Hitachi ZX240-5G ZX240LC-5G ZX250H-5G ZX250LCH-5G Hydraulic Excavator Workshop Manual (WDCE-EN-00)
File Details:
Hitachi ZX240-5G ZX240LC-5G ZX250H-5G ZX250LCH-5G Hydraulic Excavator Workshop Manual (WDCE-EN-00)
- Manual Language:English
- Pages: 502
- Size:7.23 MB
- Downloadable:Yes
- Format:PDF
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Description:
Hitachi ZX240-5G ZX240LC-5G ZX250H-5G ZX250LCH-5G Hydraulic Excavator Workshop Manual (WDCE-EN-00)
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 Workshop Manual (WDCE-EN-00)
WDCE-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 andAssembling.................. 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 3UPPERSTRUCTURE..............................................111 Group 1 Cab......................................................113 Removal and Installation of Cab..............................113 Dimensions of Cab Glass......................................129 Group 2 Counterweight............................................149 Removal and Installation of Counterweight....................149 Group 3 Main Frame...............................................151 Removal and Installation of Main Frame.......................151 Group 4 Engine...................................................157 Removal and Installation of Engine...........................157 Group 5 Radiator Assembly........................................175 Replacement of Radiator, Oil Cooler, and Intercooler.........175 Group 6 Hydraulic Oil Tank.......................................187 Removal and Installation of Hydraulic Oil Tank...............187 Group 7 Fuel Tank................................................195 Removal and Installation of Fuel Tank........................195 Group 8 Pump Device..............................................203 Removal and Installation of Pump Device......................203 Removal and Installation of Coupling.........................209 Disassembly of Pump Device...................................211 Assembly of Pump Device......................................218 Disassembly of Regulator.....................................229 Assembly of Regulator........................................231 Disassembly of Solenoid Valve................................233 Assembly of Solenoid Valve...................................235 Structure of Pilot Pump......................................237 Group 9 Control Valve............................................239 Removal Installation of Control Valve........................239 Disassembly of Housing.......................................253 Assembly of Housing..........................................255 Disassembly of Control Valve (4-Spool Side)..................257 Assembly of Control Valve (4-Spool Side).....................264 Disassembly of Control Valve (5-Spool Side)..................275 Assembly of Control Valve (5-Spool Side).....................282 Group 10 Swing Device............................................291 Removal and Installation of Swing Device.....................291 Disassembly of Swing Device..................................295 Assembly of Swing Device.....................................300 Disassembly of Swing Motor...................................307 Assembly of Swing Motor......................................310 Group 11 Pilot Valve.............................................313 Removal and Installation of Pilot Valve (Left)...............313 Removal and Installation of Pilot Valve (Right)..............319 Removal and Installation of Travel Pilot Valve...............327 Disassembly of Pilot Valves (Right and Left).................331 Assembly of Pilot Valves (Right and Left)....................334 Disassembly of Travel Pilot Valve............................337 Assembly of Travel Pilot Valve...............................341 Group 12 Solenoid Valve..........................................347 Removal and Installation of Pilot Shut-Off Solenoid Valve....347 Removal and Installation of 3-Spool Solenoid Valve Unit......351 Disassembly of Pilot Shut-Off Solenoid Valve.................355 Assembly of Pilot Shut-Off Solenoid Valve....................357 Structure of 3-Spool Solenoid Valve Unit.....................359 Group 13 Signal Control Valve....................................361 Removal and Installation of Signal Control Valve.............361 Structure of Signal Control Valve............................367 SECTION 4 UNDERCARRIAGE..............................................371 Group 1 Swing Bearing............................................373 Removal and Installation of Swing Bearing....................373 Disassembly of Swing Bearing.................................377 Assembly of Swing Bearing....................................380 Group 2 Travel Device............................................383 Removal and Installation of Travel Device....................383 Disassembly of Travel Device.................................387 Assembly of Travel Device....................................391 Disassembly of Travel Motor..................................399 Assembly of Travel Motor.....................................402 Disassembly of Brake Valve...................................407 Assembly of Brake Valve......................................409 Precautions for Using Floating Seal..........................411 Group 3 Center Joint.............................................413 Removal and Installation of Center Joint.....................413 Disassembly of Center Joint..................................417 Assembly of Center Joint.....................................419 Replacement of Body and Spindle..............................422 Group 4 Track Adjuster...........................................423 Removal and Installation of Track Adjuster...................423 Disassembly of Front Idler...................................427 Assembly of Front Idler......................................430 Disassembly of Track Adjuster................................433 Assembly of Track Adjuster...................................437 Precautions for Using Floating Seal..........................441 Group 5 Upper and Lower Rollers..................................443 Removal and Installation of Upper Roller.....................443 Removal and Installation of Lower Roller.....................447 Disassembly of Lower Roller..................................453 Assembly of Lower Roller.....................................455 Precautions for Using Floating Seal..........................457 Group 6 Track....................................................459 Removal and Installation of Track............................459 SECTION 5 FRONT ATTACHMENT...........................................467 Group 1 Front Attachment.........................................469 Removal and Installation of Front Attachment.................469 Group 2 Cylinder.................................................477 Removal and Installation of Boom Cylinder....................477 Removal and Installation of Arm Cylinder.....................481 Removal and Installation of Bucket Cylinder..................487 Disassembly of Boom, Arm, Bucket Cylinders...................491 Assembly of Boom, Arm, Bucket Cylinders......................495 SERVICE MANUAL REVISION REQUEST FORM.................................501
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