Hitachi ZW180-6 Wheel Loader Troubleshooting Technical Manual (TTPD850-EN-00) – PDF Download

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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

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
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]