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Hitachi ZW 180-5B Workshop Manual
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Hitachi ZW 180-5B Workshop Manual

Hitachi ZW 180-5B Workshop Manual

Wheel loader
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URL:http://www.hitachi-c-m.com
PRINTED IN JAPAN (K) 2015, 12
PART NO.
WNDB-EN-01
Workshop Manual
180
-5B
180PL
-5B
Wheel Loader
Service Manual consists of the following separate Part No.
Technical Manual (Operational Principle)
Technical Manual (Troubleshooting)
Workshop Manual
: Vol. No.TONDB-EN
: Vol. No.TTNDB-EN
: Vol. No.WNDB-EN

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Summary of Contents for Hitachi ZW 180-5B

  • Page 1 PART NO. WNDB-EN-01 Workshop Manual 180PL Wheel Loader URL:http://www.hitachi-c-m.com Service Manual consists of the following separate Part No. Technical Manual (Operational Principle) : Vol. No.TONDB-EN Technical Manual (Troubleshooting) : Vol. No.TTNDB-EN PRINTED IN JAPAN (K) 2015, 12 Workshop Manual : Vol. No.WNDB-EN...
  • Page 3  FAX: 81-29-831-1162  E-mail: HCM-TIC-GES@hitachi-kenki.com 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 ...
  • Page 4 INTRODUCTION Safety Alert Symbol and Headline Notations In this manual, the following safety alert symbol and CAUTION: signal words are used to alert the reader to the potential Indicates potentially hazardous situation which could, if for personal injury of machine damage. not avoided, result in personal injury or death.
  • Page 5 SYMBOL AND ABBREVIATION Symbol and Abbreviation Symbol / Name Explanation Abbreviation Technical manual (Operational principle) Technical manual (Operational Principle). Technical manual (Troubleshooting) Technical manual (Troubleshooting). Technical manual Technical manual. W, W/M Workshop manual Workshop manual (Removal and Installation, Disassembly and Assembly). Main Controller Main controller.
  • Page 6 SYMBOL AND ABBREVIATION Symbol / Name Explanation Abbreviation Diesel Particulate Filter DPF is a filter which removes particulate matter (PM) including the toxic substance of exhaust gas of the diesel engine. Exhaust particulate removal equipment. Diesel Particulate Diffuser DPD is an exhaust emission control system, a type of DPF, which cleans up particulate matter (PM) of diesel engine exhaust gas.
  • Page 7 SAFETY Recognize Safety Information  These are the SAFETY ALERT SYMBOLS.  When you see these symbols on your machine or in this manual, be alert to the potential for personal injury.  Follow recommended precautions and safe operating practices. SA-688 Understand Signal Words ...
  • Page 8  Do not use attachments and/or optional parts or equipment not authorized by Hitachi. Failure to do so may deteriorate the safety, function, and/or service life of the machine. In addition, personal accident, machine...
  • Page 9 SAFETY Prepare for Emergencies  Be prepared if a fire starts or if an accident occurs.  Keep a first aid kit and fire extinguisher on hand.  Thoroughly read and understand the label attached on the fire extinguisher to use it properly. ...
  • Page 10 SAFETY Protect Against Noise  Prolonged exposure to loud noise can cause impairment or loss of hearing.  Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises. SA-434 Inspect Machine ...
  • Page 11 SAFETY General Precautions for Cab  Before entering the cab, thoroughly remove all dirt and/or oil such as mud, grease, soil or stones that may mess up the cab from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots, the operator’s foot may slip off the pedal, possibly resulting in a personal accident.
  • Page 12 SAFETY Use Handrails and Steps  Falling is one of the major causes of personal injury.  When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails.  Do not use any controls as handholds. ...
  • Page 13 SAFETY Ensure Safety Before Rising from or Leaving Operator’s Seat  Before rising from the operator’s seat to open / close either side window or to adjust the seat position, be sure to first lower the front attachment to the ground and then move the control lever lock switch to the lock ( ) position.
  • Page 14 SAFETY Move and Operate Machine Safely  Bystanders can be run over.  Take extra care not to run over bystanders. Confirm the location of bystanders before moving, or operating the machine.  Always keep the travel alarm and horn in working condition (if equipped).
  • Page 15 SAFETY Operate Only from Operator’s Seat  Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death.  Start the engine only when seated in the operator's seat.  NEVER start the engine while standing on the tire or on ground.
  • Page 16 SAFETY Investigate Job Site Beforehand  When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death.  Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from collapsing.
  • Page 17 SAFETY Equipment of Head Guard, ROPS, FOPS In case the machine is operated in areas where the possibility of falling stones or debris exist, equip a head guard, ROPS, or FOPS according to the potential hazardous conditions. (The standard cab for this machine corresponds to ROPS and FOPS.) Any modification of the ROPS structure will modify its performances and its certification will be lost.
  • Page 18 SAFETY Keep Riders Off Machine  Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine.  Only the operator should be on the machine. Keep riders off.  Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner.
  • Page 19 SAFETY Drive Machine Safely (Work Site)  Before driving the machine, always confirm that the steering wheel / and forward / reverse lever (switch) direction corresponds to the direction you wish to drive.  Be sure to detour around any obstructions. ...
  • Page 20 SAFETY Drive Safely with Bucket Loaded  If the machine is incorrectly operated while driving with the bucket loaded, turning over of the machine may result. Be sure to follow all the instructions indicated below.  When driving the machine on a job site with the bucket loaded, hold the bucket as low as possible to keep the machine balanced and to have good visibility.
  • Page 21 SAFETY Travel on Public Roads Safely  This machine is not allowed to drive on public roads with the bucket loaded.  Be sure to empty the bucket.  Hold the bucket at mark (A) 300 mm (12 in) above the road surface as illustrated.
  • Page 22 SAFETY Avoid Accidents from Backing Up and Turning  Make sure no one is working under or close to the machine before backing up or turning the machine to avoid personal injury and / or death by being run over or entangled in the machine.
  • Page 23 SAFETY Avoid Positioning Bucket or Attachment Over Anyone  Never allow the bucket or attachment to pass over co- workers and / or the dump truck operator’s cab. Falling soil from the bucket or contact with bucket or attachment may cause serious personal accidents and / or damage to the machine.
  • Page 24 SAFETY Never Undercut a High Bank  The edges could collapse or a land slide could occur causing serious injury or death. SA-519 Dig with Caution  Accidental severing of underground cables or gas lines may cause an explosion and / or fire, possibly resulting in serious injury or death.
  • Page 25 SAFETY Avoid Power Lines Serious injury or death can result from contact with electric lines. Never move any part of the machine or load closer to any electric line than 3 m (10 ft) plus twice the line insulator length. SA-455 Precautions for Operation ...
  • Page 26 SAFETY Object Handling CRANING OPERATION USING THE MACHINE IS NOT ALLOWED.  If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, resulting in serious injury or death. Never attach a sling or chain to the bucket teeth or to the attachment (fork or grapple for example).
  • Page 27 SAFETY Park Machine Safely To avoid accidents:  Park the machine on a firm, level surface.  Lower bucket to the ground.  Put the forward / reverse lever (switch) in neutral, and turn the parking brake switch (lever) ON (parking brake) position.
  • Page 28 SAFETY Transport Safely  Take care that the machine may turn over when loading or unloading the machine onto or off of a truck or trailer.  Observe the related regulations and rules for safe transportation.  Select an appropriate truck or trailer for the machine to Less than 15 °...
  • Page 29 SAFETY Handle Fluids Safely−Avoid Fires  Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and / or a fire may occur, possibly resulting in serious injury or death.  Do not refuel the machine while smoking or when near open flame or sparks.
  • Page 30 SAFETY Practice Safe Maintenance To avoid accidents:  Understand service procedures before starting work.  Keep the work area clean and dry.  Do not spray water or steam inside cab.  Never lubricate or service the machine while it is moving. ...
  • Page 31 SAFETY  Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the machine.  Always use a work light protected with a guard. In case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.
  • Page 32 SAFETY Stay Clear of Moving Parts  Entanglement in moving parts can cause serious injury.  To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts. SA-026 Support Maintenance Properly ...
  • Page 33 SAFETY Prevent Parts from Flying  Travel reduction gears are under pressure.  As pieces may fly off, be sure to keep body and face away from AIR RELEASE PLUG to avoid injury.  GEAR OIL is hot. Wait for GEAR OIL to cool, then gradually loosen AIR RELEASE PLUG to release pressure.
  • Page 34 SAFETY Replace Rubber Hoses Periodically  Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone. ...
  • Page 35 SAFETY Prevent Fires Check for Oil Leaks:  Fuel, hydraulic oil and lubricant leaks can lead to fires.  Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts.
  • Page 36 SAFETY Clean up Flammables:  Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires.  Prevent fires by inspecting and cleaning the machine daily, and by removing adhered oil or accumulated flammables immediately. Check and clean high temperature parts such as the exhaust outlet and mufflers earlier than the normal interval.
  • Page 37 SAFETY Evacuating in Case of Fire  If a fire breaks out, evacuate the machine in the following way:  Stop the engine by turning the key switch to the OFF position if there is time.  Use a fire extinguisher if there is time. ...
  • Page 38  Keep the units away from open flames and fire.  Do not bore a hole, do not cut by torch.  Avoid giving shocks by hitting or rolling the unit.  Before disposing the unit, sealed gas must be released. Consult your nearest Hitachi dealer. SA-32...
  • Page 39  Keep bystanders out of the work site during operation.  Asbestos might be present in imitation parts. Use only genuine Hitachi Parts. SA-33...
  • Page 40 SAFETY Prevent Battery Explosions  Battery gas can explode.  Keep sparks, lighted matches, and flame away from the top of battery.  Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. ...
  • Page 41  Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries.  Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.
  • Page 42 SAFETY Notes for Muffler Filter Muffler Filter The muffler filter removes particle matters (PM) in the exhaust gas. The muffler filter traps PM, and it is automatically regenerated by burning PM when the set amount of PM is accumulated in the filter. Follow the instructions below to prevent the muffler filter from being damaged.
  • Page 43 SAFETY Precaution for Communication Terminal Equipment This machine has a communication terminal equipment emitting electrical waves installed inside a rear tray which is situated at the back of the driver's seat. There is a possibility that a medical device, including an implantable device such as a cardiac pacemaker, would be affected and would malfunction by the electrical waves emitted from the communication terminal equipment.
  • Page 44 (When required to remove or install the communication terminal, consult your nearest Hitachi dealer.)  Do not pinch or forcibly pull cables, cords or connectors. Failure to do so may cause short circuit or broken circuit that may result in damage and/or fire to the base machine or to the communication terminal.
  • Page 45 SAFETY Before Returning the Machine to the Customer  After maintenance or repair work is complete, confirm that:  The machine is functioning properly, especially the safety systems.  Worn or damaged parts have been repaired or replaced. SA-435 SA-39...
  • Page 46 SAFETY (Blank) SA-40...
  • Page 47 The right is Group 16 Ride Control Device reserved to make changes at any time without notice. Group 17 Parallel Link (Special Parts) COPYRIGHT(C)2015 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved...
  • Page 49 The right is reserved to make changes at any time without notice. COPYRIGHT(C)2015 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved...
  • Page 50 TECHNICAL MANUAL (Operational Principle) TECHNICAL MANUAL (Troubleshooting) SECTION 1 GENERAL SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Specifications Group 1 Introduction Group 2 Component Layout Group 2 Standard Group 3 Component Specifications Group 3 Engine Test SECTION 2 SYSTEM Group 4 Machine Performance Test Group 1 Controller Group 5 Component Test Group 2 Control System...
  • Page 51 SECTION 1 GENERAL CONTENTS Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling ..............W1-1-1-1 Group 2 Tightening Tightening Bolts and Nuts ..........W1-2-1-1 Piping Joint ..............W1-2-1-4 Group 3 Painting Painting ................W1-3-1-1 Painting (Parallel Link) ..........W1-3-2-1 Group 4 Bleeding Air Bleeding Air from Hydraulic Oil Tank ......W1-4-1-1 Bleeding Air from Hydraulic System .......W1-4-1-2 Bleeding Air from Fuel System ........W1-4-1-3...
  • Page 52 (Blank) NDBW-1-2...
  • Page 53 SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and  If a part or component cannot be removed after Assembling removing its securing nuts and bolts, do not attempt to remove it forcibly. Find the cause (s), then take the appropriate measures to remove it.
  • Page 54 SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling Precautions for Using Floating Seal 1. In general, replace the floating seal with a new one after disassembling. If the floating seal is required to be reused, follow these procedures: ...
  • Page 55 SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling Precautions for Using Nylon Sling 1. Follow the precautions below to use nylon slings safely.  Attach protectors (soft material) on the corners of the load so that the nylon sling does not directly contact the corners.
  • Page 56 SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling CAUTION: If a load is lifted with a damaged nylon sling, serious personal injury may result. Be sure to visually check the nylon sling for any damage before using. 2. Before using a nylon sling, visually check the nylon sling for any damage corresponding to examples shown to the right.
  • Page 57 SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling Maintenance Standard Terminology “Standard” 1. Dimension for parts on a new machine. 2. Dimension of new components or assemblies adjusted to specification. Allowable errors will be indicated if necessary. “Allowable Limit” 1.
  • Page 58 SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling (Blank) W1-1-1-6...
  • Page 59 SECTION 1 GENERAL Group 2 Tightening Tightening Bolts and Nuts CAUTION: Use tools appropriate for the work to be done. Makeshift tools and procedures can create safety hazards. For loosening and tightening nuts and bolts, use correct size tools. Otherwise, tightening tools may slip, potentially causing personal injure.
  • Page 60 SECTION 1 GENERAL Group 2 Tightening IMPORTANT: The following items are applied to both fine and coarse pitch threads.  Apply lubricant to the bolts and nuts in order to reduce friction coefficient of them. (For example, spindle oil with white zinc B dissolved in it)  Torque tolerance is ±10 %.

This manual is also suitable for:

Zw 180pl-5b