PDF Workshop Manual Hitachi ZW80 ZW90 Wheel Loader - 1 MB
This workshop manual provides detailed service and repair information for the Hitachi ZW80 and ZW90 wheel loaders.
It is a comprehensive guide for technicians, covering everything from the engine and hydraulics to the electrical system and powertrain.
The manual includes step-by-step instructions, specifications, and troubleshooting charts to help you diagnose and fix any issue.
Keep your Hitachi wheel loader in peak condition with this essential workshop resource.
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--- Page 3 ---
SAFETY
MOVE AND OPERATE MACHINE SAFELY
• Bystanders can be run over.
• Take extra care not to run over bystanders. 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 operable before operating the machine. If any SA-398
faulty illumination is present, immediately repair it.
011-E01A-0398
HANDLE STARTING AIDS SAFELY
Starting fluid:
• Starting fluid is highly flammable.
• Keep all sparks and flame away when using it.
• Keep starting fluid well away from batteries and
cables.
• Remove container from machine if engine does
not need starting fluid.
• To prevent accidental discharge when storing a
pressurized container, keep the cap on the con-
tainer, and store it in a cool, well-protected loca-
tion.
• Do not incinerate or puncture a starting fluid con- SA-293
tainer.
036-E01A-0293-3
SA-7
--- Page 4 ---
SAFETY
PRECAUTIONS FOR OPERATION
• If the front attachment or any part of the machine
comes in contact with an overhead obstacle, both
the machine and the overhead obstacle may be-
come damaged, and personal injury may result.
• Take care to avoid coming in contact with over-
head obstacles with the bucket or arm during op-
eration.
PRECAUTIONS FOR LIGHTENING
• The machine is vulnerable to lighting strikes.
• In the event of an electrical storm, immediately
stop operation, and lower the bucket to the
ground. Evacuate to a safe place far away from
the machine.
• After 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.
SA-4EK-020
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.
Never attach a sling or chain to bucket teeth or to
the attachment (fork or grapple for example). They
may come off, causing the load to fall.
SA-132
SA-17
--- Page 5 ---
SAFETY
EVACUATING IN CASE OF FIRE
• If a fire breaks out, evacuate the machine in the fol-
lowing 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.
• Exit the machine.
518-E01A-0393
SA-393
BEWARE OF EXHAUST FUMES
• Prevent asphyxiation. Engine exhaust fumes can
cause sickness or death.
• If you must operate in a building, be sure there is
adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust 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 perform
welding.
• Grinding on the machine may create fire hazards.
Store flammable objects in a safe place before
starting grinding.
• After finishing welding and grinding, recheck that
there are no abnormalities such as the area sur-
SA-818
rounding the welded area still smoldering.
523-E01A-0818
SA-27
--- Page 6 ---
GENERAL / Precautions for Disassembling and Assembling
DISASSEMBLY AND ASSEMBLY
Precautions
• Clean the machine • Measure and record the degree of wear and
Thoroughly wash the machine before bringing it into clearances.
the shop. Bringing a dirty machine into the shop may
cause machine components to be contaminated • Assembling
during disassembling/assembling, resulting in • Be sure to clean all parts and inspect them for any
damage to machine components, as well as damage. If any damage is found, repair or replace
decreased efficiency in service work. part.
• Dirt or debris on the contact or sliding surfaces
• Inspect the machine may shorten the service life of the machine. Take
Be sure to thoroughly understand all care not to contaminate any contact or sliding
disassembling/assembling procedures beforehand. surfaces.
It is helpful to avoid incorrect disassembling of • Apply a film of grease before installing. Apply new
components as well as personal injury. hydraulic oil or gear oil onto the sliding part in
Check and record the items listed below. It is helpful order to prevent seizure.
to prevent problems from occurring in the future. • Be sure to replace O-rings, backup rings, and oil
• Model, serial No., hour meter symptoms, failed seals with new ones once they are disassembled.
parts and causes • Be sure that liquid-gasket-applied surfaces are
• Clogging of filters, oil quality and quantity, and oil, clean and dry.
water or air leaks, if any. • If an anti-corrosive agent has been used on a new
• Damage or looseness of parts part, be sure to thoroughly clean the part to
remove the agent.
• Prepare and Clean Tools and Disassembly Area • Utilize matching marks when assembling.
Prepare the necessary tools to be used and the area • Be sure to use the designated tools to assemble
for disassembling work. Thoroughly clean the tools. bearings, bushings and oil seals.
• Keep a record of the number of tools used for
When Disassembling and Assembling disassembly/assembly. After assembling is
• Disassembling complete, count the number of tools, so as to
• In order to prevent dirt from entering, cap or plug make sure that no forgotten tools remain in the
the removed pipes. assembled machine.
• Before disassembling, clean the exterior of the
components. Place the components on a work
bench.
• Before disassembling, drain gear oil from the
reduction gear.
• Be sure to provide appropriate containers for
draining fluids.
• Put the matching marks in order not to confuse
when reassembling.
• 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 as necessary.
• Store common parts, such as bolts and nuts with
reference to where they are to be used and in a
manner that will prevent loss.
• Inspect the contact or sliding surfaces of
disassembled parts for abnormal wear, sticking, or
other damage.
W1-1-1
--- Page 7 ---
GENERAL / Tightening
TORQUE CHART
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 injury.
Bolt Types
Tighten nuts or bolts correctly to torque specifications.
Make sure to employ correct bolts and tighten them SA-040
correctly when assembling the machine or
components.
Specified Tightening Torque
Bolt Dia. Hexagon Wrench
(mm)
Wrench
M4FG-07-73 Size mm
Standard torque Allowable torque range
N⋅m kgf⋅m lbf⋅ft N⋅m kgf⋅m lbf⋅ft
4 1.27 0.13 0.94 1.18 to 1.37 0.12 to 0.14 0.87 to 1 7
5 2.55 0.26 1.88 2.26 to 2.84 0.23 to 0.29 1.67 to 2.1 8
6 4.31 0.44 3.18 3.92 to 4.71 0.40 to 0.48 2.9 to 3.48 10
8 10.2 1.04 7.53 9.22 to 11.2 0.94 to 1.14 6.8 to 8.27 13
10 19.7 2.01 14.5 17.8 to 21.7 1.81 to 2.21 13.2 to 16 17
12 34.5 3.52 25.5 31.1 to 38.0 3.17 to 3.87 23 to 22.1 19
14 54.3 5.54 40.1 48.9 to 59.7 4.99 to 6.09 36.1 to 44.1 22
16 83.9 8.56 61.9 75.5 to 92.4 7.70 to 9.42 55.7 to 68.2 24
18 116 11.8 85.6 104 to 127 10.6 to 13.0 76.8 to 93.7 27
20 168 17.1 124 151 to 184 15.4 to 18.8 111 to 136 30
22 221 22.5 163 199 to 243 20.3 to 24.8 147 to 179 32
24 280 28.6 207 252 to 309 25.7 to 31.5 186 to 228 36
27 346 35.3 255 312 to 380 31.8 to 38.8 230 to 221 41
30 475 48.4 351 428 to 522 43.6 to 53.2 316 to 385 46
W1-2-3
--- Page 8 ---
GENERAL / Painting
Painting
W4FG-01-03-001
Painted Surface Painting Color Painted Surface Painting Color
1 Front Fender HG Beige Deep 12 Counterweight TAXI Yellow
2 Light Bracket HG Beige Deep 13 Rear Fender HG Beige Deep
3 Body TAXI Yellow 14 Rim TAXI Yellow
4 Cowl Frame HG Beige Deep 15 Seat Support HG Beige Deep
5 Handrail HG Beige Deep 16 Operator Frame HG Beige Deep
6 Roof (Canopy) (*) HG Beige Deep 17 Step TAXI Yellow
7 Handrail (Canopy) HG Beige Deep 18 Oil Tank / Fuel Tank TAXI Yellow
(*)
8 Support (Canopy) Japan Paint 19 Articulation Lock Bar Red
Manufacturers
Association YH-65
9 Hood Base TAXI Yellow 20 Back Mirror Mounting HG Beige Deep
Part
10 Hood (Upper) (*) TAXI Yellow 21 Cab HG Beige Deep
11 Hood (Lower) (*) HG Beige Deep
(*) Material is resin.
IMPORTANT: When cleaning the front attachment,
cylinder, etc. fitted with HN bushing,
take care not to pour washing liquid
directly on the bushing. The ambient
temperature should not exceed 70 °C
when painting and drying.
W1-3-1
--- Page 9 ---
BODY / Canopy
REMOVAL AND INSTALLATION OF
FLOOR PLATE
Preparation
1. Park the machine on a level and solid surface.
Stop the engine. Lower the bucket onto the
ground horizontally.
2. Place wheel stoppers in front of and behind the
wheels in order to secure the machine.
3. Install articulation lock bar (3) to the rear frame
pin(1). Secure with link pin (2).
W4EK-03-04-001
When removing and installing the floor plate, remove
and install the following parts.
• Floor Inspection Cover
• Seat Support
• Front Console and Surroundings
• Right Console and Surroundings
W4FG-02-01-001
W2-1-5
--- Page 10 ---
BODY / Canopy
Installation of Right Console and Surroundings
1. Install right console box (8) to the floor plate with
bolts (16) (4 used), spring washers (15) (4 used),
and washers (14) (4 used).
: 17 mm
2. Connect control cables (9, 10) with bolts (12) (2
used) and nuts (13) (2 used), which are attached
to front attachment control lever (7).
3. Install key switch (7) to right console box (8).
4. Install cover (1) to right console box (8) with bolts
(3) (4 used) and washers (2) (4 used). Install the
cap part of key switch (7).
: 5 mm
5. In case the heater switch (optional) is provided,
connect connector (C) of harness (11).
6. Connect connector (B) of harness (11) to eco
mode switch.
7. Install covers (6, 17) to right console box (8) with
bolts (4) (7 used) and washers (5) (7 used).
: 5 mm
W4FG-02-01-011
W2-1-15
--- Page 11 ---
BODY / Cab
Installation of Heater
1. Install heater (1) to heater support (7) with bolts
and washers (2) (4 used).
: 17 mm
2. Install heater support (7) to the seat support with
bolts and washers (8) (4 used).
: 17 mm
3. Connect hoses (9) (2 used) to heater (1) with hose
clamps (10) (2 used).
4. Fully open the cock in valve (6) and turn to the
OPEN position.
5. Connect connector (B) of heater harness (4).
Connect ground line (12) of heater (1) to the rear
frame with bolt (13).
: 17 mm
6. Install defroster hoses (3) (2 used) to heater (1)
with hose connectors (5) (2 used).
W4FG-02-02-006
W4FG-02-02-007
W2-2-7
--- Page 12 ---
BODY / Center Hinge
CAUTION: The center hinge is required to
disassemble for the major
maintenance work such as
removal of the front frame from
the rear frame. At this time, move
the machine into the factory.
Preparation
1. When disassembling the center hinge, set the
machine to the conditions as illustrated in the
right.
2. Remove the canopy (or the cab) and the floor
plate. (Refer to W2-1 or W2-2.)
3. Remove the front attachment. (Refer to W4-1 or
W4-2.)
4. Remove the engine hood. (Refer to W2-5.) W4FG-02-04-004
5. Remove the counterweight. (Refer to W2-3.)
6. Remove the connecting parts between the front
frame (11) and the rear frame (7).
• Propeller Shaft (Refer to W3-4.)
• Steering Cylinder (Refer to W3-8.)
• Hydraulic Hose (between steering valve and
control valve) (Refer to W2-8.)
• Control Valve (Refer to W2-8.)
• Harness
7. Support front frame (11) and rear frame (7) by
using firm support stands (25, 26, and 27).
W2-4-3
--- Page 13 ---
BODY / HST Pump and Main Pump
REMOVAL AND INSTALLATION OF HST
PUMP
Preparation
1. Park the machine on a level and solid surface.
Stop the engine. Lower the bucket onto the
ground horizontally.
2. Place wheel stoppers in front of and behind the
wheels in order to secure the machine.
3. Install articulation lock bar (3) to rear frame pin (1).
Secure with link pin (2).
W4EK-03-04-001
4. Remove the canopy or the cab. (Refer to W2-1 or
W2-2.)
5. Remove the floor plate. (Refer to W2-1.)
W4FG-02-01-001
W2-6-1
--- Page 14 ---
BODY / HST Pump and Main Pump
Removal of Main Pump Installation of Main Pump
1. Disconnect hose (11) from main pump (2). Cap 1. Install coupling (12) to the connecting part of HST
the open ends. Attach an identification tag onto pump (1).
the disconnected hoses for assembling.
: 27 mm, 36 mm 2. Install O-ring (6) to HST pump (1).
2. Remove bolts (7) (4 used) and spring washers (8) 3. Install main pump (2) to HST pump (1) with bolts
(4 used) from pipe (9). Remove tube (9) from main (3) (2 used), spring washers (4) (2 used), and
pump (2). Cap the open ends. washers (5) (2 used).
: 17 mm : 17 mm
3. Remove O-ring (10) from tube (9). 4. Connect O-ring (10) to tube (9).
4. Remove bolts (3) (2 used), spring washers (4) (2 5. Install pipe (9) to main pump (2) with bolts (7) (4
used), and washers (5) (2 used) from main pump used) and spring washers (8) (4 used).
(2). Remove main pump (2) from HST pump (1). : 17 mm
: 17 mm
6. Connect hose (11) to main pump (2).
5. Remove O-ring (6) from HST pump (1). : 27 mm, 36 mm
6. Remove coupling (12) from the connecting part of 7. Install the operator frame. (Refer to W2-1.)
HST pump (1).
8. Install the canopy or cab. (Refer to W2-1 or
W2-2.)
W4FG-02-06-008
W2-6-11
--- Page 16 ---
BODY / HST Motor
DISASSEMBLY AND ASSEMBLY OF HST
MOTOR
IMPORTANT: Do not disassemble HST motor
without reason. When disassembling
HST pump, minimize the essential
removal. Surely record the
dimensions of the adjusting parts
such as adjusting screws before
disassembling. Take great care and
always pay special attention to
return to the original dimensions
when reassembling.
W4FG-02-07-006
Disassembly of HST Motor Connected Part
(Reduction Side)
1. Place HST motor on a clean stand with the drive
shaft (1) of HST motor facing upward.
NOTE: Protect the spline part of drive shaft (1).
2. Remove retaining ring (2) from housing (5).
Remove shim (3).
3. Evenly install tapping screw (6) (Nominal
Diameter 3.5 mm¯Length 25 mm) to the holes (2
places), which are blocked by the rubber of seal
ring (4). Remove seal ring (4) by using a pair of W4FG-02-07-007
pliers.
IMPORTANT: Record installing depth (A) of seal
ling (4).
Assembly of HST Motor Connected Part
(Reduction Side)
1. Check for the installing depth (A) of seal ring (4).
Install seal ring (4) to housing (5).
2. Install shim (3) to housing (5). Secure with
retaining ring (2).
W2-7-7
--- Page 17 ---
BODY / Control Valve
Removal
CAUTION: Attach an identification tag onto 24
the disconnected hose and the
pipe for assembling.
23
1. Remove bolts (24) (4 used). Remove cover (23)
from front frame (18).
: 17 mm 18
2. Disconnect connector (6) of the bucket auto
leveler proximity switch harness.
3. Remove bolts (9) (2 used), spring washers (10) (2
used), washers (11) (2 used), bolt (12), washer W4FG-02-08-003
(13), spring washer (15), and nut (16). Remove
cover (14) from front frame (18).
: 17 mm
4. Remove control cables (17) (2 used) from control
valve (1).
: 10 mm, 13 mm, 14 mm, 24 mm
5. Disconnect hoses (7, 8) from control valve (1).
Cap the open ends.
: 27 mm, 36 mm
6. Disconnect hoses (4, 5) from control valve (1).
Cap the open ends.
: 22 mm
7. Disconnect hoses (2, 3) from control valve (1).
Cap the open ends.
: 19 mm, 27 mm
8. Remove bolts (19) (3 used), washers (20) (3
used), spring washers (21) (3 used), and nuts (22)
(3 used). Remove control valve (1) from front
frame (18).
: 17 mm
W2-8-3
--- Page 18 ---
BODY / Control Valve
Disassembly of Lift Arm Spool Assembly
1. Remove O-rings (20), poppet (18) and spring (19) Screwdriver (-)
from housing (1).
2. Remove screws (21) (2 used) and seal plate (3)
from housing (1).
3. Remove retaining ring (16) and spacer (15) from
cap (7).
4. Remove socket bolts (22) (2 used) from cap (7).
Remove cap (7) from housing (1). Remove sleeve
(8) while pushing large steel ball (13) in pin (9)
with screw driver (-).
: 4 mm
5. Slowly push back large steel ball (13). Remove
large steel ball (13), small steel balls (14) (4 used) W4EK-02-08-011
and spring (12) from pin (9).
NOTE: Do not loose steel ball (13) and steel balls
(14) (4 used) as the steel balls may fly out.
6. Remove pin (9) from spool (2). Remove spring
seats (10) (2 used) and spring (11).
7. Remove spacer (6) from spool (2). Remove
O-rings (4, 17) from spacer (6).
8. Remove spool (2) from housing (1).
NOTE: For easy removal, rotate and remove spool
(2).
9. Remove wiper ring (5) and O-ring (4) from
housing (1).
W2-8-13
--- Page 19 ---
TRAVEL SYSTEM / Reduction Device
REMOVAL AND INSTALLATION OF
REDUCTION DEVICE
The reduction device and the rear axle are united into
one part.
Remove the reduction device and the rear axle from
the rear frame. (Refer to W3-3-7.)
As for assembly and disassembly of
reduction device, refer to Reduction Device
Service Manual (Part No, KM-31111214)
W3-2-1
--- Page 20 ---
TRAVEL SYSTEM / Axle
7. Remove the assembly of rear axle (15) and
reduction device (12) from rear frame (16). Place
the assembly of rear axle (15) and reduction
device (12) on stand (11). Pull the assembly of
rear axle (15), reduction device (12), and stand
(11) out.
8. Remove reduction device (12) from rear axle (15).
(Refer to Reduction Device Service Manual (Part
No, KM-31111214))
W4FG-03-03-008
W3-3-9
--- Page 21 ---
TRAVEL SYSTEM / Master Cylinder
Installation
1. Install nut (9) and yoke (11) to master cylinder (1).
: 17 mm
: 23 to 28 N⋅m
(2.3 to 2.9 kgf⋅m, 17 to 21 lbf⋅ft)
2. Install master cylinder (1) to steering support (5)
with bolts (8) (2 used), spring washers (7) (2 used)
and nuts (6) (2 used).
: 17 mm
: 44 to 54 N⋅m
(4.5 to 5.5 kgf⋅m, 32 to 40 lbf⋅ft)
3. Connect hose (4) to master cylinder (1).
: 17 mm, 19 mm
: 44 N⋅m (4.5 kgf⋅m, 32 lbf⋅ft)
4. Connect hose (3) to master cylinder (1) with hose
clamp (2).
: 3.4 N⋅m (0.35 kgf⋅m, 2.51 lbf⋅ft)
5. Fit yoke (11) with the mounting hole on brake
pedal (14) and install yoke (11) with pin (10),
washer (12) and snap pin (13).
W4FG-03-05-002
6. After completing the work, adjust the parts (Refer
to Installation Standard on W3-5-4.)
W4FG-03-05-001
W3-5-3
--- Page 22 ---
TRAVEL SYSTEM / Parking Brake Solenoid
Installation
1. Install parking brake solenoid (1) to plate (6) with
bolts (11) (2 used) and spring washers (10) (2
used).
: 10 mm
: 9.2 to 11.1 N⋅m
(0.94 to 1.14 kgf⋅m, 6.79 to 8.19 lbf⋅ft)
2. Install plate (6) with parking brake solenoid (1) to
rear frame (5) with bolts (9) (2 used), spring
washers (8) (2 used) and washers (7) (2 used).
: 17 mm
3. Connect hoses (2, 3 and 4) to parking brake
solenoid (1).
: 17 mm, 19 mm
4. Connect connector of the parking brake solenoid
(1) harness.
5. Install the inspection cover. (Refer to W2-1-7.)
W4FG-03-06-002
W4FG-03-06-001
W3-6-3
--- Page 23 ---
TRAVEL SYSTEM / Steering Valve
6. Rotate spool and sleeve assembly (02), and set IMPORTANT: Wear a pair of protective glasses as
pin (13) and the port surface of housing (1) in center spring (18) and flat spring (17)
parallel. Push spool and sleeve assembly (2) from may fly out.
the cap (7) side. Remove bushing (20) from
housing (1). 11. Push spool (2A) in sleeve (2B) forward. Remove
center springs (18) (4 used) and flat springs (17)
7. Remove oil seal (16) and dust seal (19) from (2 used) from spool (2A).
bushing (20).
NOTE: Do not damage bushing (20) when
removing oil seal (16).
8. Remove bearing races (14) (2 used) and thrust
needle (15) from spool and sleeve assembly (2).
9. Remove spool and sleeve assembly (2) from
housing (1).
NOTE: Remove spool and sleeve assembly (2)
from housing (1) by rotating in order not to
get sleeve (2B) caught in housing (1).
10. Remove pin (13) from spool and sleeve assembly
(2).
NOTE: Put the matching marks onto spool (2A)
and sleeve (2B) by using an oil-based pen
before removing pin (7). W4FG-03-07-009
12. Remove spool (2A) from sleeve (2B) by rotating.
13. Remove O-ring (3) from housing (1).
W4FG-03-07-010
Matching Mark
W3-7-9
--- Page 24 ---
TRAVEL SYSTEM / Steering Cylinder
Removal
20
1. Remove bolts (20) (4 used) from cover (21).
Remove cover (22) from front frame (1).
: 17 mm 21
2. Disconnect hoses (17, 18) from steering cylinder
(9). Disconnect hoses (19) (2 used) from steering 1
cylinder (9, 20). Cap the open ends.
: 19 mm, 22 mm
3. Disconnect remote lubrication pipings (8, 10).
: 17 mm
W4FG-03-08-015
4. Remove bolts (16) (2 used), spring washers (15)
(2 used) and washers (14) (2 used) from pins (13)
(2 used). Remove pin (13) from front frame (1).
: 17 mm
5. Remove bolts (2) (2 used), spring washers (3) (2
used) and washers (4) (2 used) from pins (5) (2
used). Remove pins (5) (2 used) from the rear
frame. Remove shims (9, 20) (2 used for each).
: 17 mm
6. Remove steering cylinders (9, 20) from front
frame (1) and the rear frame.
W3-8-3
--- Page 25 ---
TRAVEL SYSTEM / Steering Cylinder
7. Adjust seal ring (3-1) of extended seal ring 12. Insert steel ball (5) to the set screw mounting hole
assembly (3) by using special tool (C). on piston (6). Install set screw (4) to piston (6).
Crimp set screw (4) by using a punch (2 places).
: 5 mm
: 6.8 N⋅m (0.7 kgf⋅m, 5.0 lbf⋅ft)
13. Apply hydraulic oil onto the packing parts. Secure
cylinder tube (1) in a vise horizontally. Insert
piston rod (16) into cylinder tube (1).
14. Apply hydraulic oil onto the packing parts. Apply
W4FG-03-08-010 THREEBOND #1901 onto the thread part of
cylinder tube (1). Tighten cylinder head (14) to
IMPORTANT: When installing slide rings (2, 7), do cylinder tube (1) by using a hook wrench. Bend
not set the slit positions at the same the lock washer in order not to loosen.
place. (ZW80)
: 235 N⋅m (23.9 kgf⋅m, 173 lbf⋅ft)
8. Install slide rings (2, 7) to the seal grooves on (ZW90)
both sides of piston (6). : 255 N⋅m (26.0 kgf⋅m, 188 lbf⋅ft)
9. Secure piston rod (16) on a workbench
horizontally.
10. Apply a small amount of hydraulic oil onto the
piston rod (16) surface. Install cylinder head (14)
to piston rod (16).
11. Apply hydraulic oil onto the thread part of the
piston (6) bore part. Install piston (6) to piston rod
(16).
(ZW80)
: 27 mm
: 184 N⋅m (18.8 kgf⋅m, 136 lbf⋅ft)
(ZW90)
: 30 mm
: 206 N⋅m (21.0 kgf⋅m, 152 lbf⋅ft)
W3-8-13
--- Page 26 ---
SECTION 4
ATTACHMENT
⎯ CONTENTS ⎯
Group 1 Front Attachment
Removal and Installation of
Front Attachment...................................... W4-1-1
Group 2 Cylinder
Removal and Installation of Cylinder ....... W4-2-1
Disassembly of Lift Arm Cylinder ............. W4-2-6
Assembly of Lift Arm Cylinder ................ W4-2-10
Disassembly of Bucket Cylinder ............ W4-2-14
Assembly of Bucket Cylinder ................. W4-2-18
Maintenance Standard........................... W4-2-22
4FGW-4-1
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ATTACHMENT / Front Attachment
Installation
IMPORTANT: Check for the outer and inner
diameters, wear and damage of all Taper 15°
pins and bushings before
installation. If any damage is found,
replace the parts.
IMPORTANT: When installing the pin, apply grease
onto the inside of the bushing and
the dust seal. Apply the
rust-inhibiting oil onto the inside of W4EK-04-01-010
the boss.
IMPORTANT: Install the bushing as illustrated in
the right.
CAUTION: Lift arm (21) weight:ZW80 : 300 kg
(661 lb)
ZW90 : 360 kg (794 lb)
1. Hoist and fit pin (19) in lift arm (20) with the pin
hole on front frame (25).
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to
prevent personal injury.
2. Install pins (24) (2 used) to front frame (25) with
spring washers (22) (2 used), washers (23) (2
used) and bolts (21) (2 used).
: 19 mm
3. Start the engine. Extend the piston rod of lift arm
cylinder (31). Stop the engine.
4. Hoist lift arm (21). Fit the pin (29) holes on lift arm Stand
(20) and lift arm cylinder (31).
W4FG-04-01-006
CAUTION: Metal fragments may fly off when
a hammer is used. Wear necessary protection,
such as goggles, helmets, etc in order to
prevent personal injury.
5. Install shims (30) (4 used) to the pin (29) holes (2
places) on lift arm (20). Install pins (29) (2 used) to
lift arm cylinder (31) (2 used) with washers (28) (2
used), spring washers (27) (2 used) and bolts (26)
(2 used).
: 19 mm
W4-1-9