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Fiat Hitachi Wheel Loader W80 TECHNICAL HANDBOOK MANUAL – PDF DOWNLOAD
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Description
Fiat Hitachi Wheel Loader W80 TECHNICAL HANDBOOK MANUAL – PDF DOWNLOAD
FILE DETAILS:
Fiat Hitachi Wheel Loader W80 TECHNICAL HANDBOOK MANUAL – PDF DOWNLOAD
Language : English
Pages : 538
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Fiat Hitachi Wheel Loader W80 TECHNICAL HANDBOOK MANUAL – PDF DOWNLOAD
FOREWORD
- Anyone involved with commissioning, operating, inspecting and servicing for this construction machine must read through and acquaint himself with the “OPERATING MANUAL” – and especially the Section “FUNDAMENTAL SAFETY INSTRUCTIONS” – before starting work.
- The “Service Data” contains details which are important to the service staff. Data included in other parts of the general documentation have been left aside. The set of documents for this construction machine includes:
• Operating manual
• Spare parts list
- “Technical Handbooks” (THB) and “Service Information” bulletins (si) are, furthermore, to be considered as supplements to the general documentation.
- Data regarding auxiliary units for operating ancillary or special systems, as well as data on machines produced only in small numbers, have not been included.
- Filling quantities are only approximate figures intended to help in stockholding the various fluids and agents. Each unit has appropriate checking systems, e.g. dipstick or checking screws, with which the exact filling level can be checked
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Fiat Hitachi Wheel Loader W80 TECHNICAL HANDBOOK MANUAL – PDF DOWNLOAD
Wheel Loader W80............................................................................................. 1 INDEX........................................................................................................ 2 FOREWORD................................................................................................. 3 FOREWORD............................................................................................. 4 Using the Technical Handbook..................................................................... 4 Servicing and repair............................................................................. 4 FUNDAMENTAL SAFETY INSTRUCTIONS...................................................................... 5 Warnings and symbols................................................................................. 5 Danger in the event of non-observance of the safety instructions..................................... 5 Organizational measures.............................................................................. 6 Selection and qualification of personnel............................................................. 7 OPERATING, SAFETY INSTRUCTIONS....................................................................... 7 Standard operation............................................................................... 7 MAINTENANCE, SAFETY INSTRUCTIONS..................................................................... 8 WARNING OF SPECIAL DANGERS........................................................................... 9 Electric energy.................................................................................. 9 Gas, dust, steam and smoke....................................................................... 9 Hydraulic and pneumatic equipment................................................................ 10 Noise............................................................................................ 10 Oil, grease and other chemical substances........................................................ 10 TRANSPORTING AND TOWING -RECOMMISSIONING............................................................. 10 REPAIR WORK - SAFETY INSTRUCTIONS.................................................................... 11 ACCUMULATORS......................................................................................... 12 Safety instructions.................................................................................. 12 ENGINE............................................................................................... 13 Engine - repair instructions......................................................................... 13 Assisted starting (jump-starting) -Safety instructions............................................... 13 WELDING OPERATIONS................................................................................... 14 Welding operations - safety instructions......................................................... 14 Service Data................................................................................................. 16 FOREWORD..................................................................................................... 19 FOREWORD................................................................................................. 21 SI - AND ADDITIONAL UNITS................................................................................ 23 Quantities of space and mass......................................................................... 23 Time-related quantities.............................................................................. 24 Quantities of force, energy and power................................................................ 25 CONVERSIONS TABLES....................................................................................... 26 Conversion for units of length....................................................................... 26 Conversion for units of area......................................................................... 27 Conversion from foot (Fuss) and inch (Zoll) to metric measures....................................... 28 Conversion from newtonmeter "Nm" into foot pounds "ft.lb."........................................... 29 Conversion table for units of pressure in gases, steam and fluids.................................... 37 Conversion table for units of power, ernergy and heat quantity....................................... 38 Conversion table for units of mechanical stress (strength)........................................... 39 Practically equivalent units for pressure and mechanical stress (strength)........................... 40 Units of temperature and conversion formulas......................................................... 41 Power, energy and heat flow.......................................................................... 42 Speed................................................................................................ 43 Units of mass (weight)............................................................................... 44 Units of volume, flow rates.......................................................................... 45 Fuel consumption..................................................................................... 46 CALCULATION EXAMPLES..................................................................................... 47 Angles of slope...................................................................................... 47 Travel speeds........................................................................................ 47 Hydraulic outputs (pumps/motors)..................................................................... 48 Stroking times of cylinders.......................................................................... 48 Speeds of hydraulic motors........................................................................... 48 TIGHTENING TORQUES....................................................................................... 50 General information.................................................................................. 50 Bolts with standard thread DIN 13 - 13............................................................... 51 Bolts with metric fine thread DIN 13 - 13............................................................ 52 Tightening torques for SAE flange-system............................................................. 53 Tightening angles.................................................................................... 53 Foreword..................................................................................................... 58 Foreword................................................................................................. 59 Engine................................................................................................... 61 Axles and transmission gears............................................................................. 62 Front axle........................................................................................... 62 Rear axle with transfer box gearing.................................................................. 62 Travel speeds............................................................................................ 62 Hydraulic system......................................................................................... 63 Checking and setting data............................................................................ 63 Variable pump (PAG = Primary unit)................................................................... 65 Double hydraulic pump................................................................................ 65 Variable motor (SAG = Secondary unit)................................................................ 66 Hydraulic cylinders.................................................................................. 67 Service fluids........................................................................................... 68 Tightening torques....................................................................................... 69 Approx. weights.......................................................................................... 70 Diesel engine................................................................................................ 73 TRAVEL DRIVE................................................................................................. 75 TRAVEL DRIVE............................................................................................. 76 Hydraulic System, Safety Instructions.................................................................... 76 Explanations of circuit diagrams and illustrations....................................................... 76 Depressurizing the hydraulic system...................................................................... 77 Principle: hydrostatic travel drive...................................................................... 78 Hydraulic circuit diagram - travel drive................................................................. 79 Hydraulic circuit diagram, legend........................................................................ 80 Pressure measuring points............................................................................ 80 Functional description: hydrostatic travel drive of wheel loader W80..................................... 82 Travel drive installation............................................................................ 84 Pressure measuring points............................................................................ 84 Adjusting work at the hydrostatic travel drive........................................................... 85 Mechanical zero position............................................................................. 85 Checking and adjusting high pressure at travelling................................................... 85 Adjusting cylinder (A13)............................................................................. 86 High-pressure relief valve (A4)...................................................................... 87 High-pressure relief valve (A4), deblockable......................................................... 88 Pressure cutout (A8)................................................................................. 89 Switching valve (A11), electromagnetically activated................................................. 90 Feed pressure relief valve (A9)...................................................................... 91 Checking and adjusting feed pressure................................................................. 92 Control valve (A7)................................................................................... 93 Checking and adjusting the regulation threshold (driving start)...................................... 94 Checking regulation end.............................................................................. 94 Axial-piston oil motor (A15)......................................................................... 95 Checking and adjusting the regulation threshold of the hydraulic motor (displacement switch-over).... 96 Inching valve (B10).................................................................................. 97 Adjusting the inching threshold...................................................................... 98 Repair instructions, hydraulic pump......................................................................100 Repair instructions, hydraulic motor.....................................................................100 Axles........................................................................................................190 Preface..................................................................................................191 Preface..............................................................................................193 General..............................................................................................193 Design...........................................................................................193 Maintenance......................................................................................193 General Working Instructions.....................................................................194 Notes on working safety..........................................................................195 Assembling Procedure.............................................................................195 Weights..........................................................................................195 Survey...............................................................................................196 Front Axle Components, Screw Qualities, Tightening Torques, Screw Locking........................196 Front Axle.......................................................................................196 Axle Drive Assembly..............................................................................198 Wheel Hub Assembly...............................................................................200 Rear Axle Components, Screw Qualities, Tightening Torques, Screw Locking.........................202 Rear Axle Assembly...............................................................................202 Axle Drive Assembly..............................................................................204 Brake Assembly...................................................................................206 Wheel Hub Assembly...............................................................................208 Front Axle Drawing...............................................................................210 Rear Axle Drawing................................................................................210 Dismantling and Reassembling the Axles...............................................................211 Dismantling......................................................................................211 Reassembling.....................................................................................211 Dismantling the Front Axle...........................................................................214 Wheel Hub Assembly...............................................................................214 Axle Drive Assembly..............................................................................216 Differential Assembly............................................................................217 Dismantling the Rear Axle............................................................................218 Wheel Hub Assembly...............................................................................218 Brake Assembly...................................................................................218 Axle Drive Assembly..............................................................................220 Differential Assembly............................................................................222 Assembling the Front Axle............................................................................223 Wheel Hub Assembly...............................................................................223 Differential (Pre-assembling)....................................................................234 Complete Axle Drive and Axle Assemblies..........................................................238 Assembling the Rear Axle.............................................................................253 Wheel Hub Assembly...............................................................................253 Brake Assembly (Pre-Assembling)..................................................................253 Differential Assembly (Pre-Assembling)...........................................................259 Complete Axle Drive and Axle Assemblies..........................................................259 GLEASON Toothing Surface Appearances.................................................................275 GLEASON Toothing Surface Appearances.............................................................276 List of Special Tools................................................................................278 Screw Tightening Torques (DIN tables)................................................................280 General information..............................................................................280 Screw Tightening Torques.............................................................................281 Bolts with standard thread.......................................................................281 Bolts with metric fine thread DIN 13 - 13........................................................282 STEERING.....................................................................................................285 STEERING.................................................................................................286 Hydraulic System, Safety Instructions....................................................................286 Explanations of circuit diagrams and illustrations.......................................................286 Depressurizing the hydraulic system......................................................................286 Hydraulic circuit diagram - steering hydraulics..........................................................287 Hydraulic circuit diagram, legend........................................................................288 Pressure measuring points............................................................................288 Overview of the steering system..........................................................................289 Functional description...................................................................................290 Double pump (2), steering and working hydraulics, braking system.........................................291 Priority valve (L6)......................................................................................292 Steering cylinder (L1)...................................................................................293 Steering valve (L2)......................................................................................295 Installing the steering system...........................................................................299 Testing and adjusting the steering system................................................................302 BRAKES.......................................................................................................304 BRAKES...................................................................................................305 Safety instructions......................................................................................305 Explanations of circuit diagrams and illustrations.......................................................305 Braking system, circuit diagram..........................................................................306 Braking system, legend...................................................................................307 Pressure measuring points............................................................................307 Functional description of the braking system.............................................................308 Service brake (pump-storage brake)...................................................................308 Auxiliary brake......................................................................................309 Parking brake........................................................................................309 Accumulator charging valve (B2)......................................................................310 Testing and adjusting the service brake..................................................................311 Accumulator charging valve (B2)......................................................................311 Accumulator (B4), Technical data.....................................................................312 Accumulator (B4).....................................................................................313 Accumulators, safety instructions....................................................................313 Pedal-type brake valve (B5)..........................................................................314 Connecting valve (B8)................................................................................315 Inching valve (B10)..................................................................................316 Manometric switches (B6, B7).........................................................................318 Multiple-disk brakes (B9)................................................................................319 Testing and adjusting operations on the auxilliary brake.................................................319 Testing and adjusting operations on the parking brake....................................................320 Bleeding the braking system..............................................................................321 Bleeding.............................................................................................321 HYDRAULIC SYSTEM.............................................................................................323 HYDRAULIC SYSTEM.........................................................................................324 Hydraulic System, Safety Instructions....................................................................324 Explanations of circuit diagrams and illustrations.......................................................324 Depressurizing the hydraulic system......................................................................324 Hydraulic circuit diagram - working hydraulics...........................................................325 Hydraulic circuit diagram, legend........................................................................326 Pressure measuring points............................................................................326 Functional description, working hydraulics...............................................................328 Control block (H6).......................................................................................329 Double pump (2), steering and working hydraulics, braking system.........................................333 Lifting cylinder (H1)....................................................................................334 Dumping cylinder (H2)....................................................................................335 Quick change locking cylinder (H3).......................................................................336 Hydraulic tank (T1) / Hydraulic filter (T3)..............................................................338 Distributor (T5).........................................................................................339 Testing and adjustment work..............................................................................340 Pressure testing and adjustment......................................................................340 Practical testing....................................................................................341 Hydraulic circuit diagram - cooling......................................................................343 Hydraulic circuit diagram, legend........................................................................344 Pressure measuring points............................................................................344 Functional description of hydraulic system cooling.......................................................346 Praktical checking.......................................................................................346 Combined cooler (T2).....................................................................................347 Pipe-burst protection (optional).........................................................................349 Lifting cylinder load-holding valve (optional).......................................................350 Dumping cylinder load-holding valve (optional).......................................................352 ELECTRICAL SYSTEM............................................................................................354 PREFACE......................................................................................................356 PREFACE..................................................................................................359 IMPORTANT INSTRUCTIONS...................................................................................359 ELECTRICAL SYSTEMS IN GENERAL............................................................................360 The atom.................................................................................................360 Structure of atoms.......................................................................................360 Free electron........................................................................................361 Electromagnetic field................................................................................362 Alternating current diagram..........................................................................363 POWER GENERATION.........................................................................................364 Power generation in motor vehicles.......................................................................364 Battery charging.........................................................................................365 Claw-pole alternator.................................................................................366 Circuit with fault indication on interruption in the exciter circuit.................................366 Testing the charging system..............................................................................367 MAIN COMPONENTS OF AUTOMOTIVE ELECTRICAL SYSTEM..........................................................368 Battery..................................................................................................368 Types of batteries...................................................................................369 Maintenance-free starter battery.....................................................................369 Low-maintenance batteries............................................................................370 Checking the battery.................................................................................370 Density values of diluted sulphuric acid.............................................................370 Mixing fresh battery acid............................................................................371 Mixing instructions..................................................................................371 Maintenance..........................................................................................371 Troubleshooting......................................................................................372 Function of the alternator...............................................................................374 Alternator...........................................................................................374 Type designation.....................................................................................374 Alternator...........................................................................................375 Claw-pole alternator.................................................................................375 Maintenance..........................................................................................375 Electric motors..........................................................................................376 Principle of the electric motor......................................................................376 Starting motor (starter).................................................................................378 Function of the starter..............................................................................378 Checking the vehicle starter system..................................................................379 Starter..............................................................................................379 Maintenance..........................................................................................380 Lubrication..........................................................................................380 FUNDAMENTALES OF AUTOMOTIVE ELECTRICAL SYSTEMS...........................................................381 Current, voltage, resistance and power...................................................................381 MEASUREMENTS WITH THE MULTIMETER.........................................................................382 Adjustment of the multimeter.........................................................................382 Measuring voltage........................................................................................382 Measuring current........................................................................................382 Measuring resistance.....................................................................................382 Ohmmeter.............................................................................................382 SERIES AND PARALLEL CONNECTION OF ELECTRICAL COMPONENTS..................................................383 Batteries................................................................................................383 Resistors................................................................................................383 Series connection....................................................................................383 Parallel connection..................................................................................383 Capacitors...............................................................................................383 Series connection....................................................................................383 Parallel connection..................................................................................383 Electrolytic capacitors..............................................................................383 VOLTAGE LOSSES AND CABLES................................................................................385 Calculation of lines.....................................................................................386 Computation..........................................................................................386 Lines and wires in automotive electrical systems.........................................................387 Design example...........................................................................................387 LIGHTING.................................................................................................388 Headlamps adjustment hints...............................................................................388 Floodlamps...............................................................................................388 Bulbs....................................................................................................388 Malfunctions of the lighting system and their causes.....................................................388 Transition resistance in electrical circuits.............................................................388 SPECIAL CIRCUITS IN AUTOMOTIVE ELECTRICAL SYSTEMS........................................................389 The diode................................................................................................389 The "free-wheeling" diode............................................................................389 Varistors............................................................................................390 Voltage rectification in three-phase bridge circuits.................................................390 Alternator regulator.................................................................................392 FUSES IN MOTOR VEHICLES..................................................................................393 DESIGNATION OF INDIVIDUAL COMPONENTS.....................................................................394 STANDARDIZED DESIGNATIONS OF TERMINALS...................................................................395 Terminal designation.................................................................................395 Generator and generator regulator....................................................................397 Turn-signal indicator (flasher relay)................................................................397 Symbols used in electrical engineering...................................................................398 Symbols for directions of motion.....................................................................405 Automotive electrical systems in construction machinery......................................................407 PREFACE..................................................................................................408 PREFACE..............................................................................................410 NOTES ON SAFETY......................................................................................411 ELECTRICAL SYSTEM DOCUMENTATION......................................................................412 THE WIRING DIAGRAM...................................................................................413 Explanation of the wiring diagram....................................................................414 Current paths....................................................................................414 Main circuits....................................................................................414 Branches.........................................................................................414 Relay contacts...................................................................................414 Cross reference to other current paths...........................................................414 Contacts of plug-in connectors...................................................................414 Cable cross-section..............................................................................416 Identification of contacts.......................................................................416 Cable number.....................................................................................416 Electronic units (Fig. 3)........................................................................416 WIRING DIAGRAM LEGEND................................................................................417 Explanation of legend................................................................................418 Part.............................................................................................418 Quantity.........................................................................................418 Description and function.........................................................................418 Current path.....................................................................................418 Location.........................................................................................418 Part number......................................................................................418 CHECKING AND TESTING EQUIPMENT.......................................................................419 Test lamp........................................................................................419 Solenoid-valve tester............................................................................419 Multimeter.......................................................................................420 Testers..........................................................................................420 BASIC MEASURING AND TESTING PROCEDURES...............................................................421 Voltage checks...................................................................................421 Checking the continuity..........................................................................422 Checking the coil of a solenoid..................................................................423 PRACTICAL TROUBLESHOOTING............................................................................424 Notes on troubleshooting in automotive electrical systems........................................424 Example of systematic troubleshooting............................................................424 Fault-finding diagram............................................................................425 ANNEX................................................................................................429 Identification of components.........................................................................429 Schematic symbols....................................................................................431 Electrical Connections...........................................................................431 Switches, contacts...............................................................................432 Indicators, measuring devices....................................................................435 Motors, alternators..............................................................................436 Semiconductors...................................................................................437 Miscellaneous....................................................................................438 Symbols for directions of motion.................................................................439 Fuses................................................................................................440 Fuse links.......................................................................................440 Fuse strips......................................................................................440 FRAME........................................................................................................444 FRAME....................................................................................................445 Repairing the loader frame...............................................................................447 Exchanging the main pivot parts......................................................................447 Dismantling..........................................................................................447 Mounting.............................................................................................449 Fittings, pipes and hoses....................................................................................451 INTRODUCTION.............................................................................................452 INTRODUCTION.........................................................................................454 FUNDAMENTAL SAFETY INSTRUCTIONS......................................................................455 Warnings and symbols.................................................................................455 Organizational measures..............................................................................455 Selection and qualification of personnel ............................................................456 OPERATING SAFETY INSTRUCTIONS........................................................................456 Standard operation...............................................................................456 MAINTENANCE SAFETY INSTRUCTIONS......................................................................457 WARNING OF SPECIAL DANGERS...........................................................................458 Electric energy..................................................................................458 Gas, dust, steam and smoke.......................................................................458 Hydraulic and pneumatic equipment................................................................459 Noise............................................................................................459 Oil, grease and other chemical substances........................................................459 TRANSPORTING AND TOWING -RECOMMISSIONING.............................................................459 WORKING EQUIPMENT....................................................................................460 Assembling working equipment - safety instructions...................................................460 Repair work - safety instructions....................................................................462 LINES FOR VARIOUS MEDIA..............................................................................464 Materials for pipes and hoses........................................................................464 Conditions and deviations in the line system.........................................................464 Steel pipes..........................................................................................465 Hoses................................................................................................467 Plastic pipes........................................................................................469 CONNECTIONS..........................................................................................470 Pipe couplings.......................................................................................470 Sealing pipe couplings...........................................................................474 Bulkhead couplings...................................................................................475 Stud couplings and male nipples......................................................................475 Stircomatic seal rings...........................................................................476 Swivel couplings.....................................................................................477 Swivel couplings.................................................................................477 Swivel coupling with straight male thread acc. to DIN............................................477 Swivel coupling with long male adaptor...........................................................477 Fixed angle couplings................................................................................478 Banjo couplings......................................................................................478 Banjo couplings..................................................................................478 Banjo coupling with long male adaptor............................................................479 FLANGE COUPLINGS WITH SAE BOLT PATTERN...............................................................480 Flanged pipe couplings - Flanit system (F-system)................................................480 Flanged pipe couplings - Zako system (Z-system)..................................................480 Flanged hose couplings...............................................................................481 Sealing and connecting components....................................................................482 Flanges..........................................................................................482 Wedge rings......................................................................................482 Seal rings.......................................................................................482 Double-hex bolts.................................................................................483 Assembly aids for wedge rings........................................................................484 Pre-assembly device for F-rings..................................................................484 Inserter for Z-rings.............................................................................484 Inserting the Z-ring.............................................................................485 Assembling flange couplings..........................................................................486 Flange coupling - pipe / connection surface, F-system............................................486 Zako-system......................................................................................487 Flange coupling hose / connection surface........................................................489 Flange coupling - pipe / hose....................................................................489 Flange coupling - hose / hose....................................................................491 Flange coupling - pipe / pipe....................................................................492 Appendix.............................................................................................494 Table 1: Seal rings for flange couplings.........................................................494 Table 2: Double - Hex. Bolts.....................................................................495 Accessories..........................................................................................496 Pre-assembly aids for pipe flange couplings......................................................496 Flanges-90°......................................................................................497 Table 3: Parts Nos. for 90° flanges..............................................................497 Gauge connections................................................................................498 Table 4: Parts Nos. for gauge connections and accessories........................................498 Sealing, protective, testing and cleaning agents.............................................................502 INTRODUCTION.............................................................................................503 INTRODUCTION.........................................................................................505 FUNDAMENTAL SAFETY INSTRUCTIONS......................................................................505 Warnings and symbols.................................................................................505 Safety Instructions..................................................................................506 PRESERVATION OF GEARBOXES............................................................................509 Rust inhibitor...................................................................................509 Application to gearboxes and axles without oil filling...........................................509 Preservation period..............................................................................509 Gearboxes and axles with oil filling.............................................................509 Protective finishes..............................................................................509 PRESERVATION OF CYLINDER PISTON RODS.................................................................510 Corrosion inhibitor..............................................................................510 Consumption of inhibitor.........................................................................510 Application of inhibitor.........................................................................510 Removing the inhibitor...........................................................................510 Renewing the inhibitor...........................................................................510 Corrosion protection for pins and bearings (bushings and hubs).......................................511 Part nos. for Voler A.C..........................................................................511 Application of Voler A.C.........................................................................511 S0LUTION 1 CORROSION INHIBITOR FOR CYLINDER ROD THREADS..............................................512 RIVOLTA W.S.X, NU CORROSION INHIBITOR FOR ELECTRICAL SYSTEMS.........................................512 SURFACE SEALING AGENTS...............................................................................513 WKT black - H....................................................................................513 Loctite 573 (proprietary brand from Loctite Ltd.,)...............................................513 HYLOMAR SQ 32/M SEALING AGENT (THREAD SEALER)........................................................514 LIQUID THREAD ADHESIVES..............................................................................514 METAL ADHESIVES......................................................................................515 ADHESIVES FOR PLASTICS...............................................................................516 Acrylic cyanide (Loctite IS 414).................................................................516 ADHESIVE FOR O-RINGS.................................................................................516 LUBRICANTS...........................................................................................517 Solid lubricating paste..........................................................................517 Solid lubricant paste spray......................................................................517 Compound spray...................................................................................517 Mineral-based lubricating paste..................................................................518 Lithium soap grease..............................................................................518 SOLID LUBRICANT FOR MOLYCOTE-COATED BOLTS............................................................519 SILICON-CORUNDUM POWDER (REDURIT)....................................................................519 P3 COLD CLEANER......................................................................................520 SURFACE CRACK CHECKING AGENT (METAL-CHECK)...........................................................521
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