Fiat Hitachi Wheel Loader W230 Service Manual – PDF DOWNLOAD

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Fiat Hitachi Wheel Loader W230 Service Manual – PDF DOWNLOAD

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Fiat Hitachi Wheel Loader W230 Service Manual – PDF DOWNLOAD

Language : English
Pages : 371
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Fiat Hitachi Wheel Loader W230 Service Manual – PDF DOWNLOAD

SAFETY RULES
GENERALITIES

• Read this Manual carefully before starting, operating, maintaining, fuelling or servicing the machine. Read and comply with all safety precautions before any intervention. Do not allow unauthorised personnel to operate or service this machine.
• Do not wear rings, wrist watches, jewellery, loose or hanging garments, such as ties, torn clothing, scarves, unbuttoned or unzipped jackets that can get caught in moving parts. Wear certified safety clothes such as: hard hat, noslip footwear, heavy gloves, ear protection, safety glasses, reflector vests, respirators. Ask your employer about specific safety equipment requirements.
• Keep the operator’s compartment, step plates, grab-rails and handles clean and clear of foreign objects, oil, grease, mud or snow to minimize the danger of slipping or stumbling. Remove mud or grease from your shoes before attempting to mount or operate the machine. Do not jump on or off the machine.
• Always keep both hands and one foot, or both feet and one hand in contact with steps and grab rails. Do not use controls or hoses as hand holds when climbing on or off the machine. Hoses and controls are movable parts and do not provide solid support. Besides, controls may be inadvertently moved and cause unexpected movement of the machine or its attachments. Never operate the machine or its attachments from any position other than sitting in the driver’s seat. Keep head, body,
• limbs, hands and feet inside the operator’s compartment at all times to reduce exposure to external hazards . Be careful of possible slippery conditions of the steps and hand rails as well as of the ground around the machine. Do not leave the machine until it is has come to a complete stop. Check the seat safety belt at least twice per year and replace it if it shows signs of wear, fraying or other weakness that could lead to failure.

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TABLE OF CONTENTS:

Fiat Hitachi Wheel Loader W230 Service Manual – PDF DOWNLOAD

W230 Service Manual.............................................................................  1
S U M M A R Y...................................................................................  4
SAFETY RULES....................................................................................  5
SPECIFICATIONS - WHEEL LOADER W230.............................................................. 12
FLUIDS AND CAPACITY TABLE....................................................................... 14
UNITS OF MEASURE................................................................................ 15
TORQUE TABLES................................................................................... 16
SECTION 1 ENGINE................................................................................ 19
	1.1 IDENTIFICATION DATA..................................................................... 21
	1.2 GENERAL SPECIFICATIONS SERIES “C” ENGINE................................................ 23
	1.3 ENGINE SUPPORTS......................................................................... 26
	1.4 SERIES C ENGINE DIAGRAMS................................................................ 27
SECTION 2 TRANSMISSION.......................................................................... 31
	2.1 GENERAL DESCRIPTION..................................................................... 33
	2.2 TORQUE CONVERTER - TRANSMISSION......................................................... 34
	2.3 TORQUE CONVERTER........................................................................ 39
	2.4 TRANSMISSION - TORQUE CONVERTER PUMP.................................................... 41
	2.5 TRANSMISSION............................................................................ 42
		2.5.1 POWER TRAIN DIAGRAM............................................................... 46
		2.5.2 TRANSMISSION CONTROLVALVE......................................................... 48
	2.6 AUTOMATIC TRANSMISSION CONTROL SYSTEM................................................... 63
	2.7 TRANSMISSION CONTROL LEVER.............................................................. 69
	2.8 OIL CIRCUIT............................................................................. 73
	2.9 DISASSEMBLY TRANSMISSION................................................................ 75
	2.10 REASSEMBLY TRANSMISSION................................................................102
	2.11 TROUBLESHOOTING GUIDE..................................................................129
	2.12 Standard values for maintenance........................................................132
	2.13 Tightening torques of main fixture.....................................................136
	2.14 PROP SHAFTS............................................................................137
	2.15 FRONT AND REAR AXLES...................................................................139
		2.15.1 AXLE.............................................................................139
		2.15.2 DIFFERENTIAL.....................................................................144
		2.15.3 FINAL DRIVES.....................................................................146
	2.16 AXLE DISASSEMBLY.......................................................................148
	2.17 AXLE REASSEMBLY........................................................................159
	2.18 Troubleshooting........................................................................179
	2.19 STANDARD VALUES FOR MAINTENANCE........................................................180
	2.20 TIGHTENING TORQUE VALUES FOR MAIN BOLTS................................................181
	2.21 WHEELS.................................................................................182
		2.21.1 TYRES............................................................................182
SECTION 3 BRAKES SYSTEM.........................................................................183
	3.1 GENERAL DESCRIPTION.....................................................................185
	3.2 OPERATION...............................................................................187
		3.2.1 OPERATING CONDITIONS..............................................................187
	3.3 DISC BRAKE..............................................................................190
	3.4 BRAKE PEDAL VALVE.......................................................................191
		3.4.1 CIRCUIT SEPARATIONVALVE OPERATION INSIDETHE BRAKING SYSTEM........................193
	3.5 BRAKES/POWER SYSTEM PUMP................................................................194
	3.6 PARKING BRAKE CONTROL VALVE.............................................................195
	3.7 PARKING BRAKE...........................................................................196
		3.7.1 MANUAL RELEASE PROCEDURE..........................................................196
		3.7.2 DISC PARKING BRAKE OPERATION......................................................197
		3.7.3 BRAKE DISENGAGEMENT...............................................................197
	3.8 OTHER COMPONENTS........................................................................198
		3.8.1 SERVICE BRAKES ACCUMULATOR........................................................198
		3.8.2 CHECK VALVE (Parking brake).......................................................198
	3.9 BRAKE PEDAL VALVE HYDRAULIC CONNECTIONS.................................................199
	3.10 DIAGNOSTICS AND TESTING................................................................200
		3.10.1 BRAKE CONTROL PRESSURE TESTING...................................................202
		3.10.2 MINIMUM AND MAXIMUM ACCUMULATOR RECHARGE PRESSURE ADJUSTMENT.....................203
		3.10.3 PARKING BRAKE ENGAGEMENT TEST....................................................204
		3.10.4 ACCUMULATOR PRE-CHARGE TEST......................................................205
		3.10.5 INSTRUCTIONS FOR THE RESTORATION OF THE SERVICE BRAKES ACCUMULATORS PRECHARGE....206
		3.10.6 BLEEDING THE BRAKE SYSTEM........................................................207
		3.10.7 BRAKE DISC WEAR CHECK............................................................208
SECTION 4 STEERING SYSTEM.......................................................................209
	4.1 GENERAL DESCRIPTION.....................................................................211
	4.2 STEERING GROUP..........................................................................215
	4.3 STEERING VALVE..........................................................................217
	4.4 STEERING SYSTEM PUMP....................................................................219
	4.5 STEERING VALVE CONTROL LINKAGE..........................................................222
		4.5.1 Installation procedure for the linkage............................................223
		4.5.2 Operation.........................................................................224
	4.6 STEERING CYLINDERS......................................................................228
		4.6.1. Removal..........................................................................228
		4.6.2 Disassembly and reassembly........................................................229
		4.6.3 Installation......................................................................229
	4.7 STEERING EMERGENCY CIRCUIT..............................................................230
		4.7.1 COMPONENTS OF EMERGENCY STEERING..................................................231
SECTION 5 BUCKET BOOMS AND FRAME................................................................233
	5.1 GENERAL DESCRIPTION.....................................................................235
		5.1.1 BUCKET............................................................................239
		5.1.2 BUCKET POSITIONER DEVICE..........................................................240
		5.1.3 BOOMS KICK-OUT SETTING............................................................241
	5.2 FRAME...................................................................................242
		5.2.1. FRAME CENTRAL PIVOT..............................................................243
	5.3 BUCKET ABUTTING END PLUGS...............................................................245
SECTION 6 EQUIPMENT HYDRAULIC SYSTEM............................................................247
	6.1 GENERAL DESCRIPTION.....................................................................249
	6.2 HYDRAULIC SYSTEM PUMP...................................................................253
		6.2.1 BY-PASS VALVE.....................................................................255
		6.2.2 INSPECTION AND REPAIR OF EQUIPMENT PUMP...........................................256
	6.3 EQUIPMENT CONTROL VALVE.................................................................258
		6.3.1 GENERAL DESCRIPTION...............................................................258
		6.3.2 MAIN PRESSURE RELIEF VALVE........................................................260
		6.3.3 SAFETY AND ANTI-CAVITATION VALVES.................................................261
	6.4 CONTROL VALVE CONTROLS..................................................................263
		6.4.1 CONTROL VALVE HYDRAULIC CONTROL...................................................264
		6.4.2 SUPPLEMENTARY HYDRAULIC FUNCTION (Variant)........................................268
	6.5 HYDRAULIC OIL RESERVOIR.................................................................274
	6.6 CYLINDERS...............................................................................275
		6.6.1 BOOMS CYLINDER....................................................................275
		6.6.2 BUCKET TILT CYLINDER..............................................................275
	6.7 L.T.S. ANTI-PITCHING SYSTEM.............................................................278
		6.7.1 DESCRIPTION.......................................................................278
		6.7.2 DISCHARGE OF THE ACCUMULATORS.....................................................278
		6.7.3 L.T.S. HYDRAULIC DIAGRAM..........................................................280
		6.7.4 FUNCTIONAL TESTS OF L.T.S. SYSTEM.................................................281
		6.7.5 CHECK OF L.T.S. ACCUMULATOR PRECHARGE.............................................282
		6.7.6 INSTRUCTIONS FOR THE RESETTING OF ACCUMULATOR PRECHARGE...........................283
SECTION 7 ELECTRICAL SYSTEM.....................................................................285
	SAFETY RULES................................................................................287
	7.1 GENERAL LAY-OUT OF ELECTRICAL SYSTEM....................................................288
		7.2 LOGIC BOARD AND CAB CONNECTIONS.....................................................289
		7.2.1 CONNECTIONS - RELAYS - TIMERS - BUZZER............................................289
		7.2.2 FUSES TABLE.......................................................................290
	7.3 CAB INSTRUMENTS CLUSTER.................................................................291
		7.3.1 INDICATORS ON INSTRUMENT CLUSTER..................................................293
	7.4 SWITCH PANEL............................................................................293
	7.5 TRANSMISSION CONTROL SELECTOR (S41,TAB. 2)..............................................294
	7.6 ATC ELECTRONIC UNIT (K8,TAB. 2).........................................................295
	7.7 CONNECTORS..............................................................................297
	7.8 COLD START AND “LINK” FUSES.............................................................299
	7.9 STARTER SWITCH..........................................................................300
	7.10 MAIN SWITCH............................................................................300
	7.11 SOLENOID SWITCHES......................................................................302
	7.12 PRESSURE SWITCHES - SENSORS-SWITCHES...................................................303
	7.13 ACOUSTIC TRANSDUCERS...................................................................312
	7.14 ALTERNATOR.............................................................................313
	MACHINE GROUPS ELECTRIC DIAGRAMS............................................................315
SECTION 8 CAB...................................................................................341
	8.1 GENERAL DESCRIPTION.....................................................................343
	8.2 REPAIR..................................................................................344
	8.3 WINDSCREEN WIPERS AND WASHERS...........................................................346
	8.4 HEATER..................................................................................347
		8.4.1 GENERALITIES......................................................................347
		MAIN COMPONENTS AND SPECIFICATIONS......................................................347
	8.5 CAB GLAZING.............................................................................348
		8.5.1 DISASSEMBLY AND ASSEMBLY..........................................................349
	8.6 AIR CONDITIONING UNIT...................................................................353
		8.6.1 OPERATING INSTRUCTIONS............................................................353
		8.6.2 TECHNICAL DATA....................................................................354
		8.6.3 SERVICE PRECAUTIONS...............................................................355
		8.6.4 TOOL CONNECTIONS..................................................................357
		8.6.5 DISCHARGING.......................................................................358
		8.6.6 REFRIGERANT CHARGING..............................................................358
		8.6.7 LEAK INSPECTION...................................................................359
	8.7 TROUBLESHOOTING.........................................................................361

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PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

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