................................................................180 Main Component (Travel System)....................................................................181 Electrical System (Overview)......................................................................183 Electrical System (Cab)...........................................................................184 Engine and Fan Pump...............................................................................192 Pump Device.......................................................................................193 Control Valve.....................................................................................193 Fan Valve (Optional)..............................................................................194 Priority Valve....................................................................................194 Drive Unit........................................................................................195 Front Axle........................................................................................195 Manifold Valve....................................................................................196 Parking Brake Solenoid Valve Block................................................................196 Brake Charge Valve................................................................................196 Steering Valve, Emergency Steering Valve (Optional)...............................................197 Emergency Steering Pump (Optional)................................................................197 Ride Control Valve (Optional).....................................................................198 Group 5 Troubleshooting A.............................................................................199 Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure.........................199 MC Fault Code List................................................................................201 Column Display Controller Fault Code List......................................................... 0 Air Conditioner Controller Fault Code List........................................................216 ECM FAULT CODE CONTRAST LIST......................................................................217 TCU Fault Code List...............................................................................233 MC Fault Codes 111000 to 111002...................................................................253 MC Fault Code 111003..............................................................................254 MC Fault Codes 111006, 111007, 111011.............................................................257 CAN1 Harness Check................................................................................258 MC Fault Codes 111014, 111025.....................................................................262 MC Fault Code 111100..............................................................................263 MC Fault Code 111103, 111106, 111107..............................................................264 MC Fault Codes 111205.............................................................................265 MC Fault Codes 111200, 111203.....................................................................266 MC Fault Codes 111217, 111312.....................................................................267 MC Fault Codes 111204, 111206.....................................................................268 MC Fault Code 111208..............................................................................269 MC Fault Codes 111311, 111313.....................................................................270 MC Fault Code 111411..............................................................................271 MC Fault Code 111412..............................................................................272 MC Fault Code 111413..............................................................................273 MC Fault Code 111422..............................................................................274 MC Fault Code 111901..............................................................................275 MC Fault Codes 120003, 120004.....................................................................276 MC Fault Codes 120014.............................................................................277 Column Display Controller Fault Code 115001.......................................................279 Column Display Controller Fault Code 115011.......................................................280 Column Display Controller (Information) Fault Codes 120500 to120503, 120505.......................281 Column Display Controller Fault Codes 120506, 120507, 120510 to 120512, 120515, 120516, 120518....282 Group 6 Troubleshooting B.............................................................................283 Troubleshooting B (Machine Diagnosis by Using Troubleshooting Symptom) Procedure..................283 Relationship between Machine Trouble Symptoms and Related Parts...................................285 Correlation between Trouble Symptoms and Part Failures............................................306 Engine System Troubleshooting.....................................................................329 All Actuator System Troubleshooting...............................................................335 Front Attachment System Troubleshooting...........................................................341 Steering System Troubleshooting...................................................................351 Travel System Troubleshooting.....................................................................355 Brake System Troubleshooting......................................................................365 Other System Troubleshooting......................................................................369 Exchange Inspection...............................................................................383 Air Bleeding Procedures for Brake (Axle)..........................................................385 Group 7 Air Conditioner...............................................................................387 Outline...........................................................................................387 Functions of Main Parts...........................................................................392 Troubleshooting...................................................................................397 Air Conditioner Controller Fault Code List........................................................398 Air Conditioner Controller Fault Codes E11 to E22.................................................399 Air Conditioner Controller Fault Codes E43 to E92.................................................400 Work after Replacing Components...................................................................422 Refill Compressor Oil.............................................................................423 Charge Air Conditioner with Refrigerant...........................................................424 Hose and Pipe Tightening Torque...................................................................432 SERVICE MANUAL REVISION REQUEST FORM......................................................................435 The Attached Diagram List.................................................................................436
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