PDF Workshop Manual Hitachi ZW150-5B ZW150PL-5B Wheel Loader - 3 MB
Gain access to the complete workshop manual for the Hitachi ZW150-5B and ZW150PL-5B Wheel Loaders.
This comprehensive document provides in-depth service, repair, and troubleshooting information directly from the manufacturer.
Technicians will find detailed procedures for the engine, hydraulics, transmission, and electrical systems.
Keep your powerful Hitachi wheel loader operating at peak performance with this essential guide.
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--- Page 1 ---
PART NO. WNDG90-EN-00
ZW150-5B • ZW150PL-5B
Workshop Manual
WHEEL LOADER
ZW
WORKSHOP MANUAL
150-5B
150PL-5B
Wheel Loader
URL:http://www.hitachi-c-m.com
WNDG90-EN-00
Service Manual consists of the following separate Part No.
Technical Manual (Operational Principle) : Vol. No.TONDG90-EN
Technical Manual (Troubleshooting) : Vol. No.TTNDG90-EN
PRINTED IN JAPAN (K) 2016, 04 Workshop Manual : Vol. No.WNDG90-EN
--- Page 3 ---
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.
Do not mess up around the operator's seat with parts,
tools, soil, stones, obstacles that may fold up or turn
over, cans or lunch box. The levers or pedals become
inoperable if obstacle jams in operation stroke of the
accelerator pedal, brake pedals, control lever lock switch
or control levers, which may result in serious injury or
death.
Avoid storing transparent bottles in the cab. Do not
attach any transparent type window decorations 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.
After using the ashtray, always cover it to extinguish the
match and/or tobacco.
Do not leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may
explode.
Use proper floor mat dedicated to the machine. If another
floor mat is used, it may be displaced and contact
with the accelerator or brake pedals during operation,
resulting in serious injury or death.
WNDG90-EN-00 SA-5
--- Page 4 ---
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.
SA-453
Avoid Injury from Rollaway Accidents
Death or serious injury may result if you attempt to mount
or stop a moving machine.
To avoid rollaways:
Select level ground when possible to park machine.
Do not park the machine on a grade.
Lower the bucket to the ground.
Put the forward / reverse lever (switch) in neutral, and pull
up the parking brake switch (lever) in the ON (parking
brake) position. SA-457
Run the engine at low idle speed without load for 5
minutes to cool down the engine.
Stop the engine and remove the key from the key switch.
Turn the control lever lock switch to the lock ( ) position.
Block both tires and lower the bucket to the ground.
Position the machine to prevent rolling.
Park at a reasonable distance from other machines.
SA-458
WNDG90-EN-00 SA-15
--- Page 5 ---
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.
SA-037
Warn Others of Service Work
Unexpected machine movement can cause serious injury.
Before performing any work on the machine, attach a “Do
Not Operate” tag on the control lever.
This tag is available from your authorized dealer.
SS2045102
Support Machine Properly
Never attempt to work on the machine without securing
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 attachment,
securely support the machine or attachment. Do not
support the machine on cinder blocks, hollow tires, or
props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.
SA-527
WNDG90-EN-00 SA-25
--- Page 6 ---
SAFETY
Handle Chemical Products Safely
Direct exposure to hazardous chemicals can cause serious
injury. Potentially hazardous chemicals used with your
machine include such items as lubricants, coolants, paints,
and adhesives.
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health
hazards, safety procedures, and emergency response
techniques.
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and use recommended equipment.
SA-309
See your authorized dealer for MSDS’s (available only in
English) on chemical products used with your machine.
Dispose of Waste Properly
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.
Do not pour waste onto the ground, down a drain, or into
any water source.
Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to SA-226
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your authorized dealer.
WNDG90-EN-00 SA-35
--- Page 7 ---
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...................................W1-4-1-4
Bleeding Air from Radiator..........................................W1-4-1-6
Bleeding Air from Brake (Axle)...................................W1-4-1-7
Group 5 Releasing Pressure
Front Attachment Hydraulic Circuit Pressure
Release Procedure.....................................................W1-5-1-1
Ride Control Accumulator Pressure Release
Procedure.....................................................................W1-5-1-2
Group 6 Preparation
Preparation before Inspection and
Maintenance...............................................................W1-6-1-1
WNDG90-EN-00 NDGW-1-1
--- Page 8 ---
SECTION 1 GENERAL
Group 2 Tightening
Precautions for Spilt Flange
IMPORTANT:
Clean the sealing surfaces. Check if there are
any scratches and roughness on the surface of
the seal that cause oil leaks and damage to the
WDAA-01-02-005
O-ring.
Use only specified O-rings. Inspect O-rings for
any damage. Do not file the O-ring surfaces. Incorrect
When installing O-ring into a groove, use grease
in order to hold O-ring in place.
While tightening the bolt by hand, check that
flange is installed to the port correctly. Do not
pinch the O-ring.
Tighten the bolts up and down, left and right
alternately, in order to ensure even tightening
WDAA-01-02-006
to the specified torque.
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
W105-01-01-008
IMPORTANT: Do not reuse the lock plates. Do not try
to bend the same point twice.
Correct Incorrect
Split Pin
IMPORTANT: Do not turn in the loosening direction
in order to align the grooves and holes on the nut.
a b
Always turn in the tightening direction. Do not
reuse the split pins.
Correct Correct Incorrect
Wire
IMPORTANT: Attach wire to bolts in the bolt-
tightening direction. Do not reuse the wire.
a
WDAA-01-02-007
a- Bend along edge sharply b- Do not bend it round
Correct Correct
Incorrect
Correct d Incorrect
c
WDAA-01-02-008
c- Tighten d- Loosen
WNDG90-EN-00 W1-2-1-3
--- Page 9 ---
SECTION 1 GENERAL
Group 3 Painting
2
1
3
4
5
WMDF-01-03-102
Surfaces to Be Painted Painting Color
1 Rear Fender High Grade Black
2 Bracket (Full Fender) High Grade Black
3 Bracket (Mud Guard) High Grade Black
4 Deck Plate High Grade Black
5 Step High Grade Black
Paint the painted surface except the above list in YR-01(TAXI Yellow).
WNDG90-EN-00 W1-3-1-3
--- Page 10 ---
SECTION 1 GENERAL
Group 3 Painting
2
1
3
4
WMDF-01-03-103
Surfaces to Be Painted Painting Color
1 Plate P1-01 [High Grade Black]
2 Support (Real Axle) P1-01 [High Grade Black]
3 Rear Axle Refer to W1-3-2-7.
4 Front Axle Refer to W1-3-2-8.
Paint the painted surface except the above list in YR1-01 [TAXI yellow].
WNDG90-EN-00 W1-3-2-5
--- Page 11 ---
SECTION 1 GENERAL
Group 4 Bleeding Air
Bleeding Air from Brake (Axle)
dCAUTION: If air is mixed in the brake system,
the brake function is reduced and serious hazard
may occur. Bleed air from the brake system
after removing and installing the pipe lines and 1
replacing hydraulic oil. 1
In addition, bleed air from the brake system until
hydraulic oil (about 0.5 liters (0.53 US gt)) is drawn
from each wheel (4 places) after bubbles stops.
T4GB-05-04-004
fNOTE: Perform this work on all wheels (4 places) by two
or more persons. Air bleed plug (1) is located around the
center on front and rear axles.
1. Set the parking brake switch of front console to the 2
ON position, start the engine, and increases service 1
brake oil pressure.
2. Attach clear vinyl tube (2) onto one end of air bleed
plug (1). Insert other of clear vinyl tube (2) into clear
container (3) filled with hydraulic oil.
3. Depress brake pedal (4) several times. Then, depress 3
and hold brake pedal (4) to the stroke end.
4. Loosen air bleed plug (1) under condition in step 3
and drain hydraulic oil and air for several seconds.
T4GB-05-04-005
5. Tighten air bleed plug (1).
6. Drain hydraulic oil after bubbles stops in steps 3 to 5
repeatedly.
fNOTE: When bubbles does not stop after hydraulic oil
(about 0.5 liters (0.53 US gt)) is drawn, repeat step 3 to
step 5.
7. Bleed air at other 3 places in the same way as step 3
to step 5.
IMPORTANT: After air bleeding work is completed at
4 places, bleed air at 4 places again.
Bleed air in the same way as step 3 to step 5 twice
and check that no air is remained inside. 4
T4GB-05-04-006
WNDG90-EN-00 W1-4-1-7
--- Page 12 ---
SECTION 2
MAINTENANCE STANDARD
CONTENTS
Group 1 Body
Center Hinge....................................................................W2-1-1-1
Group 2 Travel System
Axle......................................................................................W2-2-1-1
Group 3 Front Attachment
Pin and Bushing...............................................................W2-3-1-1
Standard Dimensions for Lift Arm and Bucket.....W2-3-2-1
Cylinder..............................................................................W2-3-3-1
Group 4 Front Attachment (Parallel Link)
Pin and Bushing...............................................................W2-4-1-1
Standard Dimensions for Quick Coupler and
Bucket............................................................................W2-4-2-1
Cylinder..............................................................................W2-4-3-1
WNDG90-EN-00 NDGW-2-1
--- Page 13 ---
SECTION 2 MAINTENANCE STANDARD
Group 3 Front Attachment
Standard Dimensions for Lift Arm and Bucket
1 2
b
i d
h
g
a e
f c
WMDF-02-03-001
1- Bucket 2- Lift Arm
Unit: mm (in)
Dimensions
a 75 (2.95)
b 75 (2.95)
c 844 (9.23)
d 94 (3.70)
e 96 (3.78)
f 96 (3.78)
g 230 (9.06)
h 356 (2.02)
i 55 (2.17)
WNDG90-EN-00 W2-3-2-1
--- Page 15 ---
SECTION 3 BODY
Group 1 Cab
1 2
6
WMDF-03-01-006
WMDF-03-01-005
5 4 3 8 7
27. Disconnect hose (4). 30. Remove cover (5). (Refer to W3-4-2.)
j : 27 mm 31. Disconnect hose (8).
28. Disconnect hose (3). j : 17 mm
j : 19 mm 32. Remove clamp (6). Disconnect hose (7).
29. Remove clamp (1). Disconnect hose (2). j : 7 mm
j : 7 mm
WNDG90-EN-00 W3-1-1-7
--- Page 16 ---
SECTION 3 BODY
Group 1 Cab
A Detail A
1, 2
6
5
4
3 WMDF-03-01-002 6 6 WMDF-03-01-003
25. Connect hoses (6) (7 used). 28. Connect connectors (5) (3 used).
j : 19 mm 29. Install clip (2) with bolt, washer (1).
m : 30 N·m (3 kgf·m, 22 lbf·ft) j : 17 mm
26. Connect connectors (3) (2 used) only with the m : 50 N·m (5 kgf·m, 37 lbf·ft)
emergency steering attached.
27. Connect connectors (4) (2 used).
WNDG90-EN-00 W3-1-1-17
--- Page 17 ---
SECTION 3 BODY
Group 1 Cab
A Detail A
1, 2
6
5
4
3 WMDF-03-01-002 6 6
WNDF-03-01-001
20. Remove bolt, washer (1) and clip (2).
j : 17 mm
21. Disconnect connectors (5) (3 used).
22. Disconnect connectors (4) (2 used).
23. Disconnect connectors (3) (2 used) (only with the
emergency steering attached).
24. Disconnect hoses (6) (9 used).
j : 19 mm
WNDG90-EN-00 W3-1-2-5
--- Page 18 ---
SECTION 3 BODY
Group 1 Cab
1 2
a
8 a
WMDF-03-01-006
WMDF-03-01-005
10 9 7 5, 6 3, 4
a- Cab a- Cab
15. Connect hose (9) with clamp (8). 19. Apply ND-OIL8 to O-ring (4). Install O-ring (4) to
hose (3). Connect hose (3).
j : 7 mm
j : 19 mm
m : 3.5 to 5 N·m (0.35 to 0.5 kgf·m, 2.6 to 3.7
lbf·ft) m : 11.8 to 14.7 N·m (1.18 to 1.47 kgf·m, 8.5 to
11 lbf·ft)
16. Connect hose (10).
20. Apply ND-OIL8 to O-ring (6). Install O-ring (6) to
j : 17 mm hose (5). Connect hose (5).
m : 25 N·m (2.5 kgf·m, 18.5 lbf·ft) j : 27 mm
17. Install cover (7). (Refer to W3-4-2.)
m : 29.4 to 34.3 N·m (2.94 to 3.43 kgf·m, 21.5 to
18. Connect hose (2) with clamp (1). 25.5 lbf·ft)
j : 7 mm 21. Add compressor oil. (Refer to T5-8 in the separated
volume, Technical Manual.)
m : 3.5 to 5 N·m (0.35 to 0.5 kgf·m, 2.6 to 3.7
lbf·ft)
WNDG90-EN-00 W3-1-2-15
--- Page 19 ---
SECTION 3 BODY
Group 2 Counterweight
7 1
a
2
a
4
3
6
4 5
3 5
WMDF-03-02-010
a- Hoisting Position
Installation 3. Install rear combination light (2) with bolts (3) (4
used).
dCAUTION:
(2300 lb)
Counterweight (1) weight: 1040 kg
l : 5 mm
1. Attach the nylon slings onto hoisting positions
m : 20 N·m (2 kgf·m, 15 lbf·ft)
(a) (2 places) of counterweight (1). Hoist and fit
counterweight (1) to the bolt (5) holes (4 places) on 4. Install rear combination light (6) with bolts (3) (4
rear frame (7). used).
2. Install counterweight (1) with washers (4) (4 used) l : 5 mm
and bolts (5) (4 used).
m : 20 N·m (2 kgf·m, 15 lbf·ft)
j : 46 mm
m : 1510 N·m (151 kgf·m, 1110 lbf·ft)
WNDG90-EN-00 W3-2-1-3
--- Page 20 ---
SECTION 3 BODY
Group 2 Counterweight
1
11 9, 10
2, 3
7, 8
14, 15, 16 12, 13
4
6 WMDF-03-02-004
6 5 WMDF-03-02-013
Installation
Installation of Battery Box (Left)
dCAUTION: Battery (5) weight: 20 kg (45 lb)
4. Place battery (5) on battery box (5).
dCAUTION: Battery box (6) weight: 24 kg (53 lb) 5. Install bracket (1) and rods (4) (2 used) with washers
1. Pass connector (11) and terminals (8, 10) through (3) (2 used) and nuts (2) (2 used).
battery box (6). Install battery box (6) with washers
(15, 16) (4 used for each) and nuts (14) (4 used). j : 17 mm
j : 19 mm m : 20 N·m (2 kgf·m, 15 lbf·ft)
6. Connect terminal (10). Tighten nut (9).
m : 35 N·m (3.5 kgf·m, 26 lbf·ft)
2. Connect connector (11). Install the harnesses to all j : 10 mm
clips of battery box (6).
m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft)
3. Install bracket (13) with bolt, washer (12).
7. Connect terminal (8). Tighten nut (7).
j : 17 mm
j : 10 mm
m : 50 N·m (5 kgf·m, 37 lbf·ft)
m : 3 to 4 N·m (0.3 to 0.4 kgf·m, 2.2 to 3 lbf·ft)
8. Close the cover of battery box (6).
WNDG90-EN-00 W3-2-3-3
--- Page 21 ---
SECTION 3 BODY
Group 3 Center Hinge
1 2, 3 4
a
5
6
14
b
11
12, 13
7
11
10 8, 9 WMDF-03-03-003
a- Front Frame b- Control Valve
12. Remove bolts, washers (14) (2 used) and clamp (1). 16. Disconnect connectors (7) (2 used).
j : 19 mm 17. Disconnect hoses (10) (2 used).
13. Remove bolts, washers (4) (2 used), clamp (2), and j : 19 mm
rubber plate (3).
18. Disconnect hose (5).
j : 17 mm
j : 41 mm
14. Remove bolts, washers (11) (4 used), clamps (12) (2
19. Disconnect hose (6).
used), and rubber plates (13) (2 used).
j : 50 mm
j : 17 mm
15. Remove bolt, washer (8) and clip (9).
j : 17 mm
WNDG90-EN-00 W3-3-1-3
--- Page 22 ---
SECTION 3 BODY
Group 3 Center Hinge
3
8
7 a
9
6 1
6
5 WMDF-03-03-010
4
2
3
WMDF-03-03-009
a- 9 mm (3.54 in)
Upper Hinge Side 9. Apply LOCTITE #262 onto bolts (4) (6 used). Install
caps (5, 8) and shims (7) (2 used) to front frame (6)
dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
with bolts (4) (6 used).
j : 19 mm
such as goggles, hard hat, etc. in order to prevent
personal injury. m : 90 N·m (9 kgf·m, 66 lbf·ft)
IMPORTANT: Check the position to install bearing
(1). dCAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
6. Install bearing (1) to front frame (6) by using a
such as goggles, hard hat, etc. in order to prevent
copper hammer.
personal injury.
IMPORTANT: Face the end of grease fitting (9) to the 10. Install busing (2) to the position where it comes in
left side of body. contact with bearing (1) by using a copper hammer.
7. Install grease fitting (9) to front frame (6). Apply
grease.
j : 10 mm
m : 4 N·m (0.4 kgf·m, 3 lbf·ft)
IMPORTANT: Check the direction to install dust seals
(3) (2 used).
8. Apply LOCTITE #262 onto the outer surface of dust
seals (3) (2 used). Install dust seals (3) (2 used) to
caps (5, 8) by using a plastic hammer. Crimp the cap
(5, 8) side by using a punch (2 places).
WNDG90-EN-00 W3-3-1-13
--- Page 23 ---
SECTION 3 BODY
Group 3 Center Hinge
Detail A
1 2, 3 4 9
a
10
14
8
A
5
6, 7
b
5
12, 13 11
WMDF-03-03-003 WNDF-03-03-004
a- Front Frame b- Control Valve
12. Remove bolts, washers (8) (2 used) and clamp (1). 16. Disconnect connectors (11) (2 used).
j : 19 mm 17. Disconnect hoses (14) (3 used).
13. Remove bolts, washers (4) (2 used), clamp (2), and j : 19 mm
rubber plate (3).
18. Disconnect hose (9).
j : 17 mm
j : 41 mm