Hitachi ZX200-5G, ZX200LC-5G, ZX210H-5G, ZX210LCH-5G, ZX210K-5G, ZX210LCK-5G Hydraulic Excavator Service Manual – Operational Principle, Troubleshooting & Workshop Manual

Description

Hitachi ZX200-5G / ZX210-5G Series Hydraulic Excavator Service Manual

This comprehensive service manual covers the Hitachi ZX200-5G, ZX200LC-5G, ZX210H-5G, ZX210LCH-5G, ZX210K-5G, and ZX210LCK-5G hydraulic excavators. It combines three major documents into one complete resource: the Technical Manual (Operational Principle), the Technical Manual (Troubleshooting), and the Workshop Manual. Whether you are diagnosing a fault code, rebuilding a hydraulic pump, or performing scheduled maintenance, this manual provides the procedures, specifications, and system explanations needed to work on these machines correctly.

File Details

• Manual Type: Service Manual (Operational Principle, Troubleshooting, Workshop Manual)
• Brand: Hitachi
• Models Covered: ZX200-5G, ZX200LC-5G, ZX210H-5G, ZX210LCH-5G, ZX210K-5G, ZX210LCK-5G
• Engine Model: ISUZU CC-6BG1T
• Language: English
• File Format: PDF
• Part Numbers: TODCD-EN-00 (Technical Manual Operational Principle), TTDCD-EN-00 (Technical Manual Troubleshooting), WDCD-EN-00 (Workshop Manual)
• Publication Dates: 2011-04 (Operational Principle), 2011-05 (Troubleshooting), 2012-02 (Workshop Manual)
• Page Count: 1307

Chapters Covered

This service manual is organized into the following major sections:

• Section 1: General — Specifications, Component Layout, Component Specifications
• Section 2: System — Controller, Control System (Engine Control, Pump Control, Valve Control, Other Control), Hydraulic System (Pilot Circuit, Main Circuit), Electrical System (CAN Circuit, Electric Power Circuit, Monitor Circuit, Accessory Circuit)
• Section 3: Component Operation — Pump Device (Main Pump, Regulator, Solenoid Valve, Pilot Pump, Sensors), Swing Device (Swing Reduction Gear, Swing Motor, Swing Parking Brake, Valve Unit), Control Valve (Flow Combiner Valve, Main Relief Valve, Overload Relief Valve, Regenerative Valve, Anti-Drift Valve, Flow Rate Control Valve, Digging Regenerative Valve, Boom Lower Meter-In Cut Valve, Auxiliary Flow Combiner Valve), Pilot Valve, Travel Device (Travel Reduction Gear, Travel Motor, Parking Brake, Travel Brake Valve, Travel Mode Control), Signal Control Valve (Shuttle Valve, Shockless Valve, Pump Flow Rate Control Valve), Others (Pilot Shut-Off Solenoid Valve, Solenoid Valve, Pilot Relief Valve, EC Motor, Hose Rupture Valve, Swing Bearing, Center Joint, Track Adjuster)
• Section 4: Operational Performance Test — Introduction, Standard, Engine Test, Excavator Test, Component Test, Adjustment
• Section 5: Troubleshooting — Diagnosing Procedure, Monitor, e-Service, Component Layout, Troubleshooting A (Fault Codes), Troubleshooting B (Symptom Diagnosis), Air Conditioner
• Workshop Manual Sections: General Information (Precautions, Tightening Torque, Painting, Bleeding Air, Pressure Release, Preparation), Maintenance Standard (Upperstructure, Undercarriage, Front Attachment), Upperstructure (Cab, Counterweight, Main Frame, Engine, Radiator, Hydraulic Oil Tank, Fuel Tank, Pump Device, Control Valve, Swing Device, Pilot Valve, Solenoid Valve, Signal Control Valve), Undercarriage (Swing Bearing, Travel Device, Center Joint, Track Adjuster, Upper and Lower Rollers, Track), Front Attachment (Front Attachment, Cylinder)

The manual also includes electrical circuit diagrams, hydraulic circuit diagrams, connector charts, and harness layouts at the end of the document.

What This Manual Provides

The Hitachi ZX200-5G / ZX210-5G service manual gives technicians and mechanics a complete picture of how these excavators are built and how they operate. The Operational Principle section explains the theory behind each system — from the engine control dial logic and pump torque control to the swing parking brake release and travel motor displacement angle control. This is where you learn not just what a component does, but why and how it does it.

The Troubleshooting section is structured around real fault codes and symptom-based diagnosis. It lists MC fault codes, ECF fault codes, monitor controller codes, air conditioner controller codes, and communication terminal codes. For each fault, the manual shows the trouble condition, the likely cause, the symptoms the operator will notice, and the remedy. There are also detailed troubleshooting tables for engine systems, all actuator systems, front attachment systems, swing systems, travel systems, and other systems. The diagnostic procedures walk through continuity checks, voltage measurements, resistance checks, and component swap tests.

The Workshop Manual section handles the physical work: removal, installation, disassembly, assembly, inspection, and adjustment. It provides tightening torques for every major bolt and nut, maintenance standards with allowable limits, and step-by-step procedures for everything from removing the cab to disassembling the travel motor. Exploded diagrams show how components fit together so you can see exactly what you are dealing with before you start turning wrenches.

Key Technical Specifications

The engine in these machines is the ISUZU CC-6BG1T — a 6-cylinder, 4-cycle, water-cooled, direct injection diesel with an exhaust turbocharger. It displaces 6494 cm³ (396 in³) with a bore and stroke of 105 mm × 125 mm. Rated output is 118+8.6+1 kW at 2000 min-1, with travel HP mode delivering 125+1.5+4.4 kW at 2100 min-1. Maximum torque is 637+55-65 N·m at approximately 1800 min-1.

The hydraulic system uses a bent-axis type variable displacement axial plunger pump for the main pump, with a theoretical displacement of 106 cm³/rev ×2. Rated pressure is 34.3 MPa (350 kgf/cm²). The control valve is a pilot pressure operated type with 4-spool and 5-spool sections. Main relief set pressure is 34.3 MPa in normal operation and 38.0 MPa in power digging mode. The swing motor is a swash-plate type fixed displacement axial plunger motor with a theoretical displacement of 129.2 cm³/rev. The travel motor is a swash-plate type variable displacement axial plunger motor with a theoretical displacement of 79/122.5 cm³/rev (fast/slow).

Operating weights range from 19,800 kg for the ZX200-5G to 21,500 kg for the ZX210LCH-5G and ZX210LCK-5G. Bucket capacity is PCSA 0.80 m³ (1.3 yd³) or CECE 0.70 m³. Swing speed is 13.5 min-1. Travel speed is 5.5/3.5 km/h (fast/slow). Gradeability is 35° (70%).

Systems Covered in Detail

Engine Control System: The manual explains engine control dial logic, ECO control, power mode control, ECO mode control, travel HP mode control, auto-idle control, hydraulic oil temperature auto-warming up control, idle speed-up control, engine starting idle speed-up control, and attachment operation speed limit control. It covers the MC, ECF, EC motor, EC sensor, N sensor, and the various pressure sensors that feed data into the system.

Pump Control System: Speed sensing control, hydraulic oil temperature pump torque decrease control, travel torque-up control, attachment pump torque decrease control, pump 1 flow rate limit control, and pump 2 flow rate limit control are all explained. The regulator operation — including control by pump control pressure, control by own and partner pump delivery pressure, control by pilot pressure from the torque control solenoid valve, and control by pilot pressure from the maximum pump 2 flow rate limit control solenoid valve — is covered in detail.

Valve Control System: Power digging control, auto-power lift control, travel motor displacement angle control, arm regenerative control, digging regenerative control, breaker 1 control, breaker 2 control, pulverizer control, and crusher control are all described with their operating conditions and effects on machine behavior.

Hydraulic System: The pilot circuit, main circuit, single operation circuit, combined operation circuits, travel and arm roll-in combined operation, attachment operation, boom lower operation, and jack-up operation are all explained with circuit diagrams.

Electrical System: The CAN circuit (CAN 0 and CAN 1), electric power circuit, monitor circuit, accessory circuit, starting circuit, charging circuit, preheating circuit, engine stop circuit, pilot shut-off circuit, security circuit, radio circuit, air conditioner circuit, work light circuit, wiper circuit, and cab light circuit are all documented.

Who This Manual Is For

This manual is written for experienced technicians who maintain and repair Hitachi ZX200-5G and ZX210-5G series excavators. It assumes you have a working knowledge of diesel engines, hydraulic systems, and electrical circuits. The procedures are detailed enough to guide a competent mechanic through complex repairs, but they are not a substitute for proper training and experience.

If you own or operate one of these machines, this manual helps you understand what your technician is doing and why. If you are the technician, it gives you the specifications, procedures, and diagnostic logic you need to get the job done right the first time.

Get the Complete Service Manual for Your Hitachi Excavator

With this service manual, you can confidently tackle engine diagnostics, hydraulic pump rebuilds, control valve service, swing and travel device repairs, electrical troubleshooting, and scheduled maintenance on your ZX200-5G, ZX200LC-5G, ZX210H-5G, ZX210LCH-5G, ZX210K-5G, or ZX210LCK-5G excavator. The manual gives you the exact procedures, torque values, pressure settings, and diagnostic steps that Hitachi specifies for these machines.

Having the right information matters. Guessing at hydraulic pressures, using incorrect torque values, or skipping diagnostic steps can lead to damaged components, poor performance, and unsafe operating conditions. This manual removes the guesswork and puts the correct procedures at your fingertips.

You get instant access to the PDF after purchase — no shipping, no waiting. The file works on any device: laptop, tablet, or smartphone. You can print the pages you need for the shop and keep the digital copy for reference. Whether you are doing a quick adjustment or a full component overhaul, this manual is the reference you will reach for again and again.

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