Hitachi ZX200, ZX225USR, ZX225US, ZX230, ZX270 Crawler Excavator Workshop Repair Service Manual

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This complete service repair workshop manual PDF download for the ZAXIS 200, 225USR, 225US, 230 & 270 Hitachi Hydraulic Excavator  has easy to read text sections with top quality diagrams, pictures and illustrations. 

Information included in the Hitachi ZX200, ZX225USR, ZX225US, ZX230, ZX270 Crawler Hydraulic Excavator Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assemble/disassemble procedures.


APPLICABLE MODELS :

Hitachi Zaxis 200 / Hitachi ZX200
Hitachi Zaxis 225USR / Hitachi ZX225USR
Hitachi Zaxis 225US / Hitachi Zx225US
Hitachi Zaxis 230 / Hitachi ZX230
Hitachi Zaxis 270 / Hitachi ZX270


TABLE OF CONTENTS :

SECTION 1 GENERAL INFORMATION
    Precautions for Disassembling and Assembling
    Tightening
    Painting
    Bleeding Air from Hydraulic Oil Tank

SECTION 2 UPPERSTRUCTURE
    Cab
    Counterweight
    Main Frame
    Pump Device
    Control Valve
    Swing Device
    Pilot Valve
    Pilot Shut-Off Valve
    Signal Control Valve
    Solenoid Valve

SECTION 3 UNDERCARRIAGE
    Swing Bearing
    Travel Device
    Center Joint
    Track Adjuster
    Front Idler
    Upper And Lower Roller
    Track

SECTION 4 FRONT ATTACHMENT
    Front Attachment
    Cylinder

SECTION 5 ENGINE AND ACCESSORY
    General Information
    Maintenance
    Engine Assembly 1 (Disassembly)
    Engine Assembly 2 (Inspection and Repair)
    Engine Assembly 3 (Reassembly)
    Lubricating System
    Cooling System
    Fuel System
    Turbocharger
    Engine Electricals
    Troubleshooting
    Special Tool List
    Repair Standards
    Conversion Table


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Manual No. : KM-178E
Vol. No. : W178-E-02
Total Pages : 762


This service repair workshop 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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INDEX(W)
INTRODUCTION
SAFETY

SECTION 1 GENERAL INFORMATION
    Precautions for Disassembling and Assembling
        PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING
        MAINTENANCE STANDARD TERMINOLOGY
    Tightening
        TIGHTENING TORQUE SPECIFICATIONS
        TORQUE CHART
        PIPING JOINT
        PERIODIC REPLACEMENT OF PARTS
    Painting
        PAINTING
    Bleeding Air from Hydraulic Oil Tank
        BLEEDING AIR FROM HYDRAULIC OIL TANK
        
SECTION 2 UPPERSTRUCTURE
    Cab
        REMOVE AND INSTALL CAB
        DIMENTIONS 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 CONTROL VALVE 4-SPOOL AND 5-SPOOL SECTIONS
        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 (ZAXIS200, 200-E, 225US, 225USR, 230)
        ASSEMBLE SWING DEVICE (ZAXIS270)
        DISASSEMBLE SWING MOTOR (ZAXIS200, 200-E, 225US, 225USR, 230)
        DISASSEMBLE SWING MOTOR (ZAXIS270)
        ASSEMBLE SWING MOTOR (ZAXIS200, 200-E, 225US, 225USR, 230)
        ASSEMBLE SWING MOTOR (ZAXIS270)
        DISASSEMBLE AND ASSEMBLE PARKING BEAKE RELEASING VALVE (ZAXIS270)
        MAINTENANCE STANDARD
    Pilot Valve
        REMOVE AND INSTALL RIGHT PILOT VALVE
        REMOVE AND INSTALL LEFT PILOT VALVE
        REMOVE AND INSTALL TRAVEL PILOT VALVE
        DISASSEMBLE 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 PILOT SHUT-OFF VALVE (ZAXIS225US)
    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
        
SECTION 3 UNDERCARRIAGE
    Swing Bearing
        REMOVE AND INSTALL SWING BEARING
        DISASSEMBLE SWING BEARING
        ASSEMBLE SWING BEARING
    Travel Device
        REMOVE AND INSTALL TRAVEL DEVICE
        DISASSEMBLE TRAVEL REDUCER
        ASSEMBLE TRAVEL REDUCER
        DISASSEMBLE TRAVEL MOTOR ZAXIS200, 200-E
        ASSEMBLE TRAVEL MOTOR
        DISASSEMBLE BRAKE VALVE
        ASSEMBLE 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 Idler
        REMOVE AND INSTALL FRONT IDLER
        DISASSEMBLE FRONT IDLER
        ASSEMBLE FRONT IDLER
        MAINTENANCE STANDARD
    Upper And Lower Roller
        REMOVE AND INSTALL UPPER ROLLER
        REMOVE AND INSTALL LOWER ROLLER
        DISASSEMBLE LOWER ROLLER
        ASSEMBLE LOWER ROLLER
        MAINTENANCE STANDARD
    Track
        REMOVE AND INSTALL TRACKS
        MAINTENANCE STANDARD
        
SECTION 4 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
        REMOVE AND INSTALL CYLINDER
        HYDRAULIC CIRCUIT PRESSURE RELEASE PROCEDURE
        DISASSEMBLE CYLINDER
        ASSEMBLE CYLINDER
        MAINTENANCE STANDARD
        
SECTION 5 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 PART FIXING NUTS AND BOLTS
        IDENTIFICATIONS
    Maintenance
        LUBRICATING SYSTEM
        FUEL SYSTEM
        COOLING SYSTEM
        VALVE CLEARANCE AND ADJUSTMENT
        INJECTION TIMING
        COMPRESSION PRESSURE MEASUREMENT
        TURBOCHARGER INSPECTION
        ENGINE REPAIR KIT
        RECOMMENDED LUBRICANTS
        ENGINE OIL VISCOSITY CHART
    Engine Assembly 1 (Disassembly)
        EXTERNAL 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 REASSMBLY STEPS (Left-hand Side)
        EXTERNAL PARTS REASSMBLY 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
        GENERAL DESCRIPTION
        TURBOCHARGER IDENTIFICATION
        TROUBLESHOOTING
        INSPECTION AND REPAIR
    Engine Electricals
        STARTER IDENTIFICATION
        STARTER MAIN DATA AND SPECIFICATIONS
        STARTER MOTOR SECTIONAL VIEW
        PERFORMANCE
        DISASSEMBLY
        INSPECTION AND REPAIR
        REASSEMBLY
        ADJUSTMENT
        PERFORMANCE TEST
        ALTERNATOR IDENTIFICATION
        MAIN DATA AND SPECIFICATIONS
        ALTERNATOR SECTIONAL VIEW
        CHARGING CURCUIT
        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
        EXCESSUVE FUEL CONSUMPTION
        EXCESSIVE OIL CONSUMPTION
        OVERHEATING
        WHITE 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
        
SERVICE MANUAL REVISION REQUEST FORM

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