Hitachi ZW 100-G, Workshop Manual

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Page 3: ...anual parts catalog engine technical material and Hitachi training material etc in addition to this manual MANUAL COMPOSITION This manual consists the Technical Manual and the Workshop 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 proc...

Page 4: ...ANT Indicates a situation which if not conformed to the instructions could result in damage to the machine NOTE Indicates supplementary technical information or know how UNITS USED SI Units International System of Units are used in this manual MKSA system units and English units are also indicated in parenthheses just behind SI units Example 24 5 MPa 250 kgf cm2 3560 psi A table for conversion fro...

Page 5: ...WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury DANGER or WARNING safety signs are located near specific hazards General precautions are listed on CAUTION safety signs Some safety signs don t use any of the desig nated sign...

Page 6: ... Hitachi Failure to do so may deteriorate the safety function and or service life of the machine In addition personal accident machine trouble and or damage to material caused by using unauthorized attach ments and or optional parts or equipment will void Hitachi Warranty Policy The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines However it is ...

Page 7: ...ating equipment safely requires the full atten tion of the operator Do not wear radio or music headphones while operating the machine 005 E01A 0438 SA 438 PROTECT AGAINST NOISE Prolonged exposure to loud noise can cause im pairment or loss of hearing Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objec tionable or uncomfortably loud noises 006 E01A 0434 S...

Page 8: ...tore them in their specified lo cations Avoid storing transparent bottles in the cab Do not attach any transparent type window decora tions on the windowpanes as they may focus sunlight possibly starting a fire Refrain from listening to the radio or using music headphones or mobile telephones in the cab while operating the machine Keep all flammable objects and or explosives away from the machine ...

Page 9: ... If not move the seat forward or backward and check again Adjust the rear view mirror position so that the best rear visibility is obtained from the operator s seat If the mirror is broken immediately replace it with a new one 009 E01A 0462 SA 462 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 sea...

Page 10: ...tanders Con firm the location of bystanders before moving or operating the machine Always keep the travel alarm and horn in working condition if equipped It warns people when the machine starts to move Use a signal person when moving swinging or operating the machine in congested areas Coor dinate hand signals before starting the machine Use appropriate illumination Check that all lights are opera...

Page 11: ...arting the engine confirm the safety around the machine and sound the horn to alert bystanders 012 E01B 0431 SA 431 JUMP STARTING Battery gas can explode resulting in serious injury If the engine must be jump started be sure to follow the instructions shown in the OPERATING THE ENGINE chapter in the operator s manual The operator must be in the operator s seat so that the machine will be under con...

Page 12: ...e ground edges and road shoulders as necessary Keep the machine well back from the edges of excavations and road shoulders When working on an incline or on a road shoulder employ a signal person as required Confirm that your machine is equipped a FOPS cab before working in areas where the possibility of falling stones or debris exist When the footing is weak reinforce the ground before starting wo...

Page 13: ... for this machine corresponds to ROPS and FOPS ROPS Roll Over Protective Structure FOPS Falling Object Protective Structure SA 521 PROVIDE SIGNALS FOR JOBS INVOLV ING MULTIPLE NUMBERS OF MACHINES For jobs involving multiple numbers of machines provide signals commonly known by all personnel involved Also appoint a signal person to coordinate the job site Make sure that all personnel obey the signa...

Page 14: ...ering function becomes inoperative Immediately stop the machine by applying the bake to prevent personal accident 019 E07A 0448 SA 448 DRIVE MACHINE SAFELY WORK SITE Before driving the machine always confirm that the steering wheel F N R lever direction corresponds to the direction you wish to drive Be sure to detour around any obstructions Driving on a slope may cause the machine to slip or overt...

Page 15: ...death 051 E02A 0400 SA 400 DRIVE ON SNOW SAFELY Beware of the possibility of slipping or turning over the machine when driving on frozen snow surfaces The machine may slip more easily than expected on frozen snow surfaces even if the inclination is small Reduce speed when driving Avoid fast starts stops and quick turns Road shoulder and or set up utilities covered with snow are difficult to locate...

Page 16: ...et to the ground Place the F N R lever in neutral and put the park brake switch in the ON parking brake position Run the engine at slow idle speed without load for 5 minutes to cool down the engine Stop the engine and remove the key from the key switch Pull the lock lever to LOCK position Block both tires and lower the bucket to the ground Position the machine to prevent rolling Park a reasonable ...

Page 17: ...led in the machine Keep all personnel away from the machine by sounding the horn and or using hand signals Use extra care to be sure no one is in from the articu lation area before turning the machine Keep windows mirrors and lights in good condi tion Reduce travel speed when dust heavy rain fog etc reduce the visibility In case good visibility is not obtained use a signal person to guide you 021 ...

Page 18: ... PREVENT YOUR BODY FROM BEING THROWN OUT OF THE MACHINE MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT The danger of tipping is always present when oper ating on a grade possibly resulting in serious injury or death To avoid tipping Be extra careful before operating on a grade Prepare machine operating area flat Keep the bucket low to the ground and close to the machine ...

Page 19: ...les gas lines and water lines 027 E01A 0396 SA 396 PERFORM TRUCK LOADING SAFELY Do not operate the machine involuntarily Unex pected machine movement may cause personal in jury and or death Do not lower the bucket with the loader control lever in the FLOAT position The bucket may free fall possibly causing personal injury and or death Always select a level surface for truck loading 028 E01A 397 SA...

Page 20: ...the electrical storm has passed check all of the machine safety devices for any failure If any failed safety devices are found operate the ma chine only after repairing them OBJECT HANDLING If a lifted load should fall any person nearby may be struck by the falling load or may be crushed under neath it resulting in serious injury or death When using the machine for craning operations be sure to co...

Page 21: ...31 E01A 0432 SA 432 PARK MACHINE SAFELY To avoid accidents Park machine on a firm level surface Lower bucket to the ground Place the F N R lever in neutral and put the park brake switch in the ON parking brake position Run engine at slow idle speed without load for 5 minutes Turn key switch to OFF to stop engine Remove the key from the key switch Lower the lock lever to the LOCK position Close win...

Page 22: ...e transported Be sure to use a signal person Always follow the following precautions for load ing or unloading 1 Select solid and level ground 2 Always use a ramp or deck strong enough to support the machine weight 3 Use the low speed gear 4 Never steer the machine while on the ramp If the traveling direction must be changed while the ramp unload the machine from the ramp reposi tion the machine o...

Page 23: ...e smoking or when near open flame or sparks Always stop the engine before refueling the ma chine Fill the fuel tank outdoors All fuels most lubricants and some coolants are flammable Store flammable fluids well away from fire haz ards Do not incinerate or puncture pressurized con tainers Do not store oily rags they can ignite and burn spontaneously Securely tighten the fuel and oil filler cap 034 ...

Page 24: ... lever 9 Lower the lock lever to the LOCK position 10 Lock bar connects the front and rear frames 11 Allow the engine to cool If a maintenance procedure must be performed with the engine running do not leave machine unattended Never work under a machine raised by the lift arm Inspect certain parts periodically and repair or re place as necessary Refer to the section discuss ing that part in the MA...

Page 25: ...SS2045102 SUPPORT MACHINE PROPERLY Never attempt to work on the machine without se curing the machine first Always lower the attachment to the ground before you work on the machine If you must work on a lifted machine or attach ment securely support the machine or attach ment Do not support the machine on cinder blocks hollow tires or props that may crumble under continuous load Do not work under ...

Page 26: ...ou to stand to one side and not in front of or over the tire as sembly Use a safety cage it available Inspect tires and wheels daily Do not operate with low pressure cuts bubbles damaged rims or missing lug bolts and nuts Never cut or weld on an inflated tire or rim as sembly Heat from welding could cause an in crease in pressure and may result in tire explo sion 521 E02A 0249 SA 249 PREVENT PARTS...

Page 27: ...ecome hot during operation The engine hoses lines and other parts become hot as well Wait for the oil and components to cool before starting any maintenance or inspection work 505 E01B 0498 SA 039 SA 225 REPLACE RUBBER HOSES PERIODI CALLY Rubber hoses that contain flammable fluids under pressure may break due to aging fatigue and abra sion It is very difficult to gauge the extent of dete rioration...

Page 28: ...ulic or other lines Tighten all connections before applying pressure Search for leaks with a piece of cardboard take care to protect hands and body from high pressure fluids Wear a face shield or gog gles for eye protection If an accident occurs see a doctor familiar with this type of injury immediately Any fluid injected into the skin must be surgically removed within a few hours or gangrene may ...

Page 29: ...n 10 hours operation for missing or damaged terminal caps DO NOT OPERATE MACHINE if cable or wires are loose kinked etc Clean up Flammables Spilled fuel and oil and trash grease debris ac cumulated coal dust and other flammables may cause fires Prevent fires by inspecting and cleaning the ma chine daily and by removing spilled or accumu lated flammables immediately Check Key Switch If a fire break...

Page 30: ...ust fumes or open doors and windows to bring enough outside air into the area 509 E01A 0016 SA 016 PRECAUTIONS FOR WELDING AND GRINDING Welding may generate gas and or small fires Be sure to perform welding in a well ventilated and prepared area Store flammable objects in a safe place before starting welding Only qualified personnel should perform welding Never allow an unqualified person to perfo...

Page 31: ... tain flammable fluids Clean them thoroughly with nonflammable solvent before welding or flame cutting them 510 E01B 0030 REMOVE PAINT BEFORE WELDING OR HEATING Hazardous fumes can be generated when paint is heated by welding soldering or using a torch If inhaled these fumes may cause sickness Avoid potentially toxic fumes and dust Do all such work outside or in a well ventilated area Dispose of p...

Page 32: ...attery Never check battery charge by placing a metal object across the posts Use a voltmeter or hy drometer Do not charge a frozen battery it may explode Warm the battery to 16 C 60 F first Do not continue to use or charge the battery when electrolyte level is lower than specified Explosion of the battery may result Loose terminals may produce sparks Securely tighten all terminals Battery electrol...

Page 33: ...products used with your machine 515 E01A 0309 SA 309 DISPOSE OF WASTE PROPERLY Improperly disposing of waste can threaten the en vironment 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 drinki...

Page 34: ...NG 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 S517 E01A 0435 SA 435 ...

Page 35: ...ng and Assembling Group 2 Tightening Torque Group 3 Painting Group 4 Bleeding Air from Hydraulic Circuit Group 5 Hydraulic Circuit Pressure Release Procedure Group 6 Preparation SECTION 2 BODY Group 1 Cab Group 2 Counterweight Group 3 Center Hinge Group 4 Hydraulic Oil Tank Group 5 Pump Device Group 6 Control Valve Group 7 Steering Valve Group 8 Brake Valve Group 9 Priority Valve Group 10 Inching ...

Page 36: ...Valve Group 4 Steering Valve Group 5 HST Motor Group 6 Transmission Group 7 Axle Group 8 Brake Valve Group 9 Others Group 10 Ride Control Valve Optional TECHNICAL MANUAL Troubleshooting SECTION 4 OPERATIONAL PER FORMANCE TEST Group 1 Introduction Group 2 Standard Group 3 Engine Test Group 4 Wheel Loader Test Group 5 Component Test SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Group 2 Dr Z...

Page 37: ...s and Nuts W1 2 1 Piping Joint W1 2 8 Group 3 Painting Painting W1 3 1 Group 4 Bleeding Air from Hydraulic Circuit Bleeding Air from Hydraulic Oil Tank W1 4 1 Bleeding Air from Hydraulic System W1 4 2 Group 5 Hydraulic Circuit Pressure Release Procedure Hydraulic Circuit Pressure Release Procedure W1 5 1 Group 6 Preparation Preparations for Inspection and Maintenance W1 6 1 ...

Page 38: ...4FKW 1 2 Blank ...

Page 39: ...draining fluids Use matching marks for easier reassembling if necessary Be sure to use the specified special tools when instructed If a part or component cannot be removed after 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 Orderly arrange disassembled parts Mark and tag them if necessary Store common part...

Page 40: ...ting seal and seal mounting bores with cleaning solvent Use a wire brush to remove mud rust or dirt from seal mounting bores After cleaning thoroughly dry parts with compressed air Clean seal ring 1 and O ring 2 mounting bores Check the bore surface for scuffing or scoring by touching the surface with finger After installing the floating seal check that O ring 2 is not twisted and that it is insta...

Page 41: ...ted load balanced When lifting a load using an eyehole be sure to eliminate any gaps between the sling and load Refer to the right illustration Reduce the load weight so that it is less than 80 of the sling breaking force Avoid using twisted bound connected or hitched slings Do not place any object on twisted or bent slings Refer to the right illustration When removing the slings from under the lo...

Page 42: ...y damage corresponding to examples shown to the right If any damage is found cut and discard the sling Even if no damage is found do not use slings older than 7 years Damaged Appearance W162 01 01 002 W162 01 01 003 W162 01 01 004 W162 01 01 005 W162 01 01 006 W162 01 01 007 W162 01 01 008 a b d c a e a b f g c a Broken Sewing Thread b Scuffing c Fuzz d Broken Sewing Thread a Broken Sewing Thread ...

Page 43: ...able errors will be indicated if necessary Allowable Limit 1 Normal machine performance cannot be accomplished after exceeding this limit 2 Repair or adjustment is difficult after exceeding this limit 3 Repair or adjustment is impossible after exceeding this limit Therefore in consideration of operation efficiency and maintenance expense proper maintenance shall be carried out before reaching the ...

Page 44: ...GENERAL Precautions for Dissembling and Assembling W1 1 6 Blank ...

Page 45: ...ect bolts correctly when assembling the machine or components SA 040 Specified Tightening Torque M552 07 091 M552 07 090 Socket Bolt M552 07 092 Bolt Dia Wrench Size Hexagon Wrench Size N m kgf m lbf ft N m kgf m lbf ft N m kgf m lbf ft M6 10 5 3 3 to 4 2 0 3 to 0 4 2 4 to 3 0 M8 13 6 30 3 0 22 5 20 2 0 14 5 10 1 0 7 2 M10 17 8 65 6 5 47 50 5 0 36 20 2 0 14 5 M12 19 10 110 11 80 90 9 0 65 35 3 5 2...

Page 46: ... hole Also the bolts that are too short cannot develop sufficient tightening force The torque given in the chart on the previous page are for general use only however a different torque is given for a specific application Use the specified torque Clean the nut and bolt threads and remove dirt or corrosion before installing Tightening Order When tightening two or more bolts tighten them alternately...

Page 47: ...que Do not use air wrenches Using an impact wrench often causes tightening of one bolt fully before tighten the others resulting in damage to O rings or uneven tightening of bolts Nut and Bolt Locking Lock Plate IMPORTANT Do not reuse the lock plates Do not try to bend the same point twice Split Pin IMPORTANT Do not turn in the loosening direction in order to align the grooves and holes on the nut...

Page 48: ...specifications Scratches or other damage to sealing surfaces 4 or 5 will cause oil leakage at the joint Take care not to damage them when connecting disconnecting M202 07 051 W105 01 01 017 Wrench Size mm Wrench Size mm Tightening Torque Description Union Nut Hose Fittings N m kgf m lbf ft 30 male 17 17 25 2 5 19 19 19 30 3 0 22 22 22 40 4 0 30 27 27 80 8 0 59 32 32 140 14 100 36 36 180 18 130 41 ...

Page 49: ... when reinstalling Before tightening union nut 9 confirm that O ring 6 is seated correctly in O ring groove 8 Tightening union nut 9 with O ring 6 displaced will damage O ring 6 resulting in oil leakage Do not damage O ring groove 8 of adapter 7 or sealing surface 10 on the hose side Damage to O ring 6 may cause oil leakage If union nut 9 is found to be loose causing oil leakage do not tighten it ...

Page 50: ...ve the hose by rotating socket ring 1 fully counterclockwise and then pulling it Because no check function is attached inside be careful that oil flows out Cap the removed hoses using special plug CAUTION When disconnecting do not damage joint surface When disconnecting clean the joint part and thoroughly wipe off the cleaning solution to prevent any foreign material from entering Complete the joi...

Page 51: ...und threads in order to leave one to two pitch threads uncovered Wrap the seal tape in the same direction as the threads Low Pressure Hose Clamp Tightening Low pressure hose clamp tightening torque differs depending on the type of clamp T Bolt Type Band Clamp 4 5 N m 0 45 kgf m 3 3 lbf ft Worm Gear Type Band Clamp 6 to 7 N m 0 6 to 0 7 kgf m 4 4 to 5 2 lbf ft W105 01 01 018 Wrench Size mm Tighteni...

Page 52: ...tion of fitting Utilize the print marks on hoses when installing in order to prevent hose from being kinked Take necessary measures to protect hoses from rubbing against each other If the hoses rub against each other wear to the hoses may result and lead to hose rupture Take care so that the hoses do not come into contact with the moving parts or sharp objects W105 01 01 011 W105 01 01 012 W105 01...

Page 53: ...m YR 01 TAXI Yellow 6 Cockpit and mounting parts HG Beige Deep 17 Rear Fender HG Beige Deep 7 Tail Pipe Not painted 18 Step Warm Gray 8 Pre Cleaner Not painted 19 Side Cover YR 01 TAXI Yellow 9 Extension HG Beige Deep 20 Articulate Lock Bar Red 10 Cover YR 01 TAXI Yellow 21 Cockpit Skirt HG Beige Deep 11 Grill Support HG Beige Deep IMPORTANT When cleaning around front attachment or cylinder etc fi...

Page 54: ... 01 TAXI Yellow 6 Cockpit and mounting parts HG Beige Deep 17 Rear Fender HG Beige Deep 7 Tail Pipe Not painted 18 Step Warm Gray 8 Pre Cleaner Not painted 19 Side Cover YR 01 TAXI Yellow 9 Extension HG Beige Deep 20 Articulate Lock Bar Red 10 Cover YR 01 TAXI Yellow 21 Cockpit Skirt HG Beige Deep 11 Grill Support HG Beige Deep IMPORTANT When cleaning around front attachment or cylinder etc fitted...

Page 55: ... quickly Cap 2 may fly off by internal pressure Release any remaining pressure before removing cap 2 Preparation 1 Park the machine on a solid and level surface Set the front attachment in position for checking hydraulic oil level 2 Stop the engine Push air bleed button 1 of hydraulic oil tank 3 and bleed air from hydraulic oil tank 3 3 Remove cap 2 of hydraulic oil tank 3 4 Install vacuum pump a ...

Page 56: ... and bleed air from the pump until hydraulic oil comes out from the gap After bleeding all air securely tighten the plug INPORTANT If air is accumulated inside of the cylinder and if the cylinder is operated suddenly in lacking of hydraulic oil the seal may be damaged or the cylinder may seize Bleeding Air from Hydraulic Circuit After refilling hydraulic oil start the engine While operating each c...

Page 57: ...follows when front attachment etc have been removed installed 1 Set front control lever lock 1 to the UN LOCK position 2 Run the engine at low idle speed for 5 minutes to cool the engine 3 Turn key switch OFF 4 Move front control lever 2 to 4 or 5 turn of pressure release circuit 5 Set front control lever lock 1 to the LOCK position M4FJ 01 004 Lock UnLock 1 2 ...

Page 58: ...GENERAL Hydraulic Circuit Pressure Release Procedure W1 5 2 Blank ...

Page 59: ... work 1 Park the machine on a level surface 2 Lower the bucket to the ground 3 Turn rid control switch 1 OFF 4 Turn forward reverse lever 2 NEUTRAL Set neutral lever lock 3 to the LOCK position 5 Turn parking brake 4 ON 6 Wedge the tires 7 Set the key switch to the OFF position Stop the engine Remove the key from the key switch If maintenance should be performed with the engine running do not leav...

Page 60: ...securely lock and prohibit movement between the front and rear frames 4 5 Avoid accidents due to unexpected movement of the machine 1 Align the front and rear frame 4 5 centers with each other 2 Remove β pin 2 Install lock bar 1 is roated to front frame 4 3 Install β pin 2 to lock bar 1 in the LOCK position M4FJ 01 017 M4FJ 01 018 4 1 3 2 2 3 ...

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