Hitachi Zaxis 180W Workshop Manual manuals in PDF

$24.00

Factory Service Repair Manuals For Hitachi Zaxis 180W Excavators. Tons of illustrations, instructions, diagrams for step by step remove and install, assembly and disassembly, service, inspection, repair, troubleshooting, tune-ups.

Photo 8 - Hitachi Zaxis 180W Workshop Manual
Hitachi Zaxis 180W Workshop Manual $24.00
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Factory Service Repair Manuals For Hitachi Zaxis 180W Excavators. Tons of illustrations, instructions, diagrams for step by step remove and install, assembly and disassembly, service, inspection, repair, troubleshooting, tune-ups.

Format: PDF
Language: English
Pages: 720 + 413 + 369 + 13
Bookmarks: No
Searchable: Yes
Number: KM-CCBE
Wiring Diagrams: Yes
Hydraulic Diagrams: Yes

Model

Hitachi Zaxis 180W

Contents

1.Principle
2.Wiring Diagrams
3.Troubleshooting
4.Workshop Manual

Workshop Manual

  • INTRODUCTION
    SAFETY
  • -GENERAL INFORMATION
    –PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING
    Precautions for Disassembling and Assembling
    Maintenance Standard Terminology
    –TIGHTENING TORQUE
    Tightening Torque Specification
    Torque Chart
    Piping Joint
    Periodic Replacement of Parts
    –PAINTING
    Painting
    –BLEEDING AIR FROM HYDRAULIC OIL TANK
    Bleeding Air from Hydraulic Oil tank
  • -UPPERSTRUCTURE
    –CAB
    Remove and Install Cab
    Dimensions of the Cab Glass
    –COUNTERWEIGHT
    Remove and Install Counterweight
    –MAIN FRAME
    Remove and Install Main Frame
    –PUMP DEVICE
    Remove and Install Pump Device
    Disassemble Pump Device
    Assemble Pump Device
    Disassemble Regulator
    Assemble Regulator
    Disassemble Solenoid Valve
    Assemble Solenoid Valve
    Disassemble and Assemble
    Pilot Pump
    Maintenance Standard
    –CONTROL VALVE
    Remove and Install Control Valve
    Disassemble 4-Spool Control Valve
    Disassemble 5-Spool Control Valve
    Separate and Combine 4-Spool and 5-Spool Sections
    Assemble 4-Spool Control Valve
    Assemble 5-Spool Control Valve
    Remove and Install Auxiliary Control Valve
    Disassemble Auxiliary Control Valve
    Assemble Auxiliary Control Valve
    –SWING DEVICE
    Remove and Install Swing Device
    Disassemble Swing Device
    Assemble Swing Device
    Disassemble Swing Motor
    Assemble Swing Motor
    Maintenance Standard
    –PILOT VALVE
    Remove and Install Pilot Valve
    Disassemble Front/Swing Pilot Valve
    Assemble Front/Swing Pilot Valve
    Disassemble Travel,
    Positioning/Auxiliary Blade/Stabilizer Pilot Valve
    Assemble Travel, Positioning/Auxiliary Blade/Stabilizer Pilot Valve
    –PILOT SHUT-OFF VALVE
    Remove and Install
    Pilot Shut-Off Valve
    Disassemble Pilot Shut-Off Valve
    Assemble Pilot Shut-Off Valve
    –SIGNAL CONTROL VALVE
    Remove and Install Signal
    Control Valve
    –TRAVEL SHOCKLESS VALVE
    Remove and Install
    Travel Shockless Valve
    Construction of
    Travel Shockless Valve
    –SOLENOID VALVE
    Remove and Install 4-Unit Solenoid Valve Unit
    Disassemble Proportional Solenoid Valve
    Assemble Proportional Solenoid Valve
    Remove and Install Solenoid Valve (for Pump Control)
    Construction of Solenoid Valve (for Pump Control)
    Remove and Install 2-Unit Solenoid Valve (for Blade/Stabilizer)
    Construction of 2-Unit Solenoid Valve (for Blade/Stabilizer)
    –PILOT RELIEF VALVE
    Remove and Install Pilot Relief Valve
    Construction of Pilot Relief Valve
    –STEERING VALVE
    Remove and Install Steering Valve
    Disassemble Steering Valve
    Assemble Steering Valve
    Disassemble and Assemble Check Valve Unit
    –BRAKE VALVE
    Remove and Install Brake Valve
    Disassemble Brake Valve
    Assemble Brake Valve
    –ACCUMULATOR CHARGING VALVE
    Remove and Install Accumulator Charging Valve
    Construction of Accumulator Charging Valve
    –TRANSMISSION CONTROL VALVE
    Remove and Install Transmission Control Valve
    Construction of Transmission Control Valve
  • -UNDERCARRIAGE
    –Swing Bearing
    Remove and Install Swing Bearing
    Disassemble Swing Bearing
    Assemble Swing Bearing
    –Travel Motor
    Remove and Install Travel Motor
    Disassemble Travel Motor
    Assemble Travel Motor
    Disassemble Brake Valve
    Assemble Brake Valve
    –Center Joint
    Remove and Install Center Joint
    Disassemble Center Joint
    Assemble Center Joint
    Maintenance Standard
    –Transmission
    Remove and Install Transmission
    Disassemble Transmission
    Disassemble Final Drive and Differential
    Assemble Final Drive and Differential
    Assemble Transmission
    Adjusting Gear Clearance
    –AXLE
    Remove and Install Axle
    Disassemble Front Axle
    Assemble Front Axle
    Disassemble Front Differential
    Assemble Front Differential
    Disassemble Rear Axle
    Assemble Rear Axle
    Disassemble Rear Differential
    Assemble Rear Differential
    Disassemble Steering Cylinder
    Assemble Steering Cylinder
    –AXLE LOCK CYLINDER
    Remove and Install Axle Lock Cylinder
    Disassemble and Assemble Axle Lock Cylinder
    –OPERATE-CHECK VALVE
    Remove and Install Operate-Check Valve (for Axle Lock Cylinder)
    Construction of Operate-Check Valve (for Axle Lock Cylinder)
    –PROPELLER SHAFT
    Remove and Install Propeller Shaft
  • -FRONT ATTACHMENT
    –FRONT ATTACHMENT
    Hydraulic Circuit Pressure Release Procedure
    Remove and Install Monoblock Boom
    Front Attachment
    Remove and Install 2-Piece Boom Front Attachment
    Maintenance Standard
    Standard Dimensions for Arm and Bucket Connection
    Standard Dimensions for Arm and Boom Connection
    –CYLINDER
    Remove and Install Cylinder (Monoblock Boom, 2-Piece Boom)….
    Disassemble Cylinder (Boom (Monoblock/2-Piece), Positioning and Bucket)
    Assemble Cylinder (Boom (Monoblock/2-Piece),Positioning and Bucket
    Disassemble Cylinder (Arm)
    Assemble Cylinder (Arm
    Disassemble Cylinder (Stabilizer, Blade)
    Assemble Cylinder (Stabilizer, Blade)
    Maintenance Standard
    –HOSE-RUPTURE SAFETY VALVE
    Remove and Install Hose-Rupture Safety Valve
    Construction of Hose-Rupture Safety Valve
    –OPERATE-CHECK VALVE
    Remove and Install Operate-Check Valve (for Blade/Stabilizer)
    Construction of Operate-Check Valve (for Blade/Stabilizer)
  • -ENGINE AND ACCESSORY
    –GENERAL INFORMATION
    General Repair Instructions
    Notes on the Format of This Manual
    Main Data and Specifications
    Performance Curve
    External View
    Tightening Torque Specifications
    Angular Nut and Bolt Tightening Method
    Major Parts Fixing Nuts and Bolts
    Identifications
    –MAINTENANCE
    Lubricating System
    Fuel System
    Cooling System
    Valve Clearance Adjustment
    Injection Timing
    Compression Pressure Measurement
    Turbocharger Inspection
    Engine Repair Kit
    Recommended Lubricants
    Engine Oil Viscosity Chart
    –ENGINE ASSEMBLY 1 (DISASSEMBLY)
    External Parts Disassembly Steps
    Major Components
    Rocker Arm and Rocker Arm Shaft
    Disassembly Steps
    Cylinder Head Disassembly Steps
    Piston and Connecting Rod Disassembly Steps
    –ENGINE ASSEMBLY 2 (INSPECTION AND REPAIR)
    Cylinder Head
    Valve Guide
    Valve Spring
    Tappet
    Push Rod
    Rocker Arm Shaft and Rocker Arm
    Idler Gear and Idler Gear Shaft
    Camshaft
    Cylinder Body and Liner
    Piston and Piston Ring
    Piston Pin
    Connecting Rod
    Crankshaft
    Flywheel
    Timing Gear Case Cover
    –ENGINE ASSEMBLY 3 (REASSEMBLY)
    Piston and Connecting Rod Reassembly Steps
    Cylinder Head Reassembly Steps
    Rocker Arm and Rocker Arm Shaft
    Reassembly Steps
    Major Component Reassembly Steps 1
    Major Component Reassembly Steps 2
    External Parts Reassembly Steps (Left-Hand Side)
    External Parts Reassembly Steps (Right-Hand Side)
    Engine Tuning Operation
    –LUBRICATING SYSTEM
    General Description
    Oil Pump
    Oil Cooler
    –COOLING SYSTEM
    General Description
    Thermostat
    –FUEL SYSTEM
    General Description
    Injection Nozzle
    Injection Pump Calibration Data
    –TURBOCHARGER
    General Description
    Turbocharger Identification
    Troubleshooting
    Inspection and Repair
    –ENGINE ELECTRICALS
    Starter Identification
    Starter Main Data and Specifications
    Starter Sectional View
    Performance
    Disassembly
    Inspection and Repair
    Reassembly
    Adjustment
    Performance Test
    Alternator Identification
    Main Data and Specifications
    Alternator Sectional View
    Charging Circuit
    Structure
    Disassembly
    Inspections
    Reassembly
    Bench Test
    Current Output Test
    Fault Finding
    Specifications
    –TROUBLESHOOTING
    Hard Starting
    1)Starter Inoperative
    2)Starter Operates but
    Engine does not Turn Over
    3)Engine Turns Over but does not Start
    Fuel is Being Delivered to the Injection Pump
    4)Engine Turns Over but does not Start
    Unstable Low Idling
    Insufficient Power
    Excessive Fuel Consumption
    Excessive Oil Consumption
    Overheating
    Whity Exhaust Smoke
    Dark Exhaust Smoke
    Oil Pressure does not Rise
    Abnormal Engine Noise
    –SPECIAL TOOL LIST
    Special Tool List
    –REPAIR STANDARDS
    Repair Standards
    –CONVERSION TABLE
    Length
    Area
    Volume
    Mass
    Pressure
    Torque
    Temperature

Troubleshooting

  • INTRODUCTION
    SAFETY
  • -OPERATIONAL PERFORMANCE TEST
    –INTRODUCTION
    Operational Performance Tests
    Preparation for Performance Tests
    –STANDARD
    Operational Performance Standard Table
    Main Pump P-Q Diagram
    Injection Pump
    DrZX Monitor Indicating Values
    Sensor Activating Range
    –ENGINE TEST
    Engine Speed
    Engine Compression Pressure
    Valve Clearance Adjustment
    Nozzle Check
    Injection Timing
    Lubricant Consumption
    –EXCAVATOR TEST
    Travel Speed
    Service Brake Function Check
    Parking Brake Function Check
    Swing Speed
    Swing Function Drift Check
    Swing Motor Leakage
    Maximum Swingable Slant Angle
    Swing Bearing Play
    Hydraulic Cylinder Cycle Time
    Dig Function Drift Check
    Control Lever Operating Force
    Control Lever Stroke
    Combined Boom Raise/Swing Function Check
    –COMPONENT TEST
    Primary Pilot Pressure
    Secondary Pilot Pressure
    Solenoid Valve Set Pressure
    Main Pump Delivery Pressure
    Main Relief Valve Set Pressure
    Relief Pressure (When relieving Swing)
    Relief Pressure (When relieving Travel)
    Overload Relief Valve Set Pressure
    Main Pump Flow Rate Measurement
    Regulator Adjustment
    Swing Motor Drainage
    Travel Motor Drainage
    Steering Valve Relief Valve Set Pressure
    Brake Pressure (Front and Rear)
    Brake Accumulate Pressure
    Brake Warning Set Pressure (Decrease)
    Brake Warning Set Pressure (Increase)
    –ADJUSTMENT
    Engine Speed Adjustment and Engine Learning
    Governor Lever and Fuel Cut Lever
    Position
  • -TROUBLESHOOTING
    –GENERAL
    Introduction
    Diagnosing Procedure
    Built-In Diagnosing System Operation
    Built-In Diagnosing Function
    Display List
    Dr ZX Operation
    Dr ZX Fault Code List (MC)
    Dr ZX Monitoring Item List
    Dr ZX Special Function
    Dr ZX Service Mode
    Adjustment Data List
    –COMPONENT LAYOUT
    Main Component Layout
    Electrical Component Layout (Overview)
    Electrical System (Relays)
    Electrical System(Monitors and Switches)
    Ele ctrical System (Column Box)
    Pump Device
    Swing Device
    Signal Control Valve
    Control Valve
    Auxiliary control Valve
    4-Unit Solenoid Valve Unit
    3-Unit Solenoid Valve Unit
    Travel Shockless Valve / Accumulator Chrging Valve
    Transmission Control Valve
    Travel Device
    Filter
    Components in Control Valve
    Signal Control Valve Port Location
    –TROUBLESHOOTING A
    Troubleshooting A Procedure
    Fault Code List
    Fault Code 01, 02, 03
    Fault Code 04
    Fault Code 06
    Fault Code 07
    Fault Code 10, 11
    Fault Code 12, 13
    Fault Code 14, 15, 16, 18, 23, 24
    Fault Code 19
    Fault Code 20
    Fault Code 22
    –TROUBLESHOOTING B
    Troubleshooting B Procedure
    Relationship between Machine Trouble Symptoms and Related Parts
    Correlation between Trouble Symptoms and Part Failures
    Engine System Troubleshooting
    All Actuator System Troubleshooting
    Front Attachment System Troubleshooting
    Swing System Troubleshooting
    Travel System Troubleshooting
    Brake System Troubleshooting
    Steering System Troubleshooting
    Other System Troubleshooting
    Exchange Inspection
    Bleeding Air from Transmission
    Bleeding Air from Brake (Axle)
    Emergency Boom Lowering Procedure (without Hose-Rupture Safety Valve)
    Emergency Boom Lowering Procedure (with Hose-Rupture Safety Valve)
    –TROUBLESHOOTING C
    Troubleshooting C Procedure
    Malfunction of Coolant Temperature Gauge
    Malfunction of Fuel Gauge
    Malfunction of Indicator Light Check System
    Malfunction of Preheat Indicator
    Malfunction of Overheat Indicator
    Malfunction of Air Filter Restriction Indicator
    Malfunction of Fuel Level Indicator
    Malfunction of Alternator Indicator
    Malfunction of Engine Oil Pressure Indicator
    Malfunction of Hydraulic Oil Filter Indicator (Optional)
    –ELECTRICAL SYSTEM INSPECTION
    Precautions for Inspection and Maintenance
    Instructions for Disconnecting Connectors
    Fuse Inspection
    Fusible Link Inspection
    Battery Voltage Check
    How to Troubleshoot Alternator Malfunctions
    Continuity Check
    Voltage and Current Measurement
    Check by False Signal
    Test Hamess
    –ICX
    Outline
    ICX Fault Code List
    Fault Code 1 to 6
    Fault Code 7 to 10
    Some Parts of Data in Daily Report, Frequency Distribution, Cumulative Operation Hours are not Recorded

Principle

  • INTRODUCTION
  • -GENERAL
    –SPECIFICATIONS
    Specifications
    Working Ranges
    –COMPONENT LAYOUT
    Main Component Layout
    Electrical Component Layout (Overview)
    Electrical System (Relays)
    Electrical System (Monitors and Switches)
    Electrical System (Column Box)
    Pump Device
    Swing Device
    Signal Control Valve
    Control Valve
    Auxiliary control Valve
    4-Unit Solenoid Valve Unit
    Pump Control Solenoid Valve
    Travel Shockless Valve / Accumulator Charging Valve
    Transmission Control Valve
    Travel Device
    Filter
    –COMPONENT SPECIFICATIONS
    Engine
    Engine Accessories
    Hydraulic Component
    Electrical component
  • -SYSTEM
    –CONTROL SYSTEM
    Outline
    Engine Control
    Pump Control
    Valve Control
    Other Controls
    Electric and Hydraulic
    Composite Circuit Control
    –HYDRAULIC SYSTEM
    Outline
    Pilot Circuit
    Service Brake Circuit
    Steering Circuit
    Main Circuit
    –ELECTRICAL SYSTEM
    Outline
    Main Circuit
    Electric Power Circuit
    Indicator Light Check Circuit
    Accessory Circuit
    Preheat Circuit
    Starting Circuit
    Charging Circuit
    Parking Brake Circuit
    Serge Voltage Prevention Circuit
    Engine Stop Circuit
  • -COMPONENT OPERATION
    –PUMP DEVICE
    Outline
    Main Pump
    Regulator
    Solenoid Valve
    Pilot Pump, Steering Pump
    N Sensor (Engine Speed Sensor)
    Pump Delivery Pressure Sensor
    Pump Control Pressure Sensor
    –SWING DEVICE
    Outline
    Swing Reduction Gear
    Swing Motor
    Swing Parking Brake
    Valve Unit
    –CONTROL VALVE
    Outline
    Hydraulic Circuit
    Flow Combiner Valve
    Main Relief Valve
    Overload Relief Valve
    Regenerative Valve
    Anti-Drift Valve
    Flow Rate Control Valve
    Bypass Shut-Out Valve
    Auxiliary Flow Combiner Valve
    –PILOT VALVE
    Outline
    Operation
    –TRAVEL DEVICE
    Outline
    Transmission
    Front and Rear Propeller Shaft
    Front Axle
    Steering Cylinder
    Differential Gear
    Reduction Gear
    Rear Axle
    Travel Motor
    Rotor Section
    Regulator
    Brake Valve
    –SIGNAL CONTROL VALVE
    Outline
    Pilot Port
    Shuttle Valve
    Shockless Valve
    Pump 1 and Pump 2 Flow Rate
    Control Valves
    Bucket Flow Rate Control Valve Control Spool, Flow Combiner Valve Control Spool, Swing Parking Brake Release Spool, Arm Flow Rate Control Valve Control Spool
    –STEERING VALVE
    Outline
    Construction
    Operation
    Relief Valve
    Overload Relief Valve
    Make-Up Valve
    –BRAKE VALVE
    Outline
    Operation
    –TRANSMISSION CONTROL VALVE
    Outline
    Operation
    –OTHERS (UPPERSTRUCTURE)
    Pilot Shut-Off Valve
    Solenoid Valve Unit
    Travel Shockless Valve
    Pilot Relief Valve
    Accumulator
    Accumulator Charging Valve
    Hose-Rupture Safety Valve
    EC Motor
    –OTHERS (UNDERCARRIAGE)
    Swing Bearing
    Center Joint
    Slip Ring
    Cylinder

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