Hitachi Zaxis 200 User manual

(Operational Principle)
Manual No.:KM-178-E
Vol. No.:TO178-E-04
Technical Manual
Excavator
PRINTED IN SINGAPORE (PS)
200·225·230·270 class Excavator Technical Manual (Operational Principle)
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
Service Manual (Manual No. KM-178-E) consists of the following three separate volumes;
Technical Manual (Operational Principle) :Vol. No.TO178-E
Technical Manual (Troubleshooting) :Vol. No.
Workshop Manual :Vol. No.W178-E
178-E
TT

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INTRODUCTION
IN-01
TO THE READER
• This manual is written for an experienced technician
to provide technical information needed to maintain
and repair this machine.
• Be sure to thoroughly read this manual for cor-
rect product information and service procedures.
• If you have any questions or comments, at if you
found any errors regarding the contents of this
manual, please contact using “Service Manual
Revision Request Form” at the end of this man-
ual.
(Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: [phone]
FAX: [phone]
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition
to this manual.
• The Operator’s Manual
• The Parts Catalog
• Operation Manual of the Engine
• Parts Catalog of the Engine
• Hitachi Training Material
MANUAL COMPOSITION
• This manual consists of three portions: the Techni-
cal Manual (Operational Principle), the Technical
Manual (Troubleshooting) and the Workshop Man-
ual.
• Information included in the Technical Manual
(Operational Principle):
technical information needed for redelivery and
delivery, operation and activation of all devices
and systems.
• Information included in the Technical Manual
(Troubleshooting):
technical information needed for operational per-
formance tests, and troubleshooting procedures.
• Information included in the 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 assem-
ble/disassemble procedures.
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INTRODUCTION
IN-02
PAGE NUMBER
• Each page has a number, located on the center
lower part of the page, and each number contains
the following information:
Example : T 1-3-5
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and
signal words are used to alert the reader to the
potential for personal injury of machine damage.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed
along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to component/part weights.
To avoid injury and damage, be sure to use appropri-
ate lifting techniques and equipment when lifting
heavy parts.
• CAUTION:
Indicated potentially hazardous situation which
could, if not avoided, result in personal injury or
death.
• IMPORTANT:
Indicates a situation which, if not conformed to the
instructions, could result in damage to the machine.
• NOTE:
Indicates supplementary technical information or
know-how.
Consecutive Page Number for Each Group
Group Number
Section Number
T: Technical Manual W: Workshop Manual
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INTRODUCTION
IN-03
UNITS USED
• SI Units (International System of Units) are used in
this manual.
MKSA system units and English units are also
indicated in parenthheses just behind SI units.
Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
A table for conversion from SI units to other system
units is shown below for reference purposees.
Quantity To Convert
From Into Multiply By
MPa kgf/cm210.197Pressure
MPa psi 145.0
kW PS 1.360Power
kW HP 1.341
Temperature °C °F °C×1.8+32
km/h mph 0.6214Velocity
min-1 rpm 1.0
Flow rate L/min US gpm 0.2642
mL/rev cc/rev 1.0
Quantity To Convert
From Into Multiply By
mm in 0.03937Length
mm ft 0.003281
L US gal 0.2642
L US qt 1.057
Volume
m3yd31.308
Weight kg lb 2.205
N kgf 0.10197Force
N lbf 0.2248
N⋅m kgf⋅m 1.0197Torque
N⋅m lbf⋅ft 0.7375
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INTRODUCTION
IN-04
Hitachi machine models are classified into 4 classes and 1 model as
shown in the table below. When referring to the texts and/or illustrations
indicated with the applicable machine class names in this manual,
check that the machine models concerned are included using this ta-
ble.
Class
ZX200 Class ZAXIS200, 200LC, 210H, 210LCH, 210, 210LC, 210N, 240
ZX225 Class ZAXIS225USR, 225USRLC, 225US, 225USLC
ZX230 Class ZAXIS230, 230LC, 240H, 240LCH, 250, 250LC, 250LCN
ZX270 Class ZAXIS270, 270LC, 280LC, 280LCN
Model
Std. Model 200, 200LC, 210, 210LC, 210H, 210LCH, 210N, 225USR, 225USRLC,
225US, 225USLC, 230, 230LC, 240, 240H, 240LCH, 250, 250LC, 250LCN, 270,
270LC, 280LC, 280LCN
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SECTION AND GROUP
CONTENTS
TECHNICAL MANUAL
(Operational Principle)
All information, illustrations and speci-
fications in this manual are based on
the latest product information available
at the time of publication. The right is
reserved to make changes at any time
without notice.
COPYRIGHT(C)2005
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
SECTION 1 GENERAL
Group 1 Specification
Group 2 Component Layout
Group 3 Component Specifications
SECTION 2 SYSTEM
Group 1 Control System
Group 2 Hydraulic System
Group 3 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)
TECHNICAL MANUAL (Troubleshooting)
SECTION 4 OPERATIONAL PER-
FORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
Group 5 Component Test
Group 6 Adjustment
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Group 2 Component Layout
Group 3 Troubleshooting A
Group 4 Troubleshooting B
Group 5 Troubleshooting C
Group 6 Electrical System Inspection
Group 7 ICX
WORKSHOP MANUAL
SECTION 1 GENERAL INFORMA-
TION
Group 1 Precautions for Disassem-
bling and Assembling
Group 2 Tightening Torque
Group 3 Painting
Group 4 Bleeding Air from Hydrau-
lic Oil Tank
SECTION 2 UPPERSTRUCTURE
Group 1 Cab
Group 2 Counterweight
Group 3 Main Frame
Group 4 Pump Device
Group 5 Control Valve
Group 6 Swing Device
Group 7 Pilot Valve
Group 8 Pilot Shut-Off Valve
Group 9 Signal Control Valve
Group 10 Solenoid Valve
SECTION 3 UNDERCARRIAGE
Group 1 Swing Bearing
Group 2 Travel Device
Group 3 Center Joint
Group 4 Track Adjuster
Group 5 Front Idler
Group 6 Upper and Lower Roller
Group 7 Track
SECTION 4 FRONT ATTACHMENT
Group 1 Front Attachment
Group 2 Cylinder
SECTION 5 ENGINE
←これ以下
記載しない
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178T-1-1
SECTION 1
GENERAL
―CONTENTS―
Group 1 Specifications
Specifications............................................ T1-1-1
Working Ranges ..................................... T1-1-14
Group 2 Component Layout
Main Component Layout ........................... T1-2-1
Electrical Component Layout .................... T1-2-4
(Overview)
Electrical System ..................................... T-1-2-7
(Relays and Related Equipment)
Electrical System ................................... T-1-2-9
(Monitors and Switches)
Pump Device .......................................... T1-2-10
Swing Device .......................................... T1-2-10
Control Valve .......................................... T1-2-11
Signal Control Valve................................ T1-2-11
Solenoid Valve Unit................................. T1-2-11
Travel Device.......................................... T1-2-12
Positioning Control Valve ........................ T1-2-13
Group 3 Component Specifications
Engine ...................................................... T1-3-1
Engine Accessories .................................. T1-3-8
Hydraulic Component ............................... T1-3-9
Electrical Component.............................. T1-3-16
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178T-1-2
(Blank)
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