Hitachi Zaxis Class 200 225 230 270 Excavator Operational Principle+Troubleshooting+Workshop Manual
FILE DETAILS:
Hitachi Zaxis Class 200 225 230 270 Excavator Operational Principle+Troubleshooting+Workshop Manual
This Listing includes all of the manuals mentioned below:
- Hitachi Zaxis Class 200 225 230 270 Excavator Operational Principle Technical Manual
- Hitachi Zaxis Class 200 225 230 270 Excavator Troubleshooting Technical Manual
- Hitachi Zaxis Class 200 225 230 270 Excavator Workshop Manual
- Hitachi Zaxis Class 200 225 230 270 Excavator Circuit Diagram & Harness
DESCRIPTION:
Hitachi Zaxis Class 200 225 230 270 Excavator Operational Principle+Troubleshooting+Workshop Manual
INTRODUCTION:
TO THE READER:
• This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
• 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 materials listed below in addition to this manual.
• The Operator’s Manual
• The Parts Catalog
• The Engine Manual
• Parts Catalog of the Engine
• Hitachi Training Material
MANUAL COMPOSITION:
• This manual consists of three portions: the Technical Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual.
• Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems.
• Information included in the Technical Manual (Troubleshooting): technical information needed for 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 Zaxis Class 200 225 230 270 Excavator Operational Principle+Troubleshooting+Workshop Manual
- Hitachi Zaxis Class 200 225 230 270 Excavator Operational Principle Technical Manual
- SECTION 1
GENERAL
Group 1 Specifications
Specifications T1-1-1
Working Ranges T1-1-8
Group 2 Component Layout
Main Component Layout T1-2-1
Electrical Component Layout T1-2-4
(Overview)
Electrical System T-1-2-7
(Relays and Related Equipment)
Electrical System T-1-2-9
(Monitors and Switches)
Pump Device T1-2-10
Swing Device T1-2-10
Control Valve T1-2-11
Signal Control Valve T1-2-11
Solenoid Valve UnitT1-2-11
Travel Device T1-2-12
Positioning Control Valve T1-2-12
Group 3 Component Specifications
Engine T1-3-1
Engine Accessories T1-3-8
Hydraulic Component T1-3-9
Electrical Component T1-3-15
SECTION 2
SYSTEM
Group 1 Control System
Outline T2-1-1
Engine Control T2-1-2
Pump Control T2-1-23
Valve Control T2-1-32
Other Controls T2-1-46
Group 2 Hydraulic System
Outline T2-2-1
Pilot Circuit T2-2-2
Main Circuit T2-2-12
Group 3 Electrical System
Outline T2-3-1
Main Circuit T2-3-2
Electric Power Circuit T2-3-3
Indicator Light Check Circuit T2-3-4
Accessory Circuit T2-3-5
Preheat Circuit T2-3-6
Starting Circuit T2-3-8
Charging CircuitT2-3-11
Serge Voltage Prevention Circuit T2-3-14
Engine Stop Circuit T2-3-16
SECTION 3
COMPONENT OPERATION
Group 1 Pump Device
Outline T3-1-1
Main Pump T3-1-2
Regulator T3-1-6
Solenoid Valve T3-1-22
Pilot Pump T3-1-24
N Sensor (Engine Speed Sensor) T3-1-24
Pump Delivery Pressure Sensor T3-1-24
Pump Control Pressure Sensor T3-1-25
Group 2 Swing Device
Outline T3-2-1
Swing Reduction Gear T3-2-2
Swing Motor T3-2-4
Swing Parking Brake T3-2-6
Valve Unit T3-2-8
Group 3 Control Valve
Outline T3-3-1
Hydraulic Circuit T3-3-14
Flow Combiner Valve T3-3-21
Main Relief Valve T3-3-22
Overload Relief Valve T3-3-24
Regenerative Valve T3-3-26
Arm Regenerative Valve T3-3-28
Anti-Drift Valve T3-3-30
Flow Rate Control Valve T3-3-32
Auxiliary Flow Combiner Valve and
Bypass Shut-Out Valve T3-3-34
Group 4 Pilot Valve
Outline T3-4-1
Operation T3-4-2
Group 5 Travel Device
Outline T3-5-1
Travel Reduction Gear T3-5-2
Travel Motor T3-5-4
Parking Brake T3-5-6
Travel Mode Change T3-5-8
Travel Brake Valve T3-5-14
Group 6 Signal Control Valve
Outline T3-6-1
Pilot Port T3-6-2
Shuttle Valve T3-6-6
Shockless Valve T3-6-10
Pump 1 and Pump 2 Flow Rate
Control Valves T3-6-12
Bucket Flow Rate Control Valve,
Flow Combiner Valve Control Spool,
Swing Parking Brake Release Spool
Arm Flow Rate Control Valve
Control Spool T3-6-14
Group 7 Others (Upperstructure)
Pilot Shut-Off Valve T3-7-1
Solenoid Valve Unit T3-7-2
Holding Valve T3-7-6
Pilot Relief Valve T3-7-10
EC Motor T3-7-11
Group 8 Others (Undercarriage)
Swing Bearing T3-8-1
Center Joint T3-8-2
Track Adjuster T3-8-3 - Hitachi Zaxis Class 200 225 230 270 Excavator Troubleshooting Technical Manual
SECTION 4
OPERATIONAL
PERFORMANCE TEST
CONTENTS
Group 1 Introduction
Operational Performance Tests T4-1-1
Preparation for Performance Tests T4-1-2
Group 2 Standard
Operational Performance Standard Table
ZX200 class T4-2-1
ZAXIS225USR T4-2-5
ZAXIS225US T4-2-9
ZX230 class T4-2-13
ZX270 class T4-2-17
Main Pump P-Q Diagram T4-2-22
Injection Pump T4-2-24
DrZX Monitor Indicating Values
ZX200 class T4-2-28
ZAXIS225USR T4-2-32
ZAXIS225US T4-2-36
ZX230 class T4-2-40
ZX270 class T4-2-44
Sensor Activating Range T4-2-48
Group 3 Engine Test
Engine Speed T4-3-1
Engine Compression Pressure T4-3-4
Valve Clearance Adjustment T4-3-6
Nozzle Check T4-3-8
Injection Timing T4-3-10
Lubricant Consumption T4-3-12
Group 4 Excavator Test
Travel Speed T4-4-1
Track Revolution Speed T4-4-2
Mistrack Check T4-4-3
Travel Parking Function Check T4-4-4
Swing Speed T4-4-5
Swing Function Drift Check T4-4-6
Swing Motor Leakage T4-4-8
Maximum Swingable Slant Angle T4-4-10
Swing Bearing Play T4-4-12
Hydraulic Cylinder Cycle Time T4-4-14
Dig Function Drift Check T4-4-16
Control Lever Operating Force T4-4-18
Control Lever Stroke T4-4-20
Combined Boom Raise/Swing
Function Check T4-4-22
Boom Raise and Arm Roll-In
Combined Operation T4-4-24
SECTION 5
TROUBLESHOOTING
Group 1 General
Introduction T5-1-1
Diagnosing Procedure T5-1-2
Built-In Diagnosing System Operation T5-1-6
Built-In Diagnosing Function Display List T5-1-7
Dr ZX Operation T5-1-8
Dr ZX Fault Code List T5-1-10
Dr ZX Monitoring Item List T5-1-12
Dr ZX Special Function T5-1-14
Dr ZX Service Mode T5-1-15
Adjustment Data List T5-1-25
Initial Setting of Boom Electronic
Cushion T5-1-27
Group 2 Component Layout
Main Component Layout T5-2-1
Electrical Component Layout (Overview) T5-2-4
Electrical System
(Relays and Related Equipment) T5-2-7
Electrical System
(Monitors and Switches) T5-2-9
Pump Device T5-2-10
Swing Device T5-2-10
Control Valve T5-2-11
Signal Control Valve T5-2-11
Solenoid Valve UnitT5-2-11
Travel Device T5-2-12
Positioning Control Valve T5-2-12
Components in Control Valve T5-2-14
Signal Control Valve
Port Location T5-2-26
Group 3 Troubleshooting A
Troubleshooting A Procedure T5-3-1
Fault Code List T5-3-2
Fault Code 01, 02, 03 T5-3-3
Fault Code 04 T5-3-3
Fault Code 06 T5-3-4
Fault Code 07 T5-3-5
Fault Code 08 T5-3-6
Fault Code 10, 11 T5-3-7
Fault Code 12, 13 T5-3-8
Fault Code 14, 15, 16, 18 T5-3-9
Fault Code 19 T5-3-10
Group 4 Troubleshooting B
Troubleshooting B Procedure T5-4-1
Relationship between Machine Trouble
Symptoms and Related Parts T5-4-2
Correlation between Trouble
Symptoms and Part Failures T5-4-24
Engine System Troubleshooting T5-4-37
All Actuator System Troubleshooting T5-4-58
Front Attachment System
Troubleshooting T5-4-67
Swing System Troubleshooting T5-4-82
Travel System Troubleshooting T5-4-87
Other System Troubleshooting T5-4-94
Exchange InspectionT5-4-114
Emergency Boom Lowering
Procedure T5-4-116
178T-5-2
Group 5 Troubleshooting C
Troubleshooting C Procedure T5-5-1
Malfunction of Coolant
Temperature Gauge T5-5-2
Malfunction of Fuel Gauge T5-5-4
Malfunction of Indicator Light
Check System T5-5-6
Malfunction of Preheat Indicator T5-5-7
Malfunction of Engine Oil Level
Indicator T5-5-8
Malfunction of Coolant Level
Indicator T5-5-10
Malfunction of Alternator Indicator T5-5-12
Malfunction of Engine Oil Pressure
Indicator T5-5-14
Malfunction of Overheat Indicator T5-5-16
Malfunction of Air Filter Restriction
Indicator T5-5-18
Malfunction of Buzzer T5-5-20
Malfunction of LCD T5-5-22
Malfunction of Hour Meter T5-5-23
Malfunction of Hydraulic Oil Filter
Indicator (Optional) T5-5-24
Group 6 Electrical System Inspection
Precautions for Inspection and
Maintenance T5-6-1
Instructions for Disconnecting
Connectors T5-6-3
Fuse Inspection T5-6-4
Fusible Link Inspection T5-6-5
Battery Voltage Check T5-6-6
How to Troubleshoot Alternator
Malfunctions T5-6-7
Continuity Check T5-6-8
Voltage and Current MeasurementT5-6-11
Check by False Signal T5-6-15
Test Harness T5-6-16
Group 7 ICX
Outline T5-7-1
ICX Fault Code List T5-7-8
Satellite Terminal Fault Code List T5-7-8
Fault Code 1 to 4 and 6 T5-7-9
Fault Code 7 to 10 T5-7-9
Some Parts of Data in Daily Report,
Frequency Distribution, Cumulative
Operation Hours are not Recorded T5-7-10
Troubleshooting and Setting of ICX and
Satellite Terminal Using Dr ZX T5-7-12
Satellite Communication System T5-7-14
- Hitachi Zaxis Class 200 225 230 270 Excavator Workshop Manual
SECTION 1
GENERAL INFORMATION
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
AssemblingT1-1-1
Maintenance Standard TerminologyT1-1-7
Group 2 Tightening Torque
Tightening Torque Specification W1-2-1
Torque Chart W1-2-3
Piping Joint W1-2-6
Periodic Replacement of Parts W1-2-10
Group 3 Painting
Painting W1-3-1
SECTION 2
UPPERSTRUCTURE
Group 1 Cab
Remove and Install Cab W2-1-1
Dimensions of the Cab Glass W2-1-13
Group 2 Counterweight
Remove and Install CounterweightW2-2-1
Group 3 Main Frame
Remove and Install Main FrameW2-3-1
Group 4 Pump Device
Remove and Install Pump Device W2-4-1
Disassemble Pump DeviceW2-4-4
Assemble Pump Device W2-4-12
Disassemble Regulator W2-4-16
Assemble Regulator W2-4-26
Disassemble Solenoid Valve W2-4-28
Assemble Solenoid Valve W2-4-30
Disassemble and Assemble Pilot
PumpW2-4-32
Maintenance StandardW2-4-34
Group 5 Control Valve
Remove and Install Control ValveW2-5-1
Disassemble 4-Spool Control Valve W2-5-6
Disassemble 5-Spool Control Valve W2-5-12
Separate and Combine
4-Spool and 5-Spool Control Valve W2-5-18
Assemble 4-Spool Control Valve W2-5-20
Assemble 5-Spool Control Valve W2-5-28
Group 6 Swing Device
Remove and Install Swing DeviceW2-6-1
Disassemble Swing DeviceW2-6-4
Assemble Swing DeviceW2-6-16
Disassemble Swing Motor W2-6-30
Assemble Swing Motor W2-6-38
Disassemble and Assemble Parking
Release Valve W2-6-46
Maintenance Standard W2-6-47
Group 7 Pilot Valve
Remove and Install Right Pilot Valve W2-7-1
Remove and Install Left Pilot ValveW2-7-5
Remove and Install Travel
Pilot ValveW2-7-8
Disassembe Right and Left
Pilot Valves W2-7-10
Assemble Right and Left
Pilot Valves W2-7-14
Disassemble Travel Pilot ValveW2-7-18
Assemble Travel Pilot ValveW2-7-22
Group 8 Pilot Shut-Off Valve
Remove and Install Pilot Shut-Off
ValveW2-8-1
Disassemble Pilot Shut-Off Valve W2-8-4
Assemble Pilot Shut-Off Valve W2-8-8
SECTION 3
UNDERCARRIAGE
CONTENTNS
Group 1 Swing Bearing
Remove and Install Swing BearingW3-1-1
Disassemble Swing Bearing W3-1-4
Assemble Swing BearingW3-1-6
Group 2 Travel Device
Remove and Install Travel Device W3-2-1
Disassemble Travel Device W3-2-4
Assemble Travel DeviceW3-2-10
Disassemble Travel Motor W3-2-20
Assemble Travel MotorW3-2-28
Disassemble Travel Brake ValveW3-2-42
Assemble Travel Brake ValveW3-2-46
Maintenance StandardW3-2-50
Group 3 Center Joint
Remove and Install Center JointW3-3-1
Disassemble Center JointW3-3-4
Assemble Center Joint W3-3-6
Maintenance StandardW3-3-9
Group 4 Track Adjuster
Remove and Install Track AdjusterW3-4-1
Disassemble Track AdjusterW3-4-2
Assemble Track AdjusterW3-4-10
Group 5 Front Idler
Remove and Install Front Idler W3-5-1
Disassemble Front Idler W3-5-2
Assemble Front Idler W3-5-6
Maintenance Standard W3-5-8
Group 6 Upper and Lower Roller
Remove and Install Upper Roller W3-6-1
Remove and Install Lower Roller W3-6-5
Disassemble Lower Roller W3-6-8
Assemble Lower Roller W3-6-10
Maintenance Standard W3-6-12
Group 7 Track
Remove and Install Track W3-7-1
Maintenance Standard W3-7-7
SECTION 4
FRONT ATTACHMENT
CONTENTS
Group 1 Front????Attachment
Remove and Install Front AttachmentW4-1-1
Maintenance StandardW4-1-8
Standard Dimensions for
Arm and Bucket Connection W4-1-18
Standard Dimensions for
Arm and Boom Connection W4-1-19
Group 2 Cylinder
Removeand Install Cylinder W4-2-1
Hydraulic Circuit Pressure Release
Procedure W4-2-15
Disassemble Cylinder W4-2-16
Assemble Cylinder W4-2-32
Maintenance Standard W4-2-48
SECTION 5
ENGINE AND ACCESSORY
CONTENTS
General Information
General Repair Instructions 1-2
Notes on the Format of This Manual 1-2
Main Data and Specifications 1-6
Performance Curve 1-7
External View 1-9
Tightening Torque Specifications 1-11
Angular Nut and Bolt Tightening Method 1-13
Major Parts Fixing Nuts and Bolts 1-15
Identifications 1-26
Maintenance
Lubricating System 2-2
Fuel System 2-3
Cooling System 2-7
Valve Clearance Adjustment 2-7
Injection Timing 2-9
Compression Pressure Measurement 2-14
Turbocharger Inspection 2-15
Engine Repair Kit 2-16
Recommended Lubricants 2-17
Engine Oil Viscosity Chart 2-17
Engine Assembly 1 (Disassembly)
External Parts Disassembly Steps 3-2
Major Components 3-6
Rocker Arm and Rocker Arm Shaft
Disassembly Steps 3-11
Cylinder Head Disassembly Steps 3-12
Piston and Connecting Rod
Disassembly Steps 3-13
Engine Assembly 2
(Inspection and Repair)
Cylinder Head4-2
Valve Guide 4-3
Valve Spring 4-6
Tappet 4-7
Push Rod 4-8
Rocker Arm Shaft and Rocker Arm4-8
Idler Gear and Idler Gear Shaft 4-9
Camshaft 4-10
Cylinder Body and Liner 4-11
Piston and Piston Ring 4-17
Piston Pin 4-19
Connecting Rod 4-20
Crankshaft 4-22
Flywheel 4-29
Timing Gear Case Cover 4-29
Engine Assembly 3 (Reassembly)
Piston and Connecting Rod
Reassembly Steps5-2
Cylinder Head Reassembly Steps5-4
Rocker Arm and Rocker Arm Shaft
Reassembly Steps5-7
Major Component Reassembly Steps 1 5-8
Major Component Reassembly Steps 2 5-13
External Parts Reassembly Steps
(Left-Hand Side) 5-18
External Parts Reassembly Steps
(Right-Hand Side) 5-21
Engine Tuning Operation 5-25
178W-5-2
Lubricating System
General Description 6-2
Oil Pump 6-3
Oil Cooler 6-5
Cooling System
General Description 7-2
Thermostat 7-3
Fuel System
General Description 8-2
Injection Nozzle 8-3
Injection Pump Calibration Data 8-8
Turbocharger
General Description 9-2
Turbocharger Identification 9-3
Troubleshooting 9-5
Inspection and Repair 9-7
Engine Electricals
Starter Identification 10-2
Starter Main Data and Specifications 10-3
Starter Sectional View 10-4
Performance 10-4
Disassembly 10-5
Inspection and Repair 10-8
Reassembly 10-12
Adjustment 10-13
Performance Test 10-14
Alternator Identification 10-15
Main Data and Specifications 10-16
Alternator Sectional View 10-17
Charging Circuit 10-17
Structure 10-18
Disassembly 10-19
Inspections 10-22
Reassembly 10-24
Bench Test 10-25
Current Output Test 10-26
Fault Finding 10-27
Specifications 10-27
Troubleshooting
Hard Starting 11-2
1) Starter Inoperative 11-2
2) Starter Operates but
Engine does not Turn Over 11-3
3) Engine Turns Over but does not Start
Fuel is Being Delivered to the
Injection Pump 11-4
4) Engine Turns Over but does not Start 11-5
Unstable Low Idling 11-6
Insufficient Power 11-8
Excessive Fuel Consumption 11-11
Excessive Oil Consumption 11-13
Overheating 11-14
Whity Exhaust Smoke 11-16
Dark Exhaust Smoke 11-17
Oil Pressure does not Rise 11-18
Abnormal Engine Noise 11-20
Special Tool List
Special Tool List 12-2
Repair Standards
Repair Standards 13-1
Conversion Table
Length 14-2
Area 14-3
Volume 14-3
Mass 14-5
Pressure 14-6
Torque 14-7
Temperature 14-8
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