Hitachi ZW250-5B Wheel Loader Repair Manuals

Service Repair Manual (Troubleshooting) : Vol. No.TTNEC-EN0 (514 Pages)
Operation Manual : Vol. No.TONEC-EN (455 Pages)
Workshop Manual : Vol. No.WNEC-EN (788 Pages)
Circuit diagram: 22 Pages
Hitachi ZW250-5B Wheel Loader Service Manual
The manual is applicable for the Hitachi ZW250-5B Wheel Loader Model
Service Manual consists of the following:
For Model ZW250-5B as mentioned above:
Service Manual (Troubleshooting) : Vol. No.TTNEC-EN0 (514 Pages)

Table of Content of the Workshop Manual

SECTION 1 GENERAL INFORMATION

Group 1 Precautions for Disassembling and
Assembling
Group 2 Tightening
Group 3 Painting
Group 4 Bleeding Air
Group 5 Pressure Release Procedure
Group 6 Preparation

SECTION 2 MAINTENANCE STANDARD

Group 1 Body
Group 2 Front Attachment

SECTION 3 BODY

Group 1 Cab
Group 2 Counterweight
Group 3 Center Hinge
Group 4 Engine
Group 5 Radiator Assembly
Group 6 Hydraulic Oil Tank
Group 7 Fuel Tank
Group 8 Pump Device
Group 9 Control Valve
Group 10 Pilot Valve
Group 11 Brake Charge Valve
Group 12 Manifold Valve
Group 13 Solenoid Valve
Group 14 Flow Regulator Valve
Group 15 Cooling Fan System
Group 16 Muffler Filter
Group 17 Ride Control Accumulator
Group 18 Battery Disconnect Switch

Table of Content of the Technical Manual

SECTION 4 OPERATIONAL

PERFORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Machine Performance Test
Group 5 Component Test
Group 6 Adjustment

SECTION 5 TROUBLESHOOTING

Group 1 Diagnosing Procedure
Group 2 Monitor
Group 3 e-Service
Group 4 Component Layout
Group 5 Troubleshooting A
Group 6 Troubleshooting B
Group 7 Air Conditioner

Table of Content of the Operation Manual

SECTION 1 GENERAL

Group 1 Specifications
Group 2 Component Layout
Group 3 Component Specifications

SECTION 2 SYSTEM

Group 1 Controller
Group 2 Control System
Group 3 ECM System
Group 4 Hydraulic System
Group 5 Electrical System

SECTION 3 COMPONENT OPERATION

Group 1 Pump Device
Group 2 Control Valve
Group 3 Cooling Fan System
Group 4 Steering Pilot Valve
Group 5 Steering Valve
Group 6 Pilot Valve
Group 7 Charging Circuit
Group 8 Drive Unit
Group 9 Axle
Group 10 Brake Valve
Group 11 Others
Composition
Hitachi ZAXIS ZW250-5B service manual consists of the Troubleshooting and the Workshop Manual.

Information included in the Service 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.

Muffler Filter Regenerative Control

The muffler filter regenerative control burns PM which deposits in filter (CSF) (5) by using the exhaust gas and removes it. This is Regeneration. The regeneration of the muffler filter consists of own regeneration and mandatory regeneration. The mandatory regeneration consists of auto regeneration and manual regeneration. (Refer to SYSTEM / Control System.)

Own Regeneration
1. The own regeneration regenerates by using the high-temperature-exhaust gas without the diesel oxidation catalyst (DOC) (6) function.
2. A catalyst is activated in case the exhaust temperature of the inlet of filter (5) is higher. Then, regeneration amount increases.
– Mandatory Regeneration
1. Fuel is injected (post injection (11)) to exhaust gas which burns in engine cylinder (7) and exhaust gas mixed with unburnt fuel is supplied to diesel oxidation catalyst (6).
2. Diesel oxidation catalyst (6) oxidizes unburnt fuel and raises exhaust temperature.
3. Therefore, exhaust temperature of the inlet of filter (5) raises up to about 580 to 600 C and regeneration is carried out.

NOTE: When exhaust temperature before filter (5) is 250 C or more, post injection (11) is carried out. When exhaust temperature before filter (5) is 250 C or less, multi-injection (10) is carried out and raises exhaust temperature. Multi-injection (10) is carried out when coolant temperature is 70 C or more.

Auto Regeneration:
– The mandatory regeneration is automatically carried out in 8 hours after the last regeneration. (Time Regeneration)
– The mandatory regeneration is automatically carried out when the output from differential pressure sensor (4) is beyond the fixed value before 8 hours after the last regeneration.
(Differential Pressure Regeneration)
Manual Regeneration:

– When Muffler Filter Regeneration Request is displayed on the monitor, the regeneration is manually carried out by not operating the accelerator pedal (setting the engine speed at slow idle speed), activating control lever lock switch, setting the forward/reverse lever to the neutral position, applying the parking brake, and setting the muffler filter regeneration switch to the regeneration position.