Hitachi ZX200-3 / ZX225US-3 / ZX225USR-3 / ZX240-3 / ZX270-3 Class Excavator Training Text

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


APPLICABLE MODELS :
        
HITACHI ZAXIS200-3
HITACHI    ZAXIS200LC-3
HITACHI    ZAXIS210H-3
HITACHI    ZAXIS210LCH-3
HITACHI    ZAXIS210K-3
HITACHI    ZAXIS210LCK-3
HITACHI    ZAXIS240-3
HITACHI    ZAXIS240LC-3
HITACHI    ZAXIS250H-3
HITACHI    ZAXIS250LCH-3
HITACHI    ZAXIS250K-3
HITACHI    ZAXIS250LCK-3
HITACHI    ZAXIS270-3
HITACHI    ZAXIS270LC-3
HITACHI    ZAXIS330-3
HITACHI    ZAXIS330LC-3
HITACHI    ZAXIS350H-3
HITACHI    ZAXIS350LCH-3
HITACHI    ZAXIS350K-3
HITACHI    ZAXIS350LCK-3 


TABLE OF CONTENTS :

OPERATION PRINCIPLE
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 Travel Device
    Group 6 Signal Control Valve
    Group 7 Others (Upperstructure)
    Group 8 Others (Undercarriage)
        
PEFORMANCE CHECK & TROUBLESHOOTING
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

MAINTENANCE
MAINTENANCE
    CORRECT MAINTENANCE AND INSPECTIONPROCEDURES
    CHECK THE HOUR METER REGULARLY
    USE CORRECT FUELS AND LUBRICANTS
    LAYOUT
    MAINTENANCE GUIDE TABLE
    PREPARE MACHINE FOR MAINTENANCE
    HOOD AND ACCESS COVERS
    PERIODIC REPLACEMENT OF PARTS
    MAINTENANCE GUIDE
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS
    MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS
STORAGE
    STORING THE MACHINE
    REMOVING THE MACHINE FROM STORAGE
TROUBLESHOOTING
    IMPOSSIBLE TO START THE ENGINE
    ENGINE
    ELECTRICAL SYSTEM
    MODE SELECTION
    CONTROL LEVERS
    HYDRAULIC SYSTEM
    HYDRAULIC SYSTEM
SPECIFICATIONS
    SPECIFICATIONS
    WORKING RANGES
    SHOE TYPES AND APPLICATIONS
    BUCKET TYPES AND APPLICATIONS
        
GENERAL INFORMATION
Contents
Overview
    Front
    Side
    Rear
Cab (STD)
Air Conditioner (Fresh Air Filter)
Air Conditioner (Circulating Air Filter)
Cab Interior
Cab Floor
Emergency Engine Stop Switch
Multi-Function Monitor
Switch Panel (Right)
Switch Panel (Left)
Pilot Control Shut-Off Lever
Pilot Valve & Shut-Off Switch
Rear Tray
Electrical Parts in Cab
Engine Compartment with Cover
Engine
Cooled EGR System Sensors
Crank Speed Sensor & Sensors
Coolant Temp. Sensor
Common Rail Pressure Sensor
Main Fuel / Pre-Fuel Filter & Fuel Pump
Engine Oil Filter
Engine Oil Drain
Engine Oil Drainer
Utility Space
Engine Control Module (ECM)
Air Cleaner and Element
Air Cleaner Restriction Switch
Atmosphric Pressure Sensor
Intake Air Temperature Sensor
Cooling System (Inter Cooler and Radiator, Oil Cooler)
Air Conditioner Condenser and Fuel Cooler
Battery and Relays
Pump Compartment
Pump Device
Pump Regulator
Pilot Filter
Main Component Layout
Control Valve
Main and Overload Relief Valve
Arm Roll-In Pressure Sensor
Boom-Up Pressure Sensor
Signal Control Valve
Swing Device
Hydraulic Oil Tank
Hydraulic Oil Temperature Sensor
Fuel Tank
Fuel Level Gauge Sensor
Automatic Fuel Device (Option)
Undercarriage
Track Frame
Track Link and Rollers
Front Idler
Travel Device
Travel Motor
Center Joint (1)
Center Joint (2)
Front Attachment (Standard)
Attachment Piping (Standard)
Hose Rupture Valve for Mono Boom Type (Option)


MANUAL SPECIFICATION :

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


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OPERATION PRINCIPLE

SECTION 1 - GENERAL
    Group 1 Specifications
        Specifications
        Working Ranges
    Group 2 Component Layout
        Main Components
        Electrical System (Overview)
        Engine
        Pump Device
        Swing Device
        Control Valve
        Signal Control Valve
        Solenoid Valve Unit
        Travel Device
    Group 3 Component Specifications
        Engine
        Engine Accessories
        Hydraulic Component
        Electrical Component
        
SECTION 2 - SYSTEM
    Group 1 Controller
        Outline
        Can (Network Provided for Machine)
        MC: Main Controller
        ECM: Engine Control Module
        ICF: Information Controller
        Outline
    Group 2 Control System
        Outline
        Engine Control
        Pump Control
        Valve Control
        Other Controls
    Group 3 ECM System
        Outline
        Fuel Injection Control
        Engine Start Control
        EGR (Exhaust Gas Recirculation) Control
        Fuel Injection Amount Correction
        Engine Stop Control
    Group 4 Hydraulic System
        Outline
        Pilot 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
        Security Horn Circuit
        Working Light Circuit
        Wiper Circuit
        
SECTION 3 - COMPONENT OPERATION
    Group 1 Pump Device
        Outline
        Main Pump
        Regulator
        Solenoid Valve
        Pilot Pump
        Pump Delivery Pressure Sensor
        Pump Control Pressure Sensor
    Group 2 Swing Device
        Outline
        Swing Reduction Gear
        Swing Motor
        Swing Parking Brake
        Valve Unit
        Swing Dampener Valve
    Group 3 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 Ccmbiner Valve

and Bypass Shut-Out Valve
    
Group 4 Pilot Valve
        Outline
        Operation
        Shockless Function

(Only for Travel Pilot Valve)
    Group 5 Travel Device
        Outline
        Travel Reduction Gear
        Travel Motor
        Parking Brake
        Travel Mode Change
        Travel Brake Valve
    Group 6 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 7 Others (Upperstructure)
        Pilot Shut-Off Valve
        Solenoid Valve
        Hose Rupture Valve
        Pilot Relief Valve
    Group 8 Others (Undercarriage)
        Swing Bearing
        Center Joint
        Track Adjuster
        
PEFORMANCE CHECK & TROUBLESHOOTING
SECTION 4 - OPERATIONAL PERFORMANCE TEST
    Introduction
        OPERATIONAL PERFORMANCE TESTS
        PREPARATION FOR PERFORMANCE TESTS
    Standard
        ZX200-3 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
    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 SET
        FUEL RATE DISPLAY/NO DISPLAY
        BACK MONITOR SETTINGS
        MAINTENANCE SETTINGS
        LANGUAGE SETTINGS
        MAIL (Optional)
    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
        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
        INTERNAL HOUR METER SYNCHRONIZATION
        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)
        ENGINE
        PUMP DEVICE
        SWING DEVICE
        CONTROL VALVE
        SIGNAL CONTROL VALVE
        SOLENOID VALVE UNIT
        TRAVEL DEVICE
        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
        MC FAULT CODE 11410
        CAN DATA RECEPTION FAILURE MC FAULT CODE 11910
        CAN HARNESS CHECK MC FAULT CODE 11910
        MC FAULT CODE 11918
        CAN HARNESS CHECK MC FAULT CODE 11918
        MC FAULT CODE 11911
        CAN HARNESS CHECK MC FAULT CODE 11911
        MC FAULT CODE 11920
        CAN HARNESS CHECK MC FAULT CODE 11920
        MC FAULT CODE 11914
        CAN HARNESS CHECK MC FAULT CODE 11914
        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
        ONE PART OF DATA, “DAILY REPORT DATA”, “DISTRIBUTION DATA” AND TOTAL OPERATING HOURS” IN 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

MAINTENANCE
MAINTENANCE
    CORRECT MAINTENANCE AND INSPECTION

PROCEDURES
    CHECK THE HOUR METER REGULARLY
    USE CORRECT FUELS AND LUBRICANTS
    LAYOUT
    MAINTENANCE GUIDE TABLE
    PREPARE MACHINE FOR MAINTENANCE
    HOOD AND ACCESS COVERS
    PERIODIC REPLACEMENT OF PARTS
    MAINTENANCE GUIDE
        A. GREASING
        B. ENGINE
        C. TRANSMISSION
        D. HYDRAULIC SYSTEM
        E. FUEL SYSTEM
        F. AIR CLEANER
        G. COOLING SYSTEM
        H. ELECTRICAL SYSTEM
        I. MISCELLANEOUS
MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS
    MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS
STORAGE
    STORING THE MACHINE
    REMOVING THE MACHINE FROM STORAGE
TROUBLESHOOTING
    IMPOSSIBLE TO START THE ENGINE
    ENGINE
    ELECTRICAL SYSTEM
    MODE SELECTION
    CONTROL LEVERS
    HYDRAULIC SYSTEM
    HYDRAULIC SYSTEM
SPECIFICATIONS
    SPECIFICATIONS
        ZAXIS200-3, ZAXIS200LC-3, ZAXIS210H-3, ZAXIS210LCH-3
        ZAXIS210K-3, 210LCK-3
        ZAXIS240-3, 240LC-3, 250H-3, 250LCH-3
        ZAXIS250K-3, 250LCK-3
        ZAXIS270-3, 270LC-3
        ZAXIS330-3, 330LC-3, 350H-3, 350LCH-3
        ZAXIS350K-3, 350LCK-3
    WORKING RANGES
        ZAXIS200-3, ZAXIS200LC-3, ZAXIS210H-3, ZAXIS210LCH-3
        ZAXIS210K-3, 210LCK-3
        ZAXIS240-3, 240LC-3, 250H-3, 250LCH-3
        ZAXIS250K-3, 250LCK-3
        ZAXIS270-3, 270LC-3
        ZAXIS330-3, 330LC-3, 350H-3, 350LCH-3
        ZAXIS350K-3, 350LCK-3
    SHOE TYPES AND APPLICATIONS
        ZAXIS200-3
        ZAXIS200LC-3
        ZAXIS210H-3
        ZAXIS210LCH-3
        ZAXIS210K-3
        ZAXIS210LCK-3
        ZAXIS240-3
        ZAXIS240LC-3
        ZAXIS250H-3
        ZAXIS250LCH-3
        ZAXIS250K-3
        ZAXIS250LCK-3
        ZAXIS270-3
        ZAXIS270LC-3
        ZAXIS330-3
        ZAXIS330LC-3
        ZAXIS350H-3
        ZAXIS350LCH-3
        ZAXIS350K-3
        ZAXIS350LCK-3
    BUCKET TYPES AND APPLICATIONS
        ZAXIS200-3, ZAXIS200LC-3, ZAXIS210H-3, ZAXIS210LCH-3
        ZAXIS210K-3，ZAXIS210LCK-3
        ZAXIS240-3, 240LC-3, 250H-3, 250LCH-3
        ZAXIS250K-3, ZAXIS250LCK-3
        ZAXIS270-3, 270LC-3
        ZAXIS330-3, 330LC-3, 350H-3, 350LCH-3
        ZAXIS350K-3, ZAXIS350LCK-3
        
        
GENERAL INFORMATION
Contents
Overview
    Front
    Side
    Rear
Cab (STD)
Air Conditioner (Fresh Air Filter)
Air Conditioner (Circulating Air Filter)
Cab Interior
Cab Floor
Emergency Engine Stop Switch
Multi-Function Monitor
Switch Panel (Right)
Switch Panel (Left)
Pilot Control Shut-Off Lever
Pilot Valve & Shut-Off Switch
Rear Tray
Electrical Parts in Cab
Engine Compartment with Cover
Engine
Cooled EGR System Sensors
Crank Speed Sensor & Sensors
Coolant Temp. Sensor
Common Rail Pressure Sensor
Main Fuel / Pre-Fuel Filter & Fuel Pump
Engine Oil Filter
Engine Oil Drain
Engine Oil Drainer
Utility Space
Engine Control Module (ECM)
Air Cleaner and Element
Air Cleaner Restriction Switch
Atmosphric Pressure Sensor
Intake Air Temperature Sensor
Cooling System (Inter Cooler and Radiator, Oil Cooler)
Air Conditioner Condenser and Fuel Cooler
Battery and Relays
Pump Compartment
Pump Device
Pump Regulator
Pilot Filter
Main Component Layout
Control Valve
Main and Overload Relief Valve
Arm Roll-In Pressure Sensor
Boom-Up Pressure Sensor
Signal Control Valve
Swing Device
Hydraulic Oil Tank
Hydraulic Oil Temperature Sensor
Fuel Tank
Fuel Level Gauge Sensor
Automatic Fuel Device (Option)
Undercarriage
Track Frame
Track Link and Rollers
Front Idler
Travel Device
Travel Motor
Center Joint (1)
Center Joint (2)
Front Attachment (Standard)
Attachment Piping (Standard)
Hose Rupture Valve for Mono Boom Type (Option)

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