Technical Manual Hitachi ZW180-7, ZW180PL-7 Wheel Loader | TONTK50-EN-01 (2023.04.21)

Technical Manual Hitachi ZW180-7, ZW180PL-7 Wheel Loader TONTK50-EN-01 (2023.04.21) (Preview)

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
CONTRASTING LIST OF PART NAME
– Contrasting List of Part Name between Technical Manual and Parts Catalog
SECTION AND GROUP CONTENTS
CONTENTS
GENERAL
– Specifications
— Specifications (ZW180-7)
— Specifications (ZW180PL-7)
– Component Layout
— Main Component (Overview)
— Main Component (Overview) (Parallel Link Front)
— Main Component
— Main Component (Parallel Link Front)
— Electrical System (Overview)
— Air Cleaner and Radiator Assembly
— Radiator Assembly
— Battery Box
— Hydraulic Oil Tank
— Fuel Tank
— Drive Unit
— Front Axle
— Cab
— Front Console
— Panel Switch
— Right Console
— Rear Console
— Control Unit
— Column Monitor
— Engine
— Aftertreatment Device
— Fan Valve
— Pump Device
— Control Valve
— Manifold Valve
— Parking Brake Solenoid Valve Unit
— Brake Charge Valve
— Steering Priority Valve
— Emergency Steering Valve
— Emergency Steering Pump Unit
— DEF Tank
— DEF Supply Module
— Brake Valve
– Component Specifications
— Specifications of Engine
— Specifications of Engine Accessories
— Specifications of Hydraulic Component
— Specifications of Hydraulic Component (Parallel Link)
— Electrical Component
SYSTEM
– Controller
— Outline of Controller
— CAN Circuit
– Control System
— Outline of Control System
— Engine Control (ECM)
— Engine Control System Layout
— Engine Protection Control
— Accelerator Pedal Control
— Auto Warming-Up Control
— Engine Torque Idle Speed-Up Control
— Forward/Reverse Selection Speed Limit Control While Traveling
— Engine Speed Limit Control without Load
— Matching Control While Digging
— Speed Limit Control with Power Mode OFF
— Auto Power Up Speed Control
— Speed Limit Control During Clutch Cut Operation
— Overheat Prevention Speed Limit Control
— Aftertreatment Device Manual Regeneration Control
— Engine Over Speed Limit Control
— Engine Max. Speed Limit Control at Stroke End Stall and Front Relief
— Idle Speed-Up Control (Fan Reverse Rotation)
— Pump Control
— Pump Control System Layout
— Base Torque Control
— Torque Decrease Control While Digging
— Transmission Control (TCU)
— Transmission Control System Layout
— Neutral Control
— Forward/Reverse Lever Priority Control
— Manual Speed Shift Control
— Automatic Speed Shift Control
— Maximum Speed Range Select Control
— Downshift Control
— Rise Run Shift Prohibit Control
— Clutch Cutoff Control
— Shift Holding Control
— Fan Control, Valve Control
— Fan Control, Valve Control System Layout
— Fan Speed Control
— Fan Reverse Rotation Control
— Fan Speed Control During Transmission Learning
— Ride Control
— Control by Electrical and Hydraulic Combined Circuit
— Bucket Auto Leveler Control
— Lift Arm Float Control
— Front Loader Device Control
— Outline of Front Attachment Operation Control
— Process of Front Attachment Operation Control
— Front Attachment Failure Detection
— Detent Control
— 3rd/4th Lever Control
— Control Lever Lock Control
— Other Controls
— Transmission Alarm Control
— Parking Brake Operation Indicator Control
— Brake Oil Low Pressure Indicator Control
— Low Steering Oil Pressure Indicator Control
— Overrun Alarm Control
— Lift Arm Auto Leveler Height Kickout Control
— Lift Arm Auto Leveler Lower Kickout Control
— Quick Power Mode Control
— Auto Shut-Down Control
— Emergency Steering Control
— Coolant Level Switch Control
— Payload Checker Control
— Object Detection Sensor Control(Optional for European and US market)
— Process of Object Detection Sensor Control (Optional for European and US market)
— Notification Processing (Leveling) (Optional for European and US market)
— Scooping Flag (Optional for European and US market)
— User Interface (Optional for European and US market)
— Aerial Angle Control
– Engine System
— Outline of ECM System
— Fuel Injection Control
— Fuel Injection Amount Control
— Fuel Injection Timing Control
— Fuel Injection Rate Control
— Fuel Injection Pressure Control
— Fuel Injection Amount Correction Control
— Preheating Control
— Variable Turbocharger Control
— Alarm Control
— Urea SCR System
— DEF Injection Control
— Start-Up Control
— DEF Defrosting Control
— DEF Thermal Control
— After-Run Control
— Engine Output Restriction Control (INDUCEMENT)
— Insufficient DEF Level
— Malfunction of Urea SCR System
— Outline of Aftertreatment Device
— Operation of Aftertreatment Device
— Aftertreatment Device Regeneration Control
– Hydraulic System
— Outline of Hydraulic System
— Pilot Circuit of Hydraulic System
— Charging Circuit
— Charging Circuit (Outline)
— Charging Circuit (When service brake is not stepped)
— Charging Circuit (When service brake is stepped)
— Service Brake Circuit
— Service Brake Circuit (When brake is applied)
— Service Brake Circuit (When brake is released)
— Parking Brake Circuit
— Parking Brake Circuit (Outline)
— Parking Brake Circuit (When parking brake is applied)
— Parking Brake Circuit (When parking brake is released)
— Lift Arm/Bucket Operation Control Circuit
— Lift Arm/Bucket Operation Control Circuit (Outline)
— Pump Control Circuit
— Ride Control Circuit
— Quick Coupler Circuit (When Locked)
— Quick Coupler Circuit (When Released)
— Main Circuit of Hydraulic System
— Main Circuit of Hydraulic System (Outline)
— Steering Priority Circuit
— Steering Priority Circuit (When not operating steering wheel)
— Steering Priority Circuit (When operating steering wheel)
— Steering Priority Circuit (When steering wheel operation is stopped (steering cylinder stroke end))
— Front Attachment Control Circuit
— Neutral Circuit
— Relief Circuit
— Single Operation Circuit
— Bucket Tilt Circuit (Parallel Link Front)
— Bucket Dump Circuit (Parallel Link Front)
— Combined Operation Circuit (Combined Operation of Lift Arm Raise and Bucket Dump)
— Combined Operation Circuit (Combined operation of steering and lift arm raise)
— Fan Circuit
— Fan Reverse Rotation Control Circuit
— Fan Speed Control Circuit
— Fan Circuit (Prevention of Cavitation)
— Emergency Steering Circuit
– Electrical System
— Outline of Electrical System
— Main Circuit of Electrical System
— Electric Power Circuit (Key Switch: OFF)
— CAN Circuit
— Accessory Related Circuits (Key Switch: ACC)
— Starting Circuit (Key Switch: START)
— Charging Circuit (Key Switch: ON)
— Surge Voltage Prevention Circuit
— Control Lever Lock Circuit (Key Switch: ON)
— Auto Shut-down Circuit
— Engine Stop Circuit
— Air Conditioner Circuit
— Column Box Circuit
— Headlight Circuit (Clearance Light, License Light, Tail Light Circuit (Light Switch: Clearance Light Position))
— Headlight Circuit (Dimmer Switch: Low Beam Position)
— High Beam Circuit
— Hazard Light Circuit (Key Switch: OFF)
— Turn Signal Light Circuit
— Horn Circuit (Key Switch: OFF)
— Back Buzzer Circuit
— Brake Light Circuit
— Parking Brake Circuit (Parking Brake: Released (Parking Switch: Release Position))
— Parking Brake Circuit (Parking Brake: Applied (Parking Switch: Apply Position)
— Accessory Circuit of Electrical System
— Work Light Circuit
— Front Wiper Circuit
— Rear Wiper Circuit
— Washer Circuit
— Cab Light Circuit
COMPONENT OPERATION
– Pump Device
— Outline of Pump Device
— Outline of Main Pump
— Increasing and Decreasing of Main Pump Delivery Flow Rate
— Outline of Regulator
— Regulator Control Function
— Control by Pump Control Pressure
— Control by Own Pump Delivery Pressure
— Control by Pilot Pressure from Torque Control Solenoid Valve
— Flow Rate Increase Control by Pump Control Pressure
— Flow Rate Decrease Control by Pump Control Pressure
— Flow Rate Increase Control by Own Pump Delivery Pressure
— Flow Rate Decrease Control by Own Pump Delivery Pressure
— Flow Rate Decrease Control by Pilot Pressure from Torque Control Solenoid Valve
— Outline of Pilot Pump
— Outline of Pump Delivery Pressure Sensor
– Control Valve
— Outline of Control Valve
— Components in Control Valve
— Main Circuit of Control Valve
— Pilot Operation Control Circuit of Control Valve
— External Pilot Pressure Circuit of Control Valve
— Outline of Main Relief Valve
— Relief Operation of Main Relief Valve
— Outline of Overload Relief Valve (With Make-Up Function)
— Relief Operation of Overload Relief Valve
— Make-Up Operation of Overload Relief Valve
— Outline of Anti-Drift Valve
— Holding Operation of Anti-Drift Valve
— Releasing Operation of Anti-Drift Valve
— Outline of Charge-Cut Valve in Ride Control Spool
— Operation (During Accumulation) of Charge-Cut Valve in Ride Control Spool
— Operation (Accumulation Stop) of Charge-Cut Valve in Ride Control Spool
— Operation of Drain Plug
— Outline of Pump Flow Rate Control Valve
— Operation (When the Control Lever is in Neutral) of Pump Flow Rate Control Valve
— Operation (When the Control Lever is Operated) of Pump Flow Rate Control Valve
— Outline of Solenoid Valve (Built-in control valve)
– Cooling Fan System
— Outline of Fan Pump
— Outline of Fan Motor
— Outline of Fan Valve
— Operation of Fan Valve (Normal Rotation)
— Operation of Fan Valve (Reverse Rotation)
— Operation of Fan Valve (With Fan Speed Controlled)
— Make-Up Operation of Fan Valve
– Steering Valve
— Outline of Steering Valve
— Structure of Steering Valve
— Operation of Steering Valve (Left Steering)
— Outline of Steering Overload Relief Valve
— Operation of Steering Overload Relief Valve
— Outline of Make-Up Valve
— Operation of Make-Up Valve
– Steering Priority Valve
— Outline of Steering Priority Valve
— Structure of Steering Priority Valve
— Operation of Steering Priority Valve (Neutral)
— Operation of Steering Priority Valve (Right Steering)
— Operation of Steering Priority Valve (Left Steering)
— Operation of Steering Priority Valve (Steering cylinder is at stroke end)
– Brake Charge Valve/Manifold Valve
— Outline of Brake Charge Valve and Manifold Valve
— Operation of Brake Charge Valve (Between Pressure Charging Start and Pressure Charging Finish)
— Operation of Brake Charge Valve (After Pressure Charging Finish)
— Structure of Manifold Valve
— Operation of Pilot Relief Valve
— Outline of Torque Control Solenoid Valve
— Outline of Proportional Solenoid Valve
— Operation of Proportional Solenoid Valve (When in Neutral)
— Operation of Proportional Solenoid Valve (When Excited)
— Outline of Control Lever Lock Solenoid Valve
— Outline of Service Brake Accumulator
— Outline of Pilot Accumulator
– Drive Unit
— Outline of Drive Unit
— Structure of Transmission
— Operation of Torque Converter
— Outline of Transmission
— Operation of Transmission (Forward Speed 1)
— Operation of Transmission (Forward Speed 2)
— Operation of Transmission (Forward Speed 3)
— Operation of Transmission (Forward Speed 4)
— Operation of Transmission (Forward Speed 5)
— Operation of Transmission (Reverse Speed 1)
— Operation of Transmission (Reverse Speed 2)
— Operation of Transmission (Reverse Speed 3)
— Operation of Transmission Control Valve
— Drive Unit Circuit
– Axle
— Outline of Axle
— Structure of Differential Gear
— Purpose of Differential Gear
— Basic Operational Principle of Differential Gear
— Operation of Differential Gear
— Outline of Torque Proportioning Differential (TPD)
— Operation of Torque Proportioning Differential (TPD)
— Outline of Limited Slip Differential (LSD)
— Operation of Limited Slip Differential (LSD)
— Outline of Service Brake
— Operation of Service Brake (When Brake Is Applied)
— Operation of Service Brake (When Brake Is Released)
— Outline of Final Drive/Axle Shaft
– Brake Valve
— Outline of Brake Valve
— Operation of Brake Valve (When Brake Pedal Is In Neutral) (Output Curve: A to B)
— Operation of Brake Valve (During Metering or Decompressing) (Output Curve: B-C)
— Operation of Brake Valve (Full Stroke) (Output Curve: C to D)
– DEF Supply System
— Outline of DEF Supply System
— Outline of DEF Tank
— Outline of DEF Hose
— Outline of DEF Sensor Unit
— Outline of DEF Sensor Head Unit
— Functions of DEF Sensor Unit Parts
— Outline of DEF Supply Module
— Outline of Coolant Line
– Others
— Outline of Propeller Shaft
— Outline of Parking Brake Solenoid Valve Unit
— Outline of Parking Brake Solenoid Valve
— Outline of Parking Brake Accumulator
— Outline of Quick Coupling Solenoid Valve
— Outline of Quick Coupler Selector Solenoid Valve
— Outline of Steering Accumulator
— Outline of Ride Control Accumulator
— Outline of Check Valve
— Outline of Pilot Filter
— Outline of Emergency Steering Valve
— Outline of Emergency Steering Pump Unit
— Outline of Proportional Solenoid Valve
— Operation of Proportional Solenoid Valve (When in Neutral)
— Operation of Proportional Solenoid Valve (When Excited)
— Outline of Bucket Regenerative Selector Valve
— Outline of Bucket Regenerative Valve
— Operation of Bucket Regenerative Valve (During Bucket Tilt Operation)
— Operation of Bucket Regenerative Valve (During Bucket Dump Operation)
SERVICE MANUAL REVISION REQUEST FORM