Hitachi ZX 210W-5A Wheeled Excavator Workshop Manual – Hitachi ZX210W-5A – PDF Download

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Hitachi ZX 210W-5A Wheeled Excavator Workshop Manual – Hitachi ZX210W-5A

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Hitachi ZX 210W-5A Wheeled Excavator Workshop Manual – Hitachi ZX210W-5A

• Manual Language:English
• Pages: 900+
• Size:41.7 MB
• Downloadable:Yes
• Format:PDF

HITACHI ZX 210W-5A WHEELED EXCAVATOR WORKSHOP MANUAL – HITACHI ZX210W-5A – PDF DOWNLOAD:

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Hitachi ZX 210W-5A Wheeled Excavator Workshop Manual – Hitachi ZX210W-5A

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 and the Workshop 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.

Table Of Contents:

Hitachi ZX 210W-5A Wheeled Excavator Workshop Manual – Hitachi ZX210W-5A

WLCDE0-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
	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 Handholds and Steps..................................................................... 12
		Adjust the 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
		Operate Only from Operator's Seat........................................................... 14
		Jump Starting............................................................................... 15
		Keep Riders off Machine..................................................................... 15
		Precautions for Operations.................................................................. 16
		Investigate Job Site Beforehand............................................................. 17
		Install OPG Guard........................................................................... 18
		Restriction of Attachment Installation...................................................... 19
		Provide Signals for Jobs Involving Multiple Machines........................................ 19
		Confirm Direction of Machine to Be Driven................................................... 19
		Drive Machine Safely........................................................................ 20
		Avoid Injury from Rollaway Accidents........................................................ 21
		Avoid Injury from Back-Over and Swing Accidents............................................. 22
		Keep Person Clear from Working Area......................................................... 23
		Never Position Bucket Over Anyone........................................................... 23
		Avoid Undercutting.......................................................................... 24
		Avoid Tipping............................................................................... 24
		Never Undercut a High Bank.................................................................. 25
		Dig with Caution............................................................................ 25
		Operate with Caution........................................................................ 25
		Avoid Power Lines........................................................................... 26
		Precautions for Lightning................................................................... 26
		Object Handling............................................................................. 27
		Protect Against Flying Debris............................................................... 27
		Park Machine Safely......................................................................... 28
		Handle Fluids Safely−Avoid Fires............................................................ 28
		Transport Safely............................................................................ 29
		Practice Safe Maintenance................................................................... 30
		Warn Others of Service Work................................................................. 31
		Support Machine Properly.................................................................... 31
		Stay Clear of Moving Parts.................................................................. 32
		Prevent Parts from Flying................................................................... 32
		Avoid Injury from Attachment Falling Accident............................................... 33
		Support Maintenance Properly................................................................ 33
		Prevent Burns............................................................................... 34
		Replace Rubber Hoses Periodically........................................................... 34
		Avoid High-Pressure Fluids.................................................................. 35
		Prevent Fires............................................................................... 35
		Evacuating in Case of Fire.................................................................. 37
		Beware of Exhaust Fumes..................................................................... 37
		Precautions for Welding and Grinding........................................................ 38
		Avoid Heating Near Pressurized Fluid Lines.................................................. 39
		Avoid Applying Heat to Lines Containing Flammable Fluids.................................... 39
		Precautions for Handling Accumulator and Gas Damper......................................... 39
		Remove Paint Before Welding or Heating...................................................... 40
		Beware of Asbestos and Silicon Dust and Other Contamination................................. 40
		Prevent Battery Explosions.................................................................. 41
		Service Air Conditioning System Safely...................................................... 41
		Handle Chemical Products Safely............................................................. 42
		Dispose of Waste Properly................................................................... 42
		Never Ride Attachment....................................................................... 43
		Precautions for Communication Terminal...................................................... 43
		Precaution for Communication Terminal Equipment............................................. 44
		Notes on Protection of Operator’s Station when the Machine Rolls Over....................... 46
	SECTION AND GROUP CONTENTS...................................................................... 47
	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............................................................................ 69
			Painting................................................................................ 69
		Group 4 Bleeding Air........................................................................ 71
			Bleeding Air from Hydraulic System...................................................... 71
			Bleeding Air from Fuel System........................................................... 72
			Bleeding Air from Transmission.......................................................... 74
			Bleeding Air from Brake (Axle).......................................................... 77
		Group 5 Preparation......................................................................... 79
			Preparation before Inspection and Maintenance........................................... 79
			Hydraulic Circuit Pressure Release Procedure............................................ 81
			Pressure Release from Hydraulic Oil Tank................................................ 82
			Pressure Release from Expansion Tank.................................................... 83
			Pressure Release from Brake Circuit..................................................... 84
	SECTION 2 MAINTENANCE STANDARD.................................................................. 87
		Group 1 Upperstructure...................................................................... 89
			Pump Device............................................................................. 89
			Swing Motor............................................................................. 93
		Group 3 Front Attachment.................................................................... 97
			Pin and Bushing......................................................................... 97
			Side Cutter (2014503, 2014504).......................................................... 99
			Point (4427919).........................................................................100
			Standard Dimensions for Arm and Bucket Connection.......................................101
			Standard Dimensions for Arm and Boom Connection.........................................102
			Cylinder................................................................................103
	SECTION 3 UPPERSTRUCTURE........................................................................107
		Group 1 Cab.................................................................................109
			Removal and Installation of Cab.........................................................109
			Dimensions of Cab Glass.................................................................135
		Group 2 Counterweight.......................................................................155
			Removal and Installation of Counterweight...............................................155
		Group 3 Main Frame..........................................................................169
			Removal and Installation of Main Frame..................................................169
		Group 4 Engine..............................................................................183
			Removal and Installation of Engine......................................................183
		Group 8 Pump Device.........................................................................221
			Removal and Installation of Pump Device.................................................221
			Removal and Installation of Coupling....................................................247
			Disassembly of Pump Device..............................................................249
			Assembly of Pump Device.................................................................256
			Disassembly of Regulator................................................................267
			Assembly of Regulator...................................................................269
			Disassembly of Solenoid Valve Unit......................................................271
			Assembly of Solenoid Valve Unit.........................................................273
			Structure of Pilot/Steering Pump........................................................275
		Group 9 Control Valve.......................................................................277
			Removal and Installation of Control Valve...............................................277
			Removal and Installation of Positioning Control Valve...................................307
			Disassembly of Housing..................................................................311
			Assembly of Housing.....................................................................313
			Disassembly of Control Valve 4-Spool Side...............................................315
			Assembly of Control Valve 4-Spool Side..................................................322
			Disassembly of Control Valve 5-Spool Side...............................................335
			Assembly of Control Valve 5-Spool Side..................................................342
		Group 10 Swing Device.......................................................................353
			Removal and Installation of Swing Device................................................353
			Disassembly of Swing Device.............................................................357
			Assembly of Swing Device................................................................362
			Disassembly of Swing Motor..............................................................369
			Assembly of Swing Motor.................................................................372
		Group 11 Pilot Valve........................................................................375
			Removal and Installation of Pilot Valve (Left)..........................................375
			Removal and Installation of Pilot Valve (Right).........................................385
			Removal and Installation of Travel Pilot Valve..........................................391
			Disassembly of Pilot Valves (Right and Left)............................................395
			Assembly of Pilot Valves (Right and Left)...............................................398
			Disassembly of Travel Pilot Valve.......................................................401
			Assembly of Travel Pilot Valves.........................................................404
		Group 12 Solenoid Valve.....................................................................407
			Removal and Installation of Pilot Shut-Off Solenoid Valve...............................407
			Removal and Installation of 5-Spool Solenoid Valve Unit.................................411
			Removal and Installation of Axle-lock/Brake Solenoid Valve Unit.........................415
			Removal and Installation of Pump 2 Flow Control Solenoid Valve..........................417
			Disassembly of Pilot Shut-Off Solenoid Valve............................................419
			Assembly of Pilot Shut-Off Solenoid Valve...............................................421
			Structure of 3-Spool Solenoid Valve Unit................................................423
			Structure of Axle Lock/Brake Solenoid Valve Unit........................................425
			Structure of Pump 2 Flow Rate Limit Control Solenoid Valve..............................427
		Group 13 Signal Control Valve...............................................................429
			Removal and Installation of Signal Control Valve........................................429
			Structure of Signal Control Valve.......................................................433
		Group 14 Shockless Valve....................................................................437
			Removal and Installation of Travel Shockless Valve......................................437
			Structure of Travel Shockless Valve.....................................................441
		Group 15 Steering Valve.....................................................................443
			Removal and Installation of Steering Valve..............................................443
			Disassembly of Steering Valve...........................................................453
			Assembly of Steering Valve..............................................................456
		Group 16 Brake Valve........................................................................461
			Removal and Installation of Brake Valve.................................................461
			Disassembly of Brake Valve..............................................................467
			Assembly of Brake Valve.................................................................471
		Group 17 Accumulator Charging Valve.........................................................475
			Removal and Installation of Accumulator Charge Valve....................................475
			Structure of Accumulator Charging Valve.................................................481
		Group 18 Accumulator Manifold...............................................................483
			Removal and Installation of Accumulator Manifold........................................483
			Structure of Accumulator Manifold.......................................................487
	SECTION 4 UNDERCARRIAGE.........................................................................  0
		Group 1 Swing Bearing.......................................................................  0
			Removal and Installation of Swing Bearing...............................................  0
			Disassembly of Swing Bearing............................................................  0
			Assembly of Swing Bearing...............................................................  0
		Group 2 Travel Motor........................................................................  0
			Removal and Installation of Travel Motor................................................  0
			Disassembly of Travel Motor.............................................................  0
			Assembly of Travel Motor................................................................  0
			Disassembly of Brake Valve..............................................................  0
			Assembly of Brake Valve.................................................................  0
			Precautions for Using Floating Seal.....................................................  0
		Group 3 Center Joint........................................................................  0
			Removal and Installation of Center Joint................................................  0
			Disassembly of Center Joint.............................................................  0
			Assembly of Center Joint................................................................  0
		Group 4 Transmission........................................................................  0
			Removal and Installation of Transmission................................................  0
			Disassembly of Transmission.............................................................  0
			Assembly of Transmission................................................................  0
		Group 5 Axle................................................................................  0
			Removal and Installation of Front Axle..................................................  0
			Removal and Installation of Rear Axle, Transmission.....................................  0
			Disassembly of Front Axle...............................................................  0
			Assembly of Front Axle..................................................................  0
			Disassembly of Rear Axle................................................................  0
			Assembly of Rear Axle...................................................................  0
			Disassembly of Differential.............................................................  0
			Assembly of Differential................................................................  0
			Disassembly of Steering Cylinder........................................................  0
			Assembly of Steering Cylinder...........................................................  0
			Removal and Installation of Tie Rod.....................................................  0
			Adjustment of Steering..................................................................  0
		Group 6 Axle Lock Cylinder..................................................................  0
			Removal and Installation of Axle Lock Cylinder..........................................  0
			Disassembly of Axle Lock Cylinder.......................................................  0
			Assembly of Axle Lock Cylinder..........................................................  0
		Group 7 Operate Check Valve.................................................................  0
			Removal and Installation of Operate Check Valve (For Axel Lock Cylinder)................  0
			Removal and Installation of Operate Check Valve (For Blade Cylinder)....................  0
			Removal and Installation of Operate Check Valve for Outrigger Cylinder..................  0
			Structure of Operate Check Valve (For Axel Lock Cylinder)...............................  0
			Structure of Operate Check Valve (For Blade/Outrigger Cylinder).........................  0
		Group 8 Solenoid Valve......................................................................  0
			Removal and Installation of 2-Spool Solenoid Valve Unit for Blade/Outrigger Cylinder....  0
			Removal and Installation of Transmission Control Solenoid Valve.........................  0
			Structure of 2-Spool Solenoid Valve Unit (For Blade/ Outrigger Cylinder)................  0
		Group 9 Propeller Shaft.....................................................................  0
			Removal and Installation of Propeller Shaft.............................................  0
		Group 10 Cylinder...........................................................................  0
			Removal and Installation of Blade Cylinder..............................................  0
			Removal and Installation of Outrigger Cylinder..........................................  0
			Disassembly of Blade/ Outrigger Cylinders...............................................  0
			Assembly of Blade/ Outrigger Cylinders..................................................  0
	SECTION 5 FRONT ATTACHMENT......................................................................  0
		Group 1 Front Attachment....................................................................  0
			Removal and Installation of Front Attachment............................................  0
		Group 2 Cylinder............................................................................  0
			Removal and Installation of Boom Cylinder...............................................  0
			Removal and Installation of Arm Cylinder................................................  0
			Removal and Installation of Bucket Cylinder.............................................  0
			Disassembly of Boom Cylinder............................................................  0
			Assembly of Boom Cylinder...............................................................  0
			Disassembly of Arm and Bucket Cylinders.................................................  0
			Assembly of Arm and Bucket Cylinders....................................................  0
	SERVICE MANUAL REVISION REQUEST FORM............................................................  0

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.