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
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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.