Hitachi ZW180 Wheel Loader Workshop Manual (W4GD-E-00) – PDF Download

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Hitachi ZW180 Wheel Loader Workshop Manual (W4GD-E-00)

File Details:

Hitachi ZW180 Wheel Loader Workshop Manual (W4GD-E-00)

• Manual Language:English
• Pages: 476
• Size: 5.67 MB
• Downloadable:Yes
• Format:PDF

HITACHI ZW180 WHEEL LOADER WORKSHOP MANUAL (W4GD-E-00) – PDF DOWNLOAD:

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Description:

Hitachi ZW180 Wheel Loader Workshop Manual (W4GD-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 materials listed below in addition to this manual.
• The Operator’s Manual
• The Parts Catalog
• The Engine Manual
• Parts Catalog of the Engine
• Hitachi Training Material
MANUAL COMPOSITION
• This manual consists of three portions: the Technical Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual.
• Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems.
• Information included in the Technical Manual (Troubleshooting): technical information needed for 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 ZW180 Wheel Loader Workshop Manual (W4GD-E-00)

W4GD-E-00..................................................................................  0
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
		Maintenance Standard Terminology................................................... 45
	Group 2 Tightening..................................................................... 47
		Tightening Torque Specifications................................................... 47
		Torque Chart....................................................................... 48
		Piping Joint....................................................................... 51
		Periodic Replacement of Parts...................................................... 55
	Group 3 Painting....................................................................... 57
		Painting........................................................................... 57
	Group 4 Bleeding Air from Hydraulic Oil Tank........................................... 59
		Bleeding Air from Hydraulic Oil Tank............................................... 59
SECTION 2 BODY (UPPERSTRUCTURE)............................................................ 63
	Group 1 Cab............................................................................ 65
		Removal and Installation of Cab.................................................... 65
	Group 2 Counterweight.................................................................. 77
		Removal and Installation of Counterweight.......................................... 77
	Group 3 Center Hinge................................................................... 79
		Disassembly of Center Hinge........................................................ 79
		Assembly of Center Hinge........................................................... 84
	Group 4 Hood........................................................................... 89
		Removal and Installation of Hood................................................... 89
	Group 5 Hydraulic Oil Tank............................................................. 91
		Removal and Installation of Hydraulic Oil Tank..................................... 91
	Group 6 Pump Device.................................................................... 99
		Removal and Installation of Pump Device............................................ 99
		Removal and Installation of Pilot Pump and Regulator...............................106
		Disassembly of Main Pump...........................................................110
		Assembly of Main Pump..............................................................114
		Disassembly of Regulator...........................................................120
		Assembly of Regulator..............................................................122
		Disassembly of Priority Valve......................................................124
		Assembly of Priority Valve.........................................................126
		Structure of Pilot Pump............................................................128
		Maintenance Standard...............................................................130
	Group 7 Control Valve..................................................................131
		Removal and Installation of Control Valve..........................................131
		Disassembly of Control Valve.......................................................136
		Assembly of Control Valve..........................................................140
	Group 8 Pilot Valve....................................................................147
		Removal and Installation of Pilot Valve............................................147
		Disassembly of Standard Pilot Valve for Front Attachment...........................150
		Assembly of Standard Pilot Valve for Front Attachment..............................158
		Maintenance Standard...............................................................166
		Disassembly of Joy-Stick Type Pilot Valve for Additional Circuit (Optional)........168
		Assembly of Joy-Stick Type Pilot Valve for Additional Circuit (Optional)...........172
		Disassembly of 2-Way Lever Type Pilot Valve for Additional Circuit (Optional)......176
		Assembly of 2-Way Lever Type Pilot Valve for Additional Circuit (Optional).........178
	Group 9 Pilot Shut-Off Valve...........................................................181
		Removal and Installation of Pilot Shut-Off Valve...................................181
		Disassembly of Pilot Shut-Off Valve................................................184
		Assembly of Pilot Shut-Off Valve...................................................186
	Group 10 Fan Pump and Motor............................................................189
		Removal and Installation of Fan Pump...............................................189
		Removal and Installation of Fan Motor..............................................191
		Structure of Fan Pump..............................................................196
		Fan Motor Standard.................................................................198
SECTION 3 BODY (TRAVEL SYSTEM).............................................................203
	Group 1 Tire...........................................................................205
		Removal and Installation of Tire...................................................205
	Group 2 Drive Unit.....................................................................207
		Removal and Installation of Drive Unit.............................................207
		Disassembly of Drive Unit..........................................................220
		Disassembly of Torque Converter Wheel..............................................242
		Assembly of Torque Converter Wheel.................................................246
		Disassembly of Clutch Shaft (Forward Clutch and Reverse Clutch)....................248
		Assembly of Clutch Shaft (Forward Clutch and Reverse Clutch).......................250
		Disassembly of Clutch Shaft (1-Speed/2-Speed Clutch and 3-Speed/4-Speed Clutch)....252
		Assembly of Clutch Shaft (1-Speed/2-Speed Clutch and 3-Speed/4-Speed Clutch).......254
		Disassembly and Assembly of Idler Shaft............................................256
		Disassembly of Control Valve.......................................................258
		Assembly of Control Valve..........................................................260
		Disassembly of Regulator Valve.....................................................262
		Assembly of Regulator Valve........................................................264
		Assembly of Drive Unit.............................................................266
	Group 3 Axle...........................................................................289
		Removal and Installation of Axle...................................................289
		Disassembly of Axle................................................................299
		Assembly of Axle...................................................................317
	Group 4 Propeller Shaft................................................................341
		Removal and Installation of Propeller Shaft........................................341
	Group 5 Brake Valve....................................................................347
		Removal and Installation of Brake Valve............................................347
		Disassembly of Brake Valve.........................................................350
		Assembly of Brake Valve............................................................356
		Maintenance Standard...............................................................366
	Group 6 Charging Block.................................................................367
		Removal and Installation of Charging Block.........................................367
		Disassembly of Charging Block......................................................370
		Assembly of Charging Block.........................................................375
	Group 7 Steering Pilot Valve...........................................................383
		Removal and Installation of Steering Pilot Valve...................................383
		Disassembly of Steering Pilot Valve................................................386
		Assembly of Steering Pilot Valve...................................................390
	Group 8 Steering Valve.................................................................397
		Removal and Installation of Steering Valve.........................................397
		Disassembly of Steering Valve......................................................400
		Assembly of Steering Valve.........................................................402
	Group 9 Steering Cylinder..............................................................405
		Removal and Installation of Steering Cylinder......................................405
		Disassembly of Steering Cylinder...................................................410
		Assembly of Steering Cylinder......................................................416
SECTION 4 FRONT ATTACHMENT.................................................................431
	Group 1 Front Attachment...............................................................433
		Removal and Installation of Front Attachment.......................................433
	Group 2 Cylinder.......................................................................447
		Removal and Installation of Cylinder...............................................447
		Disassembly of Lift Cylinder.......................................................452
		Assembly of Lift Cylinder..........................................................456
		Disassembly of Bucket Cylinder.....................................................462
		Assembly of Bucket Cylinder........................................................466
		Maintenance Standard...............................................................472
SERVICE MANUAL REVISION REQUEST FORM.......................................................475

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