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

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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)

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