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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