Technical Manual Hitachi ZW150-6, ZW150PL-6 Wheel Loader | TTPTC50-EN-01

Technical Manual Hitachi ZW150-6, ZW150PL-6 Wheel Loader TTPTC50-EN-01 (Preview)

TTPTC50-EN-01

INTRODUCTION
To The Reader
Additional References
Manual Composition
Page Number
Trademark
Safety Alert Symbol and Headline Notations
Units Used
SYMBOL AND ABBREVIATION
Symbol and Abbreviation
SAFETY
Recognize Safety Information
Understand Signal Words
Follow Safety Instructions
Prepare for Emergencies
Wear Protective Clothing
Protect Against Noise
Inspect Machine
General Precautions for the Cab
Use Handrails and Steps
Never Ride Attachment
Adjust Operator’s Seat
Ensure Safety Before Rising from or Leaving Operator’s Seat
Fasten Your Seat Belt
Move and Operate Machine Safely
Handle Starting Aids Safely
Operate Only from Operator’s Seat
Jump Starting
Investigate Job Site Beforehand
Equipment of Head Guard, ROPS, FOPS
Provide Signals for Jobs Involving Multiple Machines
Keep Riders Off Machine
Drive Safely
Drive Machine Safely (Work Site)
Drive Safely with Bucket Loaded
Drive on Snow Safely
Travel on Public Roads Safely
Avoid Injury from Rollaway Accidents
Avoid Accidents from Backing Up and Turning
Avoid Positioning Bucket or Attachment Over Anyone
Avoid Tipping
Never Undercut a High Bank
Dig with Caution
Perform Truck Loading Safely
Avoid Power Lines
Precautions for Operation
Precautions for Lightning
Object Handling
Protect Against Flying Debris
Park Machine Safely
Store Attachments Safely
Transport Safely
Handle Fluids Safely−Avoid Fires
Practice Safe Maintenance
Warn Others of Service Work
Support Machine Properly
Stay Clear of Moving Parts
Support Maintenance Properly
Prevent Parts from Flying
Prevent Burns
Replace Rubber Hoses Periodically
Avoid High-Pressure Fluids
Prevent Fires
Evacuating in Case of Fire
Beware of Exhaust Fumes
Precautions for Welding and Grinding
Avoid Heating Near Pressurized Fluid Lines
Avoid Applying Heat to Lines Containing Flammable Fluids
Precautions for Handling Accumulator and Gas Damper
Remove Paint Before Welding or Heating
Beware of Asbestos and Silica Dust and Other Contamination
Prevent Battery Explosions
Service Air Conditioning System Safely
Handle Chemical Products Safely
Dispose of Waste Properly
Notes on Aftertreatment Device
Precautions for Communication Terminal
Precaution for Communication Terminal Equipment
Before Returning the Machine to the Customer
SECTION AND GROUP CONTENTS
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction
Operational Performance Tests
Preparation for Performance Tests
Group 2 Standard
Operational Performance Standard Table
Sensor Activating Range
Group 3 Engine Test
Engine Speed
Lubricant Consumption
Group 4 Machine Performance Test
Travel Speed
Service Brake Function Check
Service Brake Wear Amount
Parking Brake Function Check
Bucket Stopper and Bell Crank Stopper Clearance
Hydraulic Cylinder Cycle Time
Dig Function Drift Check
Bucket Levelness
Control Lever Operating Force
Control Lever Stroke
Group 5 Component Test
Primary Pilot Pressure (Including Brake Circuit)
Secondary Pilot Pressure
Combined Delivery Pressure of Main Pump and Steering Pump
HST Pump Delivery Pressure
HST Charging Pump Delivery Pressure
Transmission Charge Pump Delivery Pressure
Main Relief Set Pressure
HST Pump Relief Pressure
Steering Relief Pressure
Overload Relief Valve Set Pressure
Service Brake Pressure (Front and Rear)
Parking Brake Pressure
Brake Accumulator Pressure
Brake Warning Pressure (Pressure-Decreasing)
Brake Warning Pressure (Pressure-Increasing)
Transmission Clutch Pressure
Accumulator Gas Pressure
Gas Pressure Adjustment Procedure of Accumulator (Service Brake Circuit, Steering Circuit)
Gas Pressure Adjustment Procedure of Accumulator (Ride Control Circuit (OPT))
Group 6 Adjustment
Rewrite of Aftertreatment Device Serial No.
Clean DEF Tank
Clutch Learning
Brake Pedal Angle Learning
Lift Arm Angle Sensor Learning
Digging Position Adjustment
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Introduction
Diagnosis Procedure
Electrical System Inspection
Precautions for Inspection and Maintenance
Instructions for Disconnecting Connectors
Fuse Inspection
Fusible Link Inspection
Battery Voltage Check
Alternator Check
Continuity Check
Voltage and Current Measurement
Check by False Signal
Test Wire Harness
Group 2 Monitor
Outline
Operating Procedures of Service Menu
Coolant Temperature Gauge and HST Oil Temperature Gauge
Fuel Gauge
Group 3 e-Service
Outline
List of Operation Data
Snapshot Data
Communication System
Group 4 Component Layout
Main Component (Overview)
Main Component
Electrical System (Overview)
Air Cleaner and Radiator Assembly
Battery Box
Hydraulic Oil Tank
Fuel Tank
Cab
Engine
Aftertreatment Device
Transmission, HST Motor
Fan Valve
Fan Valve (With Fan Reverse Rotation) (Optional)
HST Pump, 3-Gear Pump Unit
Control Valve
Manifold Valve
Brake Charge Valve
Emergency Steering Block
Emergency Steering Pump
Ride Control Valve
DEF Tank
DEF Supply Module
Group 5 Troubleshooting A
Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure
MC Fault Code List
HST Controller Fault Code List
Information Controller Fault Code List
Column Display Controller Fault Code List
Air Conditioner Controller Fault Code List
Communication Terminal Fault Code List
ECM Fault Code List
MC Fault Codes 111000 to 111002
MC Fault Code 111003
MC Fault Codes 111006, 111007, 111030
CAN1 Harness Check
CAN3 (Engine) Harness Check
MC Fault Codes 111008, 111014, 111025
CAN2 Harness Check
MC Fault Code 111103
MC Fault Codes 111205, 111207
MC Fault Codes 111217
MC Fault Codes 111206
MC Fault Code 111208
MC Fault Codes 111311
MC Fault Code 111406
MC Fault Code 111411
MC Fault Code 111412
MC Fault Code 111422
MC Fault Code 111908
MC Fault Code 111909
MC Fault Codes 120003, 120004, 120014
HST Controller Fault Codes 111027, 111028
HST Controller Fault Code 111332
HST Controller Fault Codes 111330, 111331, 111333
HST Controller Fault Code 111334
HST Controller Fault Codes 111430, 111431, 111432
HST Controller Fault Code 111433
HST Controller Fault Code 111457
HST Controller Fault Codes 111450, 111451
HST Controller Fault Codes 111620, 111621
HST Controller Fault Code 111622
HST Controller Fault Code 111904
HST Controller Fault Code 111905
Column Display Controller Fault Code 115001
Column Display Controller Fault Code 115011
Column Display Controller Fault Code 115015
Column Display Controller (Information) Fault Codes 120500 to 120505
Column Display Controller Fault Codes 120506, 120507, 120510 to 120513, 120515, 120517, 120518
Air Conditioner Controller Fault Codes E11 to E22
Air Conditioner Controller Fault Codes E43 to E92
Group 6 Troubleshooting B
Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure
Relationship between Machine Trouble Symptoms and Related Parts
Correlation between Trouble Symptoms and Part Failures
Engine System Troubleshooting
All Actuator System Troubleshooting
Front Attachment System Troubleshooting
Steering System Troubleshooting
Travel System Troubleshooting
Brake System Troubleshooting
Other System Troubleshooting
Exchange Inspection
Air Bleeding Procedures for Brake (Axle)
Group 7 Troubleshooting C
Troubleshooting C (Diagnosis of Monitor) Procedure
Faulty buzzer
Faulty Coolant Temperature Gauge
Faulty Fuel Gauge
Faulty HST oil temperature gauge
Faulty Monitor Display
Faulty bulb inspection
Faulty Right/Left Turn Signal Indicator
Faulty Hazard Lighting
Faulty High Beam Indicator
Faulty Work Light Indicator
Faulty Maintenance Lamp
Faulty Preheat Indicator
Faulty HST Oil Temperature Alarm
Faulty HST Alarm
Faulty Engine Oil Pressure Alarm
Faulty Overheat Alarm
Faulty Engine Alarm
Faulty Inspection/Maintenance Alarm
Faulty Parking Brake Alarm
Faulty Clearance Light Indicator
Faulty Emergency Steering Alarm (Optional)
Faulty Steering Oil Pressure Alarm (Optional)
Faulty Alternator Indicator
Faulty Air Filter Restriction Alarm
Faulty Fuel Filter Restriction Alarm
Faulty Brake Oil Pressure Alarm
Faulty Hydraulic Oil Level Alarm
Faulty Muffler Filter Alarm
Faulty Muffler Filter Regeneration Inhibit Alarm
Faulty Water Separator Alarm (Optional)
Faulty Muffler Filter Regeneration Inhibit Indicator
Faulty Control Lever Lock Indicator
Faulty Power Mode Indicator
Faulty Fan Reverse Rotation Indicator (Optional)
Faulty Seat Belt Indicator
Group 8 Air Conditioner
Outline
Functions of Main Parts
Troubleshooting
Air Conditioner Controller Fault Code List
Air Conditioner Controller Fault Codes 11 to 22
Air Conditioner Controller Fault Codes 43 to 92
Work after Replacing Components
Refill Compressor Oil
Charge Air Conditioner with Refrigerant
Hose and Pipe Tightening Torque
SERVICE MANUAL REVISION REQUEST FORM
The Attached Diagram List