Hitachi ZX240-5G ZX240LC-5G ZX250H-5G ZX250LCH-5G Hydraulic Excavator Operational Principle Manual
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Hitachi ZX240-5G ZX240LC-5G ZX250H-5G ZX250LCH-5G Hydraulic Excavator Operational Principle Manual
- Manual Language:English
- Pages:348
- Size: 13.0 MB
- Downloadable:Yes
- Format:PDF
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Description:
Hitachi ZX240-5G ZX240LC-5G ZX250H-5G ZX250LCH-5G Hydraulic Excavator Operational Principle 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 ZX240-5G ZX240LC-5G ZX250H-5G ZX250LCH-5G Hydraulic Excavator Operational Principle Manual
TODCE-EN-00................................................................................................................................................................ 1 INTRODUCTION............................................................................................................................................................... 3 SYMBOL AND ABBREVIATION.................................................................................................................................................... 5 SECTION AND GROUP CONTENTS................................................................................................................................................. 7 SECTION 1 GENERAL.......................................................................................................................................................... 9 Group 1 Specifications................................................................................................................................................. 11 Specifications..................................................................................................................................................... 11 Specifications..................................................................................................................................................... 12 Working Ranges (Grouser shoe)...................................................................................................................................... 13 Working Ranges (Grouser shoe)...................................................................................................................................... 14 Group 2 Component Layout............................................................................................................................................... 15 Main Component..................................................................................................................................................... 15 Electrical System (Overview)....................................................................................................................................... 16 Engine............................................................................................................................................................. 17 Electrical System (In Cab)......................................................................................................................................... 17 Electrical System (Rear Tray)...................................................................................................................................... 18 Electrical System (Switch Panel)................................................................................................................................... 19 Electrical System (Around Air Cleaner)............................................................................................................................. 20 Electrical System (Relays)......................................................................................................................................... 21 Pump Device........................................................................................................................................................ 22 Control Valve...................................................................................................................................................... 23 Signal Control Valve............................................................................................................................................... 23 Swing Device....................................................................................................................................................... 25 Travel Device...................................................................................................................................................... 25 3-Spool Solenoid Valve Unit........................................................................................................................................ 26 Layout of Attachment Spec. Parts................................................................................................................................... 28 Group 3 Component Specifications....................................................................................................................................... 33 Engine............................................................................................................................................................. 33 Engine Accessories................................................................................................................................................. 37 Hydraulic Component................................................................................................................................................ 38 Electrical Component............................................................................................................................................... 42 SECTION 2 SYSTEM........................................................................................................................................................... 45 Group 1 Controller..................................................................................................................................................... 47 Outline............................................................................................................................................................ 47 CAN Circuit........................................................................................................................................................ 48 Group 2 Control System................................................................................................................................................. 51 Outline............................................................................................................................................................ 51 Engine Control..................................................................................................................................................... 54 Pump Control....................................................................................................................................................... 80 Valve Control...................................................................................................................................................... 90 Other Control......................................................................................................................................................106 Group 3 Hydraulic System...............................................................................................................................................111 Outline............................................................................................................................................................111 Pilot Circuit......................................................................................................................................................112 Main Circuit.......................................................................................................................................................122 Group 4 Electrical System..............................................................................................................................................137 Outline............................................................................................................................................................137 Main Circuit.......................................................................................................................................................138 Electric Power Circuit (Key Switch: OFF)...........................................................................................................................140 CAN Circuit........................................................................................................................................................142 Accessory Circuit..................................................................................................................................................144 Preheating Circuit (Key Switch: ON, START).........................................................................................................................146 Starting Circuit (Key Switch: START)...............................................................................................................................148 Charging Circuit (Key Switch: ON)..................................................................................................................................152 Surge Voltage Prevention Circuit...................................................................................................................................156 Pilot Shut-Off Circuit (Key switch: ON)............................................................................................................................158 Engine Stop Circuit................................................................................................................................................160 Monitor Circuit....................................................................................................................................................163 Security Circuit...................................................................................................................................................164 Radio Circuit......................................................................................................................................................166 Air Conditioner Circuit............................................................................................................................................166 Accessory Circuit..................................................................................................................................................169 Work Light Circuit.................................................................................................................................................170 Wiper/Washer Circuit...............................................................................................................................................172 Cab Light Circuit..................................................................................................................................................174 SECTION 3 COMPONENT OPERATION..............................................................................................................................................179 Group 1 Pump Device....................................................................................................................................................181 Outline............................................................................................................................................................181 Main Pump..........................................................................................................................................................182 Regulator..........................................................................................................................................................186 Solenoid Valve.....................................................................................................................................................204 Pilot Pump.........................................................................................................................................................206 Pump Delivery Pressure Sensor......................................................................................................................................206 Pump Control Pressure Sensor.......................................................................................................................................206 N Sensor (Engine Speed Sensor).....................................................................................................................................207 Group 2 Swing Device...................................................................................................................................................209 Outline............................................................................................................................................................209 Swing Reduction Gear...............................................................................................................................................210 Swing Motor........................................................................................................................................................211 Swing Parking Brake................................................................................................................................................212 Valve Unit.........................................................................................................................................................214 Group 3 Control Valve..................................................................................................................................................217 Outline............................................................................................................................................................217 Hydraulic Circuit..................................................................................................................................................238 Flow Combiner Valve................................................................................................................................................244 Main Relief Valve..................................................................................................................................................246 Overload Relief Valve (with Make-Up Function)......................................................................................................................250 Regenerative Valve.................................................................................................................................................254 Anti-Drift Valve...................................................................................................................................................258 Flow Rate Control Valve............................................................................................................................................262 Digging Regenerative Valve.........................................................................................................................................266 Boom Lower Meter-In Cut Valve......................................................................................................................................268 Auxiliary Flow Combiner Valve and Bypass Shut-Out Valve............................................................................................................270 Group 4 Pilot Valve....................................................................................................................................................275 Outline............................................................................................................................................................275 Operation (Front Attachment / Swing and Travel Pilot Valves).......................................................................................................277 Operation (Auxiliary Pilot Valve)..................................................................................................................................285 Shockless Function (Only for Travel Pilot Valve)...................................................................................................................290 Group 5 Travel Device..................................................................................................................................................291 Outline............................................................................................................................................................291 Travel Reduction Gear..............................................................................................................................................292 Travel Motor.......................................................................................................................................................294 Parking Brake......................................................................................................................................................296 Travel Brake Valve.................................................................................................................................................298 Overload Relief Valve..............................................................................................................................................302 Travel Mode Control................................................................................................................................................304 Group 6 Signal Control Valve...........................................................................................................................................309 Outline............................................................................................................................................................309 Pilot Port.........................................................................................................................................................310 Shuttle Valve......................................................................................................................................................315 Shockless Valve....................................................................................................................................................318 Pump 1 and 2 Flow Rate Control Valve...............................................................................................................................322 Bucket Flow Rate Control Valve Control Spool, Flow Combiner Valve Control Spool, Swing Parking Brake Release Spool, Arm 1 Flow Rate Control Valve Control Spool....324 Group 7 Others (Upperstructure)........................................................................................................................................327 Pilot Shut-Off Solenoid Valve......................................................................................................................................327 Solenoid Valve.....................................................................................................................................................329 Pilot Relief Valve.................................................................................................................................................332 EC Motor...........................................................................................................................................................332 Hose Rupture Valve.................................................................................................................................................334 Group 8 Others (Undercarriage).........................................................................................................................................341 Swing Bearing......................................................................................................................................................341 Center Joint.......................................................................................................................................................342 Track Adjuster (Front Idler Integrated Type).......................................................................................................................343 SERVICE MANUAL REVISION REQUEST FORM.......................................................................................................................................347
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