Hitachi ZW 180-6 User manual

TTPD850-EN-00
ZW180-6 WHEEL LOADER TECHNICAL MANUAL TROUBLESHOOTING
Service Manual consists of the following separate Part No.
Technical Manual (Operational Principle) : Vol. No.TOPD850-EN
Technical Manual (Troubleshooting) : Vol. No.TTPD850-EN
Workshop Manual : Vol. No.WPD850-EN
TTPD850-EN-00
PART NO.
Wheel Loader
Technical Manual
Troubleshooting
180-6
ZW
PRINTED IN JAPAN (K) 2016, 09
URL:http://www.hitachi-c-m.com

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Group 1 Introduction
Operational Performance Tests...................................... T4-1-1
Preparation for Performance Tests ............................... T4-1-2
Group 2 Standard
Operational Performance Standard Table ................. T4-2-1
Main Pump P-Q Diagram ...............................................T4-2-10
Sensor Activating Range................................................T4-2-12
Group 3 Engine Test
Engine Speed ....................................................................... T4-3-1
Lubricant Consumption ................................................... T4-3-3
Group 4 Machine Performance Test
Travel Speed ......................................................................... T4-4-1
Service Brake Function Check ........................................ T4-4-4
Service Brake Wear Amount............................................ T4-4-6
Parking Brake Function Check ....................................... T4-4-7
Bucket Stopper and Bell Crank Stopper
Clearance.......................................................................... T4-4-8
Hydraulic Cylinder Cycle Time......................................T4-4-10
Dig Function Drift Check................................................T4-4-12
Bucket Levelness...............................................................T4-4-13
Control Lever Operating Force.....................................T4-4-14
Control Lever Stroke ........................................................T4-4-16
Group 5 Component Test
Primary Pilot Pressure (Including Brake Circuit) ...... T4-5-1
Secondary Pilot Pressure.................................................. T4-5-4
Main Pump Delivery Pressure......................................... T4-5-6
Main Relief Set Pressure ................................................... T4-5-8
Steering Relief Pressure ..................................................T4-5-12
Overload Relief Valve Set Pressure .............................T4-5-14
Main Pump Flow Rate Measurement.........................T4-5-16
Service Brake Pressure (Front and Rear) ..................T4-5-24
Parking Brake Release Pressure ...................................T4-5-26
Brake Accumulator Pressure ........................................T4-5-28
Brake Warning Pressure (Pressure-Decreasing) .....T4-5-30
Brake Warning Pressure (Pressure-Increasing).......T4-5-32
Transmission Clutch Pressure.......................................T4-5-34
Torque Converter Pressure (Inlet) ...............................T4-5-36
Group 6 Adjustment
Rewrite of Aftertreatment Device Serial NO. ............ T4-6-1
Clean DEF Tank..................................................................... T4-6-2
Transmission Learning ...................................................... T4-6-3
Lift Arm Angle Sensor Learning..................................... T4-6-7
Digging Position Adjustment......................................... T4-6-9
SECTION 4
OPERATIONAL PERFORMANCE TEST
CONTENTS
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(Blank)
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Group 1 Diagnosing Procedure
Introduction.......................................................................... T5-1-1
Diagnosis Procedure.......................................................... T5-1-2
Electrical System Inspection ........................................... T5-1-5
Precautions for Inspection and Maintenance .......... T5-1-6
Instructions for Disconnecting Connectors .............. T5-1-8
Fuse Inspection..................................................................T5-1-10
Fusible Link Inspection ...................................................T5-1-13
Battery Voltage Check.....................................................T5-1-14
Alternator Check ...............................................................T5-1-15
Continuity Check...............................................................T5-1-16
Voltage and Current Measurement............................T5-1-18
Check by False Signal ......................................................T5-1-25
Test Wire Harness ..............................................................T5-1-26
Group 2 Monitor
Outline .................................................................................... T5-2-1
Operating Procedures of Service Menu...................... T5-2-2
Engine Tachometer ..........................................................T5-2-37
Transmission Oil Temperature Gauge and
DEF / AdBlue Level Gauge........................................T5-2-38
Coolant Temperature Gauge ........................................T5-2-39
Group 3 e-Service
Outline .................................................................................... T5-3-1
List of Operation Data....................................................... T5-3-2
Snapshot Data...................................................................... T5-3-6
Communication System................................................... T5-3-7
Group 4 Component Layout
Main Component (Overview)......................................... T5-4-1
Main Component................................................................ T5-4-3
Electrical System (Overview) .......................................... T5-4-5
Air Cleaner and Radiator Assembly.............................. T5-4-6
Battery Box............................................................................ T5-4-8
Hydraulic Oil Tank ............................................................... T5-4-9
Fuel Tank ..............................................................................T5-4-10
Drive Unit.............................................................................T5-4-11
Front Axle.............................................................................T5-4-12
Cab .........................................................................................T5-4-13
Engine...................................................................................T5-4-19
Aftertreatment Device ....................................................T5-4-20
Fan Valve (Optional).........................................................T5-4-21
Priority Valve.......................................................................T5-4-21
Pump Device ......................................................................T5-4-22
Control Valve.......................................................................T5-4-22
Manifold Valve....................................................................T5-4-23
Parking Brake Solenoid Valve Block ...........................T5-4-23
Brake Charge Valve...........................................................T5-4-23
Ride Control Valve (Optional) .......................................T5-4-24
Emergency Steering Block (Optional) .......................T5-4-25
Emergency Steering Pump (Optional)......................T5-4-25
Flow Regulator Valve .......................................................T5-4-25
DEF Tank...............................................................................T5-4-26
DEF Supply Module..........................................................T5-4-26
Group 5 Troubleshooting A
Troubleshooting A (Base Machine Diagnosis
By Using Fault MC Fault Code List ........................... T5-5-1
MC Fault Code List.............................................................. T5-5-3
Monitor Controller (Monitor) Fault Code List .........T5-5-15
Monitor Controller (Information)
Fault Code List ..............................................................T5-5-16
Column Display Controller Fault Code List..............T5-5-19
Air Conditioner Controller Fault Code List...............T5-5-21
ECM Fault Code List..........................................................T5-5-23
TCU Fault Code List ..........................................................T5-5-53
MC Fault Codes 111000 to 111002.............................T5-5-73
MC Fault Code 111003....................................................T5-5-74
MC Fault Codes 111006, 111007,
111009, 111011............................................................T5-5-77
Monitor Controller (Monitor) Fault Codes
113002, 113003, 113005, 113012..........................T5-5-77
CAN1 Harness Check .......................................................T5-5-78
CAN3 (Engine) Harness Check ....................................T5-5-82
MC Fault Codes 111008, 111010,
111014, 111025............................................................T5-5-85
Monitor Controller (Monitor) Fault Codes
113004, 113006, 113007...........................................T5-5-85
CAN2 Harness Check ......................................................T5-5-86
MC Fault Code 111100....................................................T5-5-89
MC Fault Code 111103....................................................T5-5-90
MC Fault Codes 111205, 111207 .................................T5-5-91
MC Fault Codes 111200..................................................T5-5-92
MC Fault Codes 111217, 111312 .................................T5-5-93
MC Fault Codes 111204, 111206 .................................T5-5-94
MC Fault Code 111208....................................................T5-5-95
MC Fault Codes 111311, 111313 .................................T5-5-96
MC Fault Code 111411....................................................T5-5-99
MC Fault Code 111412................................................. T5-5-100
MC Fault Code 111413................................................. T5-5-101
MC Fault Code 111422................................................. T5-5-102
MC Fault Codes 111901, 111902 .............................. T5-5-103
SECTION 5
TROUBLESHOOTING
CONTENTS
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MC Fault Codes 120000, 120002 to 120005......... T5-5-104
MC Fault Code 120014................................................. T5-5-105
Monitor Controller Fault Code 115001 .................. T5-5-107
Monitor Controller (Information)
Fault Code 113311 ................................................... T5-5-108
Monitor Controller (Information)
Fault Code 120300 ................................................... T5-5-109
Monitor Controller (Monitor) Fault Codes
120400, 120401......................................................... T5-5-110
Column Display Controller Fault Codes
120500 to 120505..................................................... T5-5-111
Group 6 Troubleshooting B
Troubleshooting B (Machine Diagnosis by
Using Trouble Symptom) Procedure ...................... T5-6-1
Relationship between Machine Trouble
Symptoms and Related Parts.................................... T5-6-3
Correlation between Trouble Symptoms and
Part Failures ...................................................................T5-6-26
Engine System Troubleshooting .................................T5-6-46
All Actuator System Troubleshooting........................T5-6-52
Front Attachment System Troubleshooting............T5-6-57
Steering System Troubleshooting ..............................T5-6-66
Travel System Troubleshooting ...................................T5-6-70
Brake System Troubleshooting ....................................T5-6-79
Other System Troubleshooting....................................T5-6-82
Exchange Inspection .......................................................T5-6-96
Air Bleeding Procedures for Brake (Axle)..................T5-6-98
Group 7 Air Conditioner
Outline .................................................................................... T5-7-1
Functions of Main Parts .................................................... T5-7-4
Troubleshooting.................................................................. T5-7-9
Air Conditioner Controller Fault Code List...............T5-7-10
Air Conditioner Controller Fault Codes 11 to 22....T5-7-11
Air Conditioner Controller Fault Codes 43 to 92....T5-7-12
Work after Replacing Components ............................T5-7-34
Refill Compressor Oil .......................................................T5-7-35
Charge Air Conditioner with Refrigerant .................T5-7-36
Hose and Pipe Tightening Torque...............................T5-7-44
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INTRODUCTION
IN-1
To The Reader
Additional References
Manual Composition
Page Number
Trademark
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.
Please refer to the other materials (operator’s manual,
parts catalog, engine technical material and Hitachi
training material etc.) in addition to this manual.
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.
Each page has a number, located on the center lower part
of the page, and each number contains the following
information:
Example:
Technical Manual: T 1-3-5
T Technical Manual
1 Section Number
3 Group Number
5 Consecutive Page Number for Each Group
AdBlue® is a registered trademark of the Verband der
Automobilindustrie e.V. (VDA).
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. (Note: Do not tear off
the form. Copy it for usage.):
Technical Information Center Hitachi Construction
Machinery Co., Ltd.
TEL: [phone]
FAX: [phone]
E-mail: HCM-TIC-[email protected]
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.
Workshop Manual: W 1-3-2-5
W Workshop Manual
1 Section Number
3 Group Number
2 Sub Group Number
5 Consecutive Page Number for Each Group
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INTRODUCTION
IN-2
Safety Alert Symbol and Headline Notations
In this manual, the following safety alert symbol and
signal words are used to alert the reader to the potential
for personal injury of machine damage.
dThis is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed
along with the safety alert symbol.
The safety alert symbol is also used to draw attention to
component/part weights.
To avoid injury and damage, be sure to use appropriate
lifting techniques and equipment when lifting heavy
parts.
dCAUTION:
Indicates potentially hazardous situation which could, if
not avoided, result in personal injury or death.
IMPORTANT:
Indicates a situation which, if not conformed to the
instructions, could result in damage to the machine.
fNOTE:
Indicates supplementary technical information or know-
how.
Units Used
Quantity To Convert From Into Multiply By
Length mm in 0.03937
mm ft 0.003281
Volume L US gal 0.2642
L US qt 1.057
m3yd31.308
Weight kg lb 2.205
Force N kgf 0.10197
N lbf 0.2248
Torque N·m kgf·m 0.10197
Pressure MPa kgf/cm210.197
MPa psi 145.0
Power kW PS 1.360
kW HP 1.341
Temperature °C °F °C×1.8+32
Velocity km/h mph 0.6214
min-1 rpm 1.0
Flow rate L/min US gpm 0.2642
mL/rev cc/rev 1.0
SI Units (International System of Units) are used in this
manual.
A table for conversion from SI units to other system units
is shown below for reference purposes.
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SYMBOL AND ABBREVIATION
SY-1
Symbol /
Abbreviation
Name Explanation
TO Technical manual (Operational principle) Technical manual (Operational Principle).
TT Technical manual (Troubleshooting) Technical manual (Troubleshooting).
T/M Technical manual Technical manual.
W, W/M Workshop manual Workshop manual (Removal and Installation, Disassembly
and Assembly).
MC Main Controller Main controller. MC controls the engine, pump, and valve
according to the machine operating condition.
ECM Engine Control Module Engine controller. ECM controls fuel injection amount
according to the machine operating condition.
VGS Variable Geometry System controller Variable turbo controller. VGS is an exhaust turbo charged
system to supercharge the exhaust energy while running
the engine at slow idle speed. VGS optimizes the turbine
rotation, improves the performance at slow-speed torque
and the acceleration, reduces fuel consumption, and reduces
particulate matter (PM) by adjusting the nozzle opening of
turbine housing.
GSM Global System for Mobile communications
controller
Communication controller. GSM is a type of wireless
communication system, is used in more than on 100
countries around Europe and Asia, and becomes the factual
global standards of the mobile telephone.
GPS Global Positioning System Global positioning system.
CAN Controller Area Network CAN communication. CAN is a serial communications
protocol internationally-standardized by ISO (International
Organization for Standardization).
A/C Air Conditioner Air conditioner.
OP, OPT Option Optional component.
MPDr. Maintenance Pro Dr. MPDr. is software that troubleshooting, monitoring, and
adjustment.
A/I Auto-Idle Auto-idle.
WU Warming-Up Warming-up.
Li Low (Slow) Idle Slow idle engine speed.
ATT Attachment Attachment. Attachment is optional parts such as breaker,
crusher, and pulverizer in this manual.
HI, Hi High Travel fast position.
LO, Lo Low Travel slow position.
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SYMBOL AND ABBREVIATION
SY-2
Symbol /
Abbreviation
Name Explanation
DPF Diesel Particulate Filter DPF is a filter which removes particulate matter (PM)
including the toxic substance of exhaust gas of the diesel
engine. Exhaust particulate removal equipment.
DPD Diesel Particulate Diffuser DPD is an exhaust emission control system, a type of DPF,
which cleans up particulate matter (PM) of diesel engine
exhaust gas. DPD is a ceramic filter which traps and filters
PM of exhaust gas. DPD burns up accumulated PM when PM
increases and regenerates the filter.
DOC Diesel Oxidation Catalyst Oxidation catalyst for the diesel engine. Diesel oxidation
catalyst oxidizes unburnt fuel and raises exhaust
temperature.
CSF Catalyzed Soot Filter Filter. The filter traps, burns, and remove particulate matter
(PM) by using high-temperature-exhaust gas with diesel
oxidation catalyst. Catalyst is applied onto the filter. This
advances PM burning.
PM Particulate Matter Particulate matter.
EGR Exhaust Gas Recirculation The EGR control re-circulates a part of exhaust gas in the
intake manifold and combines it with intake-air. Therefore,
combustion temperature is lowered and generation of oxide
of nitrogen (NOx) is controlled.
HRV Hose Rupture Valve Hose rupture valve.
LLC Long Life Coolant Long life coolant.
SCR Selective Catalytic Reduction The urea SCR system injects diesel exhaust fluid to nitrogen
oxide (NOx) exhausted from the engine and purifies NOx.
DCU Dosing Control Unit Urea SCR system controller. DCU controls the diesel exhaust
fluid injection amount according to the machine operating
condition.
S/M Supply Module Diesel exhaust fluid supply module. The diesel exhaust fluid
supply module pumps diesel exhaust fluid to the dosing
module (D/M). Then, it returns diesel exhaust fluid in the
diesel exhaust fluid circuit when the key switch is turned
OFF.
D/M Dosing Module Dosing module. The dosing module (D/M) injects diesel
exhaust fluid into the exhaust piping according to the signal
from DCU.
NOx Nitrogen Oxide Nitrogen oxide.
DEF Diesel Exhaust Fluid Diesel exhaust fluid. The diesel exhaust fluid concentration is
32.5 %, which is specified in ISO22241.
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