Hitachi ZW180-6 ZW180PL-6 Wheel Loader Workshop Manual (WPD850-EN-01) – PDF Download

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Hitachi ZW180-6 ZW180PL-6 Wheel Loader Workshop Manual (WPD850-EN-01)

File Details:

Hitachi ZW180-6 ZW180PL-6 Wheel Loader Workshop Manual (WPD850-EN-01)

• Manual Language:English
• Pages: 1185
• Size: 22.2 MB
• Downloadable:Yes
• Format:PDF

HITACHI ZW180-6 ZW180PL-6 WHEEL LOADER WORKSHOP MANUAL (WPD850-EN-01) – PDF DOWNLOAD:

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Description:

Hitachi ZW180-6 ZW180PL-6 Wheel Loader Workshop Manual (WPD850-EN-01)

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 ZW180PL-6 Wheel Loader Workshop Manual (WPD850-EN-01)

WPD850-EN-01............................................................................   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
			Painting (Parallel Link)....................................................  87
		Group 4 Bleeding Air............................................................  97
			Bleed Air from the Hydraulic System.........................................  97
			Bleed Air from the Fuel System..............................................  98
			Bleeding Air from Brake (Axle)..............................................  99
		Group 5 Preparation............................................................. 101
			Preparations for Inspection and Maintenance................................. 101
			Releasing Pressure from Hydraulic Circuit................................... 106
			Releasing Pressure from Ride Control Accumulator............................ 107
			Releasing Pressure from Parking Brake Accumulator........................... 108
			Releasing Pressure from Hydraulic Oil Tank.................................. 109
			Releasing Pressure from Expansion Tank...................................... 110
	SECTION 2 MAINTENANCE STANDARD...................................................... 113
		Group 1 Body.................................................................... 115
			Center Hinge................................................................ 115
		Group 2 Front Attachment........................................................ 117
			Pin and Bushing............................................................. 117
			Standard Dimensions for Lift Arm and Bucket................................. 119
			Cylinder.................................................................... 121
		Group 3 Front Attachment (Parallel Link)........................................ 123
			Pin and Bushing............................................................. 123
			Standard Dimensions for Quick Coupler and Bucket............................ 125
			Cylinder.................................................................... 127
	SECTION 3 BODY...................................................................... 131
		Group 1 Cab..................................................................... 133
			Removal and Installation of Cab............................................. 133
			Removal and Installation of Cab (Parallel Link)............................. 167
		Group 2 Counterweight........................................................... 201
			Removal and Installation of Counterweight................................... 201
		Group 3 Center Hinge............................................................ 205
			Removal and Installation of Center Hinge.................................... 205
			Removal and Installation of Center Hinge (Parallel Link).................... 235
		Group 4 Engine.................................................................. 269
			Removal and Installation of Engine.......................................... 269
		Group 5 Radiator Assembly....................................................... 331
			Removal and Installation of Radiator Assembly............................... 331
		Group 6 Hydraulic Oil Tank...................................................... 359
			Removal and Installation of Hydraulic Oil Tank.............................. 359
		Group 7 Fuel Tank............................................................... 379
			Removal and Installation of Fuel Tank....................................... 379
		Group 8 Pump Device............................................................. 393
			Removal and Installation of Pump Device..................................... 393
			Disassembly of Pump Device.................................................. 405
			Assembly of Pump Device..................................................... 407
			Disassembly of Main Pump.................................................... 409
			Assembly of Main Pump....................................................... 413
			Disassembly of Regulator.................................................... 419
			Assembly of Regulator....................................................... 421
			Structure of Priority Valve................................................. 423
			Structure of Pilot Pump..................................................... 425
			Removal and Installation of Priority Valve.................................. 427
		Group 9 Control Valve........................................................... 431
			Removal and Installation of Control Valve................................... 431
			Removal and Installation of Control Valve (Parallel Link)................... 443
			Disassembly of Control Valve................................................ 455
			Assembly of Control Valve................................................... 459
			Disassembly of Control Valve (Parallel Link)................................ 465
			Assembly of Control Valve (Parallel Link)................................... 474
		Group 10 Pilot Valve............................................................ 483
			Removal and Installation of Pilot Valve..................................... 483
			Removal and Installation of Pilot Valve (Two Lever Type).................... 491
			Removal and Installation of Auxiliary Pilot Valve........................... 503
			Disassembly of Pilot Valve.................................................. 509
			Assembly of Pilot Valve..................................................... 512
			Disassembly of Pilot Valve (Two Lever Type)................................. 517
			Assembly of Pilot Valve (Two Lever Type).................................... 523
			Disassembly of Auxiliary Pilot Valve........................................ 531
			Assembly of Auxiliary Pilot Valve........................................... 534
		Group 11 Brake Charge Valve..................................................... 539
			Removal and Installation of Brake Charge Valve.............................. 539
			Structure of Brake Charge Valve............................................. 547
			Removal and Installation of Brake Accumulator............................... 549
		Group 12 Manifold Valve......................................................... 557
			Removal and Installation of Manifold Valve.................................. 557
			Disassembly of Manifold Valve............................................... 569
			Assembly of Manifold Valve.................................................. 572
		Group 13 Solenoid Valve......................................................... 577
			Removal and Installation of Parking Brake Solenoid Valve Unit............... 577
			Structure of Parking Brake Solenoid Valve Unit.............................. 583
			Removal and Installation of Quick Coupler Solenoid Valve (Parallel Link).... 585
			Disassembly of Quick Coupler Solenoid Valve................................. 593
			Assembly of Quick Coupler Solenoid Valve.................................... 595
		Group 14 Flow Regulator Valve................................................... 597
			Removal and Installation of Flow Regulator Valve............................ 597
			Structure of Flow Regulator Valve........................................... 601
		Group 15 Cooling Fan System..................................................... 603
			Removal and Installation of Fan Valve....................................... 603
			Structure of Fan Valve...................................................... 607
			Removal and Installation of Fan Motor....................................... 609
			Structure of Fan Motor...................................................... 615
			Removal and Installation of Fan Pump........................................ 617
			Disassembly of Fan Pump..................................................... 625
			Assembly of Fan Pump........................................................ 627
		Group 16 Ride Control Device.................................................... 631
			Removal and Installation of Ride Control Valve.............................. 631
			Disassembly of Ride Control Valve........................................... 635
			Assembly of Ride Control Valve.............................................. 638
			Removal and Installation of Ride Control Accumulator........................ 643
		Group 17 Battery Disconnect Switch.............................................. 647
			Removal and Installation of Battery Disconnect Switch....................... 647
		Group 18 Aftertreatment Device.................................................. 653
			Removal and Installation of Aftertreatment Device........................... 653
		Group 19 DEF Tank............................................................... 679
			Removal and Installation of DEF Tank........................................ 679
		Group 20 Coolant Control Valve.................................................. 687
			Removal and Installation of Coolant Control Valve........................... 687
		Group 21 DEF Supply Module...................................................... 693
			Removal and Installation of DEF Supply Module............................... 693
		Group 22 Exterior Components.................................................... 697
			Removal and Installation of Exterior Components............................. 697
		Group 23 Parallel Link (Special Parts).......................................... 767
			Removal and Installation of Bucket Regenerative Valve....................... 767
			Structure of Bucket Regenerative Valve...................................... 777
			Removal and Installation of Bucket Regenerative Selector Valve.............. 779
			Structure of Bucket Regenerative Selector Valve............................. 785
	SECTION 4 TRAVEL SYSTEM............................................................. 789
		Group 1 Tire.................................................................... 791
			Removal and Installation of Front Tire...................................... 791
			Removal and Installation of Rear Tire....................................... 797
		Group 2 Drive Unit.............................................................. 803
			Removal and Installation of Drive Unit...................................... 803
			Disassembly and Assembly of Drive Unit...................................... 811
			Removal and Installation of Torque Converter................................ 817
			Disassembly and Assembly of Transmission.................................... 823
			Disassembly and Assembly of Transmission Control Valve...................... 873
			Removal and Installation of Parking Brake................................... 887
		Group 3 Axle.................................................................... 897
			Removal and Installation of Front Axle...................................... 897
			Removal and Installation of Rear Axle....................................... 907
			Disassembly of Axle......................................................... 923
			Assembly of Axle............................................................ 939
		Group 4 Propeller Shaft......................................................... 965
			Removal and Installation of Propeller Shaft................................. 965
		Group 5 Brake Valve............................................................. 977
			Removal and Installation of Brake Valve..................................... 977
			Disassembly of Brake Valve.................................................. 983
			Disassembly of Brake Valve.................................................. 984
			Assembly of Brake Valve..................................................... 985
			Assembly of Brake Valve..................................................... 986
		Group 6 Steering Device......................................................... 989
			Removal and Installation of Steering Valve.................................. 989
			Disassembly of Steering Valve............................................... 995
			Assembly of Steering Valve.................................................. 998
			Removal and Installation of Steering Cylinder...............................1005
			Disassembly of Steering Cylinder............................................1027
			Assembly of Steering Cylinder...............................................1031
		Group 7 Emergency Steering Device...............................................1037
			Removal and Installation of Emergency Steering Pump.........................1037
	SECTION 5 FRONT ATTACHMENT..........................................................1049
		Group 1 Front Attachment........................................................1051
			Removal and Installation of Front Attachment................................1051
			Removal and Installation of Bell Crank......................................1061
			Removal and Installation of Bucket..........................................1071
			Removal and Installation of Bushing.........................................1075
		Group 2 Cylinder................................................................1079
			Removal and Installation of Lift Arm Cylinder...............................1079
			Removal and Installation of Bucket Cylinder.................................1087
			Disassembly of Lift Arm Cylinder and Bucket Cylinder........................1099
			Assembly of Lift Arm Cylinder and Bucket Cylinder...........................1103
		Group 3 Front Attachment (Parallel Link)........................................1107
			Removal and Installation of Front Attachment................................1107
			Removal and Installation of Quick Coupler...................................1129
		Group 4 Cylinder (Parallel Link)................................................1137
			Removal and Installation of Lift Arm Cylinder...............................1137
			Removal and Installation of Bucket Cylinder.................................1145
			Removal and Installation of Quick Coupler Cylinder..........................1157
			Disassembly of Lift Arm Cylinder............................................1161
			Assembly of Lift Arm Cylinder...............................................1165
			Disassembly of Bucket Cylinder..............................................1169
			Assembly of Bucket Cylinder.................................................1173
			Disassembly of Quick Coupler Cylinder.......................................1177
			Assembly of Quick Coupler Cylinder..........................................1180
	SERVICE MANUAL REVISION REQUEST FORM................................................1185

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.