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

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