Hitachi ZW250-5B Wheel Loader Workshop Manual (WNEC-EN-00) – PDF Download

Description

Hitachi ZW250-5B Wheel Loader Workshop Manual (WNEC-EN-00)

File Details:

Hitachi ZW250-5B Wheel Loader Workshop Manual (WNEC-EN-00)

• Manual Language:English
• Pages: 788
• Size: 17.7 MB
• Downloadable:Yes
• Format:PDF

HITACHI ZW250-5B WHEEL LOADER WORKSHOP MANUAL (WNEC-EN-00) – PDF DOWNLOAD:

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Description:

Hitachi ZW250-5B Wheel Loader Workshop Manual (WNEC-EN-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 other materials (operator’s manual, parts catalog, engine technical material and Hitachi training material etc.) in addition to this manual.
Manual Composition
This manual consists the Technical Manual, the Workshop Manual and the Engine 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 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.
 Information included in the Engine Manual: Technical information needed for redelivery and delivery and maintenance and repair of the machine, operation and activation of all devices and systems, troubleshooting and assemble / disassemble procedures.

Table Of Contents:

Hitachi ZW250-5B Wheel Loader Workshop Manual (WNEC-EN-00)

WNEC-EN-00...................................................................................  1
	INTRODUCTION.............................................................................  3
		To The Reader........................................................................  3
		Additional References................................................................  3
		Manual Composition...................................................................  3
		Page Number..........................................................................  3
		Safety Alert Symbol and Headline Notations...........................................  4
		Units Used...........................................................................  4
	SYMBOL AND ABBREVIATION..................................................................  5
		Symbol and Abbreviation..............................................................  5
	SAFETY...................................................................................  7
		Recognize Safety Information.........................................................  7
		Understand Signal Words..............................................................  7
		Follow Safety Instructions...........................................................  8
		Prepare for Emergencies..............................................................  9
		Wear Protective Clothing.............................................................  9
		Protect Against Noise................................................................ 10
		Inspect Machine...................................................................... 10
		General Precautions for Cab.......................................................... 11
		Use Handrails and Steps.............................................................. 12
		Never Ride Attachment................................................................ 12
		Adjust Operator’s Seat............................................................... 12
		Ensure Safety Before Rising from or Leaving Operator’s Seat.......................... 13
		Fasten Your Seat Belt................................................................ 13
		Move and Operate Machine Safely...................................................... 14
		Handle Starting Aids Safely.......................................................... 14
		Operate Only from Operator’s Seat.................................................... 15
		Jump Starting........................................................................ 15
		Investigate Job Site Beforehand...................................................... 16
		Equipment of Head Guard, ROPS, FOPS.................................................. 17
		Provide Signals for Jobs Involving Multiple Machines................................. 17
		Keep Riders Off Machine.............................................................. 18
		Drive Safely......................................................................... 18
		Drive Machine Safely (Work Site)..................................................... 19
		Drive Safely with Bucket Loaded...................................................... 20
		Drive on Snow Safely................................................................. 20
		Travel on Public Roads Safely........................................................ 21
		Avoid Injury from Rollaway Accidents................................................. 21
		Avoid Accidents from Backing Up and Turning.......................................... 22
		Avoid Positioning Bucket or Attachment Over Anyone................................... 23
		Avoid Tipping........................................................................ 23
		Never Undercut a High Bank........................................................... 24
		Dig with Caution..................................................................... 24
		Perform Truck Loading Safely......................................................... 24
		Avoid Power Lines.................................................................... 25
		Precautions for Operation............................................................ 25
		Precautions for Lightning............................................................ 25
		Object Handling...................................................................... 26
		Protect Against Flying Debris........................................................ 26
		Park Machine Safely.................................................................. 27
		Store Attachments Safely............................................................. 27
		Transport Safely..................................................................... 28
		Handle Fluids Safely−Avoid Fires..................................................... 29
		Practice Safe Maintenance............................................................ 30
		Warn Others of Service Work.......................................................... 31
		Support Machine Properly............................................................. 31
		Stay Clear of Moving Parts........................................................... 32
		Support Maintenance Properly......................................................... 32
		Prevent Parts from Flying............................................................ 33
		Prevent Burns........................................................................ 33
		Replace Rubber Hoses Periodically.................................................... 34
		Avoid High-Pressure Fluids........................................................... 34
		Prevent Fires........................................................................ 35
		Evacuating in Case of Fire........................................................... 37
		Beware of Exhaust Fumes.............................................................. 37
		Precautions for Welding and Grinding................................................. 37
		Avoid Heating Near Pressurized Fluid Lines........................................... 38
		Avoid Applying Heat to Lines Containing Flammable Fluids............................. 38
		Precautions for Handling Accumulator and Gas Damper.................................. 38
		Remove Paint Before Welding or Heating............................................... 39
		Beware of Asbestos and Silicon Dust and Other Contamination.......................... 39
		Prevent Battery Explosions........................................................... 40
		Service Air Conditioning System Safely............................................... 40
		Handle Chemical Products Safely...................................................... 41
		Dispose of Waste Properly............................................................ 41
		Notes for Muffler Filter............................................................. 42
		Precautions for Communication Terminal............................................... 42
		Precaution for Communication Terminal Equipment...................................... 43
		Before Returning the Machine to the Customer......................................... 45
	SECTION AND GROUP CONTENTS............................................................... 47
	SECTION AND GROUP CONTENTS............................................................... 49
	SECTION 1 GENERAL........................................................................ 51
		Group 1 Precautions for Disassembling and Assembling................................. 53
			Precautions for Disassembling and Assembling..................................... 53
		Group 2 Tightening................................................................... 59
			Tightening Bolts and Nuts........................................................ 59
			Piping Joint..................................................................... 62
		Group 3 Painting..................................................................... 67
			Painting......................................................................... 67
		Group 4 Bleeding Air................................................................. 73
			Bleeding Air from Hydraulic Oil Tank............................................. 73
			Bleeding Air from Hydraulic System............................................... 74
			Bleeding Air from Fuel System.................................................... 75
			Bleeding Air from Radiator....................................................... 77
			Bleeding Air from Brake (Axle)................................................... 78
		Group 5 Pressure Release Procedure................................................... 79
			Front Attachment Hydraulic Circuit Pressure Release Procedure.................... 79
			Ride Control Accumulator Pressure Release Procedure.............................. 80
			Parking Brake Accumulator Pressure Release Procedure............................. 81
		Group 6 Preparation.................................................................. 83
			Preparation before Inspection and Maintenance.................................... 83
	SECTION 2 MAINTENANCE STANDARD........................................................... 89
		Group 1 Body......................................................................... 91
			Center Hinge..................................................................... 91
			Pilot Valve (Two Lever Type ).................................................... 93
		Group 2 Front Attachment............................................................. 95
			Pin and Bushing.................................................................. 95
			Standard Dimensions for Lift Arm and Bucket...................................... 97
	SECTION 3 BODY...........................................................................101
		Group 1 Cab..........................................................................103
			Removal and Installation of Cab..................................................103
		Group 2 Counterweight................................................................127
			Removal and Installation of Counterweight........................................127
		Group 3 Center Hinge.................................................................137
			Removal and Installation of Center Hinge.........................................137
			Removal and Installation of the Hydraulic Hoses of Front Frame side..............149
		Group 4 Engine.......................................................................165
			Removal and Installation of Engine...............................................165
			Removal and Installation of Exterior Parts.......................................203
			Removal and Installation of Air Cleaner..........................................221
		Group 5 Radiator Assembly............................................................225
			Replacement of Radiator, Oil Cooler, Intercooler, and Torque Converter Cooler....225
		Group 6 Hydraulic Oil Tank...........................................................247
			Removal and Installation of Hydraulic Oil Tank...................................247
		Group 7 Fuel Tank....................................................................263
			Removal and Installation of Fuel Tank............................................263
		Group 8 Pump Device..................................................................271
			Removal and Installation of Pump Device..........................................271
			Disassembly of Pump Device.......................................................285
			Assembly of Pump Device..........................................................287
			Disassembly of Main Pump.........................................................289
			Assembly of Main Pump............................................................293
			Disassembly of Regulator.........................................................299
			Assembly of Regulator............................................................301
			Disassembly of Priority Valve....................................................303
			Assembly of Priority Valve.......................................................305
			Structure of Pilot Pump..........................................................307
		Group 9 Control Valve................................................................309
			Removal and Installation of Control Valve........................................309
			Disassembly of Control Valve.....................................................323
			Disassembly of Control Valve.....................................................326
			Assembly of Control Valve........................................................331
			Assembly of Control Valve........................................................336
		Group 10 Pilot Valve.................................................................343
			Removal and Installation of Pilot Valve..........................................343
			Removal and Installation of Pilot Valve (Two Lever Type )........................349
			Disassembly of Pilot Valve.......................................................355
			Assembly of Pilot Valve..........................................................358
			Disassembly of Pilot Valve (Two Lever Type)......................................363
			Assembly of Pilot Valve (Two Lever Type).........................................369
		Group 11 Brake Charge Valve..........................................................377
			Removal and Installation of Brake Charge Valve...................................377
			Structure of Brake Charge Valve..................................................385
			Removal and Installation of Brake Accumulator....................................387
		Group 12 Manifold Valve..............................................................393
			Removal and Installation of Manifold Valve.......................................393
			Disassembly of Manifold Valve....................................................405
			Assembly of Manifold Valve.......................................................408
		Group 13 Solenoid Valve..............................................................413
			Removal and Installation of 3-Spool Solenoid Valve Unit..........................413
			Removal and Installation of Parking Brake Solenoid Valve.........................419
		Group 14 Flow Regulator Valve........................................................427
			Removal and Installation of Flow Regulator Valve.................................427
			Structure of Flow Regulator Valve................................................431
		Group 15 Cooling Fan System..........................................................433
			Removal and Installation of Fan Valve............................................433
			Structure of Fan Valve...........................................................437
			Removal and Installation of Fan Motor............................................439
			Structure of Fan Motor...........................................................443
			Removal and Installation of Fan Pump.............................................445
			Disassembly of Fan Pump..........................................................449
			Assembly of Fan Pump.............................................................451
		Group 16 Muffler Filter..............................................................455
			Removal and Installation of Muffler Filter.......................................455
			Disassembly of Muffler Filter....................................................467
			Assembly of Muffler Filter.......................................................469
		Group 17 Ride Control Accumulator....................................................471
			Removal and Installation of Ride Control Accumulator.............................471
		Group 18 Battery Disconnect Switch...................................................475
			Removal and Installation of Battery Disconnect Switch............................475
	SECTION 4 TRAVEL SYSTEM..................................................................481
		Group 1 Tire.........................................................................483
			Removal and Installation of Front Tire...........................................483
			Removal and Installation of Rear Tire............................................485
		Group 2 Drive Unit...................................................................489
			Removal and Installation of Drive Unit...........................................489
			Disassembly and Assembly of Drive Unit...........................................495
			Removal and Installation of Torque Converter.....................................501
			Disassembly and Assembly of Transmission.........................................507
			Disassembly and Assembly of Transmission Control Valve...........................557
		Group 3 Axle.........................................................................577
			Removal and Installation of Front Axle...........................................577
			Removal and Installation of Rear Axle............................................585
			Disassembly of Axle..............................................................595
			Assembly of Axle.................................................................612
		Group 4 Propeller Shaft..............................................................639
			Removal and Installation of Propeller Shaft......................................639
		Group 5 Brake Valve..................................................................649
			Removal and Installation of Brake Valve..........................................649
			Disassembly of Brake Valve.......................................................653
			Disassembly of Brake Valve.......................................................654
			Assembly of Brake Valve..........................................................655
			Assembly of Brake Valve..........................................................656
		Group 6 Steering Pilot Valve.........................................................659
			Removal and Installation of Steering Pilot Valve.................................659
			Disassembly of Steering Pilot Valve..............................................663
			Assembly of Steering Pilot Valve.................................................666
		Group 7 Steering Valve...............................................................671
			Removal and Installation of Steering Valve.......................................671
			(Without Emergency Steering).....................................................671
			Removal and Installation of Steering Valve.......................................677
			(With Emergency Steering)........................................................677
			Disassembly of Steering Valve....................................................683
			Assembly of Steering Valve.......................................................686
			Disassembly of Emergency Steering Check Block....................................689
			Assembly of Emergency Steering Check Block.......................................691
		Group 8 Steering Cylinder............................................................693
			Removal and Installation of Steering Cylinder....................................693
			Disassembly of Steering Cylinder.................................................701
			Assembly of Steering Cylinder....................................................704
			Removal and Installation of Steering Accumulator.................................707
		Group 9 Emergency Steering Device....................................................711
			Removal and Installation of Emergency Steering Pump..............................711
	SECTION 5 FRONT ATTACHMENT...............................................................721
		Group 1 Front Attachment.............................................................723
			Removal and Installation of Front Attachment.....................................723
			Removal and Installation of Bell Crank...........................................739
			Removal and Installation of Bucket...............................................753
		Group 2 Cylinder.....................................................................759
			Removal and Installation of Lift Arm Cylinder....................................759
			Removal and Installation of Bucket Cylinder......................................767
			Disassembly of Lift Arm Cylinder and Bucket Cylinder.............................777
			Assembly of Lift Arm Cylinder and Bucket Cylinder................................781
	SERVICE MANUAL REVISION REQUEST FORM.....................................................787

Please Note:

⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]