Hitachi ZW100 120 Wheel Loader Workshop Manual
FILE DETAILS:
Hitachi ZW100 120 Wheel Loader Workshop Manual
Language : English
Pages : 350
Downloadable : YES
Format : PDF
Size : 4.15 MB
Part No : W4FJ-E-00
DESCRIPTION:
Hitachi ZW100 120 Wheel Loader Workshop Manual
INTRODUCTION:
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 ZW100 120 Wheel Loader Workshop Manual
W4FJ-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
Group 2 Counterweight 77
Removal and Installation of Counterweight 77
Group 3 Center Hin 79
Removal and Installation of Center Hinge 79
Group 4 Hydraulic Oil Ta 85
Removal and Installation of Hydraulic Oil Tank 85
Group 5 Pump Device 97
Removal and Installation of Pump Device 97
Disassembly of HST Pump104
Assembly of HST Pump110
Structure of Forward/Reverse Selector Control Valve119
Structure of DA Valve120
Structure of Cut-Off Valve120
Structure of Low-Pressure Relief Valve121
Structure of Hi-Pressure Relief Valve121
List of Tightening Torque122
Disassembly of Gear Pump124
Assembly of Gear Pump128
Group 6 Control Valv133
Removal and Installation of Control Valve133
Disassembly and Assembly of Control Valve138
Disassembly of Bucket Spool Assembly140
Assembly of Bucket Spool Assembly142
Disassembly of Lift Arm Spool Assembly144
Assembly of Lift Arm Spool Assembly146
Group 7 Steering Valv149
Removal and Installation of Steering Valve149
Disassembly of Steering Valve156
Assembly of Steering Valve160
Group 8 Brake Valv165
Removal and Installation of Brake Valve165
Brake Circuit Air Bleeding170
Structure of Brake Valve172
Group 9 Priority Valv177
Removal and Installation of Priority Valve177
Structure of Priority Valve181
Group 10 Inching Valv183
Removal and Installation of Inching Valve183
Structure of Inching Valve186
SECTION 3 TRAVEL SYSTEM189
Group 1 Steering Cylinder191
Removal and Installation of Steering Cylinder191
Disassembly of Steering Cylinder196
Assembly of Steering Cylinder198
Group 2 HST Motor201
Removal and Installation of HST Motor201
Disassembly of HST Motor206
Structure of Rotary Block210
Assembly of HST Motor212
Structure of HST Motor Displacement Angle Control Valve215
List of Tightening Torque216
Group 3 Transmission217
Removal and Installation of Transmission217
Disassembly of Transmission226
Assembly of Transmission234
Disassembly of Clutch Assembly242
Assembly of Clutch Assembly244
Structure of Control Valve247
Maintenance Standard249
Group 4 Axle 255
Removal and Installation of Front Axle255
Removal and Installation of Rear Axle259
Disassembly of Axle268
Assembly of Axle276
Disassembly of Differential (TPD Type Axle)286
Assembly of Differential (TPD Type Axle)288
Group 5 Propeller Shaft291
Removal and Installation of Propeller Shaft291
Group 6 Tire295
Removal and Installation of Tire295
SECTION 4 ATTACHMENT303
Group 1 Front Attachment305
Removal and Installation of Front Attachment305
Maintenance Standard317
Standard Dimensions for Lift Arm and Bucket Connection318
Group 2 Cylinder 319
Removal and Installation of Cylinder319
Disassembly of Lift Arm Cylinder332
Assembly of Lift Arm Cylinder336
Disassembly of Bucket Cylinder340
Assembly of Bucket Cylinder344
Maintenance Standard347
SERVICE MANUAL REVISION REQUEST FORM350
VIDEO PREVIEW OF THE MANUAL:
IMAGES PREVIEW OF THE MANUAL:
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.