Technical Service Manual for Hitachi ZW250-6 Wheel Loader PDF

Description

Hitachi ZW250-6 Wheel Loader Workshop Manual (WNEM50-EN-00)

File Details:

Hitachi ZW250-6 Wheel Loader Workshop Manual (WNEM50-EN-00)

• Manual Language:English
• Pages: 909
• Size: 26.1 MB
• Downloadable:Yes
• Format:PDF

HITACHI ZW250-6 WHEEL LOADER WORKSHOP MANUAL (WNEM50-EN-00) – PDF DOWNLOAD:

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Description:

Hitachi ZW250-6 Wheel Loader Workshop Manual (WNEM50-EN-00)

To The Reader
This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
The machine specification and description according to destination may be explained on this manual.
 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 ZW250-6 Wheel Loader Workshop Manual (WNEM50-EN-00)

WNEM50-EN-00..........................................................................  1
CONTENTS..............................................................................  3
INTRODUCTION.......................................................................... 13
SYMBOL AND ABBREVIATION............................................................... 15
SAFETY................................................................................ 17
SECTION AND GROUP CONTENTS............................................................ 55
SECTION 1
GENERAL..................................................................... 59
	Group 1 Precautions for Disassembling and Assembling.............................. 61
		Precautions for Disassembling and
Assembling.................................. 61
	Group 2 Tightening................................................................ 67
		Tightening Bolts and Nuts..................................................... 67
		Piping Joint.................................................................. 70
	Group 3 Painting.................................................................. 77
	Group 4 Bleeding Air.............................................................. 85
		Bleed Air from the Hydraulic System........................................... 85
		Bleed Air from the Fuel System................................................ 86
		Bleeding Air from Brake (Axle)................................................ 87
	Group 5 Preparation............................................................... 89
		Preparations for Inspection and Maintenance................................... 89
		Releasing Pressure from Front Attachment
Hydraulic Circuit.................... 94
		Releasing Pressure from Ride Control
Accumulator.............................. 95
		Releasing Pressure from Parking Brake
Accumulator............................. 96
		Releasing Pressure from Hydraulic Oil Tank.................................... 97
		Releasing Pressure from Reserve Tank.......................................... 98
SECTION 2
MAINTENANCE STANDARD........................................................101
	Group 1 Body......................................................................103
		Center Hinge..................................................................103
		Pilot Valve (Two Lever Type ).................................................105
	Group 2 Front Attachment..........................................................107
		Pin and Bushing...............................................................107
		Standard Dimensions for Lift Arm and Bucket...................................109
		Cylinder......................................................................111
SECTION 3
BODY........................................................................115
	Group 1 Cab.......................................................................117
		Removal and Installation of Cab...............................................117
	Group 2 Counterweight.............................................................149
		Removal and Installation of Counterweight.....................................149
	Group 3 Center Hinge..............................................................153
		Removal and Installation of Center Hinge......................................153
	Group 4 Engine....................................................................179
		Removal and Installation of Engine............................................179
	Group 5 Radiator Assembly.........................................................219
		Removal and Installation of Radiator
Assembly.................................219
	Group 6 Hydraulic Oil Tank........................................................237
		Removal and Installation of Hydraulic Oil
Tank................................237
	Group 7 Fuel Tank.................................................................247
		Removal and Installation of Fuel Tank.........................................247
	Group 8 Pump Device...............................................................259
		Removal and Installation of Pump Device.......................................259
		Disassembly of Pump Device....................................................269
		Assembly of Pump Device.......................................................271
		Disassembly of Main Pump......................................................273
		Assembly of Main Pump.........................................................277
		Disassembly of Regulator......................................................283
		Assembly of Regulator.........................................................285
		Disassembly of Priority Valve.................................................287
		Assembly of Priority Valve....................................................289
		Structure of Pilot Pump.......................................................291
	Group 9 Control Valve.............................................................293
		Removal and Installation of Control Valve.....................................293
		Disassembly of Control Valve..................................................303
		Assembly of Control Valve.....................................................310
	Group 10 Pilot Valve..............................................................319
		Removal and Installation of Pilot Valve
(Single Lever Type)...................319
		Removal and Installation of Pilot Valve (Two
Lever Type)......................327
		Disassembly of Pilot Valve (Single Lever
Type)................................339
		Assembly of Pilot Valve (Single Lever Type)...................................342
		Disassembly of Pilot Valve (Two Lever Type)...................................347
		Assembly of Pilot Valve (Two Lever Type)......................................353
	Group 11 Brake Charge Valve.......................................................361
		Removal and Installation of Brake Charge
Valve................................361
		Structure of Brake Charge Valve...............................................369
		Removal and Installation of Brake
Accumulator.................................371
	Group 12 Manifold Valve...........................................................377
		Removal and Installation of Manifold Valve....................................377
		Disassembly of Manifold Valve.................................................385
		Assembly of Manifold Valve....................................................388
	Group 13 Solenoid Valve...........................................................393
		Removal and Installation of 2-Spool Solenoid
Valve Unit.......................393
		Structure of 2-Spool Solenoid Valve Unit......................................397
		Removal and Installation of Parking Brake
Solenoid Valve Unit.................399
		Structure of Parking Brake Solenoid Valve
Unit................................405
		Structure of Parking Brake Solenoid Valve.....................................407
	Group 14 Flow Regulator Valve.....................................................409
		Removal and Installation of Flow Regulator
Valve..............................409
		Structure of Flow Regulator Valve.............................................413
	Group 15 Cooling Fan System.......................................................415
		Removal and Installation of Fan Valve.........................................415
		Structure of Fan Valve........................................................419
		Removal and Installation of Fan Motor.........................................421
		Structure of Fan Motor........................................................427
		Removal and Installation of Pilot Pump........................................429
		Disassembly of Pilot Pump.....................................................435
		Assembly of Pilot Pump........................................................437
	Group 16 Ride Control Accumulator.................................................441
		Removal and Installation of Ride Control
Accumulator..........................441
	Group 17 Battery Disconnect Switch................................................445
		Removal and Installation of Battery
Disconnect Switch.........................445
	Group 18 Aftertreatment Device....................................................451
		Removal and Installation of Aftertreatment
Device.............................451
	Group 19 DEF Tank.................................................................477
		Removal and Installation of DEF Tank..........................................477
	Group 20 Coolant Control Valve....................................................485
		Removal and Installation of Coolant Control
Valve.............................485
	Group 21 DEF Supply Module........................................................491
		Removal and Installation of DEF Supply
Module.................................491
	Group 22 Exterior Components......................................................495
		Removal and Installation of Exterior
Components...............................495
SECTION 4
TRAVEL SYSTEM...............................................................555
	Group 1 Tire......................................................................557
		Removal and Installation of Front Tire........................................557
		Removal and Installation of Rear Tire.........................................561
	Group 2 Drive Unit................................................................565
		Removal and Installation of Drive Unit........................................565
		Disassembly and Assembly of Drive Unit........................................573
		Removal and Installation of Torque Converter..................................579
		Disassembly and Assembly of Transmission......................................583
		Disassembly and Assembly of Transmission
Control Valve........................633
		Removal and installation of parking brake
(Replace the brake friction pad)....649
	Group 3 Axle......................................................................659
		Removal and Installation of Front Axle........................................659
		Removal and Installation of Rear Axle.........................................669
		Disassembly of Axle...........................................................685
		Assembly of Axle..............................................................701
	Group 4 Propeller Shaft...........................................................727
		Removal and Installation of Propeller Shaft...................................727
	Group 5 Brake Valve...............................................................739
		Removal and Installation of Brake Valve.......................................739
		Disassembly of Brake Valve....................................................745
		Disassembly of Brake Valve....................................................746
		Assembly of Brake Valve.......................................................747
		Assembly of Brake Valve.......................................................748
	Group 6 Steering Device...........................................................751
		Removal and Installation of Steering Pilot
Valve..............................751
		Disassembly of Steering Pilot Valve...........................................757
		Assembly of Steering Pilot Valve..............................................760
		Removal and Installation of Steering Valve
(Without Emergency Steering).......765
		Removal and Installation of Steering Valve (With Emergency Steering)..........773
		Disassembly of Steering Valve.................................................781
		Assembly of Steering Valve....................................................784
		Disassembly of Emergency Steering Check
Block.................................787
		Assembly of Emergency Steering Check
Block....................................789
		Removal and Installation of Steering Cylinder.................................791
		Disassembly of Steering Cylinder..............................................813
		Assembly of Steering Cylinder.................................................817
		Removal and Installation of Steering
Accumulator..............................823
		Removal and Installation of Left Stop Valve...................................827
		Removal and Installation of Right Stop Valve..................................833
		Disassembly of Stop Valve.....................................................839
		Assembly of Stop Valve........................................................840
	Group 7 Emergency Steering Device.................................................841
		Removal and Installation of Emergency
Steering Pump...........................841
SECTION 5
FRONT ATTACHMENT............................................................851
	Group 1 Front Attachment..........................................................853
		Removal and Installation of Front
Attachment..................................853
		Removal and Installation of Bell Crank........................................863
		Removal and Installation of Bucket............................................871
		Removal and Installation of Bushing...........................................875
	Group 2 Cylinder..................................................................879
		Removal and Installation of Lift Arm Cylinder.................................879
		Removal and Installation of Bucket Cylinder...................................887
		Disassembly of Lift Arm Cylinder and Bucket Cylinder..........................899
		Assembly of Lift Arm Cylinder and Bucket Cylinder.............................903
SERVICE MANUAL REVISION REQUEST FORM..................................................909

Please Note:

⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.