Hitachi ZX250LC-6 ZX250LCN-6 Hydraulic Excavator Technical Workshop Manual (WDC150-EN-01) – PDF Download

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Hitachi ZX250LC-6 ZX250LCN-6 Hydraulic Excavator Technical Workshop Manual (WDC150-EN-01)

File Details:

Hitachi ZX250LC-6 ZX250LCN-6 Hydraulic Excavator Technical Workshop Manual (WDC150-EN-01)

• Manual Language:English
• Downloadable:Yes
• Pages: 659
• Size: 17.2 MB
• Format:PDF

HITACHI ZX250LC-6 ZX250LCN-6 HYDRAULIC EXCAVATOR TECHNICAL WORKSHOP MANUAL (WDC150-EN-01) – PDF DOWNLOAD:

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Description:

Hitachi ZX250LC-6 ZX250LCN-6 Hydraulic Excavator Technical Workshop Manual (WDC150-EN-01)

• 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 ZX250LC-6 ZX250LCN-6 Hydraulic Excavator Technical Workshop Manual (WDC150-EN-01)

WDC150-EN-01...........................................................................  1
	CONTENTS...........................................................................  3
		SECTION 1 GENERAL..............................................................  3
		SECTION 2 MAINTENANCE STANDARD.................................................  5
		SECTION 3 UPPERSTRUCTURE.......................................................  7
		SECTION 4 UNDERCARRIAGE........................................................  9
		SECTION 5 FRONT ATTACHMENT..................................................... 11
	INTRODUCTION....................................................................... 13
		To The Reader.................................................................. 13
		Additional References.......................................................... 13
		Manual Composition............................................................. 13
		Page Number.................................................................... 13
		Trademark...................................................................... 13
		Safety Alert Symbol and Headline Notations..................................... 14
		Units Used..................................................................... 14
	SYMBOL AND ABBREVIATION............................................................ 15
	SAFETY............................................................................. 17
		Recognize Safety Information................................................... 17
		Understand Signal Words........................................................ 17
		Follow Safety Instructions..................................................... 18
		Prepare for Emergencies........................................................ 19
		Wear Protective Clothing....................................................... 19
		Protect Against Noise.......................................................... 20
		Inspect Machine................................................................ 20
		General Precautions for the Cab................................................ 21
		Use Handholds and Steps........................................................ 22
		Adjust the Operator's Seat..................................................... 22
		Ensure Safety Before Rising from or Leaving Operator’s Seat.................... 23
		Fasten Your Seat Belt.......................................................... 23
		Move and Operate Machine Safely................................................ 24
		Operate Only from Operator's Seat.............................................. 24
		Jump Starting.................................................................. 25
		Keep Riders off Machine........................................................ 25
		Precautions for Operations..................................................... 26
		Investigate Job Site Beforehand................................................ 27
		Install OPG Guard.............................................................. 28
		Restriction of Attachment Installation......................................... 28
		Provide Signals for Jobs Involving Multiple Machines........................... 29
		Confirm Direction of Machine to Be Driven...................................... 29
		Drive Machine Safely........................................................... 30
		Avoid Injury from Rollaway Accidents........................................... 32
		Avoid Injury from Back-Over and Swing Accidents................................ 33
		Keep People Clear from Working Area............................................ 34
		Never Position the Bucket Over Anyone.......................................... 34
		Avoid Undercutting............................................................. 35
		Avoid Tipping.................................................................. 35
		Never Undercut a High Bank..................................................... 36
		Dig with Caution............................................................... 36
		Operate with Caution........................................................... 36
		Avoid Power Lines.............................................................. 37
		Precautions for Lightning...................................................... 37
		Object Handling................................................................ 38
		Protect Against Flying Debris.................................................. 38
		Park Machine Safely............................................................ 39
		Handle Fluids Safely−Avoid Fires............................................... 39
		Transport Safely............................................................... 40
		Practice Safe Maintenance...................................................... 41
		Warn Others of Service Work.................................................... 42
		Support Machine Properly....................................................... 42
		Stay Clear of Moving Parts..................................................... 43
		Prevent Parts from Flying...................................................... 43
		Avoid Injury from Attachment Falling Accident.................................. 44
		Prevent Burns.................................................................. 44
		Replace Rubber Hoses Periodically.............................................. 45
		Avoid High-Pressure Fluids..................................................... 45
		Prevent Fires.................................................................. 46
		Evacuating in Case of Fire..................................................... 48
		Beware of Exhaust Fumes........................................................ 48
		Precautions for Welding and Grinding........................................... 49
		Avoid Heating Near Pressurized Fluid Lines..................................... 50
		Avoid Applying Heat to Lines Containing Flammable Fluids....................... 50
		Precautions for Handling Accumulator and Gas Damper............................ 50
		Remove Paint Before Welding or Heating......................................... 51
		Beware of Asbestos and Silica Dust and Other Contamination..................... 51
		Prevent Battery Explosions..................................................... 52
		Service Air Conditioning System Safely......................................... 52
		Handle Chemical Products Safely................................................ 53
		Dispose of Waste Properly...................................................... 53
		Never Ride Attachment.......................................................... 54
		Notes on Aftertreatment Device................................................. 54
		Precautions for Communication Terminal......................................... 54
		Precautions for Communication Terminal Equipment............................... 55
		Notes on Protection of Operator’s Station when the Machine Rolls Over.......... 57
		Before Returning the Machine to the Customer................................... 58
	SECTION AND GROUP CONTENTS......................................................... 59
	SECTION 1 GENERAL.................................................................. 63
		Group 1 Precautions for Disassembling and Assembling........................... 65
			Precautions for Disassembling and Assembling............................... 65
		Group 2 Tightening............................................................. 71
			Tightening Bolts and Nuts.................................................. 71
			Piping Joint............................................................... 74
		Group 3 Painting............................................................... 81
			Painting................................................................... 81
		Group 4 Bleeding Air........................................................... 83
			Bleeding Air from Hydraulic System......................................... 83
			Bleeding Air from Fuel System.............................................. 84
			Air Bleeding from the Diesel Exhaust Fluid Defrosting Piping............... 86
		Group 5 Preparation............................................................ 87
			Preparation before Inspection and Maintenance.............................. 87
			Hydraulic Circuit Pressure Release Procedure............................... 89
			Pressure Release from Hydraulic Oil Tank................................... 90
			Pressure Release from Expansion Tank....................................... 91
	SECTION 2 MAINTENANCE STANDARD..................................................... 95
		Group 1 Upperstructure......................................................... 97
			Pump Device................................................................ 97
			Swing Motor................................................................101
		Group 2 Undercarriage..........................................................105
			Travel Motor...............................................................105
			Sprocket...................................................................107
			Front Idler................................................................109
			Upper Roller...............................................................111
			Lower Roller...............................................................112
			Track......................................................................113
		Group 3 Front Attachment.......................................................117
			Pin and Bushing............................................................117
			Side Cutter (2021232, 2021233).............................................119
			Point (4512365)............................................................120
			Standard Dimensions for Arm and Bucket Connection..........................121
			Standard Dimensions for Arm and Boom Connection............................122
			Cylinder...................................................................123
	SECTION 3 UPPERSTRUCTURE...........................................................127
		Group 1 Cab....................................................................129
			Removal and Installation of Cab............................................129
			Dimensions of Cab Glass....................................................157
		Group 2 Counterweight..........................................................177
			Removal and Installation of Counterweight..................................177
		Group 3 Main Frame.............................................................181
			Removal and Installation of Main Frame.....................................181
		Group 4 Engine.................................................................189
			Removal and Installation of Engine.........................................189
		Group 8 Pump Device............................................................219
			Removal and Installation of Pump Device....................................219
			Removal and Installation of Coupling.......................................231
			Disassembly of Pump Device.................................................233
			Assembly of Pump Device....................................................241
			Disassembly of Regulator...................................................253
			Assembly of Regulator......................................................255
			Disassembly of Solenoid Valve Unit.........................................257
			Assembly of Solenoid Valve Unit............................................259
			Structure of Pilot Pump....................................................261
		Group 9 Control Valve..........................................................263
			Removal and Installation of Control Valve..................................263
			Disassembly of Housing.....................................................289
			Assembly of Housing........................................................291
			Disassembly of Control Valve (A Side)......................................293
			Assembly of Control Valve (A Side).........................................301
			Disassembly of Control Valve (B Side)......................................313
			Assembly of Control Valve (B Side).........................................322
		Group 10 Swing Device..........................................................335
			Removal and Installation of Swing Device...................................335
			Disassembly of Swing Reduction Gear........................................339
			Assembly of Swing Reduction Gear...........................................345
			Disassembly of Swing Motor.................................................353
			Assembly of Swing Motor....................................................356
		Group 11 Pilot Valve...........................................................359
			Removal and Installation of Pilot Valve (Left).............................359
			Removal and Installation of Pilot Valve (Right)............................371
			Removal and Installation of Travel Pilot Valve.............................387
			Disassembly of Pilot Valves (Right and Left)...............................391
			Assembly of Pilot Valves (Right and Left)..................................394
			Disassembly of Travel Pilot Valve..........................................397
			Assembly of Travel Pilot Valve.............................................401
		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 2-Spool Solenoid Valve Unit....................415
			Disassembly of Pilot Shut-Off Solenoid Valve...............................419
			Assembly of Pilot Shut-Off Solenoid Valve..................................421
			Structure of 5-Spool Solenoid Valve Unit...................................423
			Structure of 2-Spool Solenoid Valve Unit...................................425
		Group 13 Signal Control Valve..................................................427
			Removal and Installation of Signal Control Valve...........................427
			Structure of Signal Control Valve..........................................431
		Group 14 Aftertreatment Device.................................................435
			Removal and Installation of Aftertreatment Device..........................435
		Group 15 DEF Tank..............................................................455
			Removal and Installation of DEF Tank.......................................455
		Group 16 Coolant Control Valve.................................................469
			Removal and Installation of Coolant Control Valve..........................469
		Group 17 DEF Supply Module.....................................................471
			Removal and Installation of DEF Supply Module..............................471
	SECTION 4 UNDERCARRIAGE............................................................477
		Group 1 Swing Bearing..........................................................479
			Removal and Installation of Swing Bearing..................................479
			Disassembly of Swing Bearing...............................................485
			Assembly of Swing Bearing..................................................488
		Group 2 Travel Device..........................................................491
			Removal and Installation of Travel Device..................................491
			Disassembly of Travel Device...............................................495
			Assembly of Travel Device..................................................499
			Disassembly of Travel Motor................................................507
			Assembly of Travel Motor...................................................510
			Disassembly of Brake Valve.................................................515
			Assembly of Brake Valve....................................................517
			Precautions for Using Floating Seal........................................519
		Group 3 Center Joint...........................................................521
			Removal and Installation of Center Joint...................................521
			Disassembly of Center Joint................................................525
			Assembly of Center Joint...................................................527
			Replacement of Body and Spindle............................................530
		Group 4 Track Adjuster.........................................................531
			Removal and Installation of Track Adjuster.................................531
			Disassembly of Front Idler.................................................535
			Assembly of Front Idler....................................................538
			Disassembly of Track Adjuster..............................................541
			Assembly of Track Adjuster.................................................545
			Precautions for Using Floating Seal........................................549
		Group 6 Upper and Lower Rollers................................................551
			Removal and Installation of Upper Roller...................................551
			Removal and Installation of Lower Roller...................................557
			Disassembly of Lower Roller................................................563
			Assembly of Lower Roller...................................................565
			Precautions for Using Floating Seal........................................567
		Group 7 Track..................................................................569
			Removal and Installation of Track..........................................569
	SECTION 5 FRONT ATTACHMENT.........................................................579
		Group 1 Front Attachment.......................................................581
			Removal and Installation of Front Attachment...............................581
		Group 2 Cylinder...............................................................591
			Removal and Installation of Boom Cylinder..................................591
			Removal and Installation of Arm Cylinder...................................599
			Removal and Installation of Bucket Cylinder................................607
			Removal and Installation of Positioning Cylinder...........................611
			Disassembly of Boom, Arm, and Bucket Cylinders.............................617
			Assembly of Boom, Arm, and Bucket Cylinders................................624
			Disassembly of Positioning Cylinder........................................631
			Assembly of Positioning Cylinder...........................................634
		Group 3 Hose Rupture Valve.....................................................637
			Removal and Installation of Hose Rupture Valve for Boom Cylinder...........637
			Removal and Installation of Hose Rupture Valve for Arm Cylinder............641
			Removal and Installation of Hose Rupture Valve for Positioning Cylinder....645
			Structure of Hose Rupture Valve for Boom Cylinder (Right)..................649
			Structure of Hose Rupture Valve for Boom Cylinder (Left)...................651
			Structure of Hose Rupture Valve for Arm Cylinder...........................653
			Structure of Hose Rupture Valve for Positioning Cylinder...................655
	SERVICE MANUAL REVISION REQUEST FORM...............................................659

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