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Hitachi Zaxis Zx200 225usr 225us 230 270 Workshop Manual – PDF Download
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Hitachi Zaxis Zx200 225usr 225us 230 270 Workshop Manual
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Description
Hitachi Zaxis Zx200 225usr 225us 230 270 Workshop Manual
FILE DETAILS:
Hitachi Zaxis Zx200 225usr 225us 230 270 Workshop Manual
LANGUAGE:ENGLISH
PAGES:762
DOWNLOADABLE:YES
FILE TYPE:PDF
HITACHI ZAXIS ZX200 225USR 225US 230 270 WORKSHOP MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Hitachi Zaxis Zx200 225usr 225us 230 270 Workshop Manual
This manual consists of two portions: the Technical Manual and the Workshop Manual. Use the manuals according to purpose. Information included in the Technical Manual: technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance 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 assemble/ disassemble procedures.
TABLE OF CONTENTS:
Hitachi Zaxis Zx200 225usr 225us 230 270 Workshop Manual
INDEX(W)......................................................................................... 1 INTRODUCTION..................................................................................... 3 SAFETY........................................................................................... 5 SECTION 1 GENERAL INFORMATION.................................................................... 37 Precautions for Disassembling and Assembling................................................. 39 PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING............................................. 39 MAINTENANCE STANDARD TERMINOLOGY......................................................... 45 Tightening................................................................................... 47 TIGHTENING TORQUE SPECIFICATIONS......................................................... 47 TORQUE CHART............................................................................. 50 PIPING JOINT............................................................................. 53 PERIODIC REPLACEMENT OF PARTS............................................................ 57 Painting..................................................................................... 59 PAINTING................................................................................. 59 Bleeding Air from Hydraulic Oil Tank......................................................... 67 BLEEDING AIR FROM HYDRAULIC OIL TANK..................................................... 67 SECTION 2 UPPERSTRUCTURE......................................................................... 71 Cab.......................................................................................... 73 REMOVE AND INSTALL CAB................................................................... 73 DIMENTIONS OF THE CAB GLASS.............................................................. 85 Counterweight................................................................................103 REMOVE AND INSTALL COUNTERWEIGHT.........................................................103 Main Frame...................................................................................105 REMOVE AND INSTALL MAIN FRAME............................................................105 Pump Device..................................................................................111 REMOVE AND INSTALL PUMP DEVICE...........................................................111 DISASSEMBLE PUMP DEVICE..................................................................112 ASSEMBLE PUMP DEVICE.....................................................................120 DISASSEMBLE REGULATOR....................................................................132 ASSEMBLE REGULATOR.......................................................................134 DISASSEMBLE SOLENOID VALVE...............................................................136 ASSEMBLE SOLENOID VALVE..................................................................138 DISASSEMBLE AND ASSEMBLE PILOT PUMP......................................................140 MAINTENANCE STANDARD.....................................................................142 Control Valve................................................................................145 REMOVE AND INSTALL CONTROL VALVE.........................................................145 DISASSEMBLE CONTROL VALVE 4-SPOOL SECTION................................................152 DISASSEMBLE CONTROL VALVE 5-SPOOL SECTION................................................158 DISASSEMBLE AND ASSEMBLE CONTROL VALVE 4-SPOOL AND 5-SPOOL SECTIONS......................164 ASSEMBLE CONTROL VALVE 4-SPOOL SECTION...................................................166 ASSEMBLE CONTROL VALVE 5-SPOOL SECTION...................................................174 Swing Device.................................................................................183 REMOVE AND INSTALL SWING DEVICE..........................................................183 DISASSEMBLE SWING DEVICE (ZAXIS200, 200-E, 225US, 225USR, 230)...........................186 DISASSEMBLE SWING DEVICE (ZAXIS270)......................................................192 ASSEMBLE SWING DEVICE (ZAXIS200, 200-E, 225US, 225USR, 230)..............................198 ASSEMBLE SWING DEVICE (ZAXIS270).........................................................206 DISASSEMBLE SWING MOTOR (ZAXIS200, 200-E, 225US, 225USR, 230)............................212 DISASSEMBLE SWING MOTOR (ZAXIS270).......................................................216 ASSEMBLE SWING MOTOR (ZAXIS200, 200-E, 225US, 225USR, 230)...............................220 ASSEMBLE SWING MOTOR (ZAXIS270)..........................................................224 DISASSEMBLE AND ASSEMBLE PARKING BEAKE RELEASING VALVE (ZAXIS270)........................228 MAINTENANCE STANDARD.....................................................................229 Pilot Valve..................................................................................231 REMOVE AND INSTALL RIGHT PILOT VALVE.....................................................231 REMOVE AND INSTALL LEFT PILOT VALVE......................................................235 REMOVE AND INSTALL TRAVEL PILOT VALVE....................................................238 DISASSEMBLE RIGHT AND LEFT PILOT VALVES..................................................240 ASSEMBLE RIGHT AND LEFT PILOT VALVES.....................................................248 DISASSEMBLE TRAVEL PILOT VALVE...........................................................256 ASSEMBLE TRAVEL PILOT VALVE..............................................................264 Pilot Shut-Off Valve.........................................................................277 REMOVE AND INSTALL PILOT SHUT-OFF VALVE..................................................277 DISASSEMBLE PILOT SHUT-OFF VALVE (ZAXIS200, 200-E, 225USR, 230, 270).....................280 DISASSEMBLE PILOT SHUT-OFF VALVE (ZAXIS225US)............................................282 ASSEMBLE PILOT SHUT-OFF VALVE (ZAXIS200, 200-E, 225USR, 230, 270)........................284 ASSEMBLE PILOT SHUT-OFF VALVE (ZAXIS225US)...............................................286 Signal Control Valve.........................................................................289 REMOVE AND INSTALL SIGNAL CONTROL VALVE..................................................289 Solenoid Valve...............................................................................291 REMOVE AND INSTALL SOLENOID VALVE UNIT...................................................291 DISASSEMBLE PROPORTIONAL SOLENOID VALVE..................................................292 ASSEMBLE PROPORTIONAL SOLENOID VALVE.....................................................294 SECTION 3 UNDERCARRIAGE..........................................................................299 Swing Bearing................................................................................301 REMOVE AND INSTALL SWING BEARING.........................................................301 DISASSEMBLE SWING BEARING................................................................304 ASSEMBLE SWING BEARING...................................................................306 Travel Device................................................................................309 REMOVE AND INSTALL TRAVEL DEVICE.........................................................309 DISASSEMBLE TRAVEL REDUCER...............................................................312 ASSEMBLE TRAVEL REDUCER..................................................................318 DISASSEMBLE TRAVEL MOTOR ZAXIS200, 200-E.................................................328 ASSEMBLE TRAVEL MOTOR....................................................................344 DISASSEMBLE BRAKE VALVE..................................................................370 ASSEMBLE BRAKE VALVE.....................................................................376 MAINTENANCE STANDARD.....................................................................382 Center Joint.................................................................................385 REMOVE AND INSTALL CENTER JOINT..........................................................385 DISASSEMBLE CENTER JOINT.................................................................388 ASSEMBLE CENTER JOINT....................................................................390 MAINTENANCE STANDARD.....................................................................393 Track Adjuster...............................................................................395 REMOVE AND INSTALL TRACK ADJUSTER........................................................395 DISASSEMBLE TRACK ADJUSTER...............................................................396 ASSEMBLE TRACK ADJUSTER..................................................................404 Front Idler..................................................................................413 REMOVE AND INSTALL FRONT IDLER...........................................................413 DISASSEMBLE FRONT IDLER..................................................................414 ASSEMBLE FRONT IDLER.....................................................................418 MAINTENANCE STANDARD.....................................................................420 Upper And Lower Roller.......................................................................421 REMOVE AND INSTALL UPPER ROLLER..........................................................421 REMOVE AND INSTALL LOWER ROLLER..........................................................425 DISASSEMBLE LOWER ROLLER.................................................................428 ASSEMBLE LOWER ROLLER....................................................................430 MAINTENANCE STANDARD.....................................................................432 Track........................................................................................435 REMOVE AND INSTALL TRACKS................................................................435 MAINTENANCE STANDARD.....................................................................441 SECTION 4 FRONT ATTACHMENT.......................................................................447 Front Attachment.............................................................................449 REMOVE AND INSTALL FRONT ATTACHMENT......................................................449 MAINTENANCE STANDARD.....................................................................458 STANDARD DIMENSIONS FOR ARM AND BUCKET CONNECTION........................................466 STANDARD DIMENSIONS FOR ARM AND BOOM CONNECTION..........................................467 Cylinder.....................................................................................469 REMOVE AND INSTALL CYLINDER..............................................................469 HYDRAULIC CIRCUIT PRESSURE RELEASE PROCEDURE.............................................487 DISASSEMBLE CYLINDER.....................................................................488 ASSEMBLE CYLINDER........................................................................506 MAINTENANCE STANDARD.....................................................................522 SECTION 5 ENGINE AND ACCESSORY...................................................................527 General Information..........................................................................529 GENERAL REPAIR INSTRUCTIONS..............................................................530 NOTES ON THE FORMAT OF THIS MANUAL.......................................................530 MAIN DATA AND SPECIFICATIONS.............................................................534 PERFORMANCE CURVE........................................................................535 EXTERNAL VIEW............................................................................537 TIGHTENING TORQUE SPECIFICATIONS.........................................................539 ANGULAR NUT AND BOLT TIGHTENING METHOD...................................................541 MAJOR PART FIXING NUTS AND BOLTS.........................................................543 IDENTIFICATIONS..........................................................................554 Maintenance..................................................................................555 LUBRICATING SYSTEM.......................................................................556 FUEL SYSTEM..............................................................................557 COOLING SYSTEM...........................................................................561 VALVE CLEARANCE AND ADJUSTMENT...........................................................561 INJECTION TIMING.........................................................................563 COMPRESSION PRESSURE MEASUREMENT.........................................................568 TURBOCHARGER INSPECTION..................................................................569 ENGINE REPAIR KIT........................................................................570 RECOMMENDED LUBRICANTS...................................................................571 ENGINE OIL VISCOSITY CHART...............................................................571 Engine Assembly 1 (Disassembly)..............................................................573 EXTERNAL PARTS DISASSEMBLY STEPS.........................................................574 MAJOR COMPONENTS.........................................................................578 ROCKER ARM, AND ROCKER ARM SHAFT DISASSEMBLY STEPS.......................................583 CYLINDER HEAD DISASSEMBLY STEPS..........................................................584 PISTON AND CONNECTING ROD DISASSEMBLY STEPS..............................................585 Engine Assembly 2 (Inspection and Repair)....................................................587 CYLINDER HEAD............................................................................588 VALVE GUIDE..............................................................................589 VALVE SPRING.............................................................................592 TAPPET...................................................................................593 PUSH ROD.................................................................................594 ROCKER ARM SHAFT AND ROCKER ARM..........................................................594 IDLER GEAR AND IDLER GEAR SHAFT..........................................................595 CAMSHAFT.................................................................................596 CYLINDER BODY AND LINER..................................................................597 PISTON AND PISTON RING...................................................................603 PISTON PIN...............................................................................605 CONNECTING ROD...........................................................................606 CRANKSHAFT...............................................................................608 FLYWHEEL.................................................................................615 TIMING GEAR CASE COVER...................................................................615 Engine Assembly 3 (Reassembly)...............................................................617 PISTON AND CONNECTING ROD REASSEMBLY STEPS...............................................618 CYLINDER HEAD REASSEMBLY STEPS...........................................................620 ROCKER ARM AND ROCKER ARM SHAFT REASSEMBLY STEPS.........................................623 MAJOR COMPONENT REASSEMBLY STEPS 1.......................................................624 MAJOR COMPONENT REASSEMBLY STEPS 2.......................................................629 EXTERNAL PARTS REASSMBLY STEPS (Left-hand Side)..........................................634 EXTERNAL PARTS REASSMBLY STEPS (Right-hand Side).........................................637 ENGINE TUNING OPERATION..................................................................641 Lubricating System...........................................................................643 GENERAL DESCRIPTION......................................................................644 OIL PUMP.................................................................................645 OIL COOLER...............................................................................647 Cooling System...............................................................................649 GENERAL DESCRIPTION......................................................................650 WATER PUMP...............................................................................651 THERMOSTAT...............................................................................656 Fuel System..................................................................................659 GENERAL DESCRIPTION......................................................................660 INJECTION NOZZLE.........................................................................661 INJECTION PUMP CALIBRATION DATA..........................................................666 Turbocharger.................................................................................669 GENERAL DESCRIPTION......................................................................670 TURBOCHARGER IDENTIFICATION..............................................................671 TROUBLESHOOTING..........................................................................673 INSPECTION AND REPAIR....................................................................675 Engine Electricals...........................................................................677 STARTER IDENTIFICATION...................................................................678 STARTER MAIN DATA AND SPECIFICATIONS.....................................................679 STARTER MOTOR SECTIONAL VIEW.............................................................680 PERFORMANCE..............................................................................680 DISASSEMBLY..............................................................................681 INSPECTION AND REPAIR....................................................................684 REASSEMBLY...............................................................................688 ADJUSTMENT...............................................................................689 PERFORMANCE TEST.........................................................................690 ALTERNATOR IDENTIFICATION................................................................691 MAIN DATA AND SPECIFICATIONS.............................................................692 ALTERNATOR SECTIONAL VIEW................................................................693 CHARGING CURCUIT.........................................................................693 STRUCTURE................................................................................694 DISASSEMBLY..............................................................................695 INSPECTIONS..............................................................................698 REASSEMBLY...............................................................................700 BENCH TEST...............................................................................701 CURRENT OUTPUT TEST......................................................................702 FAULT FINDING............................................................................703 SPECIFICATIONS...........................................................................703 Troubleshooting..............................................................................705 HARD STARTING............................................................................706 1) STARTER INOPERATIVE...................................................................706 2) STARTER OPERATES BUT ENGINE DOES NOT TURN OVER........................................707 3) ENGINE TURNS OVER BUT DOES NOT START FUEL IS BEING DELIVERED TO THE INJECTION PUMP....708 4) ENGINE TURNS OVER BUT DOES NOT START..................................................709 UNSTABLE LOW IDLING......................................................................710 INSUFFICIENT POWER.......................................................................712 EXCESSUVE FUEL CONSUMPTION...............................................................715 EXCESSIVE OIL CONSUMPTION................................................................717 OVERHEATING..............................................................................718 WHITE EXHAUST SMOKE......................................................................720 DARK EXHAUST SMOKE.......................................................................721 OIL PRESSURE DOES NOT RISE...............................................................722 ABNORMAL ENGINE NOISE....................................................................724 Special Tool List............................................................................727 SPECIAL TOOL LIST........................................................................728 Repair Standards.............................................................................731 REPAIR STANDARDS.........................................................................731 Conversion Table.............................................................................751 LENGTH...................................................................................752 AREA.....................................................................................753 VOLUME...................................................................................753 MASS.....................................................................................755 PRESSURE.................................................................................756 TORQUE...................................................................................757 TEMPERATURE..............................................................................758 SERVICE MANUAL REVISION REQUEST FORM.............................................................761
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
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