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Hitachi ZX225USLC-6 225USRLC-6 Hydraulic Excavator Troubleshooting Technical Manual – PDF Download
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- Hitachi ZX225USLC-6 225USRLC-6 Hydraulic Excavator Troubleshooting Technical Manual
- Part No:TTDFB50-EN-00
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Description
Hitachi ZX225USLC-6 225USRLC-6 Hydraulic Excavator Troubleshooting Technical Manual
File Details:
Hitachi ZX225USLC-6 225USRLC-6 Hydraulic Excavator Troubleshooting Technical Manual
- Manual Language:English
- Pages: 1000+
- Size: 4.71 MB
- Downloadable:Yes
- Format:PDF
HITACHI ZX225USLC-6 225USRLC-6 HYDRAULIC EXCAVATOR TROUBLESHOOTING TECHNICAL MANUAL – PDF DOWNLOAD:
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Description:
Hitachi ZX225USLC-6 225USRLC-6 Hydraulic Excavator Troubleshooting Technical 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 ZX225USLC-6 225USRLC-6 Hydraulic Excavator Troubleshooting Technical Manual
TTDFB50-EN-00....................................................................................... 1 CONTENTS........................................................................................ 3 INTRODUCTION.................................................................................... 7 To The Reader............................................................................... 7 Additional References....................................................................... 7 Manual Composition.......................................................................... 7 Page Number................................................................................. 7 Trademark................................................................................... 7 Safety Alert Symbol and Headline Notations.................................................. 8 Units Used.................................................................................. 8 SYMBOL AND ABBREVIATION......................................................................... 9 SAFETY.......................................................................................... 11 Recognize Safety Information................................................................ 11 Understand Signal Words..................................................................... 11 Follow Safety Instructions.................................................................. 12 Prepare for Emergencies..................................................................... 13 Wear Protective Clothing.................................................................... 13 Protect Against Noise....................................................................... 14 Inspect Machine............................................................................. 14 General Precautions for the Cab............................................................. 15 Use Handholds and Steps..................................................................... 16 Adjust the Operator's Seat.................................................................. 16 Ensure Safety Before Rising from or Leaving Operator’s Seat................................. 17 Fasten Your Seat Belt....................................................................... 17 Move and Operate Machine Safely............................................................. 18 Operate Only from Operator's Seat........................................................... 18 Jump Starting............................................................................... 19 Keep Riders off Machine..................................................................... 19 Precautions for Operations.................................................................. 20 Investigate Job Site Beforehand............................................................. 21 Install OPG Guard........................................................................... 22 Restriction of Attachment Installation...................................................... 22 Provide Signals for Jobs Involving Multiple Machines........................................ 23 Confirm Direction of Machine to Be Driven................................................... 23 Drive Machine Safely........................................................................ 24 Avoid Injury from Rollaway Accidents........................................................ 26 Avoid Injury from Back-Over and Swing Accidents............................................. 27 Keep People Clear from Working Area......................................................... 28 Never Position the Bucket Over Anyone....................................................... 28 Avoid Undercutting.......................................................................... 29 Avoid Tipping............................................................................... 29 Never Undercut a High Bank.................................................................. 30 Dig with Caution............................................................................ 30 Operate with Caution........................................................................ 30 Avoid Power Lines........................................................................... 31 Precautions for Lightning................................................................... 31 Object Handling............................................................................. 32 Protect Against Flying Debris............................................................... 32 Park Machine Safely......................................................................... 33 Handle Fluids Safely−Avoid Fires............................................................ 33 Transport Safely............................................................................ 34 Practice Safe Maintenance................................................................... 35 Warn Others of Service Work................................................................. 36 Support Machine Properly.................................................................... 36 Stay Clear of Moving Parts.................................................................. 37 Prevent Parts from Flying................................................................... 37 Avoid Injury from Attachment Falling Accident............................................... 38 Prevent Burns............................................................................... 38 Replace Rubber Hoses Periodically........................................................... 39 Avoid High-Pressure Fluids.................................................................. 39 Prevent Fires............................................................................... 40 Evacuating in Case of Fire.................................................................. 42 Beware of Exhaust Fumes..................................................................... 42 Precautions for Welding and Grinding........................................................ 43 Avoid Heating Near Pressurized Fluid Lines.................................................. 44 Avoid Applying Heat to Lines Containing Flammable Fluids.................................... 44 Precautions for Handling Accumulator and Gas Damper......................................... 44 Remove Paint Before Welding or Heating...................................................... 45 Beware of Asbestos and Silica Dust and Other Contamination.................................. 45 Prevent Battery Explosions.................................................................. 46 Service Air Conditioning System Safely...................................................... 46 Handle Chemical Products Safely............................................................. 47 Dispose of Waste Properly................................................................... 47 Never Ride Attachment....................................................................... 48 Notes on Aftertreatment Device.............................................................. 48 Precautions for Communication Terminal...................................................... 48 Precautions for Communication Terminal Equipment............................................ 49 Notes on Protection of Operator’s Station when the Machine Rolls Over....................... 51 Before Returning the Machine to the Customer................................................ 52 SECTION AND GROUP CONTENTS...................................................................... 53 SECTION 4 OPERATIONAL PERFORMANCE TEST.......................................................... 55 Group 1 Introduction........................................................................ 57 Operational Performance Tests........................................................... 57 Preparation for Performance Tests....................................................... 58 Group 2 Standard............................................................................ 59 Operational Performance Standard Table.................................................. 59 Main Pump P-Q Diagram (P1, P2).......................................................... 69 Main Pump P-Q Diagram (P3).............................................................. 70 Sensor Activating Range................................................................. 72 MPDr. Monitor Indicating Values......................................................... 74 Group 3 Engine Test......................................................................... 87 Engine Speed............................................................................ 87 Lubricant Consumption................................................................... 90 Group 4 Machine Performance Test............................................................ 91 Travel Speed............................................................................ 91 Track Revolution Speed.................................................................. 92 Mistrack Check.......................................................................... 93 Travel Parking Leakage.................................................................. 94 Swing Speed............................................................................. 95 Swing Function Drift Check.............................................................. 96 Swing Motor Leakage..................................................................... 98 Maximum Swingable Slant Angle...........................................................100 Swing Bearing Play......................................................................102 Hydraulic Cylinder Cycle Time...........................................................104 Dig Function Drift Check................................................................106 Control Lever Operating Force...........................................................110 Control Lever Stroke....................................................................111 Combined Operation of Boom Raise and Swing Function Check...............................112 Combined Operation of Boom Raise and Arm Roll-In Function Check.........................113 Clearance of Front Attachment Connecting Part...........................................114 Group 5 Component Test......................................................................115 Primary Pilot Pressure..................................................................115 Secondary Pilot Pressure................................................................117 5-Spool Solenoid Valve Set Pressure.....................................................118 2-Spool Solenoid Valve (Aftertreatment Device Regeneration Control) Set Pressure........119 Main Pump Delivery Pressure.............................................................121 Main Relief Set Pressure................................................................122 Relief Pressure (when relieving swing)..................................................128 Overload Relief Valve Set Pressure......................................................130 Main Pump Flow Rate Measurement.........................................................134 Swing Motor Drainage....................................................................144 Travel Motor Drainage...................................................................146 Group 6 Adjustment..........................................................................149 Rewrite of Aftertreatment Device Serial No..............................................149 How to Clear Fault Code.................................................................150 Procedure after Replacing DCU and ECM...................................................151 Air Bleeding from the Diesel Exhaust Fluid Defrosting Piping............................152 How to Check Manual Regeneration Switch.................................................153 Remedy at DEF Pressure Decrease.........................................................154 Remedy at DEF Abnormal Quality..........................................................156 Clean DEF Tank..........................................................................158 Remedy when Mixing Oil in DEF Tank......................................................160 SECTION 5 TROUBLESHOOTING.......................................................................163 Group 1 Diagnosing Procedure................................................................165 Introduction............................................................................165 Diagnosis Procedure.....................................................................166 Electrical System Inspection............................................................169 Precautions for Inspection and Maintenance..............................................170 Instructions for Disconnecting Connectors...............................................172 Fuse Inspection.........................................................................174 Fusible Link Inspection.................................................................177 Battery Voltage Check...................................................................178 Alternator Check........................................................................179 Continuity Check........................................................................180 Voltage and Current Measurement.........................................................182 Check by False Signal...................................................................190 Test Wire Harness.......................................................................191 Group 2 Monitor.............................................................................193 Outline.................................................................................193 Operating Procedures of Service Menu....................................................194 Setting Menu............................................................................235 Inspection of Engine Oil Level, Coolant Level, Hour Meter, and Fuel Gauge...............240 Fuel Gauge, Coolant Temperature Gauge, DEF Gauge........................................241 Group 3 e-Service...........................................................................243 Outline.................................................................................243 List of Operation Data..................................................................244 Communication System....................................................................246 Group 4 Component Layout....................................................................247 Main Component..........................................................................247 Electrical System (Overview)............................................................251 Electrical System (Rear Tray)...........................................................252 Electrical System (Switch Panel)........................................................253 Electrical System (Utility Space).......................................................254 Electrical System (Relays)..............................................................255 Engine..................................................................................256 Aftertreatment Device...................................................................257 Pump Device.............................................................................258 Around Pump Device......................................................................260 Control Valve/Signal Control Valve......................................................261 Swing Device............................................................................263 Travel Device...........................................................................263 5-Spool Solenoid Valve Unit.............................................................264 2-Spool Solenoid Valve Unit (Pilot Pressure Control (Pump 3 Flow Rate Control)).........264 2-Spool Solenoid Valve Unit (Aftertreatment Device Regeneration Control)................264 DEF Tank................................................................................265 DEF Supply Module.......................................................................265 Layout of Attachment Spec. Parts........................................................266 Components Related with Breaker.........................................................267 Components in Control Valve.............................................................270 Pilot Port..............................................................................292 Group 5 Troubleshooting A...................................................................297 Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure...............297 MC Fault Code List......................................................................299 ECM Fault Code List.....................................................................320 DCU Fault Code List.....................................................................334 Monitor Controller (Monitor) Fault Code List............................................341 Monitor Controller (Information) Fault Code List........................................342 Air Conditioner Controller Fault Code List..............................................345 Communication Terminal Fault Code List..................................................346 MC Fault Codes 11000 to 11002...........................................................347 MC Fault Code 11003.....................................................................348 MC Fault Codes 11006, 11007,11009.......................................................351 Monitor Controller (Monitor) Fault Codes 13002, 13003, 13005............................351 CAN0 Harness Check......................................................................352 ISO-CAN (Engine) Harness Check..........................................................356 MC Fault Codes 11008, 11010.............................................................359 Monitor Controller (Monitor) Fault Codes 13004, 13006, 13007............................359 CAN1 Harness Check......................................................................360 MC Fault Code 11100.....................................................................363 MC Fault Code 11101.....................................................................364 MC Fault Codes 11200 to 11202...........................................................365 MC Fault Code 11203.....................................................................366 MC Fault Codes 11206 to 11208...........................................................367 MC Fault Codes 11301 to 11303...........................................................368 MC Fault Codes 11304, 11307, 11325......................................................369 MC Fault Codes 11995, 11997.............................................................370 MC Fault Code 11400.....................................................................371 MC Fault Code 11401.....................................................................372 MC Fault Code 11402.....................................................................373 MC Fault Code 11403.....................................................................374 MC Fault Code 11406.....................................................................375 MC Fault Code 11407.....................................................................376 MC Fault Code 11408.....................................................................377 MC Fault Code 11409.....................................................................378 MC Fault Code 11410.....................................................................379 MC Fault Code 11411.....................................................................380 MC Fault Codes 11434, 11435.............................................................381 MC Fault Code 11436.....................................................................382 MC Fault Codes 11458, 11459.............................................................383 MC Fault Code 11427.....................................................................384 MC Fault Code 11428.....................................................................385 MC Fault Code 11901.....................................................................386 MC Fault Codes 20010 to 20012...........................................................387 Monitor Controller (Information) Fault Codes 13304, 13310...............................388 Monitor Controller (Information) Fault Code 13311.......................................389 Monitor Controller (Information) Fault Codes 20100 to 20114.............................390 Monitor Controller (Information) Fault Codes 20109 to 20149.............................391 Air Conditioner Controller Fault Codes 11 to 22.........................................392 Air Conditioner Controller Fault Codes 43 to 92.........................................393 Group 6 Troubleshooting B...................................................................395 Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure................395 Relationship between Machine Trouble Symptoms and Related Parts.........................397 Correlation between Trouble Symptoms and Part Failures..................................424 Engine System Troubleshooting...........................................................442 All Actuator System Troubleshooting.....................................................452 Front Attachment System Troubleshooting.................................................460 Swing System Troubleshooting............................................................475 Travel System Troubleshooting...........................................................477 Blade System Troubleshooting (Optional).................................................483 Other System Troubleshooting............................................................485 Exchange Inspection Method..............................................................490 How to Lowering Boom When Emergency and When Engine Stops without Hose Rupture Valve....493 How to Lowering Boom When Emergency and When Engine Stops with Hose Rupture Valve.......494 Attachment Circuit Pressure Release Procedure...........................................495 Group 7 Air Conditioner.....................................................................497 Outline.................................................................................497 Functions of Main Parts.................................................................500 Troubleshooting.........................................................................505 Air Conditioner Controller Fault Code List..............................................506 Air Conditioner Controller Fault Codes 11 to 22.........................................507 Air Conditioner Controller Fault Codes 43 to 92.........................................508 Work after Replacing Components.........................................................530 Refill Compressor Oil...................................................................531 Charge Air Conditioner with Refrigerant.................................................532 Hose and Pipe Tightening Torque.........................................................540 SERVICE MANUAL REVISION REQUEST FORM............................................................543 The Attached Diagram List.......................................................................544
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