Hitachi ZW100-G ZW120-G Wheel Loader Workshop Manual (W4FK-E-00) – PDF Download

Description

Hitachi ZW100-G ZW120-G Wheel Loader Workshop Manual (W4FK-E-00)

File Details:

Hitachi ZW100-G ZW120-G Wheel Loader Workshop Manual (W4FK-E-00)

• Manual Language:English
• Pages: 354
• Size: 4.56 MB
• Format:PDF
• Downloadable:Yes

HITACHI ZW100-G ZW120-G WHEEL LOADER WORKSHOP MANUAL (W4FK-E-00) – PDF DOWNLOAD:

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Description:

Hitachi ZW100-G ZW120-G Wheel Loader Workshop Manual (W4FK-E-00)

TO THE READER
• This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
• Be sure to thoroughly read this manual for correct product information and service procedures.
• If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual.
ADDITIONAL REFERENCES
• Please refer to the other materials (operator’s manual, parts catalog, engine technical material and Hitachi training material etc.) in addition to this manual.
MANUAL COMPOSITION
• This manual consists the Technical Manual and the Workshop Manual.
• Information included in the Technical Manual: technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.
• Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assemble/ disassemble procedures.

Table Of Contents:

Hitachi ZW100-G ZW120-G Wheel Loader Workshop Manual (W4FK-E-00)

W4FL-E-00..........................................................  1
INTRODUCTION.......................................................  3
SAFETY.............................................................  5
SECTION AND GROUP CONTENTS......................................... 35
SECTION 1 GENERAL.................................................. 37
	Group 1 Precautions for Disassembling and Assembling........... 39
		Precautions for Disassembling and Assembling............... 39
	Group 2 Tightening............................................. 45
		Tightening Bolts and Nuts.................................. 45
		Piping Joint............................................... 48
	Group 3 Painting............................................... 53
		Painting................................................... 53
	Group 4 Bleeding Air from Hydraulic Circuit.................... 55
		Bleeding Air from Hydraulic Oil Tank....................... 55
		Bleeding Air from Hydraulic System......................... 56
	Group 5 Hydraulic Circuit Pressure Release Procedure........... 57
		Hydraulic Circuit Pressure Release Procedure............... 57
	Group 6 Preparation............................................ 59
		Preparations for Inspection and Maintenance................ 59
SECTION 2 BODY..................................................... 63
	Group 1 Cab.................................................... 65
		Removal and Installation of Cab............................ 65
		Removal and Installation of Canopy......................... 77
	Group 2 Counterweight.......................................... 79
		Removal and Installation of Counterweight.................. 79
	Group 3 Center Hinge........................................... 81
		Removal and Installation of Center Hinge................... 81
	Group 4 Hydraulic Oil Tank..................................... 87
		Removal and Installation of Hydraulic Oil Tank............. 87
	Group 5 Pump Device............................................ 99
		Removal and Installation of Pump Device.................... 99
		Disassembly of HST Pump....................................106
		Assembly of HST Pump.......................................112
		Structure of Forward/Reverse Selector Control Valve........121
		Structure of DA Valve......................................122
		Structure of Cut-Off Valve.................................122
		Structure of Low-Pressure Relief Valve.....................123
		Structure of Hi-Pressure Relief Valve......................123
		List of Tightening Torque..................................124
		Disassembly of Gear Pump...................................126
		Assembly of Gear Pump......................................130
	Group 6 Control Valve..........................................135
		Removal and Installation of Control Valve..................135
		Disassembly and Assembly of Control Valve..................140
		Disassembly of Bucket Spool Assembly.......................142
		Assembly of Bucket Spool Assembly..........................144
		Disassembly of Lift Arm Spool Assembly.....................146
		Assembly of Lift Arm Spool Assembly........................148
	Group 7 Steering Valve.........................................151
		Removal and Installation of Steering Valve.................151
		Disassembly of Steering Valve..............................158
		Assembly of Steering Valve.................................162
	Group 8 Brake Valve............................................167
		Removal and Installation of Brake Valve....................167
		Brake Circuit Air Bleeding.................................172
		Structure of Brake Valve...................................174
	Group 9 Priority Valve.........................................179
		Removal and Installation of Priority Valve.................179
		Structure of Priority Valve................................183
	Group 10 Inching Valve.........................................185
		Removal and Installation of Inching Valve..................185
		Structure of Inching Valve.................................188
SECTION 3 TRAVEL SYSTEM............................................191
	Group 1 Steering Cylinder......................................193
		Removal and Installation of Steering Cylinder..............193
		Disassembly of Steering Cylinder...........................198
		Assembly of Steering Cylinder..............................200
	Group 2 HST Motor..............................................203
		Removal and Installation of HST Motor......................203
		Disassembly of HST Motor...................................208
		Structure of Rotary Block..................................212
		Assembly of HST Motor......................................214
		Structure of HST Motor Displacement Angle Control Valve....217
		List of Tightening Torque..................................218
	Group 3 Transmission...........................................219
		Removal and Installation of Transmission...................219
		Disassembly of Transmission................................228
		Assembly of Transmission...................................236
		Disassembly of Clutch Assembly.............................244
		Assembly of Clutch Assembly................................246
		Structure of Control Valve.................................249
		Maintenance Standard.......................................251
	Group 4 Axle...................................................257
		Removal and Installation of Front Axle.....................257
		Removal and Installation of Rear Axle......................261
		Disassembly of Axle........................................270
		Assembly of Axle...........................................278
		Disassembly of Differential (TPD Type Axle)................288
		Assembly of Differential (TPD Type Axle)...................290
	Group 5 Propeller Shaft........................................293
		Removal and Installation of Propeller Shaft................293
	Group 6 Tire...................................................297
		Removal and Installation of Tire...........................297
SECTION 4 ATTACHMENT...............................................305
	Group 1 Front Attachment.......................................307
		Removal and Installation of Front Attachment...............307
		Maintenance Standard.......................................319
		Standard Dimensions for Lift Arm and Bucket Connection.....320
	Group 2 Cylinder...............................................321
		Removal and Installation of Cylinder.......................321
		Disassembly of Lift Arm Cylinder...........................334
		Assembly of Lift Arm Cylinder..............................338
		Disassembly of Bucket Cylinder.............................342
		Assembly of Bucket Cylinder................................346
		Maintenance Standard.......................................349
SERVICE MANUAL REVISION REQUEST FORM...............................353

Please Note:

⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.