Hitachi ZW180-6 Wheel Loader Troubleshooting Manual TTPD850-EN-00 PDF

Description

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

HITACHI ZW180-6 WHEEL LOADER TROUBLESHOOTING TECHNICAL MANUAL (TTPD850-EN-00) – PDF DOWNLOAD:

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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]