PDF Workshop Manual Hitachi ZX210W-3 ZX220W-3 Hydraulic Excavator - 2 MB
This comprehensive workshop manual covers the Hitachi ZX210W-3 and ZX220W-3 Hydraulic Excavators in great detail.
It is the definitive source for repair and maintenance information, from the engine to the hydraulic systems.
With step-by-step instructions and clear illustrations, technicians can perform any task with confidence and precision.
This manual is vital for minimizing downtime and ensuring the longevity of your excavator.
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--- Page 3 ---
SAFETY
OPERATE ONLY FROM OPERATOR'S SEAT
• Inappropriate engine starting procedures may cause the
machine to runaway, possibly resulting in serious injury or
death.
• Start the engine only when seated in the operator's seat.
• NEVER start the engine while standing on the track or on
ground.
• Do not start engine by shorting across starter terminals.
• Before starting the engine, confirm that all control levers
are in neutral.
• Before starting the engine, confirm the safety around the
machine and sound the horn to alert bystanders.
SA-084
012-E01B-0431
JUMP STARTING
• Battery gas can explode, resulting in serious injury.
• If the engine must be jump started, be sure to follow the
instructions shown in the “OPERATING THE ENGINE” chap-
ter in the operator’s manual.
• The operator must be in the operator’s seat so that the
machine will be under control when the engine starts.
Jump starting is a two-person operation.
• Never use a frozen battery.
• Failure to follow correct jump starting procedures could
result in a battery explosion or a runaway machine.
SA-032
S013-E01A-0032
KEEP RIDERS OFF MACHINE
• Riders on machine are subject to injury such as being struck
by foreign objects and being thrown off the machine.
• Only the operator should be on the machine. Keep riders
off.
• Riders also obstruct the operator’s view, resulting in the
machine being operated in an unsafe manner.
014-E01B-0427
SA-091
SA-7
--- Page 4 ---
SAFETY
PROTECT AGAINST FLYING DEBRIS
• If flying debris hit eyes or any other part of the body, serious
injury may result.
• Guard against injury from flying pieces of metal or debris;
wear goggles or safety glasses.
• Keep bystanders away from the working area before strik-
ing any object.
031-E01A-0432
SA-432
PARK MACHINE SAFELY
To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket to the ground.
• Place FNR switch in neutral, and put the brake switch in
the P (parking brake) position.
• Turn auto-idle switch OFF.
• Run engine at slow idle speed without load for 5 minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK position. SA-093
• Close windows, roof vent, and cab door.
• Lock all access doors and compartments.
HANDLE FLUIDS SAFELY−AVOID FIRES
• Handle fuel with care; it is highly flammable. If fuel ignites,
an explosion and/or a fire may occur, possibly resulting in
serious injury or death.
• Do not refuel the machine while smoking or when near
open flame or sparks.
• Always stop the engine before refueling the machine.
• Fill the fuel tank outdoors.
• All fuels, most lubricants, and some coolants are flammable.
SA-018
• Store flammable fluids well away from fire hazards.
• Do not incinerate or puncture pressurized containers.
• Do not store oily rags; they can ignite and burn spontane-
ously.
• Securely tighten the fuel and oil filler cap.
034-E01A-0496
SA-019
SA-17
--- Page 5 ---
SAFETY
BEWARE OF ASBESTOS DUST
• Take care not to inhale dust produced in the work site. Inha-
lation of asbestos fibers may be the cause of lung cancer.
• Depending on the wok site conditions, the risk of inhaling
asbestos fiber may exist. Spray water to prevent asbestos
from becoming airborne. Do not use compressed air.
• When operating the machine in a work site where asbes-
tos might be present, be sure to operate the machine
from the upwind side and wear a mask rated to prevent
the inhalation of asbestos.
• Keep bystanders out of the work site during operation.
• Asbestos might be present in imitation parts. Use only SA-029
genuine Hitachi Parts.
PREVENT BATTERY EXPLOSIONS
• Battery gas can explode.
• Keep sparks, lighted matches, and flame away from the
top of battery.
• Never check battery charge by placing a metal object
across the posts. Use a voltmeter or hydrometer.
• Do not charge a frozen battery; it may explode. Warm the
battery to 16˚C ( 60˚ F ) first.
• Do not continue to use or charge the battery when elec-
trolyte level is lower than specified. Explosion of the bat-
tery may result.
• Loose terminals may produce sparks. Securely tighten all SA-032
terminals.
• Battery electrolyte is poisonous. If the battery should ex-
plode, battery electrolyte may be splashed into eyes, pos-
sibly resulting in blindness.
• Be sure to wear eye protection when checking electrolyte
specific gravity.
512-E01B-0032
SERVICE AIR CONDITIONING SYSTEM SAFELY
• If spilled onto skin, refrigerant may cause a cold contact
burn.
• Refer to the instructions described on the container for
proper use when handling the refrigerant.
• Use a recovery and recycling system to avoid leaking
refrigerant into the atmosphere.
• Never touch the refrigerant.
513-E01A-0405
SA-405
SA-27
--- Page 6 ---
GENERAL / Precautions for Disassembling and Assembling
• Bleeding Air from Hydraulic Circuit
• After refilling hydraulic oil, start the engine. While
operating each cylinder, swing motor and travel
motor evenly, operate the machine under light
loads for 10 to 15 minutes. Slowly start each op-
eration (never fully stroke the cylinders during ini-
tial operation stage). As the pilot oil circuit has an
air bleed device, air trapped in the pilot oil circuit
will be bled while performing the above operation
WCJB-01-04-001
for approx. 5 minutes.
• Reposition the front attachment to check hydrau-
lic oil level.
• Stop the engine. Recheck hydraulic oil level. Re-
plenish oil as necessary.
W1-1-3
--- Page 7 ---
GENERAL / Tightening
Service Recommendations for Split Flange
IMPORTANT: 1. Be sure to clean and Inspect
sealing surfaces. Scratches /
roughness cause leaks and seal
wear.
Unevenness causes seal extru-
sion. If defects cannot be pol-
ished out, replace the compo-
W105-01-01-015
nent.
WRONG
2. Be sure to use only specified
O-rings. Inspect O-rings for any
damage. Take care not to file
O-ring surfaces. When installing
an O-ring into a groove, use
grease to hold it in place.
3. While lightly tightening split
flange halves, check that split is
W105-01-01-016
centered and perpendicular to
the port. Hand-tighten bolts to
hold parts in place. Take care not
to pinch the O-ring.
4. Tighten bolts alternately and di-
agonally, as shown, to ensure
even tightening.
5. Do not use air wrenches. Using W105-01-01-008
an air wrench often causes tight- RIGHT WRONG
ening of one bolt fully before
tightening of the others, result-
ing in damage to O-rings or un-
even tightening of bolts. Do not bend it round
Bend along edge sharply
Nut and Bolt Locking RIGHT RIGHT WRONG
• Lock Plate
IMPORTANT: Do not reuse lock plates. Do not try
to bend the same point twice.
• Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the Bend along edge sharply
holes in the bolt and nut while tight- W105-01-01-009
RIGHT RIGHT WRONG
ening, not while loosening.
• Lock Wire
IMPORTANT: Apply wire to bolts in the
bolt-tightening direction, not in the
bolt-loosening direction.
Loosen WRONG
RIGHT
Tighten
W105-01-01-010
W1-2-5
--- Page 8 ---
GENERAL / Bleeding Air from Hydraulic Oil Tank
BLEEDING AIR FROM HYDRAULIC OIL
TANK
CAUTION: Escaping fluid under pressure
can penetrate the skin, causing serious injury.
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines.
Hydraulic oil may be hot just after operation,
and may spurt, possibly causing severe burns.
Be sure to wait for oil to cool before starting
work.
The hydraulic oil tank cap may fly off if
removed without releasing internal pressure
first. Push the air release valve on top of the
hydraulic oil tank to release any remaining
pressure.
Preparation
1. Place the machine on a firm, level surface and WCJB-01-04-001
lower the bucket to the ground.
1
2
2. Stop the engine. Push the air bleed valve (1) on
the air breather to release any remaining pressure
from hydraulic oil tank (3).
3. Remove cap (2) of hydraulic oil tank (3).
3
WCEB-01-04-001
4. Connect a vacuum pump with the hole removed Vacuum Pump
cap (2) to maintain negative pressure in the
hydraulic oil tank (3). Hose
NOTE: Be sure to run the vacuum pump
continuously while working. Adapter
W562-02-03-008
W1-4-1
--- Page 9 ---
UPPERSTRUCTURE / Cab
18. Open cover (40). 39 40 41 42
19. Remove sems bolts (41) (4 used) from cover (39).
Remove cover (39) from stay (42).
: 17 mm
WCJB-02-01-002
20. Remove clamps (44) (3 used) from the outside of 43
the cab (7) rear. Disconnect connectors (43) (5 44
used).
7
WCEB-02-01-014
CAUTION: Cab (7) weight: 550 kg (1220 lb) Lifting Bracket 47 7 Lifting Bracket
21. Attach a nylon sling onto the bracket in cab (7).
Hold cab (7).
22. Remove nuts (45) (4 used) and washers (46) (4
used) from cab (7).
: 24 mm
45, 46
45, 46
23. Remove socket bolts (47) (6 used) from cab (7).
: 8 mm
47
24. Remove bolts (48) (5 used) and washers (49) (5 45, 46
used) from cab (7). W1JB-02-01-006
: 17 mm
48, 49 47
CAUTION: Cab (7) weight: 550 kg (1220 lb)
25. Remove cab (7) from main frame (34).
7
34
WCJB-02-01-006
W2-1-5
--- Page 10 ---
UPPERSTRUCTURE / Cab
NOTE: Unit: mm (1 mm=0.039 in)
C1
C1
Black Ceramic W1JB-02-01-013
Coating Surface
Section A
W1JB-02-01-009
1646.47
1599.44
187 Black Ceramic Coating Range 313.6
R20
80 50
106 R300
2-R25
R2145 50
R30
696.73 R75
50
1230
R2940
900
(5 mm) 1205
A
R25
90 1496.7
40 R30
R3025
1636.3
R30 R50
R20 158 R10
873.14
R2875
150 145
R575 R50
R125
R1040 R30 R50
R1525 28°
W1JB-02-01-020
R55 R30
393
400
807.65
963.7
W2-1-15
--- Page 11 ---
UPPERSTRUCTURE / Counterweight
REMOVAL AND INSTALLATION OF
COUNTERWEIGHT
Removal 1
1. Open cover (1).
WCJB-02-02-002
2. Disconnect plugs (2, 3).
2
WCJB-02-02-003
3
WCJB-02-02-004
3. Open cover (4).
4
WCJB-02-02-001
5
4. Disconnect connector (5).
WCJB-02-02-005
W2-2-1
--- Page 12 ---
UPPERSTRUCTURE / Pump Device
REMOVAL AND INSTALLATION OF PUMP
DEVICE
CAUTION: Bleed air from the hydraulic oil
tank before doing any work. (Refer to BLEED
AIR FROM HYDRAULIC OIL TANK on W1-4-1.)
Removal 1
1. Open cover (1).
WCJB-02-02-002
2. Open cover (2).
2
WCJB-02-02-001
3 4 5
3. Remove sems bolts (3) (4 used) from cover (4).
Remove cover (4) from main frame (5).
: 17 mm
WCJB-02-04-007
W2-4-1
--- Page 13 ---
UPPERSTRUCTURE / Pump Device
20. Install bracket (7) to supports (13, 14) and cover 7 12 13
(16) with sems bolts (12) (6 used) and sems bolts
(15) (2 used).
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
WCJB-02-04-001
14 12 7
15
WCJB-02-04-002
16
21. Install cover (8) to supports (10, 11), cover (16) 7 8 9
WCJB-02-04-003
and bracket (7) with sems bolts (9) (6 used) and
sems bolts (6) (2 used). 10
: 17 mm
: 50 N⋅m (5 kgf⋅m, 37 lbf⋅ft)
11 9 WCJB-02-04-001
7
6
16
WCJB-02-04-003
W2-4-11
--- Page 14 ---
UPPERSTRUCTURE / Pump Device
18. Warm up set screws (76) (2 used) by using a drier.
Remove set screws (76) (2 used) from servo CAUTION: Pump casing (53) weight: 105 kg
pistons (77) (2 used). Remove pins (78) (2 used) (240 lb)
from servo pistons (77) (2 used).
: 6 mm 24. Install eyebolts (M12, Pitch 1.75 mm) (2 used) to
the socket bolt (75) hole on pump casing (53).
19. Remove servo pistons (77) (2 used) from selector Hoist and remove pump casing (53) from gear
head (70). casing (49). Shafts (13, 19) and gears (27, 29) are
removed with pump casing (53) together.
20. Both right valve plate (64) and left valve plate (81) Place pump casing (53) with the mounting surface
are very similar and their installing directions are for the regulator facing upward.
determined. Record the position and the direction
of right valve plate (64) and left valve plate (81) 25. Remove spring pins (50) (2 used) and gasket (28)
before removing. Remove retaining rings (60) (4 from gear casing (49).
used) from pins (63) (4 used). Remove right valve
plate (64) and left valve plate (81) from links (83)
(2 used). Do not remove pins (63) (4 used) unless
necessary.
21. Remove rotor (18), spring (16), the center shaft
(15) assembly and plungers (17) (7 used) from
pump casing (53) in this order. (Both right and left
pumps)
NOTE: When removing plunger (17), turn plunger
(17) inside and remove plunger (7).
IMPORTANT: As the pump performance may be
changed, do not deform link (83).
22. Remove the link (83) assemblies (2 used) from
pump casing (53). Do not disassemble the link
(83) assembly unless necessary.
NOTE: If it is difficult to remove the link (83)
assembly, use a screwdriver.
23. Remove bolts (55) (6 used) and spring washer
(54) from pump casing (53).
: 24 mm
W2-4-21
--- Page 15 ---
UPPERSTRUCTURE / Pump Device
10. Set the pre-loads of bearings (10, 12) installed on
shaft (13) according to the following procedures.
• Apply hydraulic oil onto the thread part of bearing
nut (9). Tighten bearing nut (9) until bearing nut
(9) comes in contact with bearing (10) by using
special tool (ST 3058).
ST 3058
9
10
W178-02-11-090
• Install special tool (ST 3070) to bearing (10).
Rotate 2 to 3 turns and measure the starting
torque.
ST 3070
10
W178-02-11-091
• Adjust bearing nut (9) until the starting torque
reaches specification.
: 1.96±0.49 N⋅m
(0.20±0.05 kgf⋅m, 1.45±0.36 lbf⋅ft)
NOTE: If the starting torque is higher than the limit
of specified torque, loosen bearing nut (9).
Tap the shaft end and release the load of
bearing (10).
11. Set the pre-loads of bearings (10, 12) installed on
shaft (19) in the same way as step 10.
12. Install slide ring (20) to the side to insert shaft (19)
in pump casing (53).
W2-4-31
--- Page 16 ---
UPPERSTRUCTURE / Pump Device
40. Apply hydraulic oil onto servo pistons (77) (2 45. Install O-rings (74) (2 used) to stoppers S (73) (2
used). Insert servo pistons (77) (2 used) into used). Apply grease onto O-rings (74) (2 used).
selector head (70). Install stoppers S (73) (2 used) to selector head
(70) with socket bolts (72) (8 used).
41. Apply LOCTITE LI829 onto the thread part of set : 6 mm
screws (76) (2 used). Install pins (78) (2 used) to : 19.5 N⋅m (2.0 kgf⋅m, 14 lbf⋅ft)
servo pistons (77) (2 used) with set screws (76) (2
used). 46. Install O-rings (79) (2 used) to stoppers L (80) (2
: 6 mm used). Apply grease onto O-rings (79) (2 used).
: 34.3 N⋅m (3.5 kgf⋅m, 25 lbf⋅ft) Install stoppers L (80) (2 used) to selector head
(70) with socket bolts (72) (8 used).
: 6 mm
CAUTION: Selector head (70) weight: 29 kg : 19.5 N⋅m (2 kgf⋅m, 14 lbf⋅ft)
(64 lb)
42. Install eyebolts (M12, Pitch 1.75 mm) (2 used)
into the thread hole for the suction pipe on
selector head (70). Attach a nylon sling onto
eyebolts (2 used). Hoist selector head (70).
Place selector head (70) on pump casing (53)
while aligning selector head (70) with spring pin
(67).
NOTE: Check the clearance between selector
head (70) and pump casing (53) in order to
compare with the clearance before
disassembling. If the clearance is larger,
pin (14) may not be inserted into the groove
on rotor (18), or pin (78) may not be
inserted into the holes on valve plates (64,
81).
43. Install selector head (70) to pump casing (53) with
socket bolts (75) (12 used).
: 10 mm
: 108 N⋅m (11 kgf⋅m, 80 lbf⋅ft)
44. Install O-rings (71) (4 used) to selector head (70).
W2-4-41
--- Page 17 ---
UPPERSTRUCTURE / Pump Device
Wrench Size Tightening Torque
Item Part Name Q’ty Remark
(mm) N⋅m (kgf⋅m, lbf⋅ft)
1 Plate Seal 4
2 Backup Ring 4
3 Side Plate 4
4 Rear Drive Gear 1
5 Driven Gear 1
6 Kmock Pin 8
7 Gear Plate 2
8 Cover 1
9 Socket Bolt 4
10 Coupling 1
11 Stabilizer 2
12 Center Plate 1
13 Driven Gear 1
14 Front Drive Gear 1
15 Flange 1
16 Oil Seal 1
17 Retaining Ring 1
W2-4-51
--- Page 18 ---
UPPERSTRUCTURE / Control Valve
(Blank)
W2-5-9
--- Page 19 ---
UPPERSTRUCTURE / Control Valve
J I H G F E D C
1
7
8
A
W1V1-02-05-038
J I H G F E D C WCJB-02-05-005 Section C-C
Control Valve (Upper) (4-Spool Side)
Travel Bucket Boom 1
41
39
C
40
17
39
16 1
15 15 50
47
B
1
35
49 D
46
1
45 45
15 15
16 43, 44 15 43, 44 74
42 74 48
WCJB-02-05-020
Section D-D Section E-E W1V1-02-05-036
Section F-F W1V1-02-05-028
(4-Spool Side) (4-Spool Side) (4-Spool Side)
W2-5-19
--- Page 20 ---
UPPERSTRUCTURE / Control Valve
• Assembly of Bucket Flow Rate Control Valve • Assembly of Bypass Shut-Out Valve
16. Install O-rings (96, 91) to plugs (97, 90). 23. Install spool (103), spring (104) and O-ring (4) to
housing (1). Install flange (105) to housing (1)
17. Install spring (94), spool (93), spring seat (95) and with socket bolts (6) (4 used).
plug (97) to body (92). : 8 mm
: 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft)
18. Install plug (90) to body (92).
19. Install poppet (85), spring (86) and plug (87) to • Assembly of Overload Relief Valve
poppet (84). Install the poppet (84) assembly, IMPORTANT: If the overload relief valve is
spring (88) and sleeve (89) into housing (1). disassembled, pressure must be
adjusted.
20. Install O-rings (18, 77) into housing (1). Install (Refer to TROUBLESHOOTING /
body (92) to housing (1) with socket bolts (98) (4 Operational Performance Test in the
used). separated volume, T/M.)
: 8 mm 24. Install O-rings (15) (4 used) to overload relief
: 61±3 N⋅m (6.2±0.3 kgf⋅m, 45±2 lbf⋅ft) valves (17, 74) (2 used for each). Install overload
relief valves (17, 74) (2 used for each) to housing
• Assembly of Flow Combiner Valve (1).
21. Install spring seat (71), spring (72) and spring : 32 mm
seat (71) to bolt (70). Install bolt (70) to spool (73). : 83±5 N⋅m (8.5±0.5 kgf⋅m, 61±4 lbf⋅ft)
22. Install spool (73) and O-ring (4) to housing (1).
Install cap (69) to housing (1) with socket bolts
(68) (2 used).
: 5 mm
: 10 N⋅m (1 kgf⋅m, 7 lbf⋅ft)
W2-5-29
--- Page 21 ---
UPPERSTRUCTURE / Control Valve
(Blank)
W2-5-39
--- Page 22 ---
UPPERSTRUCTURE / Control Valve
J I H G F E D C
19
1
12, 13
5