Hitachi ZW220 ZW250 Wheel Loader (Standard Specification) Workshop Manual (W4GC-E-00) – PDF Download

Description

Hitachi ZW220 ZW250 Wheel Loader (Standard Specification) Workshop Manual (W4GC-E-00)

File Details:

Hitachi ZW220 ZW250 Wheel Loader (Standard Specification) Workshop Manual (W4GC-E-00)

• Manual Language:English
• Pages: 582
• Size: 12.8 MB
• Downloadable:Yes
• Format:PDF

HITACHI ZW220 ZW250 WHEEL LOADER (STANDARD SPECIFICATION) WORKSHOP MANUAL (W4GC-E-00) – PDF DOWNLOAD:

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Description:

Hitachi ZW220 ZW250 Wheel Loader (Standard Specification) Workshop Manual (W4GC-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 (Standard Specification) Workshop Manual (W4GC-E-00)

ZW220/250_W4GC-E-00
..............................................................................  1
	INTRODUCTION..................................................................................  3
	SAFETY........................................................................................  5
	SECTION AND GROUP CONTENTS.................................................................... 35
	SECTIO
N 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 Specifications...................................................... 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 Valve for Additional Circuit (Optional)...........182
			Assembly of Joy-Stick Type Pilot Valve for 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
			Disassembly of Drive Unit.............................................................240
			Disassembly of Torque Converter Wheel.................................................274
			Assembly of Torque Converter Wheel....................................................284
			Disassembly of Clutch Shaft (Forward Clutch, Reverse Clutch)..........................292
			Assembly of Clutch Shaft (Forward Clutch, Reverse Clutch).............................296
			Disassembly of Clutch Shaft (1-Speed to 2-Speed Clutch, 3-Speed to 4-Speed Clutch)....302
			Assembly of Clutch Shaft (1-Speed to 2-Speed Clutch, 3-Speed to 4-Speed Clutch).......304
			Disassembly of Idler Shaft............................................................306
			Assembly of Idler Shaft...............................................................308
			Disassembly of Control Valve..........................................................310
			Assembly of Control Valve.............................................................314
			Disassembly of Regulator Valve........................................................322
			Assembly of Regulator.................................................................324
			Assembly of Drive Unit................................................................326
		Group 3 Axle..............................................................................363
			Removal and Installation of Axle......................................................363
			Disassembly of Axle...................................................................375
			Assembly of Axle......................................................................395
		Group 4 Propeller Shaft...................................................................427
			Removal and Installation of Propeller Shaft...........................................427
		Group 5 Brake Valve.......................................................................437
			Removal and Installation of Brake Valve...............................................437
			Disassembly of Brake Valve............................................................440
			Assembly of Brake Valve...............................................................446
			Maintenance Standard..................................................................456
		Group 6 Charging Block....................................................................457
			Removal and Installation of Charging Block............................................457
			Disassembly of Charging Block.........................................................460
			Assembly of Charging Block............................................................465
		Group 7 Steering Pilot Valve..............................................................473
			Removal and Installation of Steering Pilot Valve......................................473
			Disassembly of Steering Pilot Valve...................................................476
			Assembly of Steering Pilot Valve......................................................480
		Group 8 Steering Valve....................................................................487
			Removal and Installation of Steering Valve............................................487
			Disassembly of Steering Valve.........................................................488
			Assembly of Steering Valve............................................................490
		Group 9 Steering Cylinder.................................................................493
			Removal and Installation ofSteering Cylinder..........................................493
			Disassembly of Steering Cylinder......................................................498
			Assembly of Steering Cylinder.........................................................506
	SECTION 4FRONT ATTACHMENT.....................................................................521
		Group 1 Front Attachment..................................................................523
			Removal and Installation of Front Attachment..........................................523
		Group 2 Cylinder..........................................................................533
			Removal and Installation of Cylinder (Lift Cylinder)..................................533
			Removal and Installation of Cylinder (Bucket Cylinder)................................538
			Disassembly of Bucket Cylinder........................................................542
			Assembly of Bucket Cylinder...........................................................550
			Disassembly of Lift Cylinder..........................................................560
			Assembly of Lift Cylinder.............................................................568
	SERVICE MANUAL REVISION REQUEST FORM..........................................................581

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