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Hitachi ZX240-5G ZX240LC-5G ZX250H-5G ZX250LCH-5G Hydraulic Excavator Workshop Manual (WDCE-EN-00) – PDF Download


  • Hitachi ZX240-5G ZX240LC-5G ZX250H-5G ZX250LCH-5G Hydraulic Excavator Workshop Manual
  • Publication Number:WDCE-EN-00

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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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