Complete service repair manual with Electrical Wiring Diagrams for Hitachi Excavators ZX240-5G, ZX240LC-5G, ZX250H-5G, ZX250LCH-5G, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Hitachi Excavators ZX240G, ZX250HG Series workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

TODCE-EN-00 - Hitachi ZX240-5G, ZX240LC-5G, ZX250H-5G, ZX250LCH-5G Hydraulic Excavator Technical Manual (Operational Principle).pdf
TTDCE-EN-00 (attach to) - Hitachi ZX240-5G, ZX240LC-5G, ZX250H-5G, ZX250LCH-5G Hydraulic Excavator Electrical Wiring Diagram.pdf
TTDCE-EN-00 - Hitachi ZX240-5G, ZX240LC-5G, ZX250H-5G, ZX250LCH-5G Hydraulic Excavator Technical Manual (Troubleshooting).pdf
WDCE-EN-00 - Hitachi ZX240-5G, ZX240LC-5G, ZX250H-5G, ZX250LCH-5G Hydraulic Excavator Workshop Manual.pdf

PRODUCT DETAILS:
Total Pages: 1,312 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
TODCE-EN-00 - Hitachi ZX240-5G, ZX240LC-5G, ZX250H-5G, ZX250LCH-5G Hydraulic Excavator Technical Manual (Operational Principle)....2
  TODCE-EN-00....2
  INTRODUCTION....4
  SYMBOL AND ABBREVIATION....6
  SECTION AND GROUP CONTENTS....8
  SECTION 1 GENERAL....10
    Group 1 Specifications....12
      Specifications....12
      Specifications....13
      Working Ranges (Grouser shoe)....14
      Working Ranges (Grouser shoe)....15
    Group 2 Component Layout....16
      Main Component....16
      Electrical System (Overview)....17
      Engine....18
      Electrical System (In Cab)....18
      Electrical System (Rear Tray)....19
      Electrical System (Switch Panel)....20
      Electrical System (Around Air Cleaner)....21
      Electrical System (Relays)....22
      Pump Device....23
      Control Valve....24
      Signal Control Valve....24
      Swing Device....26
      Travel Device....26
      3-Spool Solenoid Valve Unit....27
      Layout of Attachment Spec. Parts....29
    Group 3 Component Specifications....34
      Engine....34
      Engine Accessories....38
      Hydraulic Component....39
      Electrical Component....43
  SECTION 2 SYSTEM....46
    Group 1 Controller....48
      Outline....48
      CAN Circuit....49
    Group 2 Control System....52
      Outline....52
      Engine Control....55
      Pump Control....81
      Valve Control....91
      Other Control....107
    Group 3 Hydraulic System....112
      Outline....112
      Pilot Circuit....113
      Main Circuit....123
    Group 4 Electrical System....138
      Outline....138
      Main Circuit....139
      Electric Power Circuit (Key Switch: OFF)....141
      CAN Circuit....143
      Accessory Circuit....145
      Preheating Circuit (Key Switch: ON, START)....147
      Starting Circuit (Key Switch: START)....149
      Charging Circuit (Key Switch: ON)....153
      Surge Voltage Prevention Circuit....157
      Pilot Shut-Off Circuit (Key switch: ON)....159
      Engine Stop Circuit....161
      Monitor Circuit....164
      Security Circuit....165
      Radio Circuit....167
      Air Conditioner Circuit....167
      Accessory Circuit....170
      Work Light Circuit....171
      Wiper/Washer Circuit....173
      Cab Light Circuit....175
  SECTION 3 COMPONENT OPERATION....180
    Group 1 Pump Device....182
      Outline....182
      Main Pump....183
      Regulator....187
      Solenoid Valve....205
      Pilot Pump....207
      Pump Delivery Pressure Sensor....207
      Pump Control Pressure Sensor....207
      N Sensor (Engine Speed Sensor)....208
    Group 2 Swing Device....210
      Outline....210
      Swing Reduction Gear....211
      Swing Motor....212
      Swing Parking Brake....213
      Valve Unit....215
    Group 3 Control Valve....218
      Outline....218
      Hydraulic Circuit....239
      Flow Combiner Valve....245
      Main Relief Valve....247
      Overload Relief Valve (with Make-Up Function)....251
      Regenerative Valve....255
      Anti-Drift Valve....259
      Flow Rate Control Valve....263
      Digging Regenerative Valve....267
      Boom Lower Meter-In Cut Valve....269
      Auxiliary Flow Combiner Valve and Bypass Shut-Out Valve....271
    Group 4 Pilot Valve....276
      Outline....276
      Operation (Front Attachment / Swing and Travel Pilot Valves)....278
      Operation (Auxiliary Pilot Valve)....286
      Shockless Function (Only for Travel Pilot Valve)....291
    Group 5 Travel Device....292
      Outline....292
      Travel Reduction Gear....293
      Travel Motor....295
      Parking Brake....297
      Travel Brake Valve....299
      Overload Relief Valve....303
      Travel Mode Control....305
    Group 6 Signal Control Valve....310
      Outline....310
      Pilot Port....311
      Shuttle Valve....316
      Shockless Valve....319
      Pump 1 and 2 Flow Rate Control Valve....323
      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....325
    Group 7 Others (Upperstructure)....328
      Pilot Shut-Off Solenoid Valve....328
      Solenoid Valve....330
      Pilot Relief Valve....333
      EC Motor....333
      Hose Rupture Valve....335
    Group 8 Others (Undercarriage)....342
      Swing Bearing....342
      Center Joint....343
      Track Adjuster (Front Idler Integrated Type)....344
  SERVICE MANUAL REVISION REQUEST FORM....348
TTDCE-EN-00 (attach to) - Hitachi ZX240-5G, ZX240LC-5G, ZX250H-5G, ZX250LCH-5G Hydraulic Excavator Electrical Wiring Diagram....350
  ELECTRICAL CIRCUIT DIAGRAM....350
  CONNECTORS....351
  CAB HARNESS....352
  ENGINE HARNESS....353
  PUMP HARNESS....354
  MONITOR HARNESS....355
  KEY-SWITCH HARNESS....356
  GSM (MOBILE COMMUNICATION TERMINAL) HARNESS....357
  SATELLITE COMMUNICATION HARNESS....358
  PILOT SHUT-OFF SOLENOID VALVE HARNESS....359
  REARVIEW CAMERA HARNESS....360
  HYDRAULIC CIRCUIT DIAGRAM (STANDARD)....361
  HYDRAULIC CIRCUIT DIAGRAM (OPTIONAL)....362
TTDCE-EN-00 - Hitachi ZX240-5G, ZX240LC-5G, ZX250H-5G, ZX250LCH-5G Hydraulic Excavator Technical Manual (Troubleshooting)....363
  TTDCE-EN-00....363
  INTRODUCTION....365
  SYMBOL AND ABBREVIATION....367
  SAFETY....369
  SECTION AND GROUP CONTENTS....409
  SECTION 4 OPERATIONAL PERFORMANCE TEST....411
    Group 1 Introduction....413
      Operational Performance Tests....413
      Preparation for Performance Tests....414
    Group 2 Standard....415
      Operational Performance Standard Table....415
      Main Pump P-Q Diagram....421
      Sensor Activating Range....423
      MPDr. Monitor Indicating Values....424
    Group 3 Engine Test....433
      Engine Speed....433
      Engine Compression Pressure....436
      Valve Clearance....438
      Nozzle....440
      Injection Timing....442
      Lubricant Consumption....444
    Group 4 Machine Performance Test....445
      Travel Speed....445
      Track Revolution Speed....446
      Mistrack Check....447
      Travel Parking Leakage....448
      Swing Speed....449
      Swing Function Drift Check....450
      Swing Motor Leakage....452
      Maximum Swingable Slant Angle....454
      Swing Bearing Play....456
      Hydraulic Cylinder Cycle Time....458
      Dig Function Drift Check....460
      Control Lever Operating Force....463
      Control Lever Stroke....464
      Combined Operation of Boom Raise / Swing Function Check....465
      Combined Operation of Boom Raise / Arm Roll-In Function Check....466
    Group 5 Component Test....467
      Primary Pilot Pressure....467
      Secondary Pilot Pressure....469
      Solenoid Valve Set Pressure....470
      Main Pump Delivery Pressure....472
      Main Relief Set Pressure....474
      Relief pressure (when relieving swing)....478
      Overload Relief Valve Set Pressure....480
      Main Pump Flow Rate Measurement....482
      Swing Motor Drainage....490
      Travel Motor Drainage....492
    Group 6 Adjustment....495
      Engine Speed Adjustment and Engine Learning....495
      Governor Lever and Fuel Cut Lever Position....500
  SECTION 5 TROUBLESHOOTING....505
    Group 1 Diagnosing Procedure....507
      Introduction....507
      Diagnosis Procedure....508
      Electric System Inspection....511
      Precautions for Inspection and Maintenance....512
      Instructions for Disconnecting Connectors....514
      Fuse Inspection....516
      Fusible Link Inspection....518
      Battery Voltage Check....519
      Alternator Check....520
      Continuity Check....521
      Voltage and Current Measurement....522
      Check by False Signal....529
      Test Harness....530
    Group 2 Monitor....533
      Outline....533
      Operating Procedures of Service Menu (Built-In Diagnosing System)....534
      Setting Menu....567
      Inspection of Hour Meter and Fuel Gauge....569
      Fuel Gauge and Coolant Temperature Gauge....570
    Group 3 e-Service....571
      Outline....571
      List of Operation Data....572
      Snapshot Data....576
      Communication System....577
    Group 4 Component Layout....579
      Main Component....579
      Electrical System (Overview)....580
      Engine....581
      Electrical System (In Cab)....581
      Electrical System (Rear Tray)....582
      Electrical System (Switch Panel)....583
      Electrical System (Around Air Cleaner)....584
      Electrical System (Relays)....585
      Pump Device....586
      Control Valve....587
      Signal Control Valve....587
      Swing Device....589
      Travel Device....589
      3-Spool Solenoid Valve Unit....590
      Layout of Attachment Spec. Parts....592
      Components in Control Valve....596
      Pilot Port....616
    Group 5 Troubleshooting A....621
      Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure....621
      MC Fault Code List....623
      ECF Fault Code List....633
      Monitor Controller (Monitor) Fault Code List....634
      Monitor Controller (Information) Fault Code List....635
      Air Conditioner Controller Fault Code List....638
      Communication Terminal Fault Code List....639
      MC Fault Codes 11000 to 11002....641
      MC Fault Code 11003....642
      ECF Fault Code 16603....642
      MC Fault Codes 11006, 11007, 11009....645
      ECF Fault Code 16604....645
      Monitor Controller (Monitor) Fault Codes 13002, 13003, 13005....645
      CAN0 Harness Check....646
      MC Fault Codes 11008, 11010....649
      Monitor Controller (Monitor) Fault Codes 13004, 13006, 13007....649
      CAN1 Harness Check....650
      MC Fault Code 11100....653
      MC Fault Code 11101....654
      MC Fault Codes 11200, 11202....655
      MC Fault Codes 11206, 11208....656
      MC Fault Codes 11301 to 11303....657
      MC Fault Codes 11304, 11307....658
      MC Fault Code 11400....659
      MC Fault Code 11401....660
      MC Fault Code 11402....661
      MC Fault Code 11403....662
      MC Fault Code 11407....663
      MC Fault Code 11901....664
      ECF Fault Codes 16600 to 16602....665
      ECF Fault Code 16605....666
      ECF Fault Code 16606....667
      Air Conditioner Controller Fault Codes 11 to 22....668
      Air Conditioner Controller Fault Codes 43 to 92....669
      Monitor Controller (Information) Fault Codes 13304, 13310....670
      Monitor Controller (Information) Fault Code 13311....671
      Monitor Controller (Information) Faul tCodes 20100 to 20114....672
    Group 6 Troubleshooting B....673
      Troubleshooting B (Machine Diagnosis by Using Troubleshooting Symptom) Procedure....673
      Relationship between Machine Trouble Symptoms and Related Parts....675
      Correlation between Trouble Symptoms and Part Failures....694
      Engine System Troubleshooting....708
      All Actuator System Troubleshooting....722
      Front Attachment System Troubleshooting....729
      Swing System Troubleshooting....741
      Travel System Troubleshooting....743
      Other System Troubleshooting....748
      Exchange Inspection....749
      How to Lowering Boom in Case of Emergency and When Engine Stops....752
    Group 7 Air Conditioner....753
      Outline....753
      Functions of Main Parts....756
      Troubleshooting....761
      Air Conditioner Controller Fault Code List....762
      Air Conditioner Controller Fault Codes 11 to 22....763
      Air Conditioner Controller Fault Codes 43 to 92....764
      Work after Replacing Components....786
      Refill Compressor Oil....787
      Charge Air Conditioner with Refrigerant....788
      Hose and Pipe Tightening Torque....796
  SERVICE MANUAL REVISION REQUEST FORM....799
  The Attached Diagram List....800
WDCE-EN-00 - Hitachi ZX240-5G, ZX240LC-5G, ZX250H-5G, ZX250LCH-5G Hydraulic Excavator Workshop Manual....801
  WDCE-EN-00....801
  INTRODUCTION....803
  SYMBOL AND ABBREVIATION....805
  SAFETY....807
  SECTION AND GROUP CONTENTS....847
  SECTION 1 GENERAL....849
    Group 1 Precautions for Disassembling and Assembling....851
      Precautions for Disassembling andAssembling....851
    Group 2 Tightening....857
      Tightening Bolts and Nuts....857
      Piping Joint....860
    Group 3 Painting....865
      Painting....865
    Group 4 Bleeding Air....867
      Bleeding Air from Hydraulic Oil Tank....867
      Bleeding Air from Hydraulic System....868
      Bleeding Air from Fuel System....869
      Bleeding Air from Radiator....871
    Group 5 Pressure Release Procedure....873
      Hydraulic Circuit Pressure Release Procedure....873
    Group 6 Preparation....875
      Preparation before Inspection and Maintenance....875
  SECTION 2 MAINTENANCE STANDARD....879
    Group 1 Upperstructure....881
      Pump Device....881
      Swing Motor....885
    Group 2 Undercarriage....889
      Travel Motor....889
      Sprocket....891
      Front Idler....893
      Upper Roller....895
      Lower Roller....896
      Track....897
    Group 3 Front Attachment....901
      Pin and Bushing....901
      Side Cutter (2021232, 2021233)....903
      Point (4512365)....904
      Standard Dimensions for Arm and Bucket Connection....905
      Standard Dimensions for Arm and Boom Connection....906
      Cylinder....907
  SECTION 3UPPERSTRUCTURE....911
    Group 1 Cab....913
      Removal and Installation of Cab....913
      Dimensions of Cab Glass....929
    Group 2 Counterweight....949
      Removal and Installation of Counterweight....949
    Group 3 Main Frame....951
      Removal and Installation of Main Frame....951
    Group 4 Engine....957
      Removal and Installation of Engine....957
    Group 5 Radiator Assembly....975
      Replacement of Radiator, Oil Cooler, and Intercooler....975
    Group 6 Hydraulic Oil Tank....987
      Removal and Installation of Hydraulic Oil Tank....987
    Group 7 Fuel Tank....995
      Removal and Installation of Fuel Tank....995
    Group 8 Pump Device....1003
      Removal and Installation of Pump Device....1003
      Removal and Installation of Coupling....1009
      Disassembly of Pump Device....1011
      Assembly of Pump Device....1018
      Disassembly of Regulator....1029
      Assembly of Regulator....1031
      Disassembly of Solenoid Valve....1033
      Assembly of Solenoid Valve....1035
      Structure of Pilot Pump....1037
    Group 9 Control Valve....1039
      Removal Installation of Control Valve....1039
      Disassembly of Housing....1053
      Assembly of Housing....1055
      Disassembly of Control Valve (4-Spool Side)....1057
      Assembly of Control Valve (4-Spool Side)....1064
      Disassembly of Control Valve (5-Spool Side)....1075
      Assembly of Control Valve (5-Spool Side)....1082
    Group 10 Swing Device....1091
      Removal and Installation of Swing Device....1091
      Disassembly of Swing Device....1095
      Assembly of Swing Device....1100
      Disassembly of Swing Motor....1107
      Assembly of Swing Motor....1110
    Group 11 Pilot Valve....1113
      Removal and Installation of Pilot Valve (Left)....1113
      Removal and Installation of Pilot Valve (Right)....1119
      Removal and Installation of Travel Pilot Valve....1127
      Disassembly of Pilot Valves (Right and Left)....1131
      Assembly of Pilot Valves (Right and Left)....1134
      Disassembly of Travel Pilot Valve....1137
      Assembly of Travel Pilot Valve....1141
    Group 12 Solenoid Valve....1147
      Removal and Installation of Pilot Shut-Off Solenoid Valve....1147
      Removal and Installation of 3-Spool Solenoid Valve Unit....1151
      Disassembly of Pilot Shut-Off Solenoid Valve....1155
      Assembly of Pilot Shut-Off Solenoid Valve....1157
      Structure of 3-Spool Solenoid Valve Unit....1159
    Group 13 Signal Control Valve....1161
      Removal and Installation of Signal Control Valve....1161
      Structure of Signal Control Valve....1167
  SECTION 4 UNDERCARRIAGE....1171
    Group 1 Swing Bearing....1173
      Removal and Installation of Swing Bearing....1173
      Disassembly of Swing Bearing....1177
      Assembly of Swing Bearing....1180
    Group 2 Travel Device....1183
      Removal and Installation of Travel Device....1183
      Disassembly of Travel Device....1187
      Assembly of Travel Device....1191
      Disassembly of Travel Motor....1199
      Assembly of Travel Motor....1202
      Disassembly of Brake Valve....1207
      Assembly of Brake Valve....1209
      Precautions for Using Floating Seal....1211
    Group 3 Center Joint....1213
      Removal and Installation of Center Joint....1213
      Disassembly of Center Joint....1217
      Assembly of Center Joint....1219
      Replacement of Body and Spindle....1222
    Group 4 Track Adjuster....1223
      Removal and Installation of Track Adjuster....1223
      Disassembly of Front Idler....1227
      Assembly of Front Idler....1230
      Disassembly of Track Adjuster....1233
      Assembly of Track Adjuster....1237
      Precautions for Using Floating Seal....1241
    Group 5 Upper and Lower Rollers....1243
      Removal and Installation of Upper Roller....1243
      Removal and Installation of Lower Roller....1247
      Disassembly of Lower Roller....1253
      Assembly of Lower Roller....1255
      Precautions for Using Floating Seal....1257
    Group 6 Track....1259
      Removal and Installation of Track....1259
  SECTION 5 FRONT ATTACHMENT....1267
    Group 1 Front Attachment....1269
      Removal and Installation of Front Attachment....1269
    Group 2 Cylinder....1277
      Removal and Installation of Boom Cylinder....1277
      Removal and Installation of Arm Cylinder....1281
      Removal and Installation of Bucket Cylinder....1287
      Disassembly of Boom, Arm, Bucket Cylinders....1291
      Assembly of Boom, Arm, Bucket Cylinders....1295
  SERVICE MANUAL REVISION REQUEST FORM....1301

Hitachi Excavators ZX240-5G, ZX240LC-5G, ZX250H-5G, ZX250LCH-5G Repair Service Manuals