![Hitachi Zaxis 180W Repair Manual [Excavator]](https://youfixthis.com/wp-content/uploads/2014/12/2019-12-01_15-43-27-300x300.jpg)
Part of the Hitachi Repair Manuals.
This is the factory workshop manual set for the Hitachi ZAXIS 200, 225US, 225USR, 230 and 270 excavators built from 2003 to 2013, including the separate engine sub-manual for the Isuzu-based diesel. You get full disassembly and reassembly procedures for the pump device, control valve, swing device, travel device, center joint, swing bearing, track adjuster and all boom, arm and bucket cylinders. Real torque values are printed where you need them - 210 N.m on the hydraulic tank mounting bolts, 90 N.m on the swing motor bolts, 360 N.m on the upper engine cushion rubber bolts. The air bleeding procedure alone is worth the download if you have ever had weak hydraulics after a pump or hose job.
What's Inside This Hitachi Zaxis 200–270 Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 23-43 | Safety Alert Symbols and Signal Words, Emergency Procedures, Protective Clothing, Fire Prevention, Safe Maintenance Practices |
| General Information | 44-85 | Disassembling and Assembling Precautions, Tightening Torque Specifications, Painting, Bleeding Air From Hydraulic Systems |
| Upperstructure | 86-316 | Cab, Counterweight, Main Frame, Pump Device, Control Valve, Swing Device, Pilot Valve, Pilot Shut-Off Valve, Signal Control Valve, Solenoid Valve |
| Undercarriage | 317-463 | Swing Bearing, Travel Device, Center Joint, Track Adjuster, Front Idler, Upper and Lower Roller, Track |
| Front Attachment | 464-524 | Boom, Arm and Bucket Cylinder Disassembly and Reassembly |
| Engine & Accessory (Isuzu 6BG1T) | 527-779 | Engine Assembly and Disassembly, Engine Electricals (Alternator, Starter), Repair Standards and Fuel-Injection Adjustment Data |
| Technical Manual, Safety & Operational Performance Tests | 780-928 | Safety Precautions, Engine Test and Nozzle Check, Pump and Valve Performance Measurement, Standard Values |
| Troubleshooting, Fault Codes & Electrical Inspection | 929-1431 | Troubleshooting a/B/C, Fault Code List, Icx Fault Codes, Malfunction of Gauges, Indicators and Buzzer, Electrical System Inspection, Ec Motor and Ec Sensor Diagnosis, Harness Testing |
| Wiring & Hydraulic Circuit Diagrams | 1432-1489 | ZAXIS200/225USR/230 Class Electrical Diagram, ZAXIS225US Electrical Circuit Diagram, ZAXIS225US Hydraulic Circuit Diagram, Connector Tables, Monitor / Engine / Cab Harness Layouts |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine cushion rubber mounting bolt (upper) torque | 360 N.m | p. 47 |
| Hydraulic tank mounting bolt torque | 210 N.m | p. 47 |
| Fuel tank mounting bolt torque | 210 N.m | p. 47 |
| Swing motor mounting bolt torque | 90 N.m | p. 47 |
| Battery mounting nut torque | 50 N.m | p. 47 |
Hitachi Zaxis 200–270 Common Problems This Manual Covers
Hydraulic pump noise, cavitation knocking and weak lifting or travel power, often right after a pump, filter or hose replacement.
Almost always air in the system or low oil. Follow the air bleeding procedure in the General Information section step by step, top off the tank, then verify power with the performance tests before blaming the pump itself.
Manual Section: General Information - Bleeding Air from Hydraulic Systems p. 86Frequent hose failures and sudden loss of function in the boom, arm or bucket circuits on higher-hour machines.
Replace aging hoses before they burst under load, then use the Front Attachment procedures to reseal any cylinder that started weeping. The manual gives the disassembly sequence and inspection points so you catch scored rods before they eat new seals.
Manual Section: Front Attachment - Boom/Arm/Bucket Cylinder Disassembly and ReassemblySwing device growls, hunts or leaks, or the machine needs a swing motor or swing bearing replaced.
The Upperstructure section covers swing device removal and rebuild with correct mounting torques, and the Undercarriage section handles the swing bearing itself. Getting bolt torque right here matters - the manual specifies 90 N.m on swing motor mounting bolts.
Manual Section: Upperstructure - Swing Device / Undercarriage - Swing Bearing p. 86Loose or thrown tracks, worn front idlers, or a travel device that is weak on one side.
Work through the Undercarriage section for the track adjuster, front idler and travel device procedures, and check the center joint if one side loses power. Adjust track sag to spec before replacing parts, since a loose track wears everything faster.
Manual Section: Undercarriage - Travel Device, Track Adjuster, Front Idler, Track p. 317Frequently Asked Questions
My pump is knocking and lift power is weak after I changed a hose. Does this manual cover bleeding air from the hydraulics?
Yes, and follow it exactly. The General Information section has the full procedure for bleeding air from the hydraulic system, including the pump housing. That cavitation knock you hear is air being crushed in the pump, and running it that way eats the pump. Bleed first, then check oil level and suction side for leaks. p. 86
Does it cover pulling and rebuilding the main pump and swing device?
The Upperstructure section covers removal, disassembly, inspection and reassembly of the pump device, control valve and swing device, with mounting torques included - swing motor bolts go to 90 N.m, for example. If your pump is worn internally you will still need parts or an exchange unit, but the tear-down and rebuild steps are all here. p. 86
Boom and arm are sluggish when the machine is cold. Will this manual help me sort that out?
It will point you in the right direction. Cold oil makes any of these machines lazy for the first few minutes, but if it never wakes up, the troubleshooting material walks you through checking the oil temperature sensor circuit, harness to the controller and restrictions in the circuit, plus operational performance tests to compare against spec.
Is the engine covered, or do I need a separate Isuzu manual?
The engine has its own sub-manual included as Section 5. It covers engine assembly disassembly, inspection and reassembly, engine electricals, operational performance testing and troubleshooting. For head work, injection issues or a full rebuild on these 6BG1T-based diesels you will not need to buy anything extra.
Can I do bucket pins, bushings and leaking cylinders with this manual?
Yes. The Front Attachment section covers disassembly and reassembly of the boom, arm and bucket cylinders, which is where most seal jobs happen on these machines. Pins and bushings are straightforward once you have the procedures and know what to inspect for wear. Keep everything surgical-clean during cylinder reassembly or the new seals will not last a season.
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