Hitachi Zaxis 200, 225, 230, 270 Class Hydraulic Excavator Technical Troubleshooting Manual

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This complete technical manual PDF download for the Zaxis 200, 225, 230, 270 Class Hitachi Hydraulic Excavator has easy to read text sections with top quality diagrams, pictures and illustrations.

Information included in the Technical Manual (Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures.

APPLICABLE MODELS :

200 class
200•200LC•210H•210LCH•210•210LC•210N•240
225 class
225US•225USLC•225USR•225USRLC
230 class
230•230LC•240H•240LCH•250•250LC•250LCN
270 class
270•270LC•280LC•280LCN

TABLE OF CONTENTS :

SECTION 4 OPERATIONAL PERFORMANCE TEST
SECTION 5 TROUBLESHOOTING
SERVICE MANUAL REVISION REQUEST FORM

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Manual No. : KM-178E
Total Pages : 404

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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INDEX_TT
INTRODUCTION
SAFETY
SECTION 4 OPERATIONAL PERFORMANCE TEST
Introduction
OPERATIONAL PERFORMANCE TESTS
PREPARATION FOR PERFORMANCE TESTS
Standard
ZX200 CLASS OPERATIONAL PERFORMANCE STANDARD TABLE
ZAXIS225USR OPERATIONAL PERFORMANCE STANDARD TABLE
ZAXIS225US OPERATIONAL PERFORMANCE STANDARD TABLE
ZX230 CLASS OPERATIONAL PERFORMANCE STANDARD TABLE
ZX270 CLASS OPERATIONAL PERFORMANCE STANDARD TABLE
MAIN PUMP P-Q DIAGRAM
INJECTION PUMP
ZX200 CLASS DR. ZX MONITOR INDICATING VALUES
ZAXIS225USR DR. ZX MONITOR INDICATING VALUES
ZAXIS225US DR. ZX MONITOR INDICATING VALUES
ZX230 CLASS DR. ZX MONITOR INDICATING VALUES
ZX270 CLASS DR. ZX MONITOR INDICATING VALUES
SENSOR ACTIVATING RANGE
Engine Test
ENGINE SPEED
ENGINE COMPRESSION PRESSURE
VALVE CLEARANCE ADJUSTMENT
NOZZLE CHECK
INJECTION TIMING
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 BOOM RAISE/SWING

FUNCTION CHECK
BOOM RAISE/ARM ROLL-IN COMBINED OPERATION
Component Test
PRIMARY PILOT PRESSURE
SECONDARY PILOT PRESSURE
SOLENOID VALVE SET PRESSURE
MAIN PUMP DELIVERY PRESSURE
MAIN RELIEF VALVE SET PRESSURE
RELIEF PRESSURE (When relieving Swing)
RELIEF PRESSURE (When relieving Travel)
OVERLOAD RELIEF VALVE SET PRESSURE
MAIN PUMP FLOW RATE MEASUREMENT
SWING MOTOR DRAINAGE
TRAVEL MOTOR DRAINAGE
Adjustment
ENGINE SPEED ADJUSTMENT AND ENGINE LEARNING
GOVERNOR LEVER AND FUEL CUT LEVER POSITION
SECTION 5 TROUBLESHOOTING
General
INTRODUCTION
DIAGNOSING PROCEDURE
BUILT-IN DIAGNOSING SYSTEM OPERATION
BUILT-IN DIAGNOSING FUNCTION DISPLAY LIST
Dr. ZX OPERATION
DR. ZX FAULT CODE LIST
DR. ZX MONITORING ITEM LIST
Dr. ZX SPECIAL FUNCTION
Dr. ZX SERVICE MODE
ADJUSTMENT DATA LIST
INITIAL SETTING OF BOOM ELECTRONIC CUSHION
Component Layout
MAIN COMPONENT LAYOUT
ELECTRICAL COMPONENT LAYOUT (Overview)
ELECTRICAL SYSTEM (Relays and Related Equipment)
ELECTRICAL SYSTEM (Monitors and Switches)
PUMP DEVICE
SWING DEVICE
CONTROL VALVE
SOLENOID VALVE UNIT
SIGNAL CONTROL VALVE
TRAVEL DEVICE
POSITIONING CONTROL VALVE
COMPONENTS IN CONTROL VALVE
SIGNAL CONTROL VALVE PORT LOCATION
Troubleshooting A
TROUBLESHOOTING A PROCEDURE
FAULT CODE LIST
FAULT CODE 01 (ABNORMAL EEPROM) FAULT CODE 02 (ABNORMAL RAM) FAULT CODE 03 (ABNORMAL A/D CONVERSION)
FAULT CODE 04 (ABNORMAL SENSOR VOLTAGE)
FAULT CODE 06 (ABNORMAL EC SENSOR)
FAULT CODE 07 (ABNORMAL ENGINE CONTROL DIAL ANGLE)
FAULT CODE 08 (ABNORMAL BOOM ANGLE SENSOR)
FAULT CODE 10 (ABNORMAL PUMP 1 DELIVERY PRESSURE) FAULT CODE 11 (ABNORMAL PUMP 2 DELIVERY PRESSURE)
FAULT CODE 12 (ABNORMAL PUMP 1 CONTROL PRESSURE) FAULT CODE 13 (ABNORMAL PUMP 2 CONTROL PRESSURE)
FAULT CODE 14 (ABNORMAL SWING PILOT PRESSURE) FAULT CODE 15 VPRESSURE) FAULT CODE 16(ABNORMAL ARM ROLL-IN PILOTPRESSURE) FAULT CODE 18(ABNORMAL TRAVEL PILOT PRESSURE)
FAULT CODE 19 (ABNORMAL OIL TEMPERATURE)
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
Troubleshooting C
TROUBLESHOOTING C (TROUBLESHOOTING
FOR MONITOR) PROCEDURE
MALFUNCTION OF COOLANT TEMPERATURE

GAUGE
MALFUNCTION OF FUEL GAUGE
MALFUNCTION OF INDICATOR LIGHT CHECK SYSTEM
MALFUNCTION OF PREHEAT INDICATOR
MALFUNCTION OF ENGINE OIL LEVEL INDICATOR
MALFUNCTION OF COOLANT LEVEL INDICATOR
MALFUNCTION OF ALTERNATOR INDICATOR
MALFUNCTION OF ENGINE OIL PRESSURE INDICATOR
MALFUNCTION OF OVERHEAT INDICATOR
MALFUNCTION OF AIR FILTER RESTRICTION
INDICATOR
MALFUNCTION OF BUZZER
MALFUNCTION OF LCD
MALFUNCTION OF HOUR METER
MALFUNCTION OF HYDRAULIC OIL FILTER INDICATOR (Optional)
Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND MAINTENANCE
INSTRUCTIONS FOR DISCONNECTING CONNECTORS
FUSE INSPECTION
FUSIBLE LINK INSPECTION
BATTERY VOLTAGE CHECK
HOW TO TROUBLESHOOT ALTERNATOR MALFUNCTIONS
CONTINUITY CHECK
VOLTAGE AND CURRENT MEASUREMENT
CHECK BY FALSE SIGNAL
TEST HARNESS
ICX
OUTLINE
ICX FAULT CODE LIST
SATELLITE TERMINAL FAULT CODE LIST
FAULT CODE 1 TO 4 AND 6
FAULT CODE 7 TO 10
SOME PARTS OF DATA IN DAILY REPORT, FREQUENCY DISTRIBUTION, CUMULATIVE OPERATION HOUR ARE NOT RECORDED

SERVICE MANUAL REVISION REQUEST FORM

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