PDF Workshop Manual Hitachi ZW220 & ZW250 Wheel Loader - 2 MB
This workshop manual provides complete service and repair information for the Hitachi ZW220 and ZW250 Wheel Loaders (EU Specification).
It is designed for technicians, offering detailed instructions for diagnostics, disassembly, repair, and reassembly of all machine systems.
Covering everything from the engine to the hydraulics, this manual is the definitive guide for maintaining the performance and reliability of these powerful Hitachi loaders.
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--- Page 3 ---
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
• Inappropriate engine starting procedures may cause
the machine to runaway, possibly resulting in seri-
ous injury or death.
• Start the engine only when seated in the opera-
tor's seat.
• NEVER start the engine while standing on the
track or on ground.
• Do not start engine by shorting across starter
terminals.
• Before starting the engine, confirm that all control
levers are in neutral.
• Before starting the engine, confirm the safety SA-431
around the machine and sound the horn to alert
bystanders.
012-E01B-0431
JUMP STARTING
• Battery gas can explode, resulting in serious injury.
• If the engine must be jump started, be sure to
follow the instructions shown in the “OPERATING
THE ENGINE” chapter in the operator’s manual.
• The operator must be in the operator’s seat so
that the machine will be under control when the
engine starts.
• Jump starting is a two-person operation.
• Never use a frozen battery.
• Failure to follow correct jump starting procedures
could result in a battery explosion or a runaway
machine.
SA-032
S013-E01A-0032 SA-032
SA-7
--- Page 4 ---
SAFETY
PROTECT AGAINST FLYING DEBRIS
• If flying debris hit eyes or any other part of the body,
serious injury may result.
• Guard against injury from flying pieces of metal or
debris; wear goggles or safety glasses.
• Keep bystanders away from the working area
before striking any object.
031-E01A-0432
SA-432
PARK MACHINE SAFELY
To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket to the ground.
• Place the F-N-R lever in neutral, and put the park
brake switch in the ON (parking brake) position.
• Run engine at slow idle speed without load for 5
minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Lower the lock lever to the LOCK position.
• Close windows, roof vent, and cab door.
• Lock all access doors and compartments. SA-456
033-E07B-0456
SA-17
--- Page 5 ---
SAFETY
AVOID HEATING NEAR PRESSURIZED
FLUID LINES
• Flammable spray can be generated by heating near
pressurized fluid lines, resulting in severe burns to
yourself and bystanders.
• Do not heat by welding, soldering, or using a torch
near pressurized fluid lines or other flammable
materials.
• Pressurized lines can be accidentally cut when
heat goes beyond the immediate flame area. In-
stall temporary fireresistant guards to protect
hoses or other materials before engaging in
SA-030
welding, soldering, etc..
AVOID APPLYING HEAT TO LINES CON-
TAINING FLAMMABLE FLUIDS
• Do not weld or flame cut pipes or tubes that con-
tain flammable fluids.
• Clean them thoroughly with nonflammable solvent
before welding or flame cutting them.
510-E01B-0030
REMOVE PAINT BEFORE WELDING OR
HEATING
• Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch. If
inhaled, these fumes may cause sickness.
• Avoid potentially toxic fumes and dust.
• Do all such work outside or in a well-ventilated
area. Dispose of paint and solvent properly.
• Remove paint before welding or heating:
1. If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
2. If you use solvent or paint stripper, remove strip-
per with soap and water before welding. Remove SA-029
solvent or paint stripper containers and other
flammable material from area. Allow fumes to
disperse at least 15 minutes before welding or
heating.
511-E01A-0029
SA-27
--- Page 6 ---
GENERAL / Precautions for Disassembling and Assembling
• Bleeding Air from Hydraulic Circuit
• After refilling hydraulic oil, start the engine. While
operating each cylinder, operate the machine
under light loads for 10 to 15 minutes. Slowly
start each operation (never fully stroke the cylin-
ders during initial operation stage). As the pilot oil
circuit has an air bleed device, air trapped in the
pilot oil circuit will be bled while performing the W4GB-01-01-001
above operation for approx. 5 minutes.
• Reposition the front attachment to check hydrau-
lic oil level.
• Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary.
W1-1-3
--- Page 7 ---
GENERAL / Tightening
PIPING JOINT 1 4 3 5 2
IMPORTANT: The torques given in the chart below
are for general use only.
Do not use these torques if a
different torque is given for a
specific application.
M202-07-051
Joint Body
Union Joint
Metal sealing surfaces (4) and (5) of adapter (1) and
hose (2) fit together to seal pressure oil. Union joints
are used to join small-diameter lines. 37°
30°
IMPORTANT: 1. Do not over-tighten nut (3).
Excessive force will be applied to
metal sealing surfaces (4) and (5),
possibly cracking adapter (1). Be Male Union Joint Female Union Joint
sure to tighten nut (3) to
specifications. W105-01-01-017
2. Scratches or other damage to
sealing surfaces (4) or (5) will
cause oil leakage at the joint.
Take care not to damage them
when connecting/disconnecting.
Wrench Size Wrench Size mm Tightening Torque
Description mm
Union Nut Joint Body N⋅m (kgf⋅m, lbf⋅ft)
37°female 17 14 24.5 (2.5, 18)
19 17 29.5 (3.0, 21.5)
22 19 39 (4.0, 28.5)
27 22 93 (9.5, 69)
32 27 137 (14.0, 101)
36 32 175 (18.0, 129)
NOTE: Tightening torque of 37°male coupling without union is similar
to tightening torque of 37°female.
W1-2-5
--- Page 8 ---
MEMO
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--- Page 9 ---
BODY (UPPERSTRUCTURE) / Cab
4. Connect hoses (49, 50) under cockpit (3).
Connect heater pipings (47, 48).
: 17 mm
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf·ft) Front 3
: 19 mm
: 29.4 N⋅m (3 kgf⋅m, 21.5 lbf·ft)
: 24 mm
: 39 N⋅m (4 kgf⋅m, 28.5 lbf·ft)
: 27 mm
: 78 N⋅m (8 kgf⋅m, 57.5 lbf·ft)
5. This machine uses new freon R134a as
refrigerant. Check for any gas leakage after
injecting gas for the required amount. 47
Type Refrigerant Q’ty 48
Number kg (lb)
HFC R134a 1.05±0.05
49
(2.32±0.11)
50
W4GB-02-01-012
6. Connect connectors (45, 46) of the wire harness
under the cab. 45
46
W4GB-02-01-011
7. Connect battery cable (44) to terminal minus of
battery (42) with bolt (43).
: 12 mm
: 10 N⋅m (1 kgf⋅m, 7.2 lbf·ft)
42
44 43
W4GB-02-01-010
W2-1-7
--- Page 10 ---
BODY (UPPERSTRUCTURE) / Center Hinge
Disassemble Center Hinge
2. Remove bolts (2) (ZW220 (3 used), ZW250 (4
CAUTION: The center hinge is required to
used)) and bolts (3) (ZW220 (4 used), ZW250 (6
disassemble for the major maintenance work used)) from flange (4) of the upper hinge part.
such as removal of the front frame from the Remove flange (4), shims (5) (2 used) and pin
rear frame. At this time, move the machine (22) from front frame (25).
into the factory. : 24 mm
Preparation 3. Remove bolt (11) and washers (12, 13) from pin
Carry out the following procedures before (14). Remove pin (14) from front frame (25).
disassembling the center hinge. : 24 mm
1. Remove the cab and the cockpit. 4. Remove bushing (6) from front frame (25).
(Remove bushing (6) after cutting by gas or
2. Remove the mounting component between the pulling out by welding a cardboard.)
front frame and the rear frame.
• Propeller Shaft CAUTION: Front frame (25) weight:
• Steering Cylinder ZW220: 1450 kg (3200 lb)
• Hydraulic Hose ZW250: 1910 kg (4250 lb)
• Brake Piping
• Wire Harness 5. Attach a nylon sling onto front frame (25). Hoist
and move front frame (25) so that bearing (10)
Removal of Hinge Pin can be removed.
1. Support the front frame and the rear frame by
using the firm support stands. 6. Remove bushing (20) from front frame (25).
7. Remove bolts (21) (6 used) from cap (19).
Remove caps (7, 19) and shim (8) from front
frame (25).
ZW220
: 17 mm
ZW250
: 24 mm
W4GB-02-03-002
8. Remove dust seals (9) (2 used) from caps (7, 19).
9. Remove bearing (10) from front frame (25).
W2-3-3
--- Page 11 ---
BODY (UPPERSTRUCTURE) / Hydraulic Oil Tank
REMOVAL AND INSTALLATION OF
HYDRAULIC OIL TANK 1
2
CAUTION: Hydraulic oil tank (5) weight:
ZW220: 165 kg (365 lb) 3
ZW250: 170 kg (375 lb)
4
Removal
1. Remove the hood. (Refer to W2-4-1.) 5
2. Remove the left and right side fenders.
: 17 mm
3. Remove bolts (1) (6 used) and washers (2) (6
used) from cover (3). Remove cover (3) and
suction filter (4) from hydraulic oil tank (5).
: 14 mm
4. Drain the hydraulic oil from the suction filter
mounting part of hydraulic oil tank (5) by using a
pump. W4GB-02-03-010
CAUTION: Drain the hydraulic oil from the
suction pipe at the bottom of hydraulic oil 6
tank (5). 5
CAUTION: Attach an identification tag onto
each hose connected to hydraulic oil tank (5)
for assembling.
5. Disconnect hose (6) from hydraulic oil tank (5).
: 22 mm
6. Disconnect hose (8) and remove O-ring (7) from
hydraulic oil tank (5).
: 36 mm
CAUTION: O-ring (7) cannot be reused.
7
9
7. Loosen hose clamps (9) (2 used). Disconnect 8
hose (10) from hydraulic oil tank (5) and pipe (11). 10
9
11
W4GB-02-03-011
W2-5-1
--- Page 12 ---
BODY (UPPERSTRUCTURE) / Pump Device
7. Disconnect hoses (15, 16) from pilot pump (14).
Cap the open ends.
: 27 mm, 36 mm 14
15
16
W4GB-02-04-018
8. Disconnect the connector of pump delivery
10
pressure switch (17) under priority valve (10).
17
W4GB-02-04-016
9. Remove socket bolts (18) (2 used) from pilot
pump (14). Remove pilot pump (14) from main 19
pump (6). 20
Remove reducer (20) from the regulator. Install 14
plug (19) (with eyebolt attached) (screw size G1,
wrench size 41 mm) to the regulator. 18
: 8 mm
: 41 mm 6
10. Attach a nylon sling onto eyebolt. Hoist and hold
main pump (6). Remove socket bolts (21) (4 used)
from main pump (6). Hoist and remove main
pump (6) from the engine.
21
: 10 mm
W4GB-02-04-017
W2-6-3
--- Page 13 ---
BODY (UPPERSTRUCTURE) / Pump Device
Disassembly of Main Pump
CAUTION: Pump device weight: 4. Place front casing (8) onto a wooden block of
ZW220: 83 kg (185 lb) more than 30 square mm (1.2 square in) with the
ZW250: 107 kg (240 lb) rotor (4) side facing upward.
1. Secure the pump device on a workbench with the
pilot pump side facing downward. IMPORTANT: The valve plate (3) side of rotor (4) is
a sliding surface. Do not damage the
sliding surface.
CAUTION: Front casing (8) weight: 5. Put a hand on retainer (18) and remove the rotor
ZW220: 36 kg (79.5 lb) (4) assembly from drive shaft (11). Place the rotor
ZW250: 48 kg (110 lb) (4) assembly with the valve plate side facing
downward.
2. Remove socket bolts (9) (8 used) from front
casing (8). 6. Put a hand under retainer (18) and remove
ZW220 retainer (18) with servo piston (17) together from
: 12 mm rotor (4).
ZW250
: 14 mm 7. Remove bushing (16), springs (15) (ZW220 (7
used), ZW250 (4 used)) from rotor (4).
IMPORTANT: Inner race (12) installed to drive
shaft (11) cannot be replaced. Do not 8. Remove plate (19) from swash plate (6).
damage inner race (12).
3. Remove the front casing (8) assembly from pump NOTE: By tapping the yoke part with plate (19)
casing (2). At this time, drive shaft (11), the rotor facing upward plate (19) is floated.
(4) assembly and restrictor pin (43) are removed
together with front casing (8). 9. Remove socket bolts (10) (4 used) from cradle
NOTE: When removing front casing (8), raise the plate (22). Remove cradle plate (22) from front
pump casing (2) side a little in order to casing (8).
prevent rotor (4) from falling off. : 6 mm
NOTE: Do not remove restrictor pin (43) unless
10. Remove drive shaft (11) with roller bearing (34)
necessary.
together from front casing (8) by hands.
Restrictor pin (43) may stay in pump casing
(2).
IMPORTANT: When removing retaining ring (32),
do not damage the seal lip surface of
drive shaft (11).
11. Remove retaining rings (32) (2 used) from drive
shaft (11).
12. Remove the roller and the outer ring of roller
bearing (34).
W2-6-13
--- Page 14 ---
BODY (UPPERSTRUCTURE) / Pump Device
Assembly of Regulator
IMPORTANT: Inner diameters of the two holes for 9. Install O-ring (24) and springs (21, 22) to the
sleeve on casing (9) are the same. stopper (23) assembly installed to cover (35).
The shapes of each part is similar. Install the cover (35) assembly to casing (9) with
Check the illustration when socket bolts (29) (4 used).
assembling. : 6 mm
: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf·ft)
1. Clean all parts and apply hydraulic oil.
IMPORTANT: Check the direction to install sleeve
(7) and spool (8).
2. Insert spool (8) into sleeve (7). Install the sleeve
(7) assembly to the center of casing (9) by using a
round bar.
3. Install O-ring (24) to cylinder (11).
4. Insert piston (6) into cylinder (11). Install the
cylinder (11) assembly to casing (9).
IMPORTANT: Check the direction to install sleeve
(20) and spool (19).
5. Insert spool (19) into sleeve (20). Install the
sleeve (20) assembly to the center of casing (9)
by using a round bar.
6. Install O-rings (14, 16) and backup ring (15) to
cylinder (18).
7. Insert piston (17) into cylinder (18). Install the
cylinder (18) assembly to casing (9).
8. Install O-ring (5) and piston (6) to the stopper (4)
assembly installed to cover (30). Install the cover
(30) assembly to casing (9) with socket bolts (29)
(4 used).
: 6 mm
: 19.5 N⋅m (2 kgf⋅m, 14.5 lbf·ft)
W2-6-23
--- Page 15 ---
BODY (UPPERSTRUCTURE) / Control Valve
Removal (ZW220)
5. Disconnect hoses (2, 4) from control valve (5).
CAUTION: Bleed air from the hydraulic oil
Cap the open ends.
tank before doing any work. (Refer to BLEED : 41 mm
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)
CAUTION: Attach an identification tag onto 6. Disconnect hoses (16, 17) from control valve (5).
the disconnected hose and the pipe for Cap the open ends.
assembling. : 36 mm, 41 mm
1. Remove sems bolts (27) (4 used) from cover (28). 7. Disconnect hoses (18, 19, 20, 21, 22, 23 and 24)
Remove cover (28) from front frame (29). from control valve (5). Cap the open ends.
: 14 mm : 19 mm, 22 mm
28 CAUTION: Control valve (5) weight: 41 kg
29
27 (90.5 lb)
8. Remove socket bolts (25) (3 used) from control
valve (5).
: 10 mm
9. Attach a nylon sling onto control valve (5). Hoist
and remove control valve (5) from front frame
(29).
W4GB-02-05-022
2. Remove sems bolt (8) from clamp (9). Remove
clamp (9) from piping (7).
: 17 mm
3. Remove sems bolt (12) from clamp (13). Remove
clamp (13) from piping (11).
: 17 mm
4. Remove pipings (7, 11) from control valve (5).
Cap the open ends.
: 35 mm
W2-7-3
--- Page 16 ---
BODY (UPPERSTRUCTURE) / Control Valve
Disassembly of Control Valve (ZW220) 7. Slowly turn and remove spools (33, 36) from
housing (31).
1. Remove plug (10) from housing (31).
: 17 mm 8. Secure spools (33, 36) in a vise by using wooden
pieces as illustrated.
2. Remove plug (13) from housing (31). Remove
poppet (15) and spring (14) from housing (31).
Remove O-ring (4) from plug (13).
: 36 mm
3. Remove relief valve (29) from housing (31).
: 32 mm
CAUTION: Attach a spanner onto the
hexagonal part of the relief valve case. W4GB-02-05-002
4. Remove socket bolts (11) (6 used) from pilot 9. Remove bolt (26) from spool (36). Remove spring
housings (38) (2 used), pilot housing (25). seat (20), spring (27) and spring seat (20) from
Remove pilot housing (25) and pilot housing (38) spool (36).
(2 used) from housing (31). : 19 mm
: 8 mm
10. Remove bolt (22) from spool (33). Remove spring
5. Remove socket bolts (23) (2 used) from pilot seat (20), spring (21), and spring seat (20) from
housing (24). Remove pilot housing (24) from pilot spool (33).
housing (28). : 19 mm
: 8 mm
11. Remove plug (37) from spool (33). Remove
6. Remove O-rings (12) (4 used) from pilot housings O-ring (32) from plug (37).
(24, 25) and pilot housings (38) (2 used). : 8 mm
12. Remove socket bolts (11) (3 used) from pilot
housing (28). Remove pilot housing (28).
: 8 mm
13. Remove O-rings (12, 18) and backup ring (19)
from pilot housing (28).
14. Remove spring (17) and poppet (16) from housing
(31).
W2-7-13
--- Page 17 ---
BODY (UPPERSTRUCTURE) / Control Valve
Disassembly of Control Valve (ZW250)
• Put the matching marks on the spools for 8. Remove the anti-void valve (34) assembly from
assembling. housing (32).
: 32 mm
1. Remove socket bolts (23) (4 used) from caps (22,
24). Remove caps (22, 24) from housing (32). 9. Remove socket bolts (1) (4 used) from flange (2).
: 5 mm Remove flange (2), spring (4), poppet (5), and
O-ring (3) from housing (32).
2. Remove O-rings (18) (2 used) from housing (1). : 5 mm
CAUTION: Turn and remove spools (35, 38) 10. Remove socket bolts (11) (4 used) from body (12).
slowly. If the spools stick even a little, try Remove body (12), spacer (14), spring (15),
again instead of pulling roughly. poppet (16), and O-rings (3, 13) from housing
Put the matching marks on spools (35, 38) (32).
corresponding to the matching marks on : 5 mm
housing (32) in order not to be confused.
11. Remove socket bolts (6) (2 used) from flange (7).
3. Remove the spools (35, 38) assemblies from Remove flange (7), spring (9), poppet (10), and
housing (32). O-ring (8) from housing (32).
: 5 mm
4. Remove the relief valve (28) assembly from
housing (30). 12. Remove socket bolts (29) (4 used) from housing
: 38 mm (30). Remove cover (30) and O-ring (31) from
housing (32).
5. Remove the relief valve (27) assemblies (2 used) : 12 mm
from housing (32).
: 32 mm 13. Remove socket bolts (23) (4 used) from covers
(37) (2 used). Remove caps (37) (2 used),
6. Remove the relief valve (33) assembly from spacers (36) (2 used), and O-rings (18) (2 used)
housing (32). from housing (32).
: 38 mm : 5 mm
7. Remove the relief valve (17) assembly from