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Hitachi ZW180-5B ZW180PL-5B Wheel Loader Troubleshooting Technical Manual (TTNDB90-EN-00) – PDF Download
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- Hitachi ZW180-5B ZW180PL-5B Wheel Loader Troubleshooting Technical Manual
- Part No:TTNDB90-EN-00
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Description
Hitachi ZW180-5B ZW180PL-5B Wheel Loader Troubleshooting Technical Manual (TTNDB90-EN-00)
File Details:
Hitachi ZW180-5B ZW180PL-5B Wheel Loader Troubleshooting Technical Manual (TTNDB90-EN-00)
- Manual Language:English
- Downloadable:Yes
- Pages: 448
- Size: 5.02 MB
- Format:PDF
HITACHI ZW180-5B ZW180PL-5B WHEEL LOADER TROUBLESHOOTING TECHNICAL MANUAL (TTNDB90-EN-00) – PDF DOWNLOAD:
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Description:
Hitachi ZW180-5B ZW180PL-5B Wheel Loader Troubleshooting Technical Manual (TTNDB90-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 ZW180-5B ZW180PL-5B Wheel Loader Troubleshooting Technical Manual (TTNDB90-EN-00)
TTNDB-EN-00.................................................................................... 1 INTRODUCTION............................................................................... 3 To The Reader.......................................................................... 3 Additional References.................................................................. 3 Manual Composition..................................................................... 3 Page Number............................................................................ 3 Safety Alert Symbol and Headline Notations............................................. 4 Units Used............................................................................. 4 SYMBOL AND ABBREVIATION.................................................................... 5 Symbol and Abbreviation................................................................ 5 SAFETY..................................................................................... 7 Recognize Safety Information........................................................... 7 Understand Signal Words................................................................ 7 Follow Safety Instructions............................................................. 8 Prepare for Emergencies................................................................ 9 Wear Protective Clothing............................................................... 9 Protect Against Noise.................................................................. 10 Inspect Machine........................................................................ 10 SA-5General Precautions for Cab........................................................ 11 Use Handrails and Steps................................................................ 12 Never Ride Attachment.................................................................. 12 Adjust Operator’s Seat................................................................. 12 Ensure Safety Before Rising from or Leaving Operator’s Seat............................ 13 Fasten Your Seat Belt.................................................................. 13 Move and Operate Machine Safely........................................................ 14 Handle Starting Aids Safely............................................................ 14 Operate Only from Operator’s Seat...................................................... 15 Jump Starting.......................................................................... 15 Investigate Job Site Beforehand........................................................ 16 Equipment of Head Guard, ROPS, FOPS.................................................... 17 Provide Signals for Jobs Involving Multiple Machines................................... 17 Keep Riders Off Machine................................................................ 18 Drive Safely........................................................................... 18 Drive Machine Safely (Work Site)....................................................... 19 Drive Safely with Bucket Loaded........................................................ 20 Drive on Snow Safely................................................................... 20 Travel on Public Roads Safely.......................................................... 21 Avoid Injury from Rollaway Accidents................................................... 21 Avoid Accidents from Backing Up and Turning............................................ 22 Avoid Positioning Bucket or Attachment Over Anyone..................................... 23 Avoid Tipping.......................................................................... 23 Never Undercut a High Bank............................................................. 24 Dig with Caution....................................................................... 24 Perform Truck Loading Safely........................................................... 24 Avoid Power Lines...................................................................... 25 Precautions for Operation.............................................................. 25 Precautions for Lightning.............................................................. 25 Object Handling........................................................................ 26 Protect Against Flying Debris.......................................................... 26 Park Machine Safely.................................................................... 27 Store Attachments Safely............................................................... 27 Transport Safely....................................................................... 28 Handle Fluids Safely−Avoid Fires....................................................... 29 Practice Safe Maintenance.............................................................. 30 Warn Others of Service Work............................................................ 31 Support Machine Properly............................................................... 31 Stay Clear of Moving Parts............................................................. 32 Support Maintenance Properly........................................................... 32 Prevent Parts from Flying.............................................................. 33 Prevent Burns.......................................................................... 33 Replace Rubber Hoses Periodically...................................................... 34 Avoid High-Pressure Fluids............................................................. 34 Prevent Fires.......................................................................... 35 Evacuating in Case of Fire............................................................. 37 Beware of Exhaust Fumes................................................................ 37 Precautions for Welding and Grinding................................................... 37 Avoid Heating Near Pressurized Fluid Lines............................................. 38 Avoid Applying Heat to Lines Containing Flammable Fluids............................... 38 Precautions for Handling Accumulator and Gas Damper.................................... 38 Remove Paint Before Welding or Heating................................................. 39 Beware of Asbestos and Silicon Dust and Other Contamination............................ 39 Prevent Battery Explosions............................................................. 40 Service Air Conditioning System Safely................................................. 40 Handle Chemical Products Safely........................................................ 41 Dispose of Waste Properly.............................................................. 41 Notes for Muffler Filter............................................................... 42 Precautions for Communication Terminal................................................. 42 Precaution for Communication Terminal Equipment........................................ 43 Before Returning the Machine to the Customer........................................... 45 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 Standard....................................................................... 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................................................................. 87 Primary Pilot Pressure (Including BrakeCircuit).................................... 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 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 Transmission Learning..............................................................125 Lift Arm Angle Sensor Learning.....................................................129 Digging Position Adjustment........................................................131 SECTION 5 TROUBLESHOOTING..................................................................135 Group 1 Diagnosing Procedure...........................................................137 Introduction.......................................................................137 Diagnosis Procedure................................................................138 Electric System Inspection.........................................................141 Precautions for Inspection and Maintenance.........................................142 Instructions for Disconnecting Connectors..........................................144 Fuse Inspection....................................................................146 Fusible Link Inspection............................................................148 Battery Voltage Check..............................................................149 Alternator Check...................................................................150 Continuity Check...................................................................151 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-Servic.......................................................................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.....................................................................181 Main Component.....................................................................183 Electric Component Layout (Overview)...............................................186 Electrical System (Cab)............................................................187 Engine and Fan Pump................................................................195 Pump Device........................................................................196 Control Valve......................................................................196 Fan Valve..........................................................................197 Priority Valve.....................................................................197 Drive Unit.........................................................................198 Front Axle.........................................................................198 Manifold Valve.....................................................................199 Parking Brake Solenoid Valve.......................................................199 Brake Charge Valve.................................................................199 Emergency Steering Block (Optional)................................................200 Emergency Steering Pump (Optional).................................................200 Pressure Sensor Block..............................................................200 Ride Control Valve.................................................................201 Group 5 Troubleshooting A..............................................................203 Troubleshooting A (Base Machine DiagnosisBy Using Fault Codes) Procedure...........203 MC Fault Code List.................................................................205 Information Controller Fault Code List.............................................218 Column Display Controller Fault Code List.......................................... 0 Air Conditioner Controller Fault Code List.........................................222 Communication Terminal Fault Code List.............................................224 ECM Fault Code List................................................................225 TCU Fault Code List................................................................239 MC Fault Codes 111000 to 111002....................................................259 MC Fault Code 111003...............................................................260 MC Fault Codes 111006, 111007, 111011..............................................263 CAN1 Harness Check.................................................................264 CAN3 (Engine) Harness Check........................................................268 MC Fault Codes 111008, 111014, 111.................................................271 Column Display Controller Fault Code 115002........................................271 CAN2 Harness Check.................................................................272 MC Fault Code 111100...............................................................275 MC Fault Code 111103...............................................................276 MC Fault Codes 111205, 111207......................................................277 MC Fault Codes 111200, 111202, 111203..............................................278 MC Fault Codes 111217, 111312......................................................279 MC Fault Codes 111204, 111206......................................................280 MC Fault Code 111208...............................................................281 MC Fault Codes 111311, 111313......................................................282 MC Fault Code 111411...............................................................283 MC Fault Code 111412...............................................................284 MC Fault Code 111413...............................................................285 MC Fault Code 111422...............................................................286 MC Fault Code 111901...............................................................287 MC Fault Code 111902...............................................................288 MC Fault Codes 120000, 120002 to 120005............................................289 MC Fault Codes 120014..............................................................290 MC Fault Codes 120110..............................................................291 Column Display Controller Fault Code 115001........................................292 Column Display Controller Fault Code 115011........................................293 Column Display Controller (Information) Fault Codes 120500 to 120505...............294 Air Conditioner Controller Fault Codes 11 to 22....................................295 Air Conditioner Controller Fault Codes 43 to 92....................................296 Group 6 Troubleshooting B..............................................................297 Troubleshooting B (Machine Diagnosis byUsing Troubleshooting Symptom) Procedure....297 Relationship between Machine Trouble Symptoms and Related Parts....................299 Correlation between Trouble Symptoms and Part Failures.............................320 Engine System Troubleshooting......................................................343 All Actuator System Troubleshooting................................................349 Front Attachment System Troubleshooting............................................355 Steering System Troubleshooting....................................................365 Travel System Troubleshooting......................................................369 Brake System Troubleshooting.......................................................379 Other System Troubleshooting.......................................................383 Exchange Inspection................................................................397 Air Bleeding Procedures for Brake (Axle)...........................................399 Group 7 Air Conditioner................................................................401 Outline............................................................................401 Functions of Main Parts............................................................404 Troubleshooting....................................................................409 Air Conditioner Controller Fault Code List.........................................410 Air Conditioner Controller Fault Codes 11 to 22....................................411 Air Conditioner Controller Fault Codes 43 to 92....................................412 Work after Replacing Components....................................................434 Refill Compressor Oil..............................................................435 Charge Air Conditioner with Refrigerant............................................436 Hose and Pipe Tightening Torque....................................................444 SERVICE MANUAL REVISION REQUEST FORM.......................................................447 The Attached Diagram List..................................................................448
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]
