Hitachi ZX200-5A 200LC-5A 210H-5A 210LCH-5A 210K-5A 210LCK-5A Excavator Operational Principle Manual – PDF DOWNLOAD

Description

Hitachi ZX200-5A 200LC-5A 210H-5A 210LCH-5A 210K-5A 210LCK-5A Excavator Operational Principle Manual

DESCRIPTION:

Hitachi ZX200-5A 200LC-5A 210H-5A 210LCH-5A 210K-5A 210LCK-5A Excavator Operational Principle Manual

To The Reader
This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
The machine specification and description according to destination may be explained on this manual.
 Be sure to thoroughly read this manual for correct product information and service procedures.

Additional References:

Please refer to the other materials (operator’s manual, parts catalog, engine technical material and Hitachi training material etc.) in addition to this manual.

TABLE OF CONTENTS:

Hitachi ZX200-5A 200LC-5A 210H-5A 210LCH-5A 210K-5A 210LCK-5A Excavator Operational Principle Manual

Hitachi ZX200-5A 200LC-5A 210H-5A 210LCH-5A 210K-5A 210LCK-5A Excavator Operational Priciple Manual (1)……………………………………………………………… 1
TODCX90-EN-01………………………………………………………………………………………………………………………………………….. 1
INTRODUCTION…………………………………………………………………………………………………………………………………………… 3
SYMBOL AND ABBREVIATION…………………………………………………………………………………………………………………………………. 5
SECTION AND GROUP CONTENTS………………………………………………………………………………………………………………………………. 7
SECTION 1 GENERAL………………………………………………………………………………………………………………………………………. 9
Group 1 Specifications………………………………………………………………………………………………………………………………. 11
Specifications………………………………………………………………………………………………………………………………….. 11
Working Ranges (Grouser shoe)…………………………………………………………………………………………………………………….. 13
Group 2 Component Layout…………………………………………………………………………………………………………………………….. 15
Main Component………………………………………………………………………………………………………………………………….. 15
Electrical System (Overview)……………………………………………………………………………………………………………………… 17
Electrical System (Rear Tray)…………………………………………………………………………………………………………………….. 18
Electrical System (Switch Panel)………………………………………………………………………………………………………………….. 19
Electrical System (Around Air Cleaner)…………………………………………………………………………………………………………….. 20
Electrical System (Relays)……………………………………………………………………………………………………………………….. 21
Engine…………………………………………………………………………………………………………………………………………. 22
Pump Device…………………………………………………………………………………………………………………………………….. 23
Around Pump Device………………………………………………………………………………………………………………………………. 24
Control Valve…………………………………………………………………………………………………………………………………… 25
Signal Control Valve…………………………………………………………………………………………………………………………….. 25
Swing Device……………………………………………………………………………………………………………………………………. 27
Travel Device…………………………………………………………………………………………………………………………………… 27
3-Spool Solenoid Valve Unit………………………………………………………………………………………………………………………. 28
Layout of Attachment Spec. Parts………………………………………………………………………………………………………………….. 29
Control Valve Side of Hydraulic Oil Tank…………………………………………………………………………………………………………… 31
Group 3 Component Specifications……………………………………………………………………………………………………………………… 35
Engine…………………………………………………………………………………………………………………………………………. 35
Engine Accessories………………………………………………………………………………………………………………………………. 39
Hydraulic Component……………………………………………………………………………………………………………………………… 40
Electrical Component…………………………………………………………………………………………………………………………….. 44
SECTION 2 SYSTEM……………………………………………………………………………………………………………………………………….. 47
Group 1 Controller………………………………………………………………………………………………………………………………….. 49
Outline………………………………………………………………………………………………………………………………………… 49
CAN Circuit…………………………………………………………………………………………………………………………………….. 50
Group 2 Control System………………………………………………………………………………………………………………………………. 53
Outline………………………………………………………………………………………………………………………………………… 53
Engine Control………………………………………………………………………………………………………………………………….. 56
Pump Control……………………………………………………………………………………………………………………………………. 88
Valve Control (Standard)………………………………………………………………………………………………………………………….102
Valve Control (Optional)………………………………………………………………………………………………………………………….114
Other Control……………………………………………………………………………………………………………………………………124
Group 3 ECM System…………………………………………………………………………………………………………………………………..133
Outline…………………………………………………………………………………………………………………………………………133
Fuel Injection Control……………………………………………………………………………………………………………………………134
Fuel Injection Amount Correction Control……………………………………………………………………………………………………………142
EGR Control……………………………………………………………………………………………………………………………………..144
Preheating Control……………………………………………………………………………………………………………………………….146
Alarm Control……………………………………………………………………………………………………………………………………147
Group 4 Hydraulic System……………………………………………………………………………………………………………………………..149
Outline…………………………………………………………………………………………………………………………………………149
Pilot Circuit……………………………………………………………………………………………………………………………………150
Main Circuit…………………………………………………………………………………………………………………………………….160
Breaker/Pulverizer/Crusher Circuit (Optional)……………………………………………………………………………………………………….176
Group 5 Electrical System…………………………………………………………………………………………………………………………….187
Outline…………………………………………………………………………………………………………………………………………187
Main Circuit…………………………………………………………………………………………………………………………………….188
Electric Power Circuit (Key Switch: OFF)……………………………………………………………………………………………………………190
CAN Circuit……………………………………………………………………………………………………………………………………..192
Accessory Circuit………………………………………………………………………………………………………………………………..194
Starting Circuit (Key Switch: START)……………………………………………………………………………………………………………….196
Charging Circuit (Key Switch: ON)………………………………………………………………………………………………………………….198
Surge Voltage Prevention Circuit…………………………………………………………………………………………………………………..202
Pilot Shut-Off Circuit (Key switch: ON)…………………………………………………………………………………………………………….204
Auto Shut-Down Circuit/Automatic Engine Stop Circuit at Low Temperature………………………………………………………………………………..206
Engine Stop Circuit………………………………………………………………………………………………………………………………208
Monitor Circuit………………………………………………………………………………………………………………………………….211
Security Circuit…………………………………………………………………………………………………………………………………212
Radio Circuit……………………………………………………………………………………………………………………………………214
Air Conditioner Circuit…………………………………………………………………………………………………………………………..214
Accessory Circuit………………………………………………………………………………………………………………………………..217
Work Light Circuit……………………………………………………………………………………………………………………………….218
Wiper/Washer Circuit……………………………………………………………………………………………………………………………..220
Cab Light Circuit………………………………………………………………………………………………………………………………..222
SECTION 3 COMPONENT OPERATION…………………………………………………………………………………………………………………………….227
Group 1 Pump Device………………………………………………………………………………………………………………………………….229
Outline…………………………………………………………………………………………………………………………………………229
Main Pump……………………………………………………………………………………………………………………………………….230
Regulator……………………………………………………………………………………………………………………………………….234
Solenoid Valve…………………………………………………………………………………………………………………………………..252
Pilot Pump………………………………………………………………………………………………………………………………………254
Pump Delivery Pressure Sensor……………………………………………………………………………………………………………………..254
Pump Control Pressure Sensor………………………………………………………………………………………………………………………254
Group 2 Swing Device…………………………………………………………………………………………………………………………………255
Outline…………………………………………………………………………………………………………………………………………255
Swing Reduction Gear……………………………………………………………………………………………………………………………..256
Swing Motor……………………………………………………………………………………………………………………………………..257
Swing Parking Brake………………………………………………………………………………………………………………………………258
Valve Unit………………………………………………………………………………………………………………………………………260
Group 3 Control Valve………………………………………………………………………………………………………………………………..263
Outline…………………………………………………………………………………………………………………………………………263
Hydraulic Circuit………………………………………………………………………………………………………………………………..284
Flow Combiner Valve………………………………………………………………………………………………………………………………290
Main Relief Valve………………………………………………………………………………………………………………………………..292
Overload Relief Valve (with Make-Up Function)……………………………………………………………………………………………………….296
Regenerative Valve……………………………………………………………………………………………………………………………….300
Anti-Drift Valve…………………………………………………………………………………………………………………………………304
Flow Rate Control Valve…………………………………………………………………………………………………………………………..308
Digging Regenerative Valve………………………………………………………………………………………………………………………..312
Boom Lower Meter-In Cut Valve……………………………………………………………………………………………………………………..314
Auxiliary Flow Combiner Valve and Bypass Shut-Out Valve………………………………………………………………………………………………316
Group 4 Pilot Valve………………………………………………………………………………………………………………………………….321
Outline…………………………………………………………………………………………………………………………………………321
Operation (Front Attachment / Swing and Travel Pilot Valves)………………………………………………………………………………………….323
Operation (Auxiliary Pilot Valve)………………………………………………………………………………………………………………….331
Shockless Function (Only for Travel Pilot Valve)…………………………………………………………………………………………………….336
Group 5 Travel Device………………………………………………………………………………………………………………………………..337
Outline…………………………………………………………………………………………………………………………………………337
Travel Reduction Gear…………………………………………………………………………………………………………………………….338
Travel Motor…………………………………………………………………………………………………………………………………….340
Parking Brake……………………………………………………………………………………………………………………………………342
Travel Brake Valve……………………………………………………………………………………………………………………………….344
Overload Relief Valve…………………………………………………………………………………………………………………………….348
Travel Mode Control………………………………………………………………………………………………………………………………350
Group 6 Signal Control Valve………………………………………………………………………………………………………………………….355
Outline…………………………………………………………………………………………………………………………………………355
Pilot Port………………………………………………………………………………………………………………………………………356
Shuttle Valve……………………………………………………………………………………………………………………………………361
Shockless Valve………………………………………………………………………………………………………………………………….364
Pump 1 and 2 Flow Rate Control Valve……………………………………………………………………………………………………………….368
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….370
Group 7 Others (Upperstructure)……………………………………………………………………………………………………………………….373
Pilot Shut-Off Solenoid Valve……………………………………………………………………………………………………………………..373
Solenoid Valve…………………………………………………………………………………………………………………………………..375
Hose Rupture Valve……………………………………………………………………………………………………………………………….380
Pilot Relief Valve……………………………………………………………………………………………………………………………….386
Recirculation Valve (Option)………………………………………………………………………………………………………………………387
Group 8 Others (Undercarriage)………………………………………………………………………………………………………………………..389
Swing Bearing……………………………………………………………………………………………………………………………………389
Center Joint…………………………………………………………………………………………………………………………………….390
Track Adjuster (Front Idler Integrated Type)………………………………………………………………………………………………………..391
SERVICE MANUAL REVISION REQUEST FORM………………………………………………………………………………………………………………………395
Hitachi ZX200-5A 200LC-5A 210H-5A 210LCH-5A 210K-5A 210LCK-5A Excavator Operational Priciple Manual (2)………………………………………………………………396
TODCX90-EN-00…………………………………………………………………………………………………………………………………………..396
INTRODUCTION……………………………………………………………………………………………………………………………………………398
SYMBOL AND ABBREVIATION………………………………………………………………………………………………………………………………….400
SECTION AND GROUP CONTENTS……………………………………………………………………………………………………………………………….402
SECTION 1 GENERAL……………………………………………………………………………………………………………………………………….404
Group 1 Specifications……………………………………………………………………………………………………………………………….406
Specifications…………………………………………………………………………………………………………………………………..406
Working Ranges (Grouser shoe)……………………………………………………………………………………………………………………..408
Group 2 Component Layout……………………………………………………………………………………………………………………………..410
Main Component…………………………………………………………………………………………………………………………………..410
Electrical System (Overview)………………………………………………………………………………………………………………………412
Electrical System (Rear Tray)……………………………………………………………………………………………………………………..413
Electrical System (Switch Panel)…………………………………………………………………………………………………………………..414
Electrical System (Around Air Cleaner)……………………………………………………………………………………………………………..415
Electrical System (Relays)………………………………………………………………………………………………………………………..416
Engine………………………………………………………………………………………………………………………………………….417
Pump Device……………………………………………………………………………………………………………………………………..418
Around Pump Device……………………………………………………………………………………………………………………………….419
Control Valve……………………………………………………………………………………………………………………………………420
Signal Control Valve……………………………………………………………………………………………………………………………..420
Swing Device…………………………………………………………………………………………………………………………………….422
Travel Device……………………………………………………………………………………………………………………………………422
3-Spool Solenoid Valve Unit……………………………………………………………………………………………………………………….423
Layout of Attachment Spec. Parts…………………………………………………………………………………………………………………..424
Control Valve Side of Hydraulic Oil Tank……………………………………………………………………………………………………………426
Boom Upper Side………………………………………………………………………………………………………………………………….427
Control Valve Upper Side, Lower Side……………………………………………………………………………………………………………….427
Utility Space……………………………………………………………………………………………………………………………………428
Group 3 Component Specifications………………………………………………………………………………………………………………………430
Engine………………………………………………………………………………………………………………………………………….430
Engine Accessories……………………………………………………………………………………………………………………………….434
Hydraulic Component………………………………………………………………………………………………………………………………435
Electrical Component……………………………………………………………………………………………………………………………..439
SECTION 2 SYSTEM………………………………………………………………………………………………………………………………………..442
Group 1 Controller…………………………………………………………………………………………………………………………………..444
Outline…………………………………………………………………………………………………………………………………………444
CAN Circuit……………………………………………………………………………………………………………………………………..445
Group 2 Control System……………………………………………………………………………………………………………………………….448
Outline…………………………………………………………………………………………………………………………………………448
Engine Control…………………………………………………………………………………………………………………………………..451
Pump Control…………………………………………………………………………………………………………………………………….483
Valve Control (Standard)………………………………………………………………………………………………………………………….497
Valve Control (Option)……………………………………………………………………………………………………………………………509
Other Control……………………………………………………………………………………………………………………………………519
Group 3 ECM System…………………………………………………………………………………………………………………………………..528
Outline…………………………………………………………………………………………………………………………………………528
Fuel Injection Control……………………………………………………………………………………………………………………………529
Fuel Injection Amount Correction Control……………………………………………………………………………………………………………537
EGR Control……………………………………………………………………………………………………………………………………..539
Preheating Control……………………………………………………………………………………………………………………………….541
Alarm Control……………………………………………………………………………………………………………………………………542
Group 4 Hydraulic System……………………………………………………………………………………………………………………………..544
Outline…………………………………………………………………………………………………………………………………………544
Pilot Circuit……………………………………………………………………………………………………………………………………545
Main Circuit…………………………………………………………………………………………………………………………………….555
Breaker/Pulverizer/Crusher Circuit (Optional)……………………………………………………………………………………………………….571
Group 5 Electrical System…………………………………………………………………………………………………………………………….582
Outline…………………………………………………………………………………………………………………………………………582
Main Circuit…………………………………………………………………………………………………………………………………….583
Electric Power Circuit (Key Switch: OFF)……………………………………………………………………………………………………………585
CAN Circuit……………………………………………………………………………………………………………………………………..587
Accessory Circuit………………………………………………………………………………………………………………………………..589
Starting Circuit (Key Switch: START)……………………………………………………………………………………………………………….591
Charging Circuit (Key Switch: ON)………………………………………………………………………………………………………………….593
Surge Voltage Prevention Circuit…………………………………………………………………………………………………………………..597
Pilot Shut-Off Circuit (Key switch: ON)…………………………………………………………………………………………………………….599
Auto Shut-Down Circuit/Automatic Engine Stop Circuit at Low Temperature………………………………………………………………………………..601
Engine Stop Circuit………………………………………………………………………………………………………………………………603
Monitor Circuit………………………………………………………………………………………………………………………………….606
Security Circuit…………………………………………………………………………………………………………………………………607
Radio Circuit……………………………………………………………………………………………………………………………………609
Air Conditioner Circuit…………………………………………………………………………………………………………………………..609
Accessory Circuit………………………………………………………………………………………………………………………………..612
Work Light Circuit……………………………………………………………………………………………………………………………….613
Wiper/Washer Circuit……………………………………………………………………………………………………………………………..615
Cab Light Circuit………………………………………………………………………………………………………………………………..617
SECTION 3 COMPONENT OPERATION…………………………………………………………………………………………………………………………….622
Group 1 Pump Device………………………………………………………………………………………………………………………………….624
Outline…………………………………………………………………………………………………………………………………………624
Main Pump……………………………………………………………………………………………………………………………………….625
Regulator……………………………………………………………………………………………………………………………………….629
Solenoid Valve…………………………………………………………………………………………………………………………………..647
Pilot Pump………………………………………………………………………………………………………………………………………649
Pump Delivery Pressure Sensor……………………………………………………………………………………………………………………..649
Pump Control Pressure Sensor………………………………………………………………………………………………………………………649
Group 2 Swing Device…………………………………………………………………………………………………………………………………650
Outline…………………………………………………………………………………………………………………………………………650
Swing Reduction Gear……………………………………………………………………………………………………………………………..651
Swing Motor……………………………………………………………………………………………………………………………………..652
Swing Parking Brake………………………………………………………………………………………………………………………………653
Valve Unit………………………………………………………………………………………………………………………………………655
Group 3 Control Valve………………………………………………………………………………………………………………………………..658
Outline…………………………………………………………………………………………………………………………………………658
Hydraulic Circuit………………………………………………………………………………………………………………………………..679
Flow Combiner Valve………………………………………………………………………………………………………………………………685
Main Relief Valve………………………………………………………………………………………………………………………………..687
Overload Relief Valve (with Make-Up Function)……………………………………………………………………………………………………….691
Regenerative Valve……………………………………………………………………………………………………………………………….695
Anti-Drift Valve…………………………………………………………………………………………………………………………………699
Flow Rate Control Valve…………………………………………………………………………………………………………………………..703
Digging Regenerative Valve………………………………………………………………………………………………………………………..707
Boom Lower Meter-In Cut Valve……………………………………………………………………………………………………………………..709
Auxiliary Flow Combiner Valve and Bypass Shut-Out Valve………………………………………………………………………………………………711
Group 4 Pilot Valve………………………………………………………………………………………………………………………………….716
Outline…………………………………………………………………………………………………………………………………………716
Operation (Front Attachment / Swing and Travel Pilot Valves)………………………………………………………………………………………….718
Operation (Auxiliary Pilot Valve)………………………………………………………………………………………………………………….726
Shockless Function (Only for Travel Pilot Valve)…………………………………………………………………………………………………….731
Group 5 Travel Device………………………………………………………………………………………………………………………………..732
Outline…………………………………………………………………………………………………………………………………………732
Travel Reduction Gear…………………………………………………………………………………………………………………………….733
Travel Motor…………………………………………………………………………………………………………………………………….735
Parking Brake……………………………………………………………………………………………………………………………………737
Travel Brake Valve……………………………………………………………………………………………………………………………….739
Overload Relief Valve…………………………………………………………………………………………………………………………….743
Travel Mode Control………………………………………………………………………………………………………………………………745
Group 6 Signal Control Valve………………………………………………………………………………………………………………………….750
Outline…………………………………………………………………………………………………………………………………………750
Pilot Port………………………………………………………………………………………………………………………………………751
Shuttle Valve……………………………………………………………………………………………………………………………………756
Shockless Valve………………………………………………………………………………………………………………………………….759
Pump 1 and 2 Flow Rate Control Valve……………………………………………………………………………………………………………….763
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…..765
Group 7 Others (Upperstructure)……………………………………………………………………………………………………………………….768
Pilot Shut-Off Solenoid Valve……………………………………………………………………………………………………………………..768
Solenoid Valve…………………………………………………………………………………………………………………………………..770
Hose Rupture Valve……………………………………………………………………………………………………………………………….775
Pilot Relief Valve……………………………………………………………………………………………………………………………….781
Recirculation Valve (Option)………………………………………………………………………………………………………………………782
Group 8 Others (Undercarriage)………………………………………………………………………………………………………………………..784
Swing Bearing……………………………………………………………………………………………………………………………………784
Center Joint…………………………………………………………………………………………………………………………………….785
Track Adjuster (Front Idler Integrated Type)………………………………………………………………………………………………………..786
SERVICE MANUAL REVISION REQUEST FORM………………………………………………………………………………………………………………………790

HITACHI ZX200-5A 200LC-5A 210H-5A 210LCH-5A 210K-5A 210LCK-5A EXCAVATOR OPERATIONAL PRINCIPLE MANUAL – PDF DOWNLOAD:

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