Hitachi ZW180-6 Wheel Loader Workshop Manual (WPD850-EN-00) – PDF Download

Description

Hitachi ZW180-6 Wheel Loader Workshop Manual (WPD850-EN-00)

File Details:

Hitachi ZW180-6 Wheel Loader Workshop Manual (WPD850-EN-00)

• Manual Language:English
• Pages: 951
• Size: 24.9 MB
• Downloadable:Yes
• Format:PDF

HITACHI ZW180-6 WHEEL LOADER WORKSHOP MANUAL (WPD850-EN-00) – PDF DOWNLOAD:

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Description:

Hitachi ZW180-6 Wheel Loader Workshop Manual (WPD850-EN-00)

To The Reader
This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
The machine specification and description according to destination may be explained on this manual.
 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, the Workshop Manual and the Engine 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.
 Information included in the Engine Manual: Technical information needed for redelivery and delivery and maintenance and repair of the machine, operation and activation of all devices and systems, troubleshooting and assemble / disassemble procedures.

Table Of Contents:

Hitachi ZW180-6 Wheel Loader Workshop Manual (WPD850-EN-00)

WPD850-EN-00.................................................................  1
	CONTENTS.................................................................  3
	INTRODUCTION............................................................. 13
		To The Reader........................................................ 13
		Additional References................................................ 13
		Manual Composition................................................... 13
		Page Number.......................................................... 13
		Trademark............................................................ 13
		Safety Alert Symbol and Headline Notations........................... 14
		Units Used........................................................... 14
	SYMBOL AND ABBREVIATION.................................................. 15
	SAFETY................................................................... 17
		Recognize Safety Information......................................... 17
		Understand Signal Words.............................................. 17
		Follow Safety Instructions........................................... 18
		Prepare for Emergencies.............................................. 19
		Wear Protective Clothing............................................. 19
		Protect Against Noise................................................ 20
		Inspect Machine...................................................... 20
		General Precautions for the Cab...................................... 21
		Use Handrails and Steps.............................................. 22
		Never Ride Attachment................................................ 22
		Adjust Operator’s Seat............................................... 22
		Ensure Safety Before Rising from or Leaving Operator’s Seat.......... 23
		Fasten Your Seat Belt................................................ 23
		Move and Operate Machine Safely...................................... 24
		Handle Starting Aids Safely.......................................... 24
		Operate Only from Operator’s Seat.................................... 25
		Jump Starting........................................................ 25
		Investigate Job Site Beforehand...................................... 26
		Equipment of Head Guard, ROPS, FOPS.................................. 27
		Provide Signals for Jobs Involving Multiple Machines................. 27
		Keep Riders Off Machine.............................................. 28
		Drive Safely......................................................... 28
		Drive Machine Safely (Work Site)..................................... 29
		Drive Safely with Bucket Loaded...................................... 30
		Drive on Snow Safely................................................. 30
		Travel on Public Roads Safely........................................ 31
		Avoid Injury from Rollaway Accidents................................. 31
		Avoid Accidents from Backing Up and Turning.......................... 32
		Avoid Positioning Bucket or Attachment Over Anyone................... 33
		Avoid Tipping........................................................ 33
		Never Undercut a High Bank........................................... 34
		Dig with Caution..................................................... 34
		Perform Truck Loading Safely......................................... 34
		Avoid Power Lines.................................................... 35
		Precautions for Operation............................................ 35
		Precautions for Lightning............................................ 35
		Object Handling...................................................... 36
		Protect Against Flying Debris........................................ 36
		Park Machine Safely.................................................. 37
		Store Attachments Safely............................................. 37
		Transport Safely..................................................... 38
		Handle Fluids Safely−Avoid Fires..................................... 39
		Practice Safe Maintenance............................................ 40
		Warn Others of Service Work.......................................... 41
		Support Machine Properly............................................. 41
		Stay Clear of Moving Parts........................................... 42
		Support Maintenance Properly......................................... 42
		Prevent Parts from Flying............................................ 43
		Prevent Burns........................................................ 43
		Replace Rubber Hoses Periodically.................................... 44
		Avoid High-Pressure Fluids........................................... 44
		Prevent Fires........................................................ 45
		Evacuating in Case of Fire........................................... 47
		Beware of Exhaust Fumes.............................................. 47
		Precautions for Welding and Grinding................................. 47
		Avoid Heating Near Pressurized Fluid Lines........................... 48
		Avoid Applying Heat to Lines Containing Flammable Fluids............. 48
		Precautions for Handling Accumulator and Gas Damper.................. 48
		Remove Paint Before Welding or Heating............................... 49
		Beware of Asbestos and Silica Dust and Other Contamination........... 49
		Prevent Battery Explosions........................................... 50
		Service Air Conditioning System Safely............................... 50
		Handle Chemical Products Safely...................................... 51
		Dispose of Waste Properly............................................ 51
		Notes on Aftertreatment Device....................................... 52
		Precautions for Communication Terminal............................... 52
		Precaution for Communication Terminal Equipment...................... 53
		Before Returning the Machine to the Customer......................... 54
	SECTION AND GROUP CONTENTS............................................... 55
	SECTION 1 GENERAL........................................................ 59
		Group 1 Precautions for Disassembling and Assembling................. 61
			Precautions for Disassembling and Assembling..................... 61
		Group 2 Tightening................................................... 67
			Tightening Bolts and Nuts........................................ 67
			Piping Joint..................................................... 70
		Group 3 Painting..................................................... 77
		Group 4 Bleeding Air................................................. 87
			Bleed Air from the Hydraulic System.............................. 87
			Bleed Air from the Fuel System................................... 88
			Bleeding Air from Brake (Axle)................................... 89
		Group 5 Preparation.................................................. 91
			Preparations for Inspection and Maintenance...................... 91
			Releasing Pressure from Hydraulic Circuit........................ 96
			Releasing Pressure from Ride Control Accumulator................. 97
			Releasing Pressure from Parking Brake Accumulator................ 98
			Releasing Pressure from Hydraulic Oil Tank....................... 99
			Releasing Pressure from Expansion Tank...........................100
	SECTION 2 MAINTENANCE STANDARD...........................................103
		Group 1 Body.........................................................105
			Center Hinge.....................................................105
		Group 2 Front Attachment.............................................107
			Pin and Bushing..................................................107
			Standard Dimensions for Lift Arm and Bucket......................109
			Cylinder.........................................................111
	SECTION 3 BODY...........................................................115
		Group 1 Cab..........................................................117
			Removal and Installation of Cab..................................117
		Group 2 Counterweight................................................151
			Removal and Installation of Counterweight........................151
		Group 3 Center Hinge.................................................155
			Removal and Installation of Center Hinge.........................155
		Group 4 Engine.......................................................185
			Removal and Installation of Engine...............................185
		Group 5 Radiator Assembly............................................247
			Removal and Installation of Radiator Assembly....................247
		Group 6 Hydraulic Oil Tank...........................................275
			Removal and Installation of Hydraulic Oil Tank...................275
		Group 7 Fuel Tank....................................................295
			Removal and Installation of Fuel Tank............................295
		Group 8 Pump Device..................................................309
			Removal and Installation of Pump Device..........................309
			Disassembly of Pump Device.......................................321
			Assembly of Pump Device..........................................323
			Disassembly of Main Pump.........................................325
			Assembly of Main Pump............................................329
			Disassembly of Regulator.........................................335
			Assembly of Regulator............................................337
			Structure of Priority Valve......................................339
			Structure of Pilot Pump..........................................341
			Removal and Installation of Priority Valve.......................343
		Group 9 Control Valve................................................347
			Removal and Installation of Control Valve........................347
			Disassembly of Control Valve.....................................359
			Assembly of Control Valve........................................363
		Group 10 Pilot Valve.................................................369
			Removal and Installation of Pilot Valve..........................369
			Removal and Installation of Pilot Valve (Two Lever Type).........377
			Disassembly of Pilot Valve.......................................389
			Assembly of Pilot Valve..........................................392
			Disassembly of Pilot Valve (Two Lever Type)......................397
			Assembly of Pilot Valve (Two Lever Type).........................403
		Group 11 Brake Charge Valve..........................................411
			Removal and Installation of Brake Charge Valve...................411
			Structure of Brake Charge Valve..................................419
			Removal and Installation of Brake Accumulator....................421
		Group 12 Manifold Valve..............................................429
			Removal and Installation of Manifold Valve.......................429
			Disassembly of Manifold Valve....................................441
			Assembly of Manifold Valve.......................................444
		Group 13 Solenoid Valve..............................................449
			Removal and Installation of Parking Brake Solenoid Valve Unit....449
			Structure of Parking Brake Solenoid Valve Unit...................455
			Structure of Parking Brake Solenoid Valve........................457
		Group 14 Flow Regulator Valve........................................459
			Removal and Installation of Flow Regulator Valve.................459
			Structure of Flow Regulator Valve................................463
		Group 15 Cooling Fan System..........................................465
			Removal and Installation of Fan Valve............................465
			Structure of Fan Valve...........................................469
			Removal and Installation of Fan Motor............................471
			Structure of Fan Motor...........................................477
			Removal and Installation of Fan Pump.............................479
			Disassembly of Fan Pump..........................................487
			Assembly of Fan Pump.............................................489
		Group 16 Ride Control Device.........................................493
			Removal and Installation of Ride Control Valve...................493
			Disassembly of Ride Control Valve................................497
			Assembly of Ride Control Valve...................................500
			Removal and Installation of Ride Control Accumulator.............505
		Group 17 Battery Disconnect Switch...................................509
			Removal and Installation of Battery Disconnect Switch............509
		Group 18 Aftertreatment Device.......................................515
			Removal and Installation of Aftertreatment Device................515
		Group 19 DEF Tank....................................................541
			Removal and Installation of DEF Tank.............................541
		Group 20 Coolant Control Valve.......................................549
			Removal and Installation of Coolant Control Valve................549
		Group 21 DEF Supply Module...........................................555
			Removal and Installation of DEF Supply Module....................555
		Group 22 Exterior Components.........................................559
			Removal and Installation of Exterior Components..................559
	SECTION 4 TRAVEL SYSTEM..................................................631
		Group 1 Tire.........................................................633
			Removal and Installation of Front Tire...........................633
			Removal and Installation of Rear Tire............................639
		Group 2 Drive Unit...................................................645
			Removal and Installation of Drive Unit...........................645
			Disassembly and Assembly of Drive Unit...........................653
			Removal and Installation of Torque Converter.....................659
			Disassembly and Assembly of Transmission.........................665
			Disassembly and Assembly of Transmission Control Valve...........715
			Removal and Installation of Parking Brake........................729
		Group 3 Axle.........................................................739
			Removal and Installation of Front Axle...........................739
			Removal and Installation of Rear Axle............................749
			Disassembly of Axle..............................................765
			Assembly of Axle.................................................781
		Group 4 Propeller Shaft..............................................807
			Removal and Installation of Propeller Shaft......................807
		Group 5 Brake Valve..................................................819
			Removal and Installation of Brake Valve..........................819
			Disassembly of Brake Valve.......................................825
			Disassembly of Brake Valve.......................................826
			Assembly of Brake Valve..........................................827
			Assembly of Brake Valve..........................................828
		Group 6 Steering Device..............................................831
			Removal and Installation of Steering Valve.......................831
			Disassembly of Steering Valve....................................837
			Assembly of Steering Valve.......................................840
			Removal and Installation of Steering Cylinder....................847
			Disassembly of Steering Cylinder.................................869
			Assembly of Steering Cylinder....................................873
		Group 7 Emergency Steering Device....................................879
			Removal and Installation of Emergency Steering Pump..............879
	SECTION 5 FRONT ATTACHMENT...............................................891
		Group 1 Front Attachment.............................................893
			Removal and Installation of Front Attachment.....................893
			Removal and Installation of Bell Crank...........................903
			Removal and Installation of Bucket...............................913
			Removal and Installation of Bushing..............................917
		Group 2 Cylinder.....................................................921
			Removal and Installation of Lift Arm Cylinder....................921
			Removal and Installation of Bucket Cylinder......................929
			Disassembly of Lift Arm Cylinder and Bucket Cylinder.............941
			Assembly of Lift Arm Cylinder and Bucket Cylinder................945
	SERVICE MANUAL REVISION REQUEST FORM.....................................951

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