Hitachi ZW180-5B ZW180PL-5B Wheel Loader Workshop Manual (WNDB-EN-01)
File Details:
Hitachi ZW180-5B ZW180PL-5B Wheel Loader Workshop Manual (WNDB-EN-01)
- Manual Language:English
- Downloadable:Yes
- Pages: 953
- Size: 14.3 MB
- Format:PDF
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Description:
Hitachi ZW180-5B ZW180PL-5B Wheel Loader Workshop Manual (WNDB-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 ZW180-5B ZW180PL-5B Wheel Loader Workshop Manual (WNDB-EN-01)
WNDB-EN-01............................................................................................ 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 Painting (Parallel Link)...................................................................... 75 Group 4 Bleeding Air.............................................................................. 85 Bleeding Air from Hydraulic Oil Tank.......................................................... 85 Bleeding Air from Hydraulic System............................................................ 86 Bleeding Air from Fuel System................................................................. 87 Bleeding Air from Radiator.................................................................... 88 Bleeding Air from Brake (Axle)................................................................ 89 Group 5 Releasing Pressure........................................................................ 91 Front Attachment Hydraulic Circuit Pressure Release Procedure................................. 91 Ride Control Accumulator Pressure Release Procedure........................................... 92 Parking Brake Accumulator Pressure Release Procedure.......................................... 93 Group 6 Preparation............................................................................... 95 Preparation before Inspection and Maintenance................................................. 95 SECTION 2 MAINTENANCE STANDARD........................................................................101 Group 1 Body......................................................................................103 Center Hinge..................................................................................103 Group 2 Travel System.............................................................................105 Axle..........................................................................................105 Group 3 Front Attachment..........................................................................109 Pin and Bushing...............................................................................109 Standard Dimensions for Lift Arm and Bucket...................................................111 Cylinder......................................................................................113 Group 4 Front Attachment (Parallel Link)..........................................................115 Pin and Bushing...............................................................................115 Standard Dimensions for Quick Coupler and Bucket..............................................117 Cylinder......................................................................................119 SECTION 3 BODY........................................................................................123 Group 1 Cab.......................................................................................125 Removal and Installation of Cab...............................................................125 Removal and Installation of Cab (Parallel Link)...............................................147 Group 2 Counterweight.............................................................................169 Removal and Installation of Counterweight.....................................................169 Removal and Installation of Battery Box (Without Battery Disconnect Switch)...................171 Removal and Installation of Battery Box (Attached Battery Disconnect Switch)..................175 Removal and Installation of Battery Disconnect Switch.........................................179 Group 3 Center Hinge..............................................................................183 Removal and Installation of Center Hinge......................................................183 Removal and Installation of Center Hinge (Parallel Link)......................................205 Group 4 Engine....................................................................................231 Removal and Installation of Engine............................................................231 Removal And Installation of Exterior Parts....................................................261 Removal and Installation of the air cleaner...................................................277 Group 5 Radiator Assembly.........................................................................281 Replacement of Radiator, Oil Cooler, Intercooler, Torque Converter Cooler, and Fuel Cooler....281 Group 6 Hydraulic Oil Tank........................................................................295 Removal and Installation of Hydraulic Oil Tank................................................295 Group 7 Fuel Tank.................................................................................307 Removal and Installation of Fuel Tank.........................................................307 Group 8 Pump Device...............................................................................315 Removal and Installation of Pump Device.......................................................315 Disassembly of Pump Device....................................................................323 Assembly of Pump Device.......................................................................325 Disassembly of Main Pump......................................................................327 Assembly of Main Pump.........................................................................331 Disassembly of Regulator......................................................................337 Assembly of Regulator.........................................................................339 Structure of Pilot Pump.......................................................................341 Group 9 Control Valve.............................................................................343 Removal and Installation of Control Valve.....................................................343 Removal and Installation of Control Valve (Parallel Link).....................................353 Disassembly of Control Valve..................................................................365 Assembly of Control Valve.....................................................................369 Disassembly of Control Valve (Parallel Link)..................................................375 Assembly of Control Valve (Parallel Link).....................................................384 Group 10 Pilot Valve..............................................................................393 Removal and Installation of Pilot Valve.......................................................393 Removal and Installation of Pilot Valve (Two Lever Type ).....................................399 Removal and Installation of Auxiliary Pilot Valve.............................................405 Disassembly of Pilot Valve....................................................................411 Assembly of Pilot Valve.......................................................................414 Disassembly of Pilot Valve (Two Lever Type)...................................................419 Assembly of Pilot Valve (Two Lever Type)......................................................425 Disassembly of Auxiliary Pilot Valve..........................................................433 Assembly of Auxiliary Pilot Valve.............................................................436 Group 11 Brake Charge Valve.......................................................................441 Removal and Installation of Brake Charge Valve................................................441 Structure of Brake Charge Valve...............................................................447 Removal and Installation of Brake Accumulator.................................................449 Group 12 Manifold Valve...........................................................................455 Removal and Installation of Manifold Valve....................................................455 Disassembly of Manifold Valve.................................................................465 Assembly of Manifold Valve....................................................................468 Group 13 Solenoid Valve...........................................................................473 Removal and Installation of Parking Brake Solenoid Valve Unit.................................473 Structure of Parking Brake Solenoid Valve Unit................................................477 Removal and Installation of Quick Coupler Solenoid Valve (Parallel Link)......................479 Disassembly of Quick Coupler Solenoid Valve...................................................487 Assembly of Quick Coupler Solenoid Valve......................................................489 Group 14 Priority Valve...........................................................................491 Removal and Installation of Priority Valve....................................................491 Structure of Priority Valve...................................................................495 Group 15 Cooling Fan System.......................................................................497 Removal and Installation of Fan Valve.........................................................497 Structure of Fan Valve........................................................................501 Removal and Installation of Fan Motor.........................................................503 Structure of Fan Motor........................................................................519 Removal and Installation of Fan Pump..........................................................521 Disassembly of Fan Pump.......................................................................527 Assembly of Fan Pump..........................................................................529 Group 16 Ride Control Device......................................................................533 Removal and Installation of Ride Control Valve................................................533 Disassembly of Ride Control Valve.............................................................537 Assembly of Ride Control Valve................................................................540 Removal and Installation of Ride Control Accumulator..........................................545 Group 17 Parallel Link (Special Parts)............................................................549 Removal and Installation of Bucket Regenerative Valve.........................................549 Structure of Bucket Regenerative Valve........................................................559 Removal and Installation of Bucket Regenerative Selector Valve................................561 Structure of Bucket Regenerative Selector Valve...............................................567 SECTION 4 TRAVEL SYSTEM...............................................................................571 Group 1 Tire......................................................................................573 Removal and Installation of Front Tire........................................................573 Removal and Installation of Rear Tire.........................................................577 Group 2 Drive Unit................................................................................583 Removal and Installation of Drive Unit........................................................583 Disassembly and Assembly of Drive Unit........................................................589 Removal and Installation of Torque Converter..................................................595 Disassembly and Assembly of Transmission......................................................601 Disassembly and Assembly of Transmission Control Valve........................................651 Removal and Installation of Parking Brake (Replace The Brake Friction Pad)....................665 Group 3 Axle......................................................................................675 Removal and Installation of Front Axle........................................................675 Removal and Installation of Rear Axle.........................................................683 Disassembly of Axle...........................................................................691 Assembly of Axle..............................................................................708 Group 4 Propeller Shaft...........................................................................735 Removal and Installation of Propeller Shaft...................................................735 Group 5 Brake Valve...............................................................................743 Removal and Installation of Brake Valve.......................................................743 Disassembly of Brake Valve....................................................................747 Assembly of Brake Valve.......................................................................749 Group 6 Steering Device...........................................................................753 Removal and Installation of Steering Valve....................................................753 Disassembly of Steering Valve.................................................................757 Assembly of Steering Valve....................................................................760 Removal and Installation of Steering Cylinder.................................................765 Disassembly of Steering Cylinder..............................................................779 Assembly of Steering Cylinder.................................................................783 Removal and Installation of Steering Accumulator..............................................789 Group 7 Emergency Steering Device.................................................................791 Removal and Installation of Emergency Steering Pump...........................................791 SECTION 5 FRONT ATTACHMENT............................................................................799 Group 1 Front Attachment..........................................................................801 Removal and Installation of Front Attachment (With Lift Arm Kickout)..........................801 Removal and Installation of Front Attachment (With Lift Arm Auto Leveler).....................815 Removal and Installation of Bell Crank........................................................829 Removal and Installation of Bucket............................................................839 Group 2 Cylinder..................................................................................845 Removal and Installation of Lift Arm Cylinder.................................................845 Removal and Installation of Bucket Cylinder...................................................853 Disassembly of Lift Arm Cylinder and Bucket Cylinder..........................................865 Assembly of Lift Arm Cylinder and Bucket Cylinder.............................................870 Group 3 Front Attachment (Parallel Link)..........................................................875 Removal and Installation of Front Attachment..................................................875 Removal and Installation of Quick Coupler.....................................................897 Group 4 Cylinder (Parallel Link)..................................................................905 Removal and Installation of Lift Arm Cylinder.................................................905 Removal and Installation of Bucket Cylinder...................................................913 Removal and Installation of Quick Coupler Cylinder............................................925 Disassembly of Lift Arm Cylinder..............................................................929 Assembly of Lift Arm Cylinder.................................................................933 Disassembly of Bucket Cylinder................................................................937 Assembly of Bucket Cylinder...................................................................941 Disassembly of Quick Coupler Cylinder.........................................................945 Assembly of Quick Coupler Cylinder............................................................948 SERVICE MANUAL REVISION REQUEST FORM..................................................................953
Please Note:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]