Hitachi ZX200-3 / ZX225US-3 / ZX225USR-3 / ZX240-3 / ZX270-3 Class Excavator Technical Manual


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Information included in this Technical Manual: technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures for the ZX200-3 / ZX225US-3 / ZX225USR-3 / ZX240-3 / ZX270-3 Class Hitachi Hydraulic Excavator.


APPLICABLE MODELS :

Hitachi 200-3 class
200-3 • 200LC-3 • 210H-3 • 210LCH-3 • 210K-3 • 210LCK-3 • 210-3 • 210LC-3 • 210LCN-3 • 240N-3

Hitachi 225US-3 class
225US-3 • 225USLC-3

Hitachi 225USR-3 class
225USR-3 • 225USRLC-3 • 225USRK-3 • 225USRLCK-3

Hitachi 240-3 class
240-3 • 240LC-3 • 250H-3 • 250LC-3 • 250LCN-3 • 250LCH-3 • 250K-3 • 250LCK-3

Hitachi 270-3 class
270-3 • 270LC-3 • 280LC-3 • 280LCN-3


TABLE OF CONTENTS :

Operational Principle - TO1V1-E-01

SECTION 1 GENERAL
Specifications
Component Layout
Component Specifications

SECTION 2 SYSTEM
Controller
Control System
ECM System
Hydraulic System
Electrical System

SECTION 3 COMPONENT OPERATION
Pump Device
Swing Device
Control Valve
Pilot Valve
Travel Device
Signal Control Valve
Others (Upperstructure)
Others (Undercarriage)

Troubleshooting - TT1V1-E-01

SECTION 4 OPERATIONAL PERFORMANCE TEST
Introduction
Standard
Engine Test
Excavator Test
Component Test
SECTION 5 TROUBLESHOOTING
Diagnosing Procedure
Monitor Unit
Dr. ZX
e-Shovel
Component Layout
Troubleshooting A
Troubleshooting B
Electrical System Inspection

SERVICE MANUAL REVISION REQUEST FORM
THE ATTACHED DIAGRAM LIST


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Total Pages : 1189


This complete technical manual PDF download for the Hitachi ZAXIS 200-3 / 225US-3 / 225USR-3 / 240-3 / 270-3 Class Hydraulic Excavator has easy to read text sections with top quality diagrams, pictures and illustrations.

• Information included in the Technical Manual (Operational Principle): technical information needed for redeliver 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.

This service repair workshop technical manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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COVER
INTRODUCTION
CONTENTS

SECTION 1 GENERAL
Specifications
SPECIFICATIONS
WORKING RANGES
Component Layout
MAIN COMPONENTS
ELECTRICAL SYSTEM (OVERVIEW)
ELECTRICAL SYSTEM (IN CAB)
ELECTRICAL SYSTEM (REAR TRAY)
ELECTRICAL SYSTEM (SWITCH PANEL)
ELECTRICAL SYSTEM (AROUND AIR CLEANER)
ELECTRICAL SYSTEM (RELAYS)
ENGINE
PUMP DEVICE
AROUND PUMP DEVICE
SWING DEVICE
CONTROL VALVE
SIGNAL CONTROL VALVE
SOLENOID VALVE UNIT
TRAVEL DEVICE
LAYOUT OF ATTACHMENT SPEC. PARTS
Component Specifications
ENGINE
ENGINE ACCESSORIES
HYDRAULIC COMPONENT
ELECTRICAL COMPONENT

SECTION 2 SYSTEM
Controller
OUTLINE
CAN (NETWORK PROVIDED FOR MACHINE)
MC: MAIN CONTROLLER
ECM: ENGINE CONTROL MODULE
ICF: INFORMATION CONTROLLER
OUTLINE
Control System
OUTLINE
ENGINE CONTROL
PUMP CONTROL
VALVE CONTROL
OTHER CONTROLS
ECM System
OUTLINE
FUEL INJECTION CONTROL
ENGINE START CONTROL
EGR (EXHAUST GAS RECIRCULATION) CONTROL
FUEL INJECTION AMOUNT CORRECTION
ENGINE STOP CONTROL
Hydraulic System
OUTLINE
PILOT CIRCUIT
MAIN CIRCUIT
BOOM LOWER METER-IN CUT CONTROL
Electrical System
OUTLINE
MAIN CIRCUIT
ELECTRIC POWER CIRCUIT (KEY SWITCH: OFF)
ACCESSORY CIRCUIT
STARTING CIRCUIT (KEY SWITCH: START)
CHARGING CIRCUIT (KEY SWITCH: ON)
SERGE VOLTAGE PREVENTION CIRCUIT
PILOT SHUT-OFF CIRCUIT (KEY SWITCH: ON)
SEUCURITY LOCK CIRCUIT
ENGINE STOP CIRCUIT (KEY SWITCH: OFF)
SECURITY HORN CIRCUIT
WORKING LIGHT CIRCUIT
WIPER CIRCUIT

SECTION 3 COMPONENT OPERATION
Pump Device
OUTLINE
MAIN PUMP
REGULATOR
SOLENOID VALVE
PILOT PUMP
PUMP DELIVERY PRESSURE SENSOR
PUMP CONTROL PRESSURE SENSOR
Swing Device
OUTLINE
SWING REDUCTION GEAR
SWING MOTOR
SWING PARKING BRAKE
VALVE UNIT
SWING DAMPENER VALVE
Control Valve
OUTLINE
HYDRAULIC CIRCUIT
FLOW COMBINER VALVE
MAIN RELIEF VALVE
OVERLOAD RELIEF VALVE
REGENERATIVE VALVE
ANTI-DRIFT VALVE
FLOW RATE CONTROL VALVE
DIGGING REGENERATIVE VALVE
BOOM LOWER METER-IN CUT 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
PILOT 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 1 FLOW RATE CONTROL VALVE CONTROL SPOOL
Others (Upperstructure)
PILOT SHUT-OFF SOLENOID VALVE
SOLENOID VALVE
HOSE RUPTURE VALVE
PILOT RELIEF VALVE
Others (Undercarriage)
SWING BEARING
CENTER JOINT
TRACK ADJUSTER

SERVICE MANUAL REVISION REQUEST FORM


COVER
INTRODUCTION
SAFETY
CONTENTS

SECTION 4 OPERATIONAL PERFORMANCE TEST
Introduction
OPERATIONAL PERFORMANCE TESTS
PREPARATION FOR PERFORMANCE TESTS
Standard
ZX200-3 CLASS OPERATIONAL PERFORMANCE STANDARD TABLE
ZX225US-3 CLASS OPERATIONAL PERFORMANCE STANDARD TABLE
ZX225USR-3 CLASS OPERATIONAL PERFORMANCE STANDARD TABLE
ZX240-3 CLASS OPERATIONAL PERFORMANCE STANDARD TABLE
ZX270-3 CLASS OPERATIONAL PERFORMANCE STANDARD TABLE
MAIN PUMP P-Q DIAGRAM
SENSOR ACTIVATING RANGE
ZX200-3 CLASS DR. ZX MONITOR INDICATING VALUES
ZX225US-3 CLASS DR. ZX MONITOR INDICATING VALUES
ZX225USR-3 CLASS DR. ZX MONITOR INDICATING VALUES
ZX240-3 CLASS DR. ZX MONITOR INDICATING VALUES
ZX270-3 CLASS DR. ZX MONITOR INDICATING VALUES
Engine Test
ENGINE SPEED
ENGINE COMPRESSION PRESSURE
VALVE CLEARANCE
LUBRICANT CONSUMPTION
Excavator Test
TRAVEL SPEED
TRACK REVOLUTION SPEED
MISTRACK CHECK
TRAVEL PARKING LEAKAGE
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 OPERATION OF BOOM RAISE / SWING FUNCTION CHECK
COMBINED OPERATION OF BOOM RAISE / ARM ROLL-IN FUNCTION CHECK
Component Test
PRIMARY PILOT PRESSURE
SECONDARY PILOT PRESSURE
SOLENOID VALVE SET PRESSURE
MAIN PUMP DELIVERY PRESSURE
MAIN RELIEF SET PRESSURE
RELIEF PRESSURE (WHEN RELIEVING SWING)
OVERLOAD RELIEF VALVE SET PRESSURE
MAIN PUMP FLOW RATE MEASUREMENT
SWING MOTOR DRAINAGE
TRAVEL MOTOR DRAINAGE

SECTION 5 TROUBLESHOOTING
Diagnosing Procedure
INTRODUCTION
DIAGNOSING PROCEDURE
Monitor Unit
OUTLINE
HOW TO USE SCREENS
PRIMARY SCREEN
SCREEN DISPLAY WHEN AN ALARM IS ISSUED
CONTENTS OF ALARMS
TROUBLESHOOTING
CONTROLLER VERSION
MONITORING
DISPLAYING OPERATING CONDITIONS
PUMP 2 FLOW RATE ADJUSTMENT (Only Machines Equipped with Optional Parts)
ATTACHMENT SELECTION (Only Machines Equipped with Optional Parts)
TIME SETTING
FUEL RATE DISPLAY/NO DISPLAY
BACK MONITOR SETTINGS
MAINTENANCE SETTINGS
LANGUAGE SETTINGS
MAIL

(Optional)
LIST OF MONITOR UNIT SETTING FUNCTION
Dr. ZX
OUTLINE
SELECT CONTROLLER
MAIN CONTROLLER
MAIN MENU MONITOR DISPLAY
SPECIAL FUNCTION
SETTING
ADJUSTMENT DATA LIST
ATTACHMENT ADJUSTMENT DATA LIST
ATTACHMENT SETTING
ENGINE CONTROLLER
MAIN MENU

MONITOR DISPLAY
DATA UPLOAD FROM ECM
DATA DOWNLOAD TO ECM
WRITE INJECTOR ID CODE
ECM DATA DISPLAY
ACTUATOR TEST
EXAMPLE OF HOW ENGINE SPEED DOWN & STOP CYLINDER FUNCTION USED (ON A FOUR-CYLINDER ENGINE)
RECORED DATA DISPLAY
PASSWORD CHANGE
ICF CONTROLLER
MAIN MENU INFORMATION C/U VARIOUS SETUP
INFORMATION C/U: INITIALIZE
ENTER MODEL AND SERIAL No.
ENTER DATE AND TIME
CONTROL DATA: INITIALIZE
SATELLITE TERMINAL: INITIALIZE
SATELLITE TERMINAL No. CONFIRMATION
COMMUNICATING STATE CHECK
ENTER SATELLITE COMM. START / STOP
DATE DOWNLOAD
SAVE DATA CHECK
PASSWORD CHANGE
MONITOR CONTROLLER
MONITORING
VARIOUS SETTINGS
OPTIONAL FUNCTION ALLOCATION
OVERLOAD ALARM ENABLE / DISABLE SELECTION
BACK MONITOR SETTING
OPERATING CONDITION ENABLE / DISABLE SELECTION
TIME SETTING FUNCTION ENABLE / DISABLE SELECTION
MAINTENANCE SETTING MAINTENANCE OPERATION ALLOW / NOT ALLOW SELECTION
NOTIFICATION FUNCTION ENABLE / DISABLE SELECTION
MAINTENANCE DISPLAY ITEM ON/OFF SELECTION
FUEL CONSUMPTION GAUGE DISPLAY ENABLE / DIABLE SELECTION
PASSWORD CHANGE

e-Shovel
OUTLINE
LIST OF DAILY REPORT DATA
LIST OF FREQUENCY DISTRIBUTION DATA
LIST OF TOTAL OPERATING HOURS
HOW TO DOWNLOAD AND UPLOAD DATA OF ICF
VARIOUS SETUP OF ICF AND SATELLITE COMMUNICATION TERMINAL BY USING Dr. ZX
LIST OF FAULT CODE
SATELLITE COMMUNICATION SYSTEM

Component Layout
MAIN COMPONENTS
ELECTRICAL SYSTEM (OVERVIEW)
ELECTRICAL SYSTEM (IN CAB)
ELECTRICAL SYSTEM (REAR TRAY)
ELECTRICAL SYSTEM (SWITCH PANEL)
ELECTRICAL SYSTEM (AROUND AIR CLEANER)
ELECTRICAL SYSTEM (RELAYS)
ENGINE
PUMP DEVICE
AROUND PUMP DEVICE
SWING DEVICE
CONTROL VALVE
SIGNAL CONTROL VALVE
SOLENOID VALVE
TRAVEL DEVICE
LAYOUT OF ATTACHMENT SPEC. PARTS
PILOT PORT (Signal Control Valve)

Troubleshooting A
TROUBLESHOOTING A PROCEDURE
FAULT CODE LIST
ECM
ICF
CONTROLLER HARDWARE FAILURE MC FAULT CODE 11000 to 11002
MC FAULT CODE 11003
MC FAULT CODE 11004
CAN HARNESS CHECK
ENGINE FAILURE MC FAULT CODE 11100
MC FAULT CODE 11101
PUMP FAILURE MC FAULT CODE 11200
MC FAULT CODE 11202
MC FAULT CODE 11206
MC FAULT CODE 11208
PILOT FAILURE MC FAULT CODE 11301
MC FAULT CODE 11302
MC FAULT CODE 11303
MC FAULT CODE 11304
MC FAULT CODE 11307
PROPORTIONAL SOLENOID VALVE FAILURE MC FAULT CODE 11400
MC FAULT CODE 11401
MC FAULT CODE 11402
MC FAULT CODE 11403
MC FAULT CODE 11404
MC FAULT CODE 11405
CAN DATA RECEPTION FAILURE MC FAULT CODE 11910, 11914, 11920
CAN HARNESS CHECK (MC FAULT CODE 11910, 11914, 11920)
MC FAULT CODE 11911, 11918
CAN HARNESS CHECK (MC FAULT CODE 11911, 11918)
OTHER FAILURES MC FAULT CODE 11901
ECM, SENSOR SYSTEM ECM FAULT CODES 100, 102, 105, 108, 110, 157, 172
ECM FAULT CODES 174, 636, 723, 10001
ECM, EXTERNAL DEVICE SYSTEM ECM FAULT CODES 651, 652, 653, 654, 655, 656, 1347, 10002
ECM, FUEL SYSTEM ECM FAULT CODES 157, 633, 1239, 1240
ECM, ENGINE PROTECTION ECM FAULT CODES 110, 190
ECM, ENGINE PROTECTION ECM FAULT CODES 987, 1485
ECM, INTERNAL CIRCUIT SYSTEM ECM FAULT CODES 628, 1077, 1079, 1080, 10003, 10004, 10005
ECM FAULT CODES 10006, 10007, 10008, 10009, 10010, 10011, 10013
ECM, COMMUNICATION SYSETEM ECM FAULT CODE 639
ICF, SATELLITE TERMINAL FAULT CODES 14000 to 14003
ICF, SATELLITE TERMINAL FAULT CODES 14006, 14008, 14100 to 14106
MONITOR UNIT FAULT CODE 13303
MONITOR UNIT FAULT CODE 13304
MONITOR UNIT FAULT CODES 13306, 13308
MONITOR UNIT FAULT CODE 13310
MONITOR UNIT FAULT CODE 13311
PILOT SHUT-OFF LEVER ALARM

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
ATTACHMENT PILOT CIRCUIT PRESSURE RELEASE PROCEDURE
ONE PART OF DATA, “DAILY REPORT DATA”, “DISTRIBUTION DATA” AND TOTAL OPERATING HOURS” IS NOT RECORDED

Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND MAINTENANCE
INSTRUCTIONS FOR DISCONNECTING CONNECTORS
FUSE INSPECTION
FUSIBLE LINK INSPECTION
BATTERY VOLTAGE CHECK
ALTERNATOR CHECK
CONTINUITY CHECK
VOLTAGE AND CURRENT MEASUREMENT
CHECK BY FALSE SIGNAL
TEST HARNESS
SERVICE MANUAL REVISION REQUEST FORM
THE ATTACHED DIAGRAM LIST

ZX2OO-3_330-3 CLASS ELECTRICAL DIAGRAM
ZX225US-3_225USR-3 CLASS ELECTRICAL DIAGRAM
ZX200-3_330-3 CLASS CONNECTORS
ZX225US-3_225USR-3 CLASS CONNECTORS
ZX200-3 ENGINE HARNESS 1
ZX225US-3_225USR-3 CLASS ENGINE HARNESS 1
ZX240-3 CLASS ENGINE HARNESS 1
ZX270-3 CLASS ENGINE HARNESS 1
ZX200-3_330-3 CLASS ENGINE HARNESS 2
ZX200-3_330-3 CLASS MONITOR UNIT HARNESS
ZX200-3_330-3 CLASS CAB HARNESS
ZX225US-3_225USR-3 CLASS HARNESS
ZX225US-3_225USR-3 CLASS CONSOLE HARNESS
ZX200-3_270-3 CLASS HYDRAULIC DIAGRAM
ZX240-3_270-3 CLASS HYDRAULIC CIRCUIT DIAGRAM
ZX200-3_270-3 CLASS HYDRAULIC CIRCUIT DIAGRAM

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