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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