Hitachi ZW220 ZW250 Wheel Loader (EU Specification) Workshop Manual (W4GB-E-00) – PDF Download

Description

Hitachi ZW220 ZW250 Wheel Loader (EU Specification) Workshop Manual (W4GB-E-00)

File Details:

Hitachi ZW220 ZW250 Wheel Loader (EU Specification) Workshop Manual (W4GB-E-00)

• Manual Language:English
• Pages: 532
• Size: 12.4 MB
• Downloadable:Yes
• Format:PDF

HITACHI ZW220 ZW250 WHEEL LOADER (EU SPECIFICATION) WORKSHOP MANUAL (W4GB-E-00) – PDF DOWNLOAD:

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Description:

Hitachi ZW220 ZW250 Wheel Loader (EU Specification) Workshop Manual (W4GB-E-00)

TO THE READER
• This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
• Be sure to thoroughly read this manual for correct product information and service procedures.
• If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual.
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition to this manual.
• The Operator’s Manual
• The Parts Catalog
• The Engine Manual
• Parts Catalog of the Engine
• Hitachi Training Material
MANUAL COMPOSITION
• This manual consists of three portions: the Technical Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual.
• Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems.
• Information included in the Technical Manual (Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures.
• Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assemble/ disassemble procedures.

Table Of Contents:

Hitachi ZW220 ZW250 Wheel Loader (EU Specification) Workshop Manual (W4GB-E-00)

ZX220/250_W4GB-E-00
.........................................................................  1
	INTRODUCTION.............................................................................  3
	SAFETY...................................................................................  5
	SECTION AND GROUP CONTENTS............................................................... 35
	SECTION 1 GENERAL........................................................................ 37
		Group 1 Precautions for Disassembling and Assembling................................. 39
			Precautions for Disassembling and Assembling..................................... 39
			Maintenance Standard Terminology................................................. 45
		Group 2 Tightening................................................................... 47
			Tightening Torque Specification.................................................. 47
			Torque Chart..................................................................... 48
			Piping Joint..................................................................... 51
			Periodic Replacement of Parts.................................................... 55
		Group 3 Painting..................................................................... 57
			Painting......................................................................... 57
		Group 4 Bleeding Air from Hydraulic Oil Tank......................................... 59
			Bleeding Air from Hydraulic Oil Tank............................................. 59
	SECTION 2 BODY (UPPERSTRUCTURE).......................................................... 63
		Group 1 Cab.......................................................................... 65
			Remove and Install Cab........................................................... 65
		Group 2 Counterweight................................................................ 77
			Remove and Install Counterweight................................................. 77
		Group 3 Center Hinge................................................................. 79
			Disassemble Center Hinge......................................................... 79
			Assemble Center Hinge............................................................ 84
		Group 4 Hood......................................................................... 89
			Removal and Installation of Hood................................................. 89
		Group 5 Hydraulic Oil Tank........................................................... 91
			Removal and Installation of Hydraulic Oil Tank................................... 91
		Group 6 Pump Device.................................................................. 99
			Removal and Installation of Pump Device.......................................... 99
			Removal and Installation of Pilot Pump and Regulator.............................106
			Disassembly of Main Pump.........................................................110
			Assembly of Main Pump............................................................112
			Disassembly of Regulator.........................................................118
			Assembly of Regulator............................................................120
			Disassembly of Priority Valve....................................................122
			Assembly of Priority Valve.......................................................124
			Structure of Pilot Pump..........................................................126
			Maintenance Standard.............................................................128
		Group 7 Control Valve................................................................129
			Removal and Installation of Control Valve (ZW220)................................129
			Removal and Installation of Control Valve (ZW250)................................134
			Disassembly of Control Valve (ZW220).............................................140
			Assembly of Control Valve (ZW220)................................................144
			Disassembly of Control Valve (ZW250).............................................150
			Assembly of Control Valve (ZW250)................................................154
		Group 8 Pilot Valve..................................................................161
			Removal and Installation of Pilot Valve..........................................161
			Disassembly of Standard Pilot Valve for Front Attachment.........................164
			Assembly of Standard Pilot Valve for Front Attachment............................172
			Maintenance Standard.............................................................180
			Disassembly of Joy-Stick Type Pilot Valvefor Additional Circuit (Optional).......182
			Assembly of Joy-Stick Type Pilot Valvefor Additional Circuit (Optional)..........186
			Disassembly of 2-Way Lever Type Pilot Valve for Additional Circuit (Optional)....190
			Assembly of 2-Way Lever Type Pilot Valve for Additional Circuit..................192
		Group 9 Pilot Shut-Off Valve.........................................................195
			Removal and Installation of Pilot Shut-Off Valve.................................195
			Disassembly of Pilot Shut-Off Valve..............................................198
			Assembly of Pilot Shut-Off Valve.................................................200
		Group 10 Hydraulic Fan Pump and Motor................................................203
			Removal and Installation of Hydraulic Fan Pump...................................203
			Removal and Installation of Hydraulic Fan Motor..................................205
			Disassembly of Fan Pump..........................................................210
			Assembly of Fan Pump.............................................................212
			Fan Motor Standard...............................................................216
	SECTION 3 BODY (TRAVEL SYSTEM)...........................................................221
		Group 1 Tire.........................................................................223
			Removal and Installation of Tire.................................................223
		Group 2 Drive Unit...................................................................225
			Removal and Installation of Drive Unit...........................................225
			Removal of Torque Converter and Converter Housing................................238
			Installation of Torque Converter and Converter Housing...........................240
			Removal of Flange (Front, Rear) and Parking Brake................................242
			Installation of Flange (Front, Rear) and Parking Brake...........................244
			Disassembly of Parking Brake.....................................................246
			Assembly of Parking Brake........................................................248
			Removal of Oil Filter............................................................250
			Installation of Oil Filter.......................................................251
			Disassembly of Duct Plate........................................................252
			Assembly of Duct Plate...........................................................254
			Disassembly of Control Valve.....................................................256
			Assembly of Control Valve........................................................258
			Removal of Oil Feeder and Pump...................................................263
			Assembly of Oil Feeder...........................................................264
			Assembly of Pump.................................................................265
			Removal of PTO Shaft.............................................................268
			Installation of PTO Shaft........................................................269
			Removal of Clutch and Input/Output Shaft.........................................270
			Installation of Clutch and Input/Output Shaft....................................275
			Disassembly of Clutches K1, K2, and K3...........................................282
			Assembly of Clutches K1, K2 and K3...............................................286
			Disassembly of Clutches KR and KV................................................293
			Assembly of Clutches KR and KV...................................................296
			Disassembly of Clutch K4.........................................................302
			Assembly of K4 Clutch............................................................304
		Group 3 Axle.........................................................................309
			Removal and Installation of Axle.................................................309
			Disassembly of Axle..............................................................321
			Assembly of Axle.................................................................341
		Group 4 Propeller Shaft..............................................................373
			Removal and Installation of Propeller Shaft......................................373
		Group 5 Brake Valve..................................................................383
			Removal and Installation of Brake Valve..........................................383
			Disassembly of Brake Valve.......................................................386
			Assembly of Brake Valve..........................................................392
			Maintenance Standard.............................................................402
		Group 6 Charging Block...............................................................403
			Removal and Installation of Charging Block.......................................403
			Disassembly of Charging Block....................................................406
			Assembly of Charging Block.......................................................411
		Group 7 Steering Pilot Valve.........................................................419
			Removal and Installation of Steering Pilot Valve.................................419
			Disassembly of Steering Pilot Valve..............................................422
			Assembly of Steering Pilot Valve.................................................426
		Group 8 Steering Valve...............................................................433
			Removal and Installation of Steering Valve.......................................433
			Disassembly of Steering Valve....................................................434
			Assembly of Steering Valve.......................................................436
		Group 9 Steering Cylinder............................................................439
			Removal and Installation of Steering Cylinder....................................439
			Disassembly of Steering Cylinder.................................................444
			Assembly of Steering Cylinder....................................................452
		Group 10 Parking Brake Solenoid......................................................465
			Removal and Installation of Parking Brake Solenoid Valve.........................465
			Construction of Solenoid Valve...................................................467
	SECTION 4 FRONT ATTACHMENT...............................................................471
		Group 1 Front Attachment.............................................................473
			Removal and Installation of Front Attachment.....................................473
		Group 2 Cylinder.....................................................................483
			Removal and Installation of Cylinder (Lift Cylinder).............................483
			Removal and Installation of Cylinder (Bucket Cylinder)...........................488
			Disassembly of Bucket Cylinder...................................................492
			Assembly of Bucket Cylinder......................................................500
			Disassembly of Lift Cylinder.....................................................510
			Assembly of Lift Cylinder........................................................518
	SERVICE MANUAL REVISION REQUEST FORM.....................................................531

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