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ZW180
Hitachi ZW180 Manuals
Manuals and User Guides for Hitachi ZW180. We have
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Hitachi ZW180 manuals available for free PDF download: Technical Manual, Operator's Manual, Manual
Hitachi ZW180 Technical Manual (558 pages)
Wheel loader
Brand:
Hitachi
| Category:
Compact Loader
| Size: 11 MB
Table of Contents
Additional References
3
Manual Composition
3
Units Used
4
Recognize Safety Information
5
Understand Signal Words
5
Follow Safety Instructions
6
Prepare for Emergencies
6
Wear Protective Clothing
7
Protect against Noise
7
Adjust the Operator's Seat
9
Jump Starting
11
Keep Riders off Machine
14
Drive Safely
14
Avoid Tipping
18
Precautions for Operation
20
Object Handling
20
Store Attachments Safely
22
Transport Safely
22
Handle Fluids Safely-Avoid Fires
23
Practice Safe Maintenance
24
Support Machine Properly
25
Stay Clear of Moving Parts
25
Prevent Burns
27
Avoid High-Pressure Fluids
28
Prevent Fires
29
Avoid Heating Near Pressurized Fluid Lines
31
Remove Paint before Welding or Heating
31
Prevent Battery Explosions
32
Handle Chemical Products Safely
33
Dispose of Waste Properly
33
Workshop Manual
36
Tire Inflation
44
Engine Speed
51
Travel Speed
55
Table of Contents
74
Push the Air Bleed Valve of the Hydraulic Oil Tank and Release any Remaining Pressure
76
Remove the Plug from the Main Pump Delivery Port. Install an Adapter, a Hose and a Pressure Gauge
76
Maintain Hydraulic Oil Temperature at 50±5 °C (122±9 °F)
78
Set Engine Speed at Fast Idle. Depress the Accel- Erator Pedal Fully
78
Repeat the Measurement Three Times and Calcu- Late the Average Values
78
T4Gb-04-05-008
78
Regulator Adjustment
86
Transmission Clutch Pressure
98
Drive Belt Tension Adjustment
108
Troubleshooting Section
111
Introduction
115
Diagnosing Procedure
116
How to Operate Service Mode of Monitor
120
Display List of Monitor Service Mode
121
Outline
123
Operation
124
Self-Diagnostic Result
126
Select Controller
128
Main Controller
129
Setting
134
Password Change
142
Engine Controller
143
Monitor Display
144
Recorded Data Display
148
Password Change
149
ICF Controller
151
Information C/U Various Setup
152
Save Data Check
162
Password Change
163
Monitor Unit
165
Monitoring
166
Various Settings
168
Internal Hour Meter Synchronization
169
Password Change
170
Outline
171
List of Daily Report Data
172
List of Frequency Distribution Data
173
List of Total Operationg Hours
174
List of Alarm
175
List of Failure
176
How to Download and Upload Data of ICF
177
Various Setup of ICF and Satellite Communication Terminal by Using Dr.zx
180
List of ICF Fault Code
192
List of Fault Code of Sattellite
193
Communication Terminal
193
Main Component (Overview)
197
Main Component (Upperstructure)
198
Main Component (Travel System)
199
Electric System (Overview)
200
Electrical System (Cab)
201
Engine and Fan Pump
206
Pump Device
207
Drive Unit
207
Control Valve
208
Ride Control Valve
209
Charging Block
209
Fan Motor
209
Steering Valve
210
Emergency Steering Pump (Optional)
210
Components in Control Valve
212
Components in Steering Valve
218
Components in Charging Block
222
Components in Ride Control Valve
228
Front View of Transmission
232
Side View of Transmission
233
Rear View of Transmission
234
Cross-Sectional Drawing of Torque Converter
235
Cross-Sectional Drawing of Transmission
236
Cross-Sectional Drawing of Clutch Shaft
237
Cross-Sectional Drawing of Transmission Regulator Valve
238
Cross-Sectional Drawing of Transmission Control Valve
239
Troubleshooting a Procedure
241
MC Fault Code List
242
ECM Fault Code List
262
ICF Fault Code List
278
Satellite Terminal Fault Code List
280
Monitor Unit Fault Code List
282
Controller Hardware Failure MC Fault Codes 11000 to 11002
283
MC Fault Code 11003
284
MC Fault Code 11004
285
CAN Harness Check
286
Engine Failure MC Fault Code 11103
306
MC Fault Code 11105
307
Pump Failure MC Fault Code 11204
308
Pilot Failure MC Fault Code 11312
309
MC Fault Code 11313
310
Proportional Solenoid Valve Failure MC Fault Code 11412
311
MC Fault Code 11413
312
MC Fault Code 11414, 11415, 11416, 11417, 11418, 11419
313
Transmission Failure MC Fault Code 11600
316
MC Fault Code 11601
317
MC Fault Code 11602
318
MC Fault Code 11904
319
MC Fault Code 11905
320
CAN Data Reception Failure MC Fault Codes 11910, 11920
321
Can Harness Check MC Fault Codes 11910, 11920
322
MC Fault Code 11914
325
CAN Harness Check Fault Code 11914
326
Other Failures MC Fault Code 11901
329
Check
330
TROUBLESHOOTING / Troubleshooting
330
Proportional Solenoid Valve Truble
330
Ecm Fault Code Contrast List
333
ICF, Satellite Terminal Fault Codes 14000To14003
349
ICF, Satellite Terminal Fault Codes 14006, 14008, 14100 to 14106
353
Monitor Unit Fault Codes 13306, 13308
355
Monitor Unit Fault Code 13312
356
Monitor Unit Fault Code 13314
357
Troubleshooting B Procedure
359
Symptoms and Related Parts
359
Correlation between Trouble Symptoms and Part Failures
376
Engine System Troubleshooting
390
Front Attachment System Troubleshooting
399
Travel System Troubleshooting
418
Brake System Troubleshooting
434
Steering System Troubleshooting
442
Other System Troubleshooting
445
Air Conditioner
457
Exchange Inspection
467
Bleeding Air from Brake (Axle)
469
One Part of Data, "Daily Report
470
Data", "Distribution Data", "Total
470
Operationg Hours" and "Alarm" Is
470
Not Recorded
470
Troubleshooting C (Trouble Shooting for Monitor) Procedure
485
Malfunction of Indicator Light Check System
486
Malfunction of Buzzer in Monitor
488
Gauge
490
Malfunction of Transmission Oil Temperature Gauge
492
Malfunction of Fuel Gauge
494
Malfunction of Turn Signal Indicators (Left and Right)
496
Malfunction of Hazard Light Indicator
497
Malfunction of High Beam Indicator
498
Malfunction of Working Light Indicator
500
Malfunction of FNR Switch Indicator
502
Malfunction of Maintenance Indicator
504
Malfunction of Preheat Indicator
505
Malfunction of Transmission Oil Temperature Indicator
506
Malfunction of Hydraulic Oil Temperature Indicator
508
Malfunction of Transmission Warning Indicator
510
Malfunction of Air Filter Restriction Indicator
512
Malfunction of Engine Oil Pressure Indicator
514
Faulty Overheat Indicator
516
Malfunction of Engine Warning Indicator
518
Malfunction of Stop Indicator
519
Malfunction of Service Indicator
520
Malfunction of Parking Brake Indicator
522
Malfunction of Clearance Light Indicator
524
Malfunction of Brake Low Oil Pressure Indicator
525
Malfunction of Brake Low Oil Level Indicator
526
Malfunction of Emergency Steering Indicator (Optional)
528
Malfunction of Low Steering Oil Pressure Indicator (Optional)
530
Malfunction of Discharge Warning Indicator
532
Malfunction of Monitor Display
534
Malfunction of Ride Control Indicator
535
Malfunction of Engine Coolant Temperature Display
536
Precautions for Inspection and Maintenance
537
Instructions for Disconnecting Connectors
539
Fuse Inspection
542
Fusible Link Inspection
544
Battery Voltage Check
545
Alternator Check
546
Continuity Check
548
Check by False Signal
553
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Hitachi ZW180 Operator's Manual (334 pages)
Wheel Loader
Brand:
Hitachi
| Category:
Compact Loader
| Size: 6 MB
Table of Contents
Table of Contents
9
Safety
13
Recognize Safety Information
13
Understand Signal Words
13
Follow Safety Instructions
14
Prepare for Emergencies
14
Wear Protective Clothing
15
Protect against Noise
15
Inspect Machine
15
General Precautions for Cab
16
Use Handholds and Steps
17
Adjust the Operator's Seat
17
Ensure Safety before Rising from or Leaving Operator's Seat
17
Fasten Your Seat Belt
18
Move and Operate Machine Safely
18
Handle Starting Aids Safely
18
Operate Only from Operator's Seat
19
Jump Starting
19
Investigate Job Site Beforehand
20
Equipment of Head Guard, Rops, Fops
21
Provide Signals for Jobs Involving Multiple Numbers of Machines
21
Keep Riders off Machine
22
Drive Safely
22
Drive Machine Safely (Work Site
23
Drive Safely with Bucket Loaded
23
Drive on Snow Safely
24
Travel on Public Roads Safely
24
Avoid Injury from Rollaway Accidents
25
Avoid Accidents from Backing up and Turning
26
Avoid Positioning Bucket over Anyone
27
Avoid Tipping
27
Never Undercut a High Bank
28
Dig with Caution
28
Perform Truck Loading Safely
28
Avoid Power Lines
29
Precautions for Operation
29
Precautions for Lightening
29
Object Handling
29
Protect against Flying Debris
30
Park Machine Safely
30
Store Attachments Safely
31
Transport Safely
31
Handle Fluids Safely−Avoid Fires
32
Practice Safe Maintenance
33
Warn Others of Service Work
34
Support Machine Properly
34
Stay Clear of Moving Parts
34
Support Maintenance Properly
35
Prevent Parts from Flying
35
Prevent Burns
36
Replace Rubber Hoses Periodically
36
Avoid High-Pressure Fluids
37
Prevent Fires
38
Evacuating in Case of Fire
39
Beware of Exhaust Fumes
39
Precautions for Welding and Grinding
39
Avoid Heating Near Pressurized Fluid Lines
40
Avoid Applying Heat to Lines Containing Flammable Fluids
40
Remove Paint before Welding or Heating
40
Beware of Asbestos Dust
41
Prevent Battery Explosions
41
Service Air Conditioning System Safely
41
Handle Chemical Products Safely
42
Dispose of Waste Properly
42
Safety Signs
43
Components Name
53
Operator's Station
54
Cab Features
54
Front Console
55
Right Console
56
Monitor Panel
57
Stop Indicator
58
Service Indicator
58
Parking Brake Indicator
59
Brake Oil Low Pressure Indicator
59
Brake Oil Low Level Indicator
59
Emergency Steering Indicator (Optional)
59
Low Steering Oil Pressure Indicator (Optional)
60
Seat Belt Indicator
60
Discharge Warning Indicator
60
Engine Warning Indicator
60
Overheat Indicator
61
Engine Oil Low Pressure Indicator
61
Fuel Filter Restriction Indicator
61
Air Filter Restriction Indicator
61
Transmission Warning Indicator
62
Transmission Oil Filter Restriction Indicator
62
Hydraulic Oil Temperature Indicator
62
Transmission Oil Temperature Indicator
62
Engine Coolant Temperature Gauge
63
Transmission Oil Temperature Gauge
63
Fuel Gauge
63
Preheat Lamp
64
Turn Signal Indicator
64
High Beam Indicator
64
Work Light Indicator
64
Clealance Light Indicator
64
Lever Steering Indicator (Optional)
65
Maintenance Indicator
65
Forward/Reverse Selector Switch Indicator
65
Monitor Display
66
FNR (Forward/Reverse) Position Indicator
67
Hold Indicator
68
Shift Position Indicator
68
Speedometer
69
Automatic Mode Indicator
70
Ride Control Indicator
71
Clutch Cut Position Indicator
71
Machine Information Display
72
Clock Setting Mode
77
Switches, Steering Wheel and Pedals
78
Forward/Reverse Lever/Shift Switch
79
Neutral Lever Lock (Forward/Reverse Lever)
80
Horn Switch
80
Turn Signal Lever
80
Light Switch
81
High-Low Beam Switch
82
Key Switch
82
Windshield Wiper Switch
83
Rear Window Wiper Switch
83
Hazard Switch
84
Work Light Switch
85
Driving Mode Switch (ZW180)
86
Clutch Cut Position Switch
88
Work Mode Switch
88
Parking Brake Switch
89
Accelerator Pedal
90
Brake Pedal
90
Steering Column Tilt & Telescopic Lever
90
Air Conditioner Operation
91
Auto Air Conditioner
92
Defroster Operation
97
Tips for Optimal Air Conditioner Usage
98
Right Console/Switches
99
Loader Control Lever
100
Front Control Lever Lock
103
Armrest Adjust Handle
103
Finger Type
104
Hold Switch
104
DSS/USS (down Shift/ up Shift) Switch
104
DSS (down Shift) Switch
104
Multi-Function Type
105
Hold Switch
105
DSS (down Shift) Switch
105
USS (up Shift) Switch
105
Right Console Switch Panel
106
Quick Coupler Switch (Optional)
106
Lift Arm Auto Lever Switch (Optional)
107
Forward/Reverse Selector Switch
108
Ride Control Switch (Optional)
109
Fog Lamp Switch (Optional)
110
Fan Reversing Switch
110
Emergency Steering Operation Check Switch
111
Cigarette Lighter
111
Ashtray
111
Section 1
112
1- Weight Support Adjustment
112
2- Height Adjustment
113
3- Damper Adjustment
113
4- Fore-Aft Position Adjustment
113
5- Inclination Adjustment
114
6- Seat Depth Adjustment
114
7- Armrest Angle Adjustment
114
8- Reclining Angle Adjustment
114
10- Lumbar Support Adjustment
115
11- Seat Heater
115
12- Headrest
115
9- Armrest Adjustment
115
Section 2
116
Adjusting Operator's Seat (Mechanical Suspension Type Seat)
116
2- Height Adjustment
116
3- Inclination Adjustment
117
4- Fore-Aft Depth Adjustment
117
5- Fore-Aft Position Adjustment
117
6- Armrest Angle Adjustment
117
7- Armrest Adjustment
118
8- Reclining Angle Adjustment
118
Seat Belt
119
Rear Tray
120
Fuse Box
121
Hot&Cool Box
123
Tray and Drink Holder
123
ROPS Cab
124
Front Room Light
126
Rear Room Light
126
Coat Hook
127
Emergency Evacuation Hammer
127
Sun Visor
127
AM/FM Radio Operation
128
Digital Clock Setting Procedure
129
Upper Switch Panel (Optional)
130
Front Hot-Wire Heater Switch (Optional)
130
Rear Hot-Wire Heater Switch (Optional)
130
Rotary Light Switch (Optional)
130
Cab Door
131
Door Lock Knob
132
Rear View Mirror
131
Room Mirror
131
Door Open/Close Lever
132
Window Open/Close Lever
132
Door Lock Disengage Lever
133
When Fully Opening the Door
133
Articulate Lock Bar
134
Seat Pocket
135
Tool Box
135
Towing Pin
135
Inspection/ Maintenance Side Access Cover
136
Rear Grille
137
Steps
137
Vandal-Proof Devices
138
Break-In
141
Observe Engine Operation Closely
141
Check before Starting
143
Operating the Engine
143
Starting Engine
145
Check after Starting
147
Using Booster Batteries
148
Finger Type
150
Multi-Function Type
150
Warming up Operation
150
Steering
160
Provisional Stop and Restart of Driving
161
Precautions for Driving on Slopes
163
Precautions to be Taken if the Machine Failure Occurs
164
Stop/Parking
165
Loader Control Lever
169
Operating the Machine
169
Front Control Lever Lock
172
Clutch Cut Position Switch
173
Adjustment of Loader Front
174
Lift Arm Auto Lever Switch (Optional)
175
Adjustment of Bucket Auto Leveler
176
Adjustment of Lift Arm Auto Leveler (Optional)
177
Adjustment of Lift Arm Kick out
177
Before Operation
178
Ensure Safety When Operating on Road Shoulders
178
Precautions for Operation
178
Avoid Overloading
179
Avoid Rapid Steering Changes And/Or Sudden Braking
179
Excavation
180
Digging and Loading Level Ground
181
Grading
182
Loading
183
Dozing
185
Scooping
185
Lifting Wheel Loader
186
Removing Snow
186
Precautions for after Operations
187
Loading/Unloading on Trailer
189
Transporting
189
Transporting by Road
189
Transporting by Trailer
189
Transporting
190
Transporting Wheel Loader (Urgent Situation)
192
Towing Method
198
Lifting Machine
199
Correct Maintenance and Inspection Procedures
201
Maintenance
201
Check the Hour Meter Regularly
202
Use Correct Fuels and Lubricants
202
Layout
203
Maintenance Guide Table
206
Preparations for Inspection and Maintenance
208
Lock Frames
209
Inspection/Maintenance Access Side Cover
210
Rear Grille
211
Periodic Replacement of Parts
212
Maintenance Guide
213
Kind of Oils
219
Greasing
222
Engine
228
Check Engine Oil Level
228
Change Engine Oil
228
Replace Engine Oil Filter
230
Power Train
233
Check Transmission Oil Level
233
Change Transmission Oil and Transmission Oil Filter
234
Clean Transmission Oil Strainer
234
Change Axle Oil
236
Clean Torque Converter Air Breather
238
Clean Axle Housing Air Breather
239
Hydraulic System
240
Inspection and Maintenance of Hydraulic Equipment
240
Check Hydraulic Oil Level
241
Change Hydraulic Oil
242
Clean Suction Filter
245
Replace Pilot Oil Filter
246
Replace Hydraulic Tank Oil Filter
247
Check Hoses and Lines
248
Service Recommendations for Hydraulic Fittings
251
Fuel System
253
Check Fuel Level
253
Drain Water and Sediment from Fuel Tank
254
Check and Drain Water Separator
254
Replace Fuel Main Filter
258
Replace Fuel Pre-Filter
260
Clean Fuel Solenoid Pump Strainer
262
Check Fuel Hoses
263
Air Cleaner
264
Clean and Replace Air Cleaner Element
264
Cooling System
265
Check Coolant Level
267
Check Fan Belt
268
Check Fan Belt Tension
268
Adjust Fan Belt Tension
268
Change Coolant
269
Clean Radiator/Oil Cooler Cores and Other Cooling System
273
Electrical System
274
Replace Batteries
277
Check Monitor Functions and All Other Instrument Operation
278
Check Work Lights
279
Check Horn and Reverse Buzzer
279
Check Electrical Harnesses and Fuses
280
Brake System
282
Check Right and Left Brake Interlocking Performance
282
Check Parking Brake Force
282
Check Accumulator Function, Gas Leakage, Looseness, and Damage
283
Check Gas Pressure in Accumulator
283
Check Brake Disks (Service and Paring)
284
Tire
285
Check and Replace Tire (Tire Pressure) Check
285
Check Tire for Damage
286
Check Wheel Bolt Torque
286
Air Conditioner
290
Clean/Replace Air Conditioner Circulation/Fresh Air Filters
290
Check Air Conditioner
292
Check Air Conditioner Piping
292
Check Air Conditioner Condenser
293
Check Air Conditioner Fan Belt
293
Check Refrigerant
294
Check Compressor and Pulley
294
Check Switch Operation
294
Miscellaneous
295
Check Bucket Teeth and Cutting Edge
295
Check and Replace Seat Belt
296
Check ROPS Cab, Resin Cab Roof, and Roof Mounting Bolts
296
Check Windshield Washer Fluid Level
296
Check Play Amount in Steering Wheel Stroke
297
Check Accelerator Pedal Operation, and Exhaust Gas Color and Noise
298
Check Rearview Mirror and Inside Rearview Mirror
299
Check Turbocharger Bearing
299
Check Engine Cylinder Head and Manifold
299
Check and Adjust Valve Clearance
299
Check Fuel Injection Timing
300
Check Engine Compression Pressure
300
Check and Clean Starter and Generator
300
Retighten Front Axle and Rear Axle Support Mounting Bolts
300
Tightening and Retightening Torque of Nuts and Bolts
301
Maintenance under Special Environmental Conditions
315
Storing the Machine
319
Removing the Machine from Storage
320
Troubleshooting
321
Specifications
325
Sound Level Results (2000/14/Ec)
326
Optional Attachments
327
Specifications
327
Index
331
Hitachi ZW180 Technical Manual (374 pages)
Operational Principle, Wheel loader
Brand:
Hitachi
| Category:
Front End Loaders
| Size: 16 MB
Table of Contents
Section 1 General
7
Table of Contents
7
Specifications
9
Main Component (Overview)
11
Main Component (Upperstructure)
12
Main Component Layout (Travel System)
13
Electrical System (Overview)
14
Electrical System (in Cab)
15
Engine and Fan Pump
20
Pump Device
21
Drive Unit
21
Control Valve
22
Ride Control Valve(Optional)
23
Charging Block
23
Fan Motor
23
Steering Valve
24
Emergency Steering Pump (Optional)
24
Engine
25
Engine Accessories
29
Hydraulic Component
31
Electrical Component
36
Section 2 System
41
General
43
Engine Control
48
Pump Control
57
Transmission Control
62
Other Controls
83
Control by Electric and Hydraulic Combined Circuit
93
Outline
107
Fuel Injection Control
108
Engine Start Control
110
Other Controls
111
Outline
117
Main Circuit
118
Pilot Circuit
129
Steering Circuit
142
Hydraulic Drive Fan Circuit
148
Outline
151
Main Circuit
152
Electric Power Circuit
153
Indicator Light Check Circuit
154
Accessory Circuit
155
Preheat Circuit
156
Starting Circuit
158
Charging Circuit
162
Engine Stop Circuit
168
Lamplight Circuit
169
Head Light Circuit
170
Turn Signal Circuit
174
Brake Light Circuit
175
Hazard Light Circuit
176
Horn Circuit
177
Reverse Light/Buzzer Circuit
178
Parking Brake Circuit
180
Emergency Steering Check Circuit (Optional)
182
Section 3 Component Operation
187
Outline
189
Main Pump
190
Regulator
192
Priority Valve
206
Pilot Pump
207
Pump Delivery Pressure Sensor
207
Steering Main Relief Valve
208
Outline
209
Hydraulic Circuit
216
Main Relief Valve
220
Overload Relief Valve
222
Restriction Valve
227
Negative Control Valve
228
Flow Rate Control Valve
230
Outline
233
Operation
236
Flow Rate Control Valve
238
Reverse Rotation Control Valve
240
Outline
243
Construction
244
Operation
245
Outline
249
Operation
252
Steering Overload Relief Valve
256
Front Attachment
259
Outline
259
Operation
260
Electromagnetic Detent
264
Outline (Joystick Type Pilot Valve for Front Attachment)
265
Operation
266
Electromagnetic Detent
270
Outline (Two-Derectional Lever Type Pilot Valve for Additional Circuit) (Optional)
271
Operation
272
Outline (Joystick Type Pilot Valve for Additional Circuit) (Optional)
275
Operation
276
Outline
283
Priority Valve
288
Pilot Relief Valve
289
Pump Torque Control Proportional Solenoid Valve
290
Service Brake Accumulator / Pilot Accumulator
291
Parking Brake Solenoid Valve
292
Parking Brake Pressure Sensor
294
Service Brake Pressure Sensor
294
Outline
295
Operation
298
Charge-Cut Spool
300
Overload Relief Valve
302
Ride Control Accumlator
304
Drain Plug
305
Outline
307
Torque Converter
308
Transmission
310
Transmisson Regulator Valve
332
Transmission Control Valve
334
Manual Spool (Emergency Travel Spool)
342
Proportional Solenoid Valve
344
Parking Brake
346
Outline
349
Differential
350
Torque Proportioning Differential (TPD)
354
Limited Slip Differential (LSD) (Optional)
356
Service Brake
358
Final Drive / Axle Shaft
360
Outline
361
Operation
364
Pilot Shut-Off Valve
367
Propeller Shaft
368
Emergency Steering Check Block
369
Emergency Steering Pump (Optional)
370
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Hitachi ZW180 Manual (11 pages)
WHEEL LOADER
Brand:
Hitachi
| Category:
Compact Loader
| Size: 4 MB
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