Hitachi ZH210-6, ZH210LC-6 Hybrid Excavator WDFX50-EN-00 (Preview)
WDFX50-EN-00
CONTENTS
INTRODUCTION
To The Reader
Additional References
Manual Composition
Page Number
Trademark
Safety Alert Symbol and Headline Notations
Units Used
SYMBOL AND ABBREVIATION
SAFETY
Recognize Safety Information
Understand Signal Words
Follow Safety Instructions
Prepare for Emergencies
Wear Protective Clothing
Protect Against Noise
Inspect Machine
General Precautions for the Cab
Use Handholds and Steps
Adjust the Operator’s Seat
Ensure Safety Before Rising from or Leaving Operator’s Seat
Fasten Your Seat Belt
Move and Operate Machine Safely
Operate Only from Operator’s Seat
Jump Starting
Keep Riders off Machine
Precautions for Operations
Investigate Job Site Beforehand
Install OPG Guard
Restriction of Attachment Installation
Provide Signals for Jobs Involving Multiple Machines
Confirm Direction of Machine to Be Driven
Drive Machine Safely
Avoid Injury from Rollaway Accidents
Avoid Injury from Back-Over and Swing Accidents
Keep People Clear from Working Area
Never Position the Bucket Over Anyone
Avoid Undercutting
Avoid Tipping
Never Undercut a High Bank
Dig with Caution
Operate with Caution
Avoid Power Lines
Precautions for Lightning
Object Handling
Protect Against Flying Debris
Park Machine Safely
Handle Fluids Safely−Avoid Fires
Transport Safely
Practice Safe Maintenance
Warn Others of Service Work
Support Machine Properly
Stay Clear of Moving Parts
Prevent Parts from Flying
Avoid Injury from Attachment Falling Accident
Prevent Burns
Replace Rubber Hoses Periodically
Avoid High-Pressure Fluids
Prevent Fires
Evacuating in Case of Fire
Beware of Exhaust Fumes
Precautions for Welding and Grinding
Avoid Heating Near Pressurized Fluid Lines
Avoid Applying Heat to Lines Containing Flammable Fluids
Precautions for Handling Accumulator and Gas Damper
Remove Paint Before Welding or Heating
Beware of Asbestos and Silica Dust and Other Contamination
Prevent Battery Explosions
Service Air Conditioning System Safely
Handle Chemical Products Safely
Dispose of Waste Properly
Never Ride Attachment
Notes for Muffler Filter
Precautions for Communication Terminal
Precautions for Communication Terminal Equipment
Notes on Protection of Operator’s Station when the Machine Rolls Over
Warnings about the Hybrid Shovel
SAFETY SIGNS
Before Returning the Machine to the Customer
SECTION AND GROUP CONTENTS
SECTION 1 GENERAL
Group 1 Precautions for Disassembling and Assembling
Precautions for Disassembling and Assembling
Group 2 Tightening
Tightening Bolts and Nuts
Piping Joint
Group 3 Painting
Painting
Group 4 Air Bleeding
Bleeding Air from Hydraulic System
Bleeding Air from Fuel System
Group 5 Preparation
Preparation before Inspection and Maintenance
Hydraulic Circuit Pressure Release Procedure
Pressure Release from Hydraulic Oil Tank
Pressure Release from Expansion Tank
Pressure Release from radiator (for hybrid systems)
Precautions for Inspection and Maintenance
Instructions for Disconnecting Connectors
Group 6 Precautions for the Hybrid System
Hybrid Component Inspection
Precautions for Inspection and Maintenance
Voltage Detection
Appearance Check
Ground check
Removal and installation of lithium-ion battery disconnect switch
How to Connect/Disconnect of Power Connector
How to Disconnect Control Connector
SECTION 2 MAINTENANCE STANDARDS
Group 1 Upper structure
Pump Device
Swing Hydraulic Motor
Group 2 Undercarriage
Travel Motor
Sprocket
Front Idler
Upper Roller
Lower Roller
Track
Group 3 Front Attachment
Pin and Bushing
Side Cutter (2014503, 2014504)
Point (4427919)
Standard Dimensions for Arm and Bucket Connection
Standard Dimensions for Arm and Boom Connection
Cylinder
SECTION 3 UPPER STRUCTURE
Group 1 Cab
Removal and Installation of the cab
Dimensions of Cab Glass
Group 2 Counterweights
Removal and Installation of Counterweights
Group 3 Main Frame
Removal and Installation of Main Frame
Group 4 Engine
Removal and Installation of the Engine
Removal and Installation of Timing Belt Cover
Group 8 Pump Device
Removal and Installation of Pump Device
Removal and Installation of Coupling
Disassembly of Pump Device
Assembly of Pump Device
Disassembly of Regulator
Assembly of Regulator
Disassembly of Solenoid Valve Unit
Assembly of Solenoid Valve Unit
Structure of Pilot Pump
Group 9 Control Valve
Removal and Installation of Control Valve
Disassembly of Housing
Assembly of Housing
Disassembly of Control Valve (A side)
Assembly of Control Valve (A side)
Disassembly of Control Valve (B side)
Assembly of Control Valve (B side)
Group 10 Swing Device
Removal and Installation of Swing Device
Disassembly of Swing Device
Assembly of Swing Device
Disassembly of Swing Reduction Gear
Assembly of Swing Reduction Gear
Disassemble of Swing Hydraulic Motor
Assembly of Swing Hydraulic Motor
Group 11 Pilot Valve
Removal and Installation of Pilot Valve (Left)
Removal and Installation of Pilot Valve (Right)
Removal and Installation of Travel Pilot Valve
Disassembly of Pilot Valves (Right and Left)
Assembly of Pilot Valves (Right and Left)
Disassembly of Travel Pilot Valve
Assembly of Travel Pilot Valve
Group 12 Solenoid Valve
Removal and Installation of Pilot Shut-Off Solenoid Valve
Removal and Installation of the 5-spool Solenoid Valve Unit
Removal and Installation of 3-spool Solenoid Valve
Disassembly of Pilot Shut-Off Solenoid Valve
Assembly of Pilot Shut-Off Solenoid Valve
Structure of 5-Spool Solenoid Valve Unit
Structure of 3-spool Solenoid Valve Unit
Group 13 Signal Control Valve
Removal and Installation of Signal Control Valve
Structure of Signal Control Valve
Group 14 Muffler Filter
Removal and Installation of Muffler Filter
SECTION 4 UNDERCARRIAGE
Group 1 Swing Bearing
Removal and Installation of Swing Bearing
Disassembly of Swing Bearing
Assembly of Swing Bearing
Group 2 Travel Device
Removal and Installation of Travel Device
Disassembly of Travel Device
Assembly of Travel Device
Disassembly of Travel Motor
Assembly of Travel Motor
Disassembly of Brake Valve
Assembly of Brake Valve
Precautions for Using Floating Seal
Group 3 Center Joint
Removal and Installation of Center Joint
Disassembly of Center Joint
Assembly of Center Joint
Replacement of Body and Spindle
Group 4 Track Adjuster
Removal and Installation of Track Adjuster
Disassembly of Front Idler
Assembly of Front Idler
Disassembly of Track Adjuster
Assembly of Track Adjuster
Precautions for Using Floating Seal
Group 6 Upper and Lower Rollers
Removal and Installation of Upper Roller
Removal and Installation of Lower Roller
Disassembly of Lower Roller
Assembly of Lower Roller
Precautions for Using Floating Seal
Group 7 Track
Removal and Installation of Track
SECTION 5 FRONT ATTACHMENT
Group 1 Front Attachment
Removal and Installation of Front Attachment
Group 2 Cylinder
Removal and Installation of Boom Cylinder
Removal and Installation of Arm Cylinder
Removal and Installation of Bucket Cylinder
Disassembly of Boom, Arm, and Bucket Cylinders
Assembly of Boom, Arm, and Bucket Cylinders
SECTION 6 HYBRID
Group 1 PCU
Removal and Installation of PCU
Group 2 Lithium Ion Battery Unit
Removal and Installation of Lithium Ion Battery Unit
Group 3 Solenoid Valve
Removal and Installation of Swing Control Solenoid Valve Unit
Structure of Swing Control Solenoid Valve Unit
Group 4 Relief Valve
Removal and Installation of Swing Low-Pressure Relief Valve Unit
Structure of Swing Low-Pressure Relief Valve Unit
SERVICE MANUAL REVISION REQUEST FORM
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