Hitachi ZX 220LC-GI Hydraulic Excavator Workshop Manual – PDF Download

Description

Hitachi ZX 220LC-GI Hydraulic Excavator Workshop Manual

File Details:

Hitachi ZX 220LC-GI Hydraulic Excavator Workshop Manual

• Manual Language:English
• Pages: 518 
• Size: 12.7 MB
• Downloadable:Yes
• Format:PDF

HITACHI ZX 220LC-GI HYDRAULIC EXCAVATOR WORKSHOP MANUAL – PDF DOWNLOAD:

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Description:

Hitachi ZX 220LC-GI Hydraulic Excavator Workshop 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.
• 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 manual.
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.
MANUAL COMPOSITION
 This manual consists the Technical Manual and the Workshop Manual.
• Information included in the Technical Manual: technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.
• Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assemble/ disassemble procedures.

Table Of Contents:

Hitachi ZX 220LC-GI Hydraulic Excavator Workshop Manual

WDCR-EN-00...........................................................  1
INTRODUCTION.........................................................  3
SYMBOL AND ABBREVIATION..............................................  5
SAFETY...............................................................  7
SECTION AND GROUP CONTENTS........................................... 47
SECTION 1 GENERAL.................................................... 49
	Group 1 Precautions for Disassembling and Assembling............. 51
		Precautions for Disassembling and Assembling................. 51
	Group 2 Tightening............................................... 57
		Tightening Bolts and Nuts.................................... 57
		Piping Joint................................................. 61
	Group 3 Painting................................................. 67
		Painting..................................................... 67
	Group 4 Bleeding Air............................................. 69
		Bleeding Air from Hydraulic Oil Tank......................... 69
		Bleeding Air from Hydraulic System........................... 70
		Bleeding Air from Fuel System................................ 71
		Bleeding Air from Radiator................................... 73
	Group 5 Pressure Release Procedure............................... 75
		Hydraulic Circuit Pressure Release Procedure................. 75
	Group 6 Preparation.............................................. 77
		Preparation before Inspection and Maintenance................ 77
SECTION 2 MAINTENANCE STANDARD....................................... 81
	Group 1 Upperstructure........................................... 83
		Pump Device.................................................. 83
		Swing Motor.................................................. 87
	Group 2 Undercarriage............................................ 91
		Travel Motor................................................. 91
		Sprocket..................................................... 93
		Front Idler.................................................. 95
		Upper Roller................................................. 97
		Lower Roller................................................. 98
		Track........................................................ 99
	Group 3 Front Attachment.........................................103
		Pin and Bushing..............................................103
		Side Cutter (ZC00000040, ZC00000041).........................105
		Point (ZC00000042)...........................................106
		Standard Dimensions for Arm and Bucket Connection............107
		Standard Dimensions for Arm and Boom Connection..............108
		Cylinder.....................................................109
SECTION 3 UPPERSTRUCTURE.............................................113
	Group 1 Cab......................................................115
		Removal and Installation of Cab..............................115
		Dimensions of Cab Glass......................................135
	Group 2 Counterweight............................................155
		Removal and Installation of Counterweight....................155
	Group 3 Main Frame...............................................157
		Removal and Installation of Main Frame.......................157
	Group 4 Engine...................................................165
		Removal and Installation of Engine...........................165
	Group 5 Radiator Assembly........................................183
		Replacement of Radiator, Oil Cooler, and Intercooler.........183
	Group 6 Hydraulic Oil Tank.......................................195
		Removal and Installation of Hydraulic Oil Tank...............195
	Group 7 Fuel Tank................................................203
		Removal and Installation of Fuel Tank........................203
	Group 8 Pump Device..............................................211
		Removal and Installation of Pump Device......................211
		Removal and Installation of Coupling.........................219
		Disassembly of Pump Device...................................221
		Assembly of Pump Device......................................228
		Disassembly of Regulator.....................................239
		Assembly of Regulator........................................241
		Disassembly of Solenoid Valve................................243
		Assembly of Solenoid Valve...................................245
		Structure of Pilot Pump......................................247
	Group 9 Control Valve............................................249
		Removal and Installation Control Valve.......................249
		Disassembly of Housing.......................................265
		Assembly of Housing..........................................267
		Disassembly of Control Valve (4-Spool Side)..................269
		Assembly of Control Valve (4-Spool Side).....................276
		Disassembly of Control Valve (5-Spool Side)..................287
		Assembly of Control Valve (5-Spool Side).....................294
	Group 10 Swing Device............................................303
		Removal and Installation of Swing Device.....................303
		Disassembly of Swing Device..................................309
		Assembly of Swing Device.....................................314
		Disassembly of Swing Motor...................................321
		Assembly of Swing Motor......................................324
	Group 11 Pilot Valve.............................................327
		Removal and Installation of Pilot Valve (Left)...............327
		Removal and Installation of Pilot Valve (Right)..............333
		Removal and Installation of Travel Pilot Valve...............341
		Disassembly of Pilot Valves (Right and Left).................345
		Assembly of Pilot Valves (Right and Left)....................348
		Disassembly of Travel Pilot Valve............................351
		Assembly of Travel Pilot Valve...............................355
	Group 12 Solenoid Valve..........................................361
		Removal and Installation of Pilot Shut-Off Solenoid Valve....361
		Removal and Installation of 3-Spool Solenoid Valve Unit......365
		Disassembly of Pilot Shut-Off Solenoid Valve.................369
		Assembly of Pilot Shut-Off Solenoid Valve....................371
		Structure of 3-Spool Solenoid Valve Unit.....................373
	Group 13 Signal Control Valve....................................375
		Removal and Installation of Signal ControlValve..............375
		Structure of Signal Control Valve............................381
SECTION 4 UNDERCARRIAGE..............................................385
	Group 1 Swing Bearing............................................387
		Removal and Installation of Swing Bearing....................387
		Disassembly of Swing Bearing.................................391
		Assembly of Swing Bearing....................................394
	Group 2 Travel Device............................................397
		Removal and Installation of Travel Device....................397
		Disassembly of Travel Device.................................401
		Assembly of Travel Device....................................405
		Disassembly of Travel Motor..................................413
		Assembly of Travel Motor.....................................416
		Disassembly of Brake Valve...................................421
		Assembly of Brake Valve......................................423
		Precautions for Using Floating Seal..........................425
	Group 3 Center Joint.............................................427
		Removal and Installation of Center Joint.....................427
		Disassembly of Center Joint..................................431
		Assembly of Center Joint.....................................433
	Group 4 Track Adjuster...........................................437
		Removal and Installation of Track Adjuster...................437
		Disassembly of Track Adjuster................................439
		Assembly of Track Adjuster...................................444
		Precautions for Using Floating Seal..........................447
	Group 5 Front Idler..............................................449
		Removal and Installation of Front Idler......................449
		Disassembly of Front Idler...................................451
		Assembly of Front Idler......................................454
		Precautions for Using Floating Seal..........................457
	Group 6 Upper and Lower Rollers..................................459
		Removal and Installation of Upper Roller.....................459
		Removal and Installation of Lower Roller.....................463
		Disassembly of Lower Roller..................................467
		Assembly of Lower Roller.....................................469
		Precautions for Using Floating Seal..........................471
	Group 7 Track....................................................473
		Removal and Installation of Track............................473
SECTION 5 FRONT ATTACHMENT...........................................481
	Group 1 Front Attachment.........................................483
		Removal and Installation of Front Attachment.................483
	Group 2 Cylinder.................................................489
		Removal and Installation of Boom Cylinder....................489
		Removal and Installation of Arm Cylinder.....................493
		Removal and Installation of Bucket Cylinder..................499
		Disassembly of Boom, Arm, Bucket Cylinder....................503
		Assembly of Boom, Arm, Bucket Cylinder.......................510
SERVICE MANUAL REVISION REQUEST FORM.................................517

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⦁ This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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