Hitachi Zaxis ZX140-3 Zx310 Excavator Service Manual.pdf

Hitachi Zaxis ZX140-3 Zx310 Excavator
Service Manual
Explore the detailed specifications of the Hitachi
ZX70-3 Zx350, ZX450-3, Zx870, ZX140-3
Excavator, including its features, capacity, and performance.
Hitachi Zaxis ZX70-3 Zx350, ZX450-3, Zx870, ZX140-3,
Zx310 Excavator Service Manual
Hitachi Zaxis ZX70-3 Zx350, ZX450-3, Zx870, ZX140-3,
Zx310 Excavator Service Manual

INTRODUCTION
IN-01
TO THE READER
• This manual is written for an experienced technician
to provide technical information needed to maintain
and repair this machine.
• Be sure to thoroughly read this manual for cor-
rect product information and service procedures.
• If you have any questions or comments, at if you
found any errors regarding the contents of this
manual, please contact using “Service Manual
Revision Request Form” at the end of this man-
ual.
(Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-29-832-7084
FAX: 81-29-831-1162
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition
to this manual.
MANUAL COMPOSITION
• This manual consists of Technical Manual
Check technical manual T/M for the corresponding
machine when using this book.
PAGE NUMBER
• Each page has a number, located on the center
lower part of the page, and each number contains
the following information:
Example : T 1-3-5
Consecutive Page Number for Each Group
Group Number
Section Number
T: Technical Manual W: Workshop Manual

INTRODUCTION
IN-02
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and
signal words are used to alert the reader to the
potential for personal injury of machine damage.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury.
Never fail to follow the safety instructions prescribed
along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to component/part weights.
To avoid injury and damage, be sure to use appropri-
ate lifting techniques and equipment when lifting
heavy parts.
• CAUTION:
Indicated potentially hazardous situation which
could, if not avoided, result in personal injury or
death.
• IMPORTANT:
Indicates a situation which, if not conformed to the
instructions, could result in damage to the machine.
• NOTE:
Indicates supplementary technical information or
know-how.
UNITS USED
• SI Units (International System of Units) are used in
this manual.
MKSA system units and English units are also
indicated in parenthheses just behind SI units.
Example : 24.5 MPa (250 kgf/cm2
, 3560 psi)
A table for conversion from SI units to other system
units is shown below for reference purposees.
Quantity
To Convert
From
Into Multiply By
MPa kgf/cm2
10.197
Pressure
MPa psi 145.0
kW PS 1.360
Power
kW HP 1.341
Temperature °C °F °C×1.8+32
km/h mph 0.6214
Velocity
min-1
rpm 1.0
Flow rate L/min US gpm 0.2642
mL/rev cc/rev 1.0
Quantity
To Convert
From
Into Multiply By
mm in 0.03937
Length
mm ft 0.003281
L US gal 0.2642
L US qt 1.057
Volume
m3
yd3
1.308
Weight kg lb 2.205
N kgf 0.10197
Force
N lbf 0.2248
N⋅m kgf⋅m 1.0197
Torque
N⋅m lbf⋅ft 0.7375

SECTION AND GROUP
CONTENTS
TECHNICAL MANUAL
All information, illustrations and speci-
fications in this manual are based on
the latest product information available
at the time of publication. The right is
reserved to make changes at any time
without notice.
COPYRIGHT(C)2009
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
SECTION 1 GENERAL
Group 1 Outline
Group 2 Object Model
SECTION 2 OPERATION
Group 1 Start of Win Dr.
Group 2 Data Download
Group 3 Troubleshooting
Group 4 Monitoring
Group 5 Machine Setting
Group 6 Information Setting
Group 7 Kind Setting
Group 8 Option
Group 9 Help
SECTION 3 MONITOR ITEM
Group 1 Middle / Minimum-Sized
Hydraulic Excavators
Group 2 Wheel Excavator
Group 3 Wheel Loader
Group 4 Large-Sized Hydraulic
Excavator
SECTION 4 BODY ADJUSTMENT DATA
Excavator
SECTION 5 ATTACHMENT ADJUSTMENT
DATA
Excavator
SECTION 6 FAULT CODE
Group 2 Wheel Excavator
Group 3 Wheel Loader
Excavator

WDRT-1-1
SECTION 1
GENERAL
CONTENTS
Group 1 Outline
Outline...................................................... T1-1-1
Operational Performance Tests. ............... T1-1-2
Preparation for Performance Tests ........... T1-1-3
Group 2 Object Model
Object Model ............................................ T1-2-1

GENERAL / Outline
T1-1-1
OUTLINE
WinDr. (a PC version Dr.ZX) is used for diagnosis of
electrical control system including MC, ECM, ICF, and
the monitor unit or for each controller setting.
1. WinDr. displays a failure of each controller, each
sensor, and the solenoid valve as a fault code.
2. WinDr. can set the engine speed, the pump
delivery flow rate, the solenoid valve output
pressure, and the special function.
3. WinDr. displays the input status of sensors and
switches connected to each controller and the
output status to the actuator including the
solenoid valve from the controller with the
machine operated in real time.
IMPORTANT: The item that the section that uses
WinDr. can download is limited.

GENERAL / Outline
T1-1-2
OPERATIONAL PERFORMANCE TESTS
Use operational performance test procedure to
quantitatively check all system and functions on the
machine.
Purpose of Performance Tests
1. To comprehensively evaluate each operational
function by comparing the performance test data
with the standard values.
2. According to the evaluation results, repair, adjust,
or replace parts or components as necessary to
restore the machine’s performance to the desired
standard.
3. To economically operate the machine under
optimal conditions.
Kinds of Tests
1. Base machine performance test is to check the
operational performance of each system such as
engine, travel, swing, and hydraulic cylinders.
2. Hydraulic component unit test is to check the
operational performance of each component such
as hydraulic pump, motor, and various kinds of
valves.
Performance Standards
“Performance Standard” is shown in tables to
evaluate the performance test data.
Precautions for Evaluation of Test Data
1. To evaluate not only that the test data are correct,
but also in what range the test data are.
2. Be sure to evaluate the test data based on the
machine operation hours, kinds and state of work
loads, and machine maintenance conditions.
The machine performance does not always deteriorate
as the working hours increase. However, the machine
performance is normally considered to reduce in
proportion to the increase of the operation hours.
Accordingly, restoring the machine performance by
repair, adjustment, or replacement shall consider the
number of the machine’s working hours.
Definition of “Performance Standard”
1. Operation speed values and dimensions of the
new machine.
2. Operational performance of new components
adjusted to specifications. Allowable errors will be
indicated as necessary.

GENERAL / Outline
T1-1-3
PREPARATION FOR PERFORMANCE
TESTS
Observe the following rules in order to carry out
performance tests accurately and safely.
THE MACHINE
1. Repair any defects and damage found, such as oil
or water leaks, loose bolts, cracks and so on,
before starting to test.
TEST AREA
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to run
straight more than 20 m (65 ft 7 in), and to make a
full swing with the front attachment extended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel away.
PRECAUTIONS
1. Before starting to test, agree upon the signals to
be employed for communication among
coworkers. Once the test is started, be sure to
communicate with each other using these signals,
and to follow them without fail.
2. Operate the machine carefully and always give
first priority to safety.
3. While testing, always take care to avoid accidents
due to landslides or contact with high-voltage
power lines. Always confirm that there is sufficient
space for full swings.
4. Avoid polluting the machine and the ground with
leaking oil. Use oil pans to catch escaping oil. Pay
special attention to this when removing hydraulic
pipings.
MAKE PRECISE MEASUREMENT
1. Accurately calibrate test instruments in advance
to obtain correct data.
2. Carry out tests under the exact test conditions
prescribed for each test item.
3. Repeat the same test and confirm that the test
data obtained can be produced repeatedly. Use
mean values of measurements if necessary.
T105-06-01-003
T105-06-01-004

GENERAL / Outline
T1-1-4
(Blank)

GENERAL / Object Model
T1-2-1
OBJECT MODEL
The object models for WinDr. are as follows.
Middle / Minimum-Sized Hydraulic Excavators
Category Object Model
ZX70 ZX70-3/70LC-3/80LCK-3
ZX75 ZX75US-3/75UR-3
ZX80 ZX80LCK-3
ZX85 ZX85USB-3
ZX110 ZX110-3/110M-3
ZX120 ZX120-3
ZX130 ZX130L-3
ZX135 ZX130US-3/130USK-3/130USL-3/135USOS-3
ZX160 ZX160-3/160LC-3
ZX180 ZX180-3/180LC-3/180LCN-3
ZX200 ZX200-3/200LC-3/210H-3/210LCH-3/210K-3/210LCK-3/210LCN-3
ZX225 ZX225US-3/225USLC-3/225USR-3/225USRLC-3/225USRK-3/225USRLCK-3
ZX240 ZX240-3/240LC-3
ZX250 ZX250H-3/250LCH-3/250K-3/250LCK-3
ZX270 ZX270-3/270LC-3
ZX280 ZX280LC-3/280LCN-3
ZX330 ZX330-3/330LC-3
ZX350 ZX350H-3/350LCH-3/350K-3/350LCK-3
Wheel Excavator
ZX140W ZX140W-3/140W-3F
ZX145W ZX145W-3
ZX170W ZX170W-3/170W-3F
ZX190W ZX190W-3/190W-3M/190W-3F
ZX210W ZX210W-3/210W-3F
ZX220W ZX220W-3/220W-3M

GENERAL / Object Model
T1-2-2
Wheel Loader
ZW140 ZW140/140PL
ZW150 ZW150/150PL
ZW180 ZW180/180PL
ZW220 ZW220
ZW250 ZW250
ZW310 ZW310/310-A
Large-Sized Hydraulic Excavator
ZX450 ZX450-3/450LC-3/450-3F, JD450DLC
ZX470 ZX470H-3/470LCH-3/470R-3/470LCR-3/470K-3/470LCK-3/470H-3F/470R-3F
ZX480 ZX480LCK-3
ZX500 ZX500LC-3/500LC-3F
ZX520 ZX520LCH-3/520LCR-3/520LCH-3F/520LCR-3F
ZX650 ZX650LC-3/650LC-3F, JD650DLC
ZX670 ZX670LCH-3/670LCR-3/ZX670LCH-3F/670LCR-3F
ZX850 ZX850-3/850LC-3/850-3F, JD850DLC
ZX870 ZX870H-3/870LCH-3/870R-3/870LCR-3/870H-3F/870R-3F

MEMO
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WDRT-2-1
SECTION 2
OPERATION
—CONTENTS—
Group 1 Start of WinDr.
Connection ............................................... T2-1-1
Communication Port Confirmation ............ T2-1-2
At Initial Start, Start of WinDr. ................... T2-1-4
Group 2 Data Download
Outline...................................................... T2-2-1
Download ................................................. T2-2-2
Download Interruption .............................. T2-2-3
Download History Confirmation ................ T2-2-4
Group 3 Troubleshooting
Outline...................................................... T2-3-1
Troubelshooting........................................ T2-3-2
Retry......................................................... T2-3-3
Group 4 Monitoring
Outline...................................................... T2-4-1
Start of Monitoring .................................... T2-4-2
Main Controller Monitoring ....................... T2-4-3
Engine Controller Monitoring .................... T2-4-4
Monitor Controller Monitoring ................... T2-4-5
Group 5 Machine Setting
Outline...................................................... T2-5-1
Start of Machine Setting ........................... T2-5-4
Main Controller ......................................... T2-5-6
Engine Controller.................................... T2-5-17
Monitor Controller................................... T2-5-24
Group 6 Information Setting
Outline ...................................................... T2-6-1
Start of Information Setting ....................... T2-6-2
Enter Time ................................................ T2-6-4
Enter Model and Serial No........................ T2-6-5
Satellite Setting and Confirmation............. T2-6-6
Data Initialization .................................... T2-6-10
Group 7 Kind Setting
Kind Setting .............................................. T2-7-1
Group 8 Option
Start .......................................................... T2-8-1
Communication Port Setting ..................... T2-8-2
Disp. Record............................................. T2-8-3
Password Change..................................... T2-8-5
Language Change .................................... T2-8-6
Group 9 Help
Version Information................................... T2-9-1

OPERATION / Start of WinDr.
T2-1-1
CONNECTION
1. Connect WinDr. to the WinDr. connector by using
the USB serial cable, the inter link cross cable,
and the connecting harness.
2. Turn the key switch ON or start the engine.
T1T1-06-01-001
WinDr. Connector
• ZX-3 Series (excluding US and USR Series),
Wheel Excavator
T1V1-05-07-001
• ZX-3 US and USR Series
T1V1-01-02-047
• Wheel Loader
TWDR-02-01-006
WinDr. Connector
WinDr. Connector
Personal Computer (WinDr.)
Inter Link
Cross cable
USB Serial
Cable
Connecting
Harness
WinDr. Connector

T2-1-2
COMMUNICATION PORT CONFIRMATION
When starting WinDr. for the first time, communication
port setting is necessary.
Be sure to confirm the communication port of the
personal computer to be used.
When starting WinDr. after the second time, this
operation is not required.
Windows 2000
Right-click “My Computer”.
Click “Properties”.
T1T1-06-02-001
Click “Hardware”.
T1T1-06-02-002
Click “Device Manager”.
T1T1-06-02-003
Confirm “COM No.” of “USB Serial Port”.
“COM 9” applies to this case.
TWDR-02-01-001E

T2-1-3
Windows XP
Right-click “My Computer”.
Click “Properties”.
T1T1-06-02-004
Click “Hardware”.
T1T1-06-02-005
Click “Device Manager”.
T1T1-06-02-006
Confirm “COM No.” of “USB Serial Port”.
“COM 6” applies to this case.
TWDR-02-01-002E

T2-1-4
START OF WinDr.
At Initial Start
IMPORTANT: At initial start, communication port
setting is necessary. Prior to starting,
be sure to confirm the
communication port of the personal
computer to be used.
(Communication Port Confirmation:
T2-1-2, 3)
Click the “WinDr”. icon on the WinDr. screen.
T1T1-06-01-002
Click “Yes (Y)” of Communication Port Setting. Click
“No (N)”, and start of WinDr. is cancelled, and closed.
TWDR-02-01-003E
Select Communication Port from a pull-down menu
and click “Yes (Y)”. Click “No (N)”, and start of WinDr.
is cancelled, and closed.
TWDR-02-01-004E
WinDr. Select Kind Screen appears.
Click an applicable model on this screen, and Function
Selection Initial Screen appears. Then, a variety of
data for the model can be obtained.
NOTE: Click “(A) ZX-3” for the ZX series wheel
loaders.
TWDR-02-01-005E
NOTE: Function Selection Initial Screen
TWDR-02-02-007E
Select Kind Screen
Select “Data Download”, “Troubleshooting”,
“Monitoring”, and others as required.

T2-1-5
At 2nd start and after
Click the “WinDr.” icon on the WinDr. screen.
T1T1-06-01-002
WinDr. Select Kind Screen appears.
Click an applicable model on this screen, and Function
Selection Initial Screen appears. Then, a variety of
data for the model can be obtained.
NOTE: Click “(A) ZX-3” for the ZW series wheel
loaders.
TWDR-02-01-005E
NOTE: Function Selection Initial Screen
TWDR-02-02-007E
Select Kind Screen
Click “Data Download”, “Troubleshooting”,
“Monitoring”, and others as required.

T2-1-6
(Blank)

OPERATION / Data Download
T2-2-1
OUTLINE
Download
Daily report data, frequency distribution data, total
operating hours, alarm, and failure which are recorded
in ICF can be downloaded to WinDr.
Download History Confirmation
The date and time, the model, and the serial No. that
were downloaded can be confirmed.
TWDR-02-02-001E
Start of Download
Download History
Confirmation
Data Download (A)
Save Data Check (B)

T2-2-2
DOWNLOAD
Click an applicable model on Select Kind Screen.
TWDR-02-01-005E
Click “[F1] Data Download”.
TWDR-02-02-007E
Click “Data Download (A)”.
TWDR-02-02-001E
TWDR-02-02-002E
Click “Close (Q)”.
TWDR-02-02-003E
TWDR-02-02-001E
Select Kind Screen
Function Selection Initial Screen

T2-2-3
DOWNLOAD INTERRUPTION
Click “Cancel (C)” while downloading.
TWDR-02-02-002E
Click “Yes (Y)”.
TWDR-02-02-004E
Click “Close (Q)”.
TWDR-02-02-005E
TWDR-02-02-001E

T2-2-4
DOWNLOAD HISTORY CONFIRMATION
Click an applicable model on Select Kind Screen.
TWDR-02-01-005E
Click “[F1] Data Download”.
TWDR-02-02-007E
Click “Save Data Check (B)”.
TWDR-02-02-001E
The saved data history is displayed.
TWDR-02-02-006E
Select Kind Screen
Function Selection Initial Screen

OPERATION / Troubleshooting
T2-3-1
OUTLINE
The self-diagnostic result of each controller is
displayed.
Each controller name which is displayed on the trouble
display box is different depending on models which are
connected to WinDr.
ZX-3 is explained as an example here.
NOTE: Main C/U: MC
Engine C/U: ECM
Monitor Unit: Monitor Unit
Information C/U: ICF
TWDR-02-03-001E
TWDR-02-03-002E
Troubleshooting Function
Selection Screen
Trouble Display
Box

T2-3-2
TROUBELSHOOTING
Click “[F2] Troubleshooting” on Function Selection
Screen.
TWDR-02-02-007E
Click “Self-Diagnostic Results (G)”.
TWDR-02-03-001E
If the controller malfunctions, “Fault” is displayed. If not,
“Not Fault” is displayed.
Click “Fault”, and Fault Code, Contents, and Corrective
Action of the controller are displayed.
TWDR-02-03-002E
TWDR-02-03-003E
Function Selection Screen
Trouble Contents Display
Screen

T2-3-3
RETRY
Click “Retry B (B)”, and retry B is executed.
TWDR-02-03-003E
TWDR-02-03-002E
Trouble Contents Display
Screen

T2-3-4
(Blank)

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