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Hitachi ZX220LC-GI Hydraulic Excavator Troubleshooting Technical Manual – Hitachi ZX220LC-GI – PDF Download
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- Hitachi ZX220LC-GI Hydraulic Excavator Troubleshooting Technical Manual
- PART NO:TTDCR-EN-00
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Description
Hitachi ZX220LC-GI Hydraulic Excavator Troubleshooting Technical Manual – Hitachi ZX220LC-GI
File Details:
Hitachi ZX220LC-GI Hydraulic Excavator Troubleshooting Technical Manual – Hitachi ZX220LC-GI
- Manual Language:English
- Pages: 430
- Size: 5.22 MB
- Downloadable:Yes
- Format:PDF
HITACHI ZX220LC-GI HYDRAULIC EXCAVATOR TROUBLESHOOTING TECHNICAL MANUAL – HITACHI ZX220LC-GI – PDF DOWNLOAD:
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Description:
Hitachi ZX220LC-GI Hydraulic Excavator Troubleshooting Technical Manual – Hitachi ZX220LC-GI
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 ZX220LC-GI Hydraulic Excavator Troubleshooting Technical Manual – Hitachi ZX220LC-GI
TTDCR-EN-00.................................................................................... 1 INTRODUCTION............................................................................... 3 To The Reader.......................................................................... 3 Additional References.................................................................. 3 Manual Composition..................................................................... 3 Page Number............................................................................ 3 Safety Alert Symbol and Headline Notations............................................. 4 Units Used............................................................................. 4 SYMBOL AND ABBREVIATION.................................................................... 5 SAFETY..................................................................................... 7 Recognize Safety Information........................................................... 7 Understand Signal Words................................................................ 7 Follow Safety Instructions............................................................. 8 Prepare for Emergencies................................................................ 9 Wear Protective Clothing............................................................... 9 Protect Against Noise.................................................................. 10 Inspect Machine........................................................................ 10 General Precautions for Cab............................................................ 11 Use Handholds and Steps................................................................ 12 Adjust the Operator's Seat............................................................. 12 Ensure Safety Before Rising from or Leaving Operator’s Seat............................ 13 Fasten Your Seat Belt.................................................................. 13 Move and Operate Machine Safely........................................................ 14 Operate Only from Operator's Seat...................................................... 14 Jump Starting.......................................................................... 15 Keep Riders off Machine................................................................ 15 Precautions for Operations............................................................. 16 Investigate Job Site Beforehand........................................................ 17 Install OPG Guard...................................................................... 18 Provide Signals for Jobs Involving Multiple Machines................................... 19 Confirm Direction of Machine to Be Driven.............................................. 19 Drive Machine Safely................................................................... 20 Avoid Injury from Rollaway Accidents................................................... 22 Avoid Injury from Back-Over and Swing Accidents........................................ 23 Keep Person Clear from Working Area.................................................... 24 Never Position Bucket Over Anyone...................................................... 24 Avoid Undercutting..................................................................... 25 Avoid Tipping.......................................................................... 25 Never Undercut a High Bank............................................................. 26 Dig with Caution....................................................................... 26 Operate with Caution................................................................... 26 Avoid Power Lines...................................................................... 27 Precautions for Lightning.............................................................. 27 Object Handling........................................................................ 28 Protect Against Flying Debris.......................................................... 28 Park Machine Safely.................................................................... 29 Handle Fluids Safely−Avoid Fires....................................................... 29 Transport Safely....................................................................... 30 Practice Safe Maintenance.............................................................. 31 Warn Others of Service Work............................................................ 32 Support Machine Properly............................................................... 32 Stay Clear of Moving Parts............................................................. 33 Prevent Parts from Flying.............................................................. 33 Store Attachments Safely............................................................... 34 Prevent Burns.......................................................................... 34 Replace Rubber Hoses Periodically...................................................... 35 Avoid High-Pressure Fluids............................................................. 35 Prevent Fires.......................................................................... 36 Evacuating in Case of Fire............................................................. 38 Beware of Exhaust Fumes................................................................ 38 Precautions for Welding and Grinding................................................... 39 Avoid Heating Near Pressurized Fluid Lines............................................. 40 Avoid Applying Heat to Lines Containing Flammable Fluids............................... 40 Precautions for Handling Accumulator and Gas Damper.................................... 40 Remove Paint Before Welding or Heating................................................. 41 Beware of Asbestos and Silicon Dust and Other Contamination............................ 41 Prevent Battery Explosions............................................................. 42 Service Air Conditioning System Safely................................................. 42 Handle Chemical Products Safely........................................................ 43 Dispose of Waste Properly.............................................................. 43 Never Ride Attachment.................................................................. 44 Precautions for Communication Terminal................................................. 44 Precaution for Communication Terminal Equipment........................................ 45 Before Returning the Machine to the Customer........................................... 46 SECTION AND GROUP CONTENTS................................................................. 47 SECTION 4 OPERATIONAL PERFORMANCE TEST..................................................... 49 Group 1 Introduction................................................................... 51 Operational Performance Tests...................................................... 51 Preparation for Performance Tests.................................................. 52 Group 2 Standard....................................................................... 53 Operational Performance Standard Table............................................. 53 Main Pump P-Q Diagram.............................................................. 59 Sensor Activating Range............................................................ 61 MPDr. Monitor Indicating Values.................................................... 62 Group 3 Engine Test.................................................................... 71 Engine Speed....................................................................... 71 Engine Compression Pressure........................................................ 74 Valve Clearance.................................................................... 76 Nozzle............................................................................. 78 Injection Timing................................................................... 80 Lubricant Consumption.............................................................. 82 Group 4 Machine Performance Test....................................................... 83 Travel Speed....................................................................... 83 Track Revolution Speed............................................................. 84 Mistrack Check..................................................................... 85 Travel Parking Leakage............................................................. 86 Swing Speed........................................................................ 87 Swing Function Drift Check......................................................... 88 Swing Motor Leakage................................................................ 90 Maximum Swingable Slant Angle...................................................... 92 Swing Bearing Play................................................................. 94 Hydraulic Cylinder Cycle Time...................................................... 96 Dig Function Drift Check........................................................... 98 Control Lever Operating Force......................................................101 Control Lever Stroke...............................................................102 Combined Operation of Boom Raise / Swing Function Check............................103 Combined Operation of Boom Raise / Arm Roll-In Function Check......................104 Group 5 Component Test.................................................................105 Primary Pilot Pressure.............................................................105 Secondary Pilot Pressure...........................................................107 Solenoid Valve Set Pressure........................................................108 Main Pump Delivery Pressure........................................................110 Main Relief Set Pressure...........................................................112 Relief pressure (when relieving swing).............................................116 Overload Relief Valve Set Pressure.................................................118 Main Pump Flow Rate Measurement....................................................120 Swing Motor Drainage...............................................................128 Travel Motor Drainage..............................................................130 Group 6 Adjustment.....................................................................133 Engine Speed Adjustment and EngineLearning.........................................133 Governor Lever and Fuel Cut Lever Position.........................................138 SECTION 5 TROUBLESHOOTING..................................................................143 Group 1 Diagnosing Procedure...........................................................145 Introduction.......................................................................145 Diagnosis Procedure................................................................146 Electric System Inspection.........................................................149 Precautions for Inspection and Maintenance.........................................150 Instructions for Disconnecting Connectors..........................................152 Fuse Inspection....................................................................154 Fusible Link Inspection............................................................156 Battery Voltage Check..............................................................157 Alternator Check...................................................................158 Continuity Check...................................................................159 Voltage and Current Measurement....................................................160 Check by False Signal..............................................................167 Test Harness.......................................................................168 Group 2 Monitor........................................................................171 Outline............................................................................171 Built-In Diagnosing System Operation...............................................172 Built-In Diagnosing Function Display List..........................................173 Inspection of Hour Meter and Fuel Gauge............................................175 Fuel Gauge and Coolant Temperature Gauge...........................................176 Group 3 e-Service......................................................................177 Outline............................................................................177 List of Operation Data.............................................................178 Snapshot Data......................................................................182 Communication System...............................................................183 Group 4 Component Layout...............................................................185 Main Component.....................................................................185 Electrical System (Overview).......................................................186 Engine.............................................................................187 Electrical System (In Cab).........................................................187 Electrical System (Rear Tray)......................................................188 Electrical System (Monitors).......................................................189 Electrical System (Switch Panel)...................................................190 Electrical System (Around Air Cleaner).............................................191 Electrical System (Relays).........................................................192 Pump Device........................................................................193 Control Valve......................................................................194 Signal Control Valve...............................................................194 Swing Device.......................................................................196 Travel Device......................................................................196 3-Spool Solenoid Valve Unit........................................................197 Layout of Attachment Spec. Parts...................................................198 Pilot Port.........................................................................222 Group 5 Troubleshooting A..............................................................227 Troubleshooting A (Base Machine DiagnosisBy Using Fault Codes) Procedure...........227 MC Fault Code List.................................................................229 ECF Fault Code List................................................................239 Monitor Fault Code List............................................................240 Information Controller Fault Code List.............................................244 Communication Terminal Fault Code List.............................................245 MC Fault Codes 11000 to 11002......................................................247 MC Fault Code 11003................................................................248 ECF Fault Code 16603...............................................................248 MC Fault Codes 11006, 11007,11009..................................................251 ECF Fault Code 16604...............................................................251 Monitor Fault Codes 14212, 14213, 14215............................................251 CAN Harness Check..................................................................252 MC Fault Code 11100................................................................255 MC Fault Code 11101................................................................256 MC Fault Codes 11200, 11202........................................................257 MC Fault Codes 11206, 11208........................................................258 MC Fault Codes 11301 to 11303......................................................259 MC Fault Codes 11304, 11307........................................................260 MC Fault Code 11400................................................................261 MC Fault Code 11401................................................................262 MC Fault Code 11402................................................................263 MC Fault Code 11403................................................................264 MC Fault Code 11407................................................................265 MC Fault Code 11901................................................................266 ECF Fault Codes 16600 to 16602.....................................................267 ECF Fault Code 16605...............................................................268 ECF Fault Code 16606...............................................................269 Monitor Fault Codes 14224, 14230...................................................270 Monitor Fault Code 14231...........................................................271 Monitor Fault Codes 20100 to 20114.................................................272 Group 6 Troubleshooting B..............................................................273 Troubleshooting B (Machine Diagnosis byUsing Troubleshooting Symptom) Procedure....273 Relationship between Machine Trouble Symptoms and Related Parts....................275 Correlation between Trouble Symptoms and Part Failures.............................294 Engine System Troubleshooting......................................................308 All Actuator System Troubleshooting................................................322 Front Attachment System Troubleshooting............................................329 Swing System Troubleshooting.......................................................341 Travel System Troubleshooting......................................................343 Other System Troubleshooting.......................................................348 Exchange Inspection................................................................349 How to Lowering Boom in Case of Emergency and When Engine Stops....................352 Group 7 Troubleshooting C..............................................................353 Troubleshooting C (Monitor Diagnosis)Procedure.....................................353 Malfunction of Monitor Buzzer......................................................356 Malfunction of Coolant Temperature Gauge...........................................358 Malfunction of Fuel Gauge..........................................................360 Malfunction of Hour Meter..........................................................361 Malfunction of Light Bulb Check System.............................................362 Malfunction of Fuel Level Indicator................................................363 Malfunction of Air Filter Restriction Indicator....................................364 Malfunction of Overheat Indicator..................................................365 Malfunction of Engine Oil Pressure Indicator.......................................366 Malfunction of Alternator Indicator................................................367 Malfunction of Engine Warning Indicator............................................368 Malfunction of Pilot Control Shut-Off Lever Indicator..............................369 Malfunction of Preheat Indicator...................................................370 Malfunction of Hydraulic Oil Filter Restriction Indicator..........................372 Malfunction of LCD.................................................................373 Malfunction of Auto-Idle Indicator.................................................374 Malfunction of ECO Mode Indicator..................................................375 Malfunction of PWR Mode Indicator..................................................376 Malfunction of Digging Mode Indicator..............................................378 Malfunction of Attachment Mode Indicator...........................................380 Group 8 Air Conditioner................................................................383 Outline............................................................................383 Functions of Main Parts............................................................386 Troubleshooting....................................................................391 Air Conditioner Controller Fault Code List.........................................392 Air Conditioner Controller Fault Codes E11 to E22..................................393 Air Conditioner Controller Fault Codes E43 to E57..................................394 Work after Replacing Components....................................................416 Refill Compressor Oil..............................................................417 Charge Air Conditioner with Refrigerant............................................418 Hose and Pipe Tightening Torque....................................................426
Please Note:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]
