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
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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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