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PRINTED IN JAPAN (K) 2016, 09
PART NO.
TTPD850-EN-00
Technical Manual
Troubleshooting
ZW
180
-6
Wheel Loader
Service Manual consists of the following separate Part No.
Technical Manual (Operational Principle)
Technical Manual (Troubleshooting)
Workshop Manual
: Vol. No.TOPD850-EN
: Vol. No.TTPD850-EN
: Vol. No.WPD850-EN
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Summary of Contents for Hitachi ZW 180-6
- Page 1 PART NO. TTPD850-EN-00 Technical Manual Troubleshooting Wheel Loader URL:http://www.hitachi-c-m.com Service Manual consists of the following separate Part No. Technical Manual (Operational Principle) : Vol. No.TOPD850-EN Technical Manual (Troubleshooting) : Vol. No.TTPD850-EN PRINTED IN JAPAN (K) 2016, 09 Workshop Manual : Vol. No.WPD850-EN...
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- Page 3 SECTION 4 OPERATIONAL PERFORMANCE TEST CONTENTS Group 1 Introduction Group 6 Adjustment Operational Performance Tests ........T4-1-1 Rewrite of Aftertreatment Device Serial NO..... T4-6-1 Preparation for Performance Tests ....... T4-1-2 Clean DEF Tank..............T4-6-2 Transmission Learning ............T4-6-3 Group 2 Standard Lift Arm Angle Sensor Learning ........
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- Page 5 SECTION 5 TROUBLESHOOTING CONTENTS Group 1 Diagnosing Procedure Parking Brake Solenoid Valve Block ......T5-4-23 Brake Charge Valve ............T5-4-23 Introduction ................T5-1-1 Ride Control Valve (Optional) ........T5-4-24 Diagnosis Procedure ............T5-1-2 Emergency Steering Block (Optional) .......T5-4-25 Electrical System Inspection ........... T5-1-5 Emergency Steering Pump (Optional) ......T5-4-25 Precautions for Inspection and Maintenance ..
- Page 6 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 ............
- Page 7 FAX: 81-29-831-1162 E-mail: HCM-TIC-GES@hitachi-kenki.com 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 ...
- Page 8 INTRODUCTION Safety Alert Symbol and Headline Notations In this manual, the following safety alert symbol and CAUTION: signal words are used to alert the reader to the potential Indicates potentially hazardous situation which could, if for personal injury of machine damage. not avoided, result in personal injury or death.
- Page 9 SYMBOL AND ABBREVIATION Symbol / Name Explanation Abbreviation Technical manual (Operational principle) Technical manual (Operational Principle). Technical manual (Troubleshooting) Technical manual (Troubleshooting). Technical manual Technical manual. W, W/M Workshop manual Workshop manual (Removal and Installation, Disassembly and Assembly). Main Controller Main controller.
- Page 10 SYMBOL AND ABBREVIATION Symbol / Name Explanation Abbreviation 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. 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.
- Page 11 SAFETY Recognize Safety Information These are the SAFETY ALERT SYMBOLS. When you see these symbols on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe operating practices. SA-688 Understand Signal Words ...
- Page 12 Do not use attachments and/or optional parts or equipment not authorized by Hitachi. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine...
- Page 13 SAFETY Prepare for Emergencies Be prepared for a fire or an accident. Keep a first aid kit and fire extinguisher on hand. Thoroughly read and understand the label attached on the fire extinguisher to use it properly. ...
- Page 14 SAFETY Protect Against Noise Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises. SA-434 Inspect Machine ...
- Page 15 SAFETY General Precautions for the Cab Before entering the cab, thoroughly remove all dirt and/ or oil such as mud, grease, soil or stones from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots, the operator’s foot may slip off the pedal, possibly resulting in a personal accident.
- Page 16 SAFETY Use Handrails and Steps Falling is one of the major causes of personal injury. When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails. Do not use any controls as handholds. ...
- Page 17 SAFETY Ensure Safety Before Rising from or Leaving Operator’s Seat Before rising from the operator’s seat to open / close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the control lever lock switch to the lock ( ) position.
- Page 18 SAFETY Move and Operate Machine Safely Bystanders can be run over. Take extra care not to run over bystanders. Confirm the location of bystanders before moving, or operating the machine. Always keep the travel alarm and horn in working condition (if equipped).
- Page 19 SAFETY Operate Only from Operator’s Seat Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death. Start the engine only when seated in the operator's seat. Never start the engine while standing on the tire or on ground.
- Page 20 SAFETY Investigate Job Site Beforehand When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death. Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from collapsing.
- Page 21 SAFETY Equipment of Head Guard, ROPS, FOPS If the machine is operated in areas where the possibility of falling stones or debris, equip a head guard, ROPS, or FOPS according to the potential hazardous conditions. (The standard cab for this machine corresponds to ROPS and FOPS.) Any modification of the ROPS structure will modify its performance and its certification will be lost.
- Page 22 SAFETY Keep Riders Off Machine Riders on the machine are subject to injury such as being struck by foreign objects and being thrown off the machine. Only the operator should be on the machine. Keep riders off. Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner.
- Page 23 SAFETY Drive Machine Safely (Work Site) Before driving the machine, always confirm that the steering wheel / and forward / reverse lever (switch) direction corresponds to the direction you wish to drive. Be sure to detour around any obstructions. ...
- Page 24 SAFETY Drive Safely with Bucket Loaded If the machine is incorrectly operated while driving with the bucket loaded, turning over of the machine may result. Be sure to follow all the instructions indicated below. When driving the machine on a job site with the bucket loaded, hold the bucket as low as possible to keep the machine balanced and to have good visibility.
- Page 25 SAFETY Travel on Public Roads Safely This machine is not allowed to drive on public roads with the bucket loaded. Be sure to empty the bucket. Hold the bucket at mark (A) 300 mm (12 in) above the road surface as illustrated.
- Page 26 SAFETY Avoid Accidents from Backing Up and Turning Make sure no one is working under or close to the machine before backing up or turning the machine to avoid personal injury and/or death by being run over or entangled in the machine.
- Page 27 SAFETY Avoid Positioning Bucket or Attachment Over Anyone Never allow the bucket or attachment to pass over co- workers and/or the dump truck operator’s cab. Falling soil from the bucket or contact with bucket or attachment may cause serious personal accidents and/or damage to the machine.
- Page 28 SAFETY Never Undercut a High Bank The edges could collapse or a land slide could occur causing serious injury or death. SA-519 Dig with Caution Accidental severing of underground cables or gas lines may cause an explosion and/or fire, possibly resulting in serious injury or death.
- Page 29 SAFETY Avoid Power Lines Serious injury or death can result from contact with electric lines. When operating near an electric line, never move any part of the machine or load to within 3 m (10 ft) plus twice the line insulator length of overhead wires.
- Page 30 SAFETY Object Handling CRANING OPERATION USING THE MACHINE IS NOT ALLOWED. If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, resulting in serious injury or death. Never attach a sling or chain to the bucket teeth or to the attachment (fork or grapple for example).
- Page 31 SAFETY Park Machine Safely To avoid accidents: Park the machine on a firm, level surface. Lower bucket to the ground. Put the forward / reverse lever (switch) in neutral, and turn the parking brake switch (lever) ON (parking brake) position.
- Page 32 SAFETY Transport Safely Be aware care that the machine may turn over when loading or unloading the machine onto or off of a truck or trailer. Observe the related regulations and rules for safe transportation. Less than 15 ° ...
- Page 33 SAFETY Handle Fluids Safely−Avoid Fires Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death. Do not refuel the machine while smoking or when near open flame or sparks.
- Page 34 SAFETY Practice Safe Maintenance To avoid accidents: Understand service procedures before starting work. Keep the work area clean and dry. Do not spray water or steam inside cab. Never lubricate or service the machine while it is moving. ...
- Page 35 SAFETY Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the machine. Always use a work light protected with a guard. If the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.
- Page 36 SAFETY Stay Clear of Moving Parts Entanglement in moving parts can cause serious injury. To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts. SA-026 Support Maintenance Properly ...
- Page 37 SAFETY Prevent Parts from Flying Travel reduction gears are under pressure. As pieces may fly off, be sure to keep body and face away from AIR RELEASE PLUG to avoid injury. GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually loosen AIR RELEASE PLUG to release pressure.
- Page 38 SAFETY Replace Rubber Hoses Periodically Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone. ...
- Page 39 SAFETY Prevent Fires Check for Oil Leaks: Fuel, hydraulic oil and lubricant leaks can lead to fires. Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts.
- Page 40 SAFETY Clean up Flammable Materials: Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammable materials may cause fires. Prevent fires by inspecting and cleaning the machine daily, and by removing adhered oil or accumulated flammable materials immediately.
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