Hitachi ZW180-5A Wheel Loader Workshop Manual (WNDJ-EN-00)
File Details:
Hitachi ZW180-5A Wheel Loader Workshop Manual (WNDJ-EN-00)
- Manual Language:English
- Pages: 744
- Size: 7.00 MB
- Downloadable:Yes
- Format:PDF
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Description:
Hitachi ZW180-5A Wheel Loader Workshop Manual (WNDJ-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 ZW180-5A Wheel Loader Workshop Manual (WNDJ-EN-00)
WNDJ-EN-00............................................................................................ 1 INTRODUCTION.......................................................................................... 3 SYMBOL AND ABBREVIATION............................................................................... 5 SAFETY................................................................................................ 7 SECTION AND GROUP CONTENTS............................................................................ 47 SECTION 1 GENERAL..................................................................................... 51 Group 1 Precautions for Disassembling and Assembling.............................................. 53 Precautions for Disassembling and Assembling.................................................. 53 Group 2 Tightening................................................................................ 59 Tightening Bolts and Nuts..................................................................... 59 Piping Joint.................................................................................. 62 Group 3 Painting.................................................................................. 69 Painting...................................................................................... 69 Group 4 Bleeding Air.............................................................................. 77 Bleeding Air from Hydraulic Oil Tank.......................................................... 77 Bleeding Air from Hydraulic System............................................................ 78 Bleeding Air from Fuel System................................................................. 79 Bleeding Air from Radiator.................................................................... 80 Bleeding Air from Brake (Axle)................................................................ 81 Group 5 Releasing Pressure........................................................................ 83 Front Attachment Hydraulic Circuit Pressure Release Procedure................................. 83 Ride Control Accumulator Pressure Release Procedure........................................... 84 Parking Brake Accumulator Pressure Release Procedure.......................................... 85 Group 6 Preparation............................................................................... 87 Preparation before Inspection and Maintenance................................................. 87 SECTION 2 MAINTENANCE STANDARD........................................................................ 93 Group 1 Body...................................................................................... 95 Center Hinge.................................................................................. 95 Group 2 Front Attachment.......................................................................... 97 Pin and Bushing............................................................................... 97 Standard Dimensions for Lift Arm and Bucket................................................... 99 Cylinder......................................................................................101 SECTION 3 BODY........................................................................................105 Group 1 Cab.......................................................................................107 Removal and Installation of Cab...............................................................107 Group 2 Counterweight.............................................................................141 Removal and Installation of Counterweight.....................................................141 Removal and Installation of Battery Box.......................................................143 Group 3 Center Hinge..............................................................................147 Removal and Installation of Center Hinge......................................................147 Group 4 Engine....................................................................................169 Removal and Installation of Engine............................................................169 Removal And Installation of Exterior Parts....................................................215 Group 5 Radiator Assembly.........................................................................227 Removal and Installation of Radiator, Oil Cooler, Intercooler, and Torque Converter Cooler....227 Group 6 Hydraulic Oil Tank........................................................................257 Removal and Installation of Hydraulic Oil Tank................................................257 Group 7 Fuel Tank.................................................................................277 Removal and Installation of Fuel Tank.........................................................277 Group 8 Pump Device...............................................................................283 Removal and Installation of Pump Device.......................................................283 Disassembly of Pump Device....................................................................291 Assembly of Pump Device.......................................................................293 Disassembly of Main Pump......................................................................295 Assembly of Main Pump.........................................................................299 Disassembly of Regulator......................................................................305 Assembly of Regulator.........................................................................307 Structure of Pilot Pump.......................................................................309 Group 9 Control Valve.............................................................................311 Removal and Installation of Control Valve.....................................................311 Disassembly of Control Valve..................................................................321 Assembly of Control Valve.....................................................................325 Group 10 Pilot Valve..............................................................................331 Removal and Installation of Pilot Valve.......................................................331 Removal and Installation of Pilot Valve (Two Lever Type ).....................................337 Disassembly of Pilot Valve....................................................................343 Assembly of Pilot Valve.......................................................................346 Disassembly of Pilot Valve (Two Lever Type)...................................................351 Assembly of Pilot Valve (Two Lever Type)......................................................357 Group 11 Brake Charge Valve.......................................................................365 Removal and Installation of Brake Charge Valve................................................365 Structure of Brake Charge Valve...............................................................371 Removal and Installation of BrakeAccumulator..................................................373 Group 12 Manifold Valve...........................................................................379 Removal and Installation of Manifold Valve....................................................379 Disassembly of Manifold Valve.................................................................389 Assembly of Manifold Valve....................................................................392 Group 13 Solenoid Valve...........................................................................397 Removal and Installation of Parking Brake Solenoid Valve Unit.................................397 Structure of Parking Brake Solenoid Valve Unit................................................401 Group 14 Priority Valve...........................................................................403 Removal and Installation of Priority Val......................................................403 Structure of Priority Valve...................................................................415 Group 15 Cooling Fan System.......................................................................417 Removal and Installation of Fan Motor.........................................................417 Structure of Fan Motor........................................................................433 Removal and Installation of Fan Pump..........................................................435 Disassembly of Fan Pump.......................................................................441 Assembly of Fan Pump..........................................................................443 Group 16 Ride Control Device......................................................................447 Removal and Installation of Ride Control Valve................................................447 Disassembly of Ride Control Valve.............................................................451 Assembly of Ride Control Valve................................................................454 Removal and Installation of Ride Control Accumulator..........................................459 SECTION 4 TRAVEL SYSTEM...............................................................................465 Group 1 Tire......................................................................................467 Removal and Installation of Front Tire........................................................467 Removal and Installation of Rear Tire.........................................................471 Group 2 Drive Unit................................................................................475 Removal and Installation of Drive Unit........................................................481 Disassembly and Assembly of Drive Unit........................................................481 Removal and Installation of Torque Converter..................................................487 Disassembly and Assembly of Transmission......................................................493 Disassembly and Assembly of Transmission Control Valve........................................543 Removal and Installation of Parking Brake (Replace The Brake Friction Pad)....................557 Group 3 Axle......................................................................................567 Removal and Installation of Front Axle........................................................567 Removal and Installation of Rear Axle.........................................................573 Disassembly of Axle...........................................................................583 Assembly of Axle..............................................................................584 Group 4 Propeller Shaft...........................................................................585 Removal and Installation of Propeller Shaft...................................................585 Group 5 Brake Valve...............................................................................595 Removal and Installation of Brake Valve (One Pedal)...........................................595 Removal and Installation of Brake Valve (Two Pedals)..........................................601 Disassembly of Brake Valve....................................................................607 Assembly of Brake Valve.......................................................................610 Group 6 Steering Device...........................................................................617 Removal and Installation of Steering Valve....................................................617 Disassembly of Steering Valve.................................................................621 Assembly of Steering Valve....................................................................624 Removal and Installation of Steering Cylinder.................................................629 Disassembly of Steering Cylinder .............................................................643 Assembly of Steering Cylinder.................................................................647 Removal and Installation of Steering Accumulator..............................................653 Group 7 Emergency Steering Device.................................................................655 Removal and Installation of Emergency Steering Pump...........................................655 SECTION 5 FRONT ATTACHMENT............................................................................663 Group 1 Front Attachment..........................................................................665 Removal and Installation of Front Attachment (With Lift Arm Kickout)..........................665 Removal and Installation of Front Attachment (With Lift Arm Auto Leveler).....................679 Removal and Installation of Bell Crank........................................................695 Removal and Installation of Bucket............................................................705 Group 2 Cylinder..................................................................................711 Removal and Installation of Lift Arm Cylinder.................................................711 Removal and Installation of Bucket Cylinder...................................................719 Disassembly of Lift Arm Cylinder and Bucket Cylinder..........................................731 Assembly of Lift Arm Cylinder and Bucket Cylinder.............................................736 SERVICE MANUAL REVISION REQUEST FORM..................................................................743
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