Hitachi ZX240-5A , ZX240LC-5A , ZX250H-5A , ZX250LCH-5A , ZX250K-5A , ZX250LCK-5A Hydraulic Excavator Service Repair Manual
File Details:
Hitachi ZX240-5A , ZX240LC-5A , ZX250H-5A , ZX250LCH-5A , ZX250K-5A , ZX250LCK-5A Hydraulic Excavator Service Repair Manual
- Manual Language:English
- Pages: 1500+
- Size: 5.57 MB
- Downloadable:Yes
- Format:PDF
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Description:
Hitachi ZX240-5A , ZX240LC-5A , ZX250H-5A , ZX250LCH-5A , ZX250K-5A , ZX250LCK-5A Hydraulic Excavator Service Repair Manual
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 ZX240-5A , ZX240LC-5A , ZX250H-5A , ZX250LCH-5A , ZX250K-5A , ZX250LCK-5A Hydraulic Excavator Service Repair Manual
WDCY-EN-00........................................................... 1 INTRODUCTION......................................................... 3 SYMBOL AND ABBREVIATION.............................................. 5 SAFETY............................................................... 7 SECTION AND GROUP CONTENTS........................................... 47 SECTION 1 GENERAL.................................................... 49 Group 1 Precautions for Disassembling and Assembling............. 51 Precautions for Disassembling and Assembling................. 51 Group 2 Tightening............................................... 57 Tightening Bolts and Nuts.................................... 57 Piping Joint................................................. 60 Group 3 Painting................................................. 65 Painting..................................................... 65 Group 4 Bleeding Air............................................. 67 Bleeding Air from Hydraulic Oil Tank......................... 67 Bleeding Air from Hydraulic System........................... 68 Bleeding Air from Fuel System................................ 69 Bleeding Air from Radiator................................... 71 Group 5 Pressure Release Procedure............................... 73 Hydraulic Circuit Pressure Release Procedure................. 73 Group 6 Preparation.............................................. 75 Preparation before Inspection and Maintenance................ 75 SECTION 2 MAINTENANCE STANDARD....................................... 79 Group 1 Upperstructure........................................... 81 Pump Device.................................................. 81 Swing Motor.................................................. 85 Group 2 Undercarriage............................................ 89 Travel Motor................................................. 89 Sprocket..................................................... 91 Front Idler.................................................. 93 Upper Roller................................................. 95 Lower Roller................................................. 96 Track........................................................ 97 Group 3 Front Attachment.........................................101 Pin and Bushing..............................................101 Side Cutter (2021232, 2021233)...............................103 Point (4512365)..............................................104 Standard Dimensions for Arm and Bucket Connection............105 Standard Dimensions for Arm and Boom Connection..............106 Cylinder.....................................................107 SECTION 3 UPPERSTRUCTURE.............................................111 Group 1 Cab......................................................113 Removal and Installation of Cab..............................113 Dimensions of Cab Glass......................................139 Group 2 Counterweight............................................159 Removal and Installation of Counterweight....................159 Group 3 Main Frame...............................................161 Removal and Installation of Main Frame.......................161 Group 4 Engine...................................................169 Removal and Installation of Engine...........................169 Group 8 Pump Device..............................................199 Removal and Installation of Pump Device......................199 Removal and Installation of Coupling.........................215 Disassembly of Pump Device...................................217 Assembly of Pump Device......................................224 Disassembly of Regulator.....................................235 Assembly of Regulator........................................237 Disassembly of Solenoid Valve................................239 Assembly of Solenoid Valve...................................241 Structure of Pilot Pump......................................243 Group 9 Control Valve............................................245 Removal Installation of Control Valve........................245 Disassembly of Housing.......................................267 Assembly of Housing..........................................269 Disassembly of Control Valve (4-Spool Side)..................271 Assembly of Control Valve (4-Spool Side).....................278 Disassembly of Control Valve (5-Spool Side)..................289 Assembly of Control Valve (5-Spool Side).....................296 Group 10 Swing Device............................................305 Removal and Installation of Swing Device.....................305 Disassembly of Swing Device..................................309 Assembly of Swing Device.....................................314 Disassembly of Swing Motor...................................321 Assembly of Swing Motor......................................324 Group 11 Pilot Valve.............................................327 Removal and Installation of Pilot Valve (Left)...............327 Removal and Installation of Pilot Valve (Right)..............333 Removal and Installation of Travel Pilot Valve...............341 Disassembly of Pilot Valves (Right and Left).................345 Assembly of Pilot Valves (Right and Left)....................348 Disassembly of Travel Pilot Valve............................351 Assembly of Travel Pilot Valve...............................355 Group 12 Solenoid Valve..........................................361 Removal and Installation of Pilot Shut-Off Solenoid Valve....361 Removal and Installation of 3-Spool Solenoid Valve Unit......365 Disassembly of Pilot Shut-Off Solenoid Valve.................371 Assembly of Pilot Shut-Off Solenoid Valve....................373 Structure of 3-Spool Solenoid Valve Unit.....................375 Group 13 Signal Control Valve....................................377 Removal and Installation of Signal Control Valve.............377 Structure of Signal Control Valve............................381 SECTION 4 UNDERCARRIAGE..............................................385 Group 1 Swing Bearing............................................387 Removal and Installation of Swing Bearing....................387 Disassembly of Swing Bearing.................................391 Assembly of Swing Bearing....................................394 Group 2 Travel Device............................................397 Removal and Installation of Travel Device....................397 Disassembly of Travel Device.................................401 Assembly of Travel Device....................................405 Disassembly of Travel Motor..................................413 Assembly of Travel Motor.....................................416 Disassembly of Brake Valve...................................421 Assembly of Brake Valve......................................423 Precautions for Using Floating Seal..........................425 Group 3 Center Joint.............................................427 Removal and Installation of Center Joint.....................427 Disassembly of Center Joint..................................431 Assembly of Center Joint.....................................433 Replacement of Body and Spindle..............................436 Group 4 Track Adjuster...........................................437 Removal and Installation of Track Adjuster...................437 Disassembly of Front Idler...................................441 Assembly of Front Idler......................................444 Disassembly of Track Adjuster................................447 Assembly of Track Adjuster...................................451 Precautions for Using Floating Seal..........................455 Group 5 Upper and Lower Rollers..................................457 Removal and Installation of Upper Roller.....................457 Removal and Installation of Lower Roller.....................461 Disassembly of Lower Roller..................................467 Assembly of Lower Roller.....................................469 Precautions for Using Floating Seal..........................471 Group 6 Track....................................................473 Removal and Installation of Track............................473 SECTION 5 FRONT ATTACHMENT...........................................481 Group 1 Front Attachment.........................................483 Removal and Installation of Front Attachment.................483 Group 2 Cylinder.................................................491 Removal and Installation of Boom Cylinder....................491 Removal and Installation of Arm Cylinder.....................495 Removal and Installation of Bucket Cylinder..................501 Disassembly of Boom, Arm, and Bucket Cylinders...............505 Assembly of Boom, Arm, and Bucket Cylinders..................509 SERVICE MANUAL REVISION REQUEST FORM.................................515
Please Note:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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