Factory Service Repair Manuals set For Hitachi Zaxis 200, 225USR, 225US, 230, 270 Excavators. Tons of illustrations, instructions, diagrams for step by step remove and install, assembly and disassembly, service, inspection, repair, troubleshooting, tune-ups.
Format: PDF
Language: English
Pages: 1489
Bookmarks: Yes
Searchable: Yes
Wiring Diagrams: Yes
Hydraulic Diagrams: Yes
Model
Hitachi Zaxis 200, 225USR, 225US, 230, 270
Contents
1.Workshop Manual
2.Technical Manual(Troubleshooting)
3.Technical Manual(Operational Principle)
1.Workshop Manual
-GENERAL INFORMATION
–PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING
Precautions for Disassembling and Assembling
Maintenance Standard Terminology
–TIGHTENING TORQUE
Tightening Torque Specification
Torque Chart
Piping Joint
Periodic Replacement of Parts
–PAINTING
Painting
–BLEEDING AIR
Bleed Air from Hydraulic Oil Tank
-UPPERSTRUCTURE
–CAB
Remove and Install Cab
Dimensions of the Cab Glass
–COUNTERWEIGHT
Remove and Install Counterweight
–MAIN FRAME
Remove and Install Main Frame
–PUMP DEVICE
Remove and Install Pump Device
Disassemble Pump Device
Assemble Pump Device
Disassemble Regulator
Assemble Regulator
Disassemble Solenoid Valve
Assemble Solenoid Valve
Disassemble and Assemble Pilot Pump
Maintenance Standard
–CONTROL VALVE
Remove and Install Control Valve
Disassemble Control Valve 4-Spool Section
Disassemble Control Valve 5-Spool Section
Disassemble and Assemble 4-Spooi and 5-Spool Section
Assemble Control Valve 4-Spool Section
Assemble Control Valve 5-Spool Section
–SWING DEVICE
Remove and Install Swing Device
Disassemble Swing Device (ZAXIS200, 200-E, 225US, 225USR, 230)
Disassemble Swing Device (ZAXIS270) Assemble Swing Device (ZAXIS2O0, 200-E 225US, 225USR, 230)
Assemble Swing Device (ZAXIS270) Disassemble Swing Motor (ZAXIS200 200-E 225US, 225USR 230)
Disassemble Swing Motor (ZAX1S270)
Assemble Swing Motor (ZAXIS200, 200-E, 225US 225USR 230)
Assemble Swing Motor (ZAXIS270)
Disassemble and Assemble Parking Release Valve (ZAXIS270)
Maintenance Standard
–PILOT VALVE
Remove and Install Right Pilot Valve
Remove and Install I eft Pilot Valve
Remove and Install Travel Pilot Valve
Disassembe Right and Left Pilot Valves
Assemble Right and Left Pilot Valves
Disassemble Travel Pilot Valve
Assemble Travel Pilot Valve
–PILOT SHUT-OFF VALVE
Remove and Install Pilot Shut-Off Valve
Disassemble Pilot Shut-Off Valve (ZAXIS200 200-E, 225USR, 230, 270)
Disassemble Pilot Shut-Off Valve (ZAXIS225US)
Assemble Pilot Shut-Off Valve (ZAXIS200, 200-E, 225USR, 230, 270)
Assemble Riot Shut-Off Valve (ZAX1S225US)
–SIGNAL CONTROL VALVE
Remove and Install Signal Control Valve
–SOLENOID VALVE
Remove and Install Solenoid Valve Unit
Disassemble Proportional Solenoid Valve
Assemble Proportional Solenoid Valve
-UNDERCARRIAGE
–SWING BEARING
Remove and Install Swing Bearing Disassemble Swing Bearing
Assemble Swing Bearing
–TRAVEL DEVICE
Remove and Install Travel Device
Disassemble Travel Device
Assemble Travel Device
Disassemble Travel Motor
Assemble Travel Motor
Disassemble Travel Brake Valve
Assemble Travel Brake Valve
Maintenance Standard
–CENTER JOINT
Remove and Install Center Joint
Disassemble Center Joint
Assemble Center Joint
Maintenance Standard
–TRACK ADJUSTER
Remove and Install Track Adjuster
Disassemble Track Adjuster
Assemble Track Adjuster
-FRONT ATTACHMENT
–FRONT ATTACHMENT
Remove and Install Front Attachment
Maintenance Standard
Standard Dimensions for Arm and Bucket Connection
Standard Dimensions for Arm and Boom Connection
–CYLINDER
Removeand Install Cylinder
Hydraulic Circuit Pressure Release Procedure
Disassemble Cylinder
Assemble Cylinder
Maintenance Standard
-ENGINE AND ACCESSORY
–GENERAL INFORMATION
General Repair Instructions
Notes on the Format of This Manual
Main Data and Specifications
Performance Curve
External View
Tightening Torque Specifications
Angular Nut and Bolt Tightening Method
Major Parts Fixing Nuts and Bolts
Identifications
–MAINTENANCE
Lubricating System
Fuel System
Cooling System
Valve Clearance Adjustment
Injection Timing
Compression Pressure Measurement
Turbocharger Inspection
Engine Repair Kit
Recommended Lubricants
Engine Oil Viscosity Chart
–ENGINE ASSEMBLY 1 (DISASSEMBLY)
Fxternal Parts Disassembly Steps Major Components
Rocker Arm and Rocker Arm Shaft Disassembly Steps
Cylinder Head Disassembly Steps
Piston and Connecting Rod Disassembly Steps
–ENGINE ASSEMBLY 2 (INSPECTION AND REPAIR)
Cylinder Head
Valve Guide
Valve Spring
Tappet
Push Rod
Rocker Arm Shaft and Rocker Arm
Idler Gear and Idler Gear Shaft
Camshaft
Cylinder Body and Liner
Piston and Piston Ring
Piston Pin
Connecting Rod
Crankshaft
Flywheel
Timing Gear Case Cover
–ENGINE ASSEMBLY 3 (REASSEMBLY)
Piston and Connecting Rod
Reassembly Steps
Cylinder Head Reassembly Steps
Rocker Arm and Rocker Arm Shaft
Reassembly Steps
Major Component Reassembly Steps 1
Major Component Reassembly Steps 2
External Parts Reassembly Steps (Left-Hand Side)
External Parts Reassembly Steps (Right-Hand Side)
Engine Tuning Operation
–LUBRICATING SYSTEM
General Description
Oil Pump
Oil Cooler
–COOLING SYSTEM
General Description
Water Pump
Thermostat
–FUEL SYSTEM
General Description
Injection Nozzle
Injection Pump Calibration Data
–TURBOCHARGER
Gereral Description
Turbocharger Identification
Troubleshooting
Inspection and Repair
–ENGINE ELECTRICALS
Starter Identification
Starter Mam Data and Specifications
Starter Sectional View
Performance
Disassembly
Inspection and Repair
Reassembly
Adjustment
Performance Test
Alternator Identification
Mam Data and Specifications
Alternator Sectional View
Charging Circuit
Structure
Disassembly
Inspections
Reassembly
Bench Test
Current Output Test
Fault Finding
Specifications
–TROUBLESHOOTING
HARD STARTING
1)STARTER INOPERATIVE
2)STARTER OPERATES BUT ENGINE DOES NOT TURN OVER
3)ENGINE TURNS OVER BUT DOES NOT START
FUEL IS BEING DELIVERED TO THE INJECTION PUMP
4)ENGINE TURNS OVER BUT DOES NOT START
Unstable Low Idling
Insufficient Power
Excessive Fuel Consumption
Excessive Oil Consumption
Overheating
Whity Exhaust Smoke
Dark Exhaust Smoke
Oil Pressure does not Rise
Abnormal Engine Noise
–SPECIAL TOOL LIST
Special Tool List
–REPAIR STANDARDS
Repair Standards
–CONVERSION TABLE
Length
Area
Volume
Mass
Pressure
Torque
Temperature
2.Technical Manual(Troubleshooting)
–INTRODUCTION
Operational Performance Tests
Preparation for Performance Tests
–STANDARD
Operational Performance Standard Table
ZX200 class
ZAXIS225USR
ZAXIS225US
ZX230 class
ZX270 class
Main Pump P-Q Diagram
Injection Pump
DrZX Monitor Indicating Values
ZX200 class
ZAXIS225USR
ZAXIS225US
ZX230 Class
ZX270 class
Sensor Activating Range
–ENGINE TEST
Engine Speed
Engine Compression Pressure
Valve Clearance Adjustment
Nozzle Check
Injection Timing
Lubricant Consumption
–EXCAVATOR TEST
Travel Speed
Track Revolution Speed
Mistrack Check
Travel Parking Function Check
Swing Speed
Swing Function Drift Check
Swing Motor Leakage
Maximum Swingable Slant Angle
Swing Bearing Play
Hydraulic Cylinder Cycle Time
Dig Function Drift Check
Control Lever Operating Force
Control Lever Stroke
Combined Boom Raise/Swing Function Check
Boom Raise and Arm Roll-In Combined Operation
–COMPONENT TEST
Primary Pilot Pressure
Secondary Pilot Pressure
Solenoid Valve Set Pressure
Main Pump Delivery Pressure
Main Relief Valve Set Pressure
Relief Pressure (When relieving Swing)
Relief Pressure (When relieving Travel)
Overload Relief Valve Set Pressure
Main Pump Flow Rate Measurement Swing Motor Drainage
Travel Motor Drainage
–ADJUSTMENT
Engine Speed Adjustment and Engine Learning
Govenor Lever and Fuel Cut Lever Position
-TROUBLESHOOTING
–GENERAL
Introduction
Diagnosing Procedure
Built-In Diagnosing System Operation
Built-In Diagnosing Function Display List
Dr ZX Operation
Dr ZX Fault Code List
Dr ZX Monitoring Item List
Dr ZX Special Function
Dr ZX Service Mode
Adjustment Data List
Initial Setting of Boom Electronic Cushion
–COMPONENT LAYOUT
Main Component Layout
Electrical Component Layout (Overview) Electrical System (Relays and Related Equipment)
Electrical System (Monitors and Switches)
Pump Dcvwc
Swing Device
control valve
Signal Control Valve
Solenoid Valve Unit
Travel Device
Positioning Control Valve
Components in Control Valve
Signal Control valve Port Location
–TROUBLESHOOTING A
Troubleshooting A Procedure Fault Code List
Fault Code 01, 02 03
Fault Code 04
Fault Code 06
Fault Code 07
Fault Code 08
Fault Code 10, 11
Fault Code 12, 13
Fault Code 14, 15, 16, 18
Fault Code 19
–TROUBLESHOOTING B
Troubleshooting B Procedure
Relationship between Machine Trouble Symptoms and Related Parts
Correlation between Trouble Symptoms and Part Failures
Engine System Troubleshooting
All Actuator System Troubleshooting
Front Attachment System Troubleshooting
Swing System Troubleshooting
Travel System Troubleshooting
Other System Troubleshooting
Exchange Inspection
Emergency Boom Lowering Procedure
–TROUBLESHOOTING C
Troubleshooting C Procedure
Malfunction of Coolant Temperature Gauge
Malfunction of Fuel Gauge
Malfunction of Indicator Light Check System
Malfunction of Preheat Indicator
Malfunction of Engine Oil Level Indicator
Malfunction of Coolant Level Indicator
Malfunction of Alternator Indicator
Malfunction of Engine Oil Pressure Indicator
Malfunction of Overheat Indicator
Malfunction of Air Filter Restriction Indicator
Malfunction of Buzzer
Malfunction of LCD
Malfunction of Hour Meter
Malfunction of Hydraulic Oil Filter Indicator (Optional)
–ELECTRICAL SYSTEM INSPECTION
Precautions for Inspection and Maintenance
Instructions for Disconnecting Connectors
Fuse Inspection
Fusible Link Inspection
Battery Voltage Check How to Troubleshoot Alternator Malfunctions
Continuity Check
Voltage and Current Measurement Check by False Signal Test Harness
–ICX
Outline
ICX Fault Code List
Satellite Terminal Fault Code List
Fault Code 1 to 4 and 6
Fault Code 7 to 10
Some Parts of Data in Daily Report
Frequency Distribution, Cumulative Operation Hours are not Recorded
3.Technical Manual(Operational Principle)
-GENERAL
–SPECIFICATIONS
Specifications
Working Ranges
Group 2 Component Layout
Main Component Layout
Electrical Component Layout
(Overview) Electrical System
(Relays and Related Equipment) Electrical System
(Monitors and Switches)
Pump Device
Swing Device
Control Valve
Signal Control Valve
Solenoid Valve Unit
Travel Device
Positioning Control Valve
–COMPONENT SPECIFICATIONS
Engine
Engine Accessories
Hydraulic Component
Electrical Component
-SYSTEM
–CONTROL SYSTEM
Outline
Engine Control
Pump Control
Valve Control
Other Controls
–HYDRAULIC SYSTEM
Outline
Pilot Circuit
Mam Circuit
–ELECTRICAL SYSTEM
Outline
Mam Circuit
Electric Power Circuit(Key SwitchOff)
Indicator Light Check Circuit (Key Switch On)
Accessory Circuit
Preheat Circuit
Starting Circuit(Key Switch:Start)
Charging Circuit(Key Switch On)
Serge Voltage Prevention Circuit
Engine Stop Circuit
-COMPONENT OPERATION
–PUMP DEVICE
Outline
Mam Pump
Regulator
Solenoid Valve
Pilot Pump
N Sensor (Engine Speed Sensor)
Pump Delivery Pressure Sensor
Pump Control Pressure Sensor
–SWING DEVICE
Outline
Swing Reduction Gear
Swing Motor
Swing Parking Brake
Valve Unit
–CONTROL VALVE
Outline
Hydraulic Circuit
Flow Combiner Valve
Mam Relief Valve
Overload Relief Valve
Regenerative Valve
Arm Regenerative Valve
Anti-Dnft Valve
Flow Rate Control Valve
Auxiliary Flow Combiner Valve and Bypass Shut-Out Valve
–PILOT VALVE
Outline
Operation
Shockless Function (Only For Travel Pilot Valve)
–TRAVEL DEVICE
Outline
Travel Reduction Gear
Travel Motor
Parking Brake
Travel Mode Change
Travel Brake Valve
–SIGNAL CONTROL VALVE
Outline
Pitot Port
Shuttle Valve
Shockless Valve
Pump 1 and Pump 2 Flow Rate Control Valves
Bucket Flow Rate Control Valve Control Spool, Flow Combiner Valve Control Spool, Swing Parking Brake Release Spool Arm Flow Rate Control Valve Control Spool
–OTHERS (UPPERSTRUCTURE)
Pitot Shut-Off Valve
Solenoid Valve Unit
Holding Valve
Pitot Relief Valve
EC Motor
–OTHERS (UNDERCARRIAGE)
Swing Bearing
Center Joint
Track Adjuster
What you get
You will receive PDF file with high-quality manual on your email immediately after the payment.
Reviews
There are no reviews yet