Hitachi ZX210W-3 & ZX220W-3 Wheeled Excavator Technical Repair Service Manual


-
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 ZX210W-3 & ZX220W-3 Class Hitachi Wheeled Hydraulic Excavator.


APPLICABLE MODELS :

Hitachi Excavator ZAXIS 210W-3
Hitachi Excavator ZAXIS 220W-3


TABLE OF CONTENTS :

Operational Principle - TOCJB-E-00

SECTION 1 GENERAL
Group 1 Specifications
Group 2 Component Layout
Group 3 Component Specifications

SECTION 2 SYSTEM
Group 1 Controller
Group 2 Control System
Group 3 ECM System
Group 4 Hydraulic System
Group 5 Electrical System

SECTION 3 COMPONENT OPERATION
Group 1 Pump Device
Group 2 Swing Device
Group 3 Control Valve
Group 4 Pilot Valve
Group 5 Electric Lever
Group 6 Transmission
Group 7 Axle
Group 8 Travel Motor
Group 9 Signal Control Valve
Group 10 Steering Valve
Group 11 Brake Valve
Group 12 Others (Upperstructure)
Group 13 Others (Undercarriage)

Troubleshooting - TTCJB-E-00

SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
Group 5 Component Test

SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Group 2 Monitor Unit
Group 3 Dr. ZX
Group 4 ICF
Group 5 Component Layout
Group 6 Troubleshooting A
Group 7 Troubleshooting B
Group 8 Electrical System Inspection

SERVICE MANUAL REVISION REQUEST FORM
THE ATTACHED DIAGRAM LIST

CIRCUIT DIAGRAM


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Total Pages : 1217


This complete technical manual PDF download for the Hitachi ZAXIS 210W-3 / 220W-3 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.

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

-

TOCJB-E-00_ZX210W-3/220W-3
INTRODUCTION
SECTION AND GROUP CONTENTS

SECTION 1 GENERAL
Group 1 Specifications
Specifications
Working Ranges
Group 2 Component Layout
Main Component Layout
Electrical System (Overview)
Electrical System (Monitors and Switches)
Electrical System (Controllers and Relays)
Engine
Pump Device
Swing Device
Signal Control Valve
Control Valve
Brake Valve
4-Spool Solenoid Valve Unit
Solenoid Valve Unit (for Electric Lever)
Travel Shockless Valve
Transmission Changeover Solenoid Valve
Travel Device
Filter
Group 3 Component Specifications
Engine
Engine Accessories
Hydraulic Component
Electrical Component

SECTION 2 SYSTEM
Group 1 Controller
Outline
Can: Controller Area Network (Network Provided for Machine)
MC: Main Controller
ECM: Engine Control Module
ICF: Information Controller
Monitor Unit
Option Controller
Steering Column Monitor
Group 2 Control System
Outline
Engine Control
Pump Control
Valve Control
Other Controls
Option Controller Control
Electric and Hydraulic Composite Circuit Control
Group 3 ECM System
Outline
Fuel Injection Control
Fuel Injection Amount Correction Control
Preheating Control
EGR (Exhaust Gas Recirculation) Control
Engine Stop Control
Group 4 Hydraulic System
Outline
Pilot Circuit
Service Brake Circuit
Steering Circuit
Main Circuit
Boom Lower Meter-In Cut Control
Group 5 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)
Security Lock Circuit
Engine Stop Circuit (Key Switch: OFF)
Security Horn Circuit
Wiper/Washer Circuit
Light Circuit

SECTION 3 COMPONENT OPERATION
Group 1 Pump Device
Outline
Main Pump
Regulator
Solenoid Valve
Pilot Pump, Steering Pump
Pump Delivery Pressure Sensor
Pump Control Pressure Sensor
Group 2 Swing Device
Outline
Swing Reduction Gear
Swing Motor
Swing Parking Brake
Valve Unit
Combination Valve
Group 3 Control Valve
Outline
Hydraulic Circuit
Flow Combiner Valve
Main Relief Valve
Overload Relief Valve
Make-Up Valve
Regenerative Valve
Anti-Drift Valve
Flow Rate Control Valve
Boom Lower Meter-In Cut Valve
Auxiliary Flow Combiner Valve and Bypass Shut-Out Valve
Group 4 Pilot Valve
Outline
Operation
Group 5 Electric Lever
Outline
Operation
Group 6 Transmission
Outline
Transmission
Shift Interlock Control
Shock Reducing Function
Disconnect Device
Group 7 Axle
Front Axle
Differential Gear
Reduction Gear
Steering Cylinder
Rear Axle
Group 8 Travel Motor
Outline
Rotor Section
Regulator
Overload Relief Valve
Travel Brake Valve
Group 9 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
Group 10 Steering Valve
Outline
Steering Valve
Operation
Overload Relief Valve
Make-Up Valve
Priority Valve
Operation
Relief Valve
Group 11 Brake Valve
Outline
Operation
Group 12 Others (Upperstructure)
Pilot Shut-Off Solenoid Valve
Transmission Changeover Solenoid Valve
Solenoid Valve
Travel Shockless Valve
Accumulator Charging Valve
Hose Rupture Valve
Accumulator
Pilot Relief Valve
Group 13 Others (Undercarriage)
Swing Bearing
Center Joint
Slip Ring
Cylinder
SERVICE MANUAL REVISION REQUEST FORM

Technical Manual (Troubleshooting)

INTRODUCTION
SAFETY
SECTION AND GROUP CONTENTS

SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction
Operational Performance Tests
Preparation for Performance Tests
Group 2 Standard
Performance Standard
Main Pump P-Q Diagram
Sensor Activating Range
Group 3 Engine Test
Engine Speed
Engine Compression Pressure
Valve Clearance
Lubricant Consumption
Group 4 Excavator Test
Travel Speed
Brake Control Function
Parking Brake Control Function
Swing Speed
Swing Function Drift Check
Swing Motor Leakage
Maximum Swingable Slant Angle
Swing Bearing Play
Hydraulic Cylinder Cycle Time
Hydraulic Cylinder Drift Check
Control Lever Operating Control Force
Control Lever Stroke
Combined Operation of Boom Raise/ Swing Function Check
Group 5 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
Steering Valve Relief Pressure
Brake Pressure (Front and Rear)
Brake Accumulated Pressure
Brake Warning Set Pressure (Decrease)
Brake Warning Set Pressure (Increase)

SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Introduction
Diagnosing Procedure
Group 2 Monitor Unit
Outline
How to Use Screens
Screen Display When An Alarm is Issued
Contents of Alarms
Time Setting
Attachment Adjustment (Pump 2 Flow Rate Adjustment)
Displaying Operating Conditions
Maintenance Settings
Work Mode (Attachment Selection)
Mail (Optional)
Meter Display Selection
Password Change (Optional)
Back Monitor Settings
Language Settings
Meter Combination Settings
Unit Settings
Service Menu (Built-In Diagnosing System) Operation
Troubleshooting
Monitoring
Controller Version
Blade/Outrigger Settings
Keyless Hour Meter
List of Monitor Unit Sitting Function
Group 3 Dr. ZX
Outline
MC Monitoring List
ECM Monitoring List
Monitor Unit Monitoring List
Steering Column Monitor Monitoring List
Option Controller Monitoring List
MC Adjustment List
MC Attachment Adjustment List
ICF Adjustment Item List
Option Controller Adjustment List
Dr. ZX Operation Procedure
Group 4 ICF
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
Group 5 Component Layout
Main Component Layout
Electrical Component Layout (Overview)
Electrical Component Layout (Monitors and Switches)
Electrical Component Layout (Controllers and Relays)
Engine
Pump Device
Swing Device
Signal Control Valve
Control Valve
Brake Valve
4-Spool Solenoid Valve Unit
Solenoid Valve Unit (for Electric Lever)
Travel Shockless Valve
Transmission Changeover Solenoid Valve
Travel Device
Filter
Components in Control Valve
Pilot Port
Group 6 Troubleshooting A
Troubleshooting A Procedure
MC Fault Code List
ECM Fault Code List
ICF Fault Code List
Satellite Terminal Fault Code List
Monitor Unit Fault Code List
Option Controller Fault Code List
Steering Column Monitor Fault Code
MC Fault Codes 11000 to 11002
MC Fault Code 11003
MC Fault Code 11004
CAN Harness Check
MC Fault Code 11100
MC Fault Code 11101
MC Fault Code 11200
MC Fault Code 11202
MC Fault Code 11203
MC Fault Code 11206
MC Fault Code 11208
MC Fault Code 11301
MC Fault Code 11302
MC Fault Code 11303
MC Fault Code 11305
MC Fault Code 11306
MC Fault Code 11307
MC Fault Code 11310
MC Fault Code 11311
MC Fault Code 11400
MC Fault Code 11401
MC Fault Code 11403
MC Fault Code 11404
MC Fault Code 11410
MC Fault Code 11422
MC Fault Code 11424
MC Fault Code 11425
MC Fault Codes 11910 to 11920
MC Fault Code 11901
ECM Fault Codes 100 to 190
ECM Fault Codes 628 to 1485
ECM Fault Codes 10001 to 10013
ICF Fault Codes 14000 to 14003
Information C/U: Intialize
Control Data: Intialize
Enter Model and Serial No
ICF Fault Codes 14006, 14008
Satellite Terminal Fault Codes 14100 to 14106
Monitor Unit Fault Code 13303
Monitor Unit Fault Code 13304
Monitor Unit Fault Codes 13306 and 13308
Monitor Unit Fault Code 13310
Monitor Unit Fault Code 13311
Pilot Shut-Off Lever Alarm
Option Controller Fault Codes 15500 to 15504
Option Controller Fault Code 15505
Option Controller Fault Code 15506
Option Controller Fault Code 15510
Option Controller Fault Code 15511
Option Controller Fault Code 15514
Option Controller Fault Code 15515
Option Controller Fault Code 15516
Option Controller Fault Code 15517
Option Controller Fault Code 15518
Option Controller Fault Code 15519
Option Controller Fault Code 15570
Option Controller Fault Code 15571
Option Controller Fault Code 15572
Option Controller Fault Code 15573
Option Controller Fault Codes 15574-3 and 15578-3
Option Controller Fault Codes 15574-4 and 15578-4
Option Controller Fault Codes 15575-3 and 15579-3
Option Controller Fault Codes 15575-4 and 15579-4
Option Controller Fault Codes 20300 to 20303
Option Controller Fault Code 15520
Option Controller Fault Code 15521
Option Controller Fault Code 15522
Option Controller Fault Code 15523
Option Controller Fault Code 15524
Option Controller Fault Code 15525
Option Controller Fault Code 15526
Option Controller Fault Code 15527
Option Controller Fault Code 15528
Option Controller Fault Code 15529
Option Controller Fault Code 15530
Option Controller Fault Codes 15565 to 15577
Steering Column Monitor Fault Code 16000
Group 7 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
Brake System Troubleshooting
Steering System Troubleshooting
Other System Troubleshooting
Exchange Inspection
Bleeding Air from Transmission
Bleeding Air from Brake (Axle)
Emergency Boom Lowering Procedure (without Hose Rupture Valve)
Attachment Circuit Pressure Release Procedure
Group 8 Electrical System Inspection
Precautions for Inspection and Maintenance
Instructions for Disconnecting Connectors
Fuse Inspection
Fusible Link Inspection
Battery Voltage Check
How to Check Alternator
Continuity Check
Voltage and Current Measurement
Check by False Signal
Test Harness

SERVICE MANUAL REVISION REQUEST FORM

THE ATTACHED DIAGRAM LIST

Updated Information - 15 pages (070618)
T4-2-1
T4-2-2
T4-2-4
T5-2-74
T5-3-8
T5-3-9
T5-3-18
T5-3-19
T5-3-20
T5-3-21
T5-3-22
T5-4-1
T5-7-2
T5-7-75
T5-7-111


ZAXIS140W-3/170W-3/190W-3/210W-3/220W-3 ELECTRICAL CIRCUIT DIAGRAM (STANDARD)
ZAXIS140W-3/170W-3/190W-3/210W-3/220W-3 ELECTRICAL CIRCUIT DIAGRAM (OPTIONAL)
ZAXIS140W-3/170W-3/190W-3/210W-3/220W-3 CONNECTORS
ZAXIS140W-3/170W-3/190W-3/210W-3/220W-3 CAB HARNESS
ZAXIS210W-3/220W-3 ENGINE HARNESS
ZAXIS140W-3/170W-3/190W-3/210W-3/220W-3 FLOOR HARNESS
ZAXIS140W-3/170W-3/190W-3/210W-3/220W-3 MONITOR HARNESS
ZAXIS170W-3/190W-3/210W-3/220W-3 CHASSIS HARNESS
ZAXIS140W-3/170W-3/190W-3/210W-3/220W-3 LEFT CONSOLE HARNESS
ZAXIS140W-3/170W-3/190W-3/210W-3/220W-3 AUXILIARY / POSITIONING SELECTION HARNESS
ZAXIS140W-3/170W-3/190W-3/210W-3/220W-3 BLADE / OUTRIGGER HARNESS
ZAXIS140W-3/170W-3/190W-3/210W-3/220W-3 LICENSE PLATE HARNESS
ZAXIS210W-3/220W-3 POSITIONING HARNESS
ZAXIS140W-3/170W-3/190W-3/210W-3/220W-3 PRESSURE SENSOR (POSITIONING) HARNESS
ZAXIS170W-3/190W-3/210W-3/220W-3 SWING PARKING BRAKE RELEASE HARNESS
ZAXIS210W-3/220W-3 POWER DIGGING HARNESS
ZAXIS210W-3/220W-3 HYDRAULIC CIRCUIT DIAGRAM (2-PIECE BOOM, FULLY OPTIONAL)
ZAXIS210W-3/220W-3 HYDRAULIC CIRCUIT DIAGRAM (MONOBLOCK BOOM, FULLY OPTIONAL)


ZAXIS210W-3/220W-3 FRONT ATTACHMENT HARNESS (OPTIONAL)
ZAXIS210W-3/220W-3 FLOW RATE SELECTOR HARNESS (OPTIONAL)
ZAXIS210W-3/220W-3 SELECTOR VALVE / SECONDARY PILOT RELIEF SELECTOR HARNESS (OPTIONAL)
ZAXIS140W-3/170W-3/190W-3/210W-3/220W-3 BOOM BOTTOM PRESSURE SENSOR HARNESS (OPTIONAL)
ZAXIS210W-3/220W-3 ASSIST HARNESS (OPTIONAL)
ZAXIS140W-3/170W-3/190W-3/210W-3/220W-3 FLOW RATE ADJUSTMENT ASSIST HARNESS (OPTIONAL)
ZAXIS140W-3/170W-3/190W-3/210W-3/220W-3 ASSIST HARNESS (1) (OPTIONAL)
ZAXIS140W-3/170W-3/190W-3/210W-3/220W-3 ASSIST HARNESS (2) (OPTIONAL)
ZAXIS140W-3/170W-3/190W-3/210W-3/220W-3 OVERLOAD ALARM HARNESS (OPTIONAL)
ZAXIS140W-3/170W-3/190W-3/210W-3/220W-3 OVERLOAD ALARM SUB HARNESS (OPTIONAL)
ZAXIS140W-3/170W-3/190W-3/210W-3/220W-3 GRIP EXTENSION HARNESS (OPTIONAL)
ZAXIS140W-3/170W-3/190W-3/210W-3/220W-3 GRIP EXTENSION HARNESS (FNR)
ZAXIS140W-3/170W-3/190W-3/210W-3/220W-3 HEATER SEAT HARNES (OPTIONAL)
ZAXIS140W-3/170W-3/190W-3/210W-3/220W-3 AUTO-CRUISE HARNESS (OPTIONAL)

-