Hitachi ZX225USLC-6 225USRLC-64 Hydraulic Excavator Workshop Manual (WDFB50-EN-00) – PDF Download

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Hitachi ZX225USLC-6 225USRLC-64 Hydraulic Excavator Workshop Manual (WDFB50-EN-00)

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Hitachi ZX225USLC-6 225USRLC-64 Hydraulic Excavator Workshop Manual (WDFB50-EN-00)

• Manual Language:English
• Pages: 345 
• Size: 39.1 MB
• Downloadable:Yes
• Format:PDF

HITACHI ZX225USLC-6 225USRLC-64 HYDRAULIC EXCAVATOR WORKSHOP MANUAL (WDFB50-EN-00) – PDF DOWNLOAD:

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Description:

Hitachi ZX225USLC-6 225USRLC-64 Hydraulic Excavator Workshop Manual (WDFB50-EN-00)

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-64 Hydraulic Excavator Workshop Manual (WDFB50-EN-00)

WDFB50-EN-00...........................................................................  1
	CONTENTS...........................................................................  3
	INTRODUCTION....................................................................... 13
		To The Reader.................................................................. 13
		Additional References.......................................................... 13
		Manual Composition............................................................. 13
		Page Number.................................................................... 13
		Trademark...................................................................... 13
		Safety Alert Symbol and Headline Notations..................................... 14
		Units Used..................................................................... 14
	SYMBOL AND ABBREVIATION............................................................ 15
	SAFETY............................................................................. 17
		Recognize Safety Information................................................... 17
		Understand Signal Words........................................................ 17
		Follow Safety Instructions..................................................... 18
		Prepare for Emergencies........................................................ 19
		Wear Protective Clothing....................................................... 19
		Protect Against Noise.......................................................... 20
		Inspect Machine................................................................ 20
		General Precautions for the Cab................................................ 21
		Use Handholds and Steps........................................................ 22
		Adjust the Operator's Seat..................................................... 22
		Ensure Safety Before Rising from or Leaving Operator’s Seat.................... 23
		Fasten Your Seat Belt.......................................................... 23
		Move and Operate Machine Safely................................................ 24
		Operate Only from Operator's Seat.............................................. 24
		Jump Starting.................................................................. 25
		Keep Riders off Machine........................................................ 25
		Precautions for Operations..................................................... 26
		Investigate Job Site Beforehand................................................ 27
		Install OPG Guard.............................................................. 28
		Restriction of Attachment Installation......................................... 28
		Provide Signals for Jobs Involving Multiple Machines........................... 29
		Confirm Direction of Machine to Be Driven...................................... 29
		Drive Machine Safely........................................................... 30
		Avoid Injury from Rollaway Accidents........................................... 32
		Avoid Injury from Back-Over and Swing Accidents................................ 33
		Keep People Clear from Working Area............................................ 34
		Never Position the Bucket Over Anyone.......................................... 34
		Avoid Undercutting............................................................. 35
		Avoid Tipping.................................................................. 35
		Never Undercut a High Bank..................................................... 36
		Dig with Caution............................................................... 36
		Operate with Caution........................................................... 36
		Avoid Power Lines.............................................................. 37
		Precautions for Lightning...................................................... 37
		Object Handling................................................................ 38
		Protect Against Flying Debris.................................................. 38
		Park Machine Safely............................................................ 39
		Handle Fluids Safely−Avoid Fires............................................... 39
		Transport Safely............................................................... 40
		Practice Safe Maintenance...................................................... 41
		Warn Others of Service Work.................................................... 42
		Support Machine Properly....................................................... 42
		Stay Clear of Moving Parts..................................................... 43
		Prevent Parts from Flying...................................................... 43
		Avoid Injury from Attachment Falling Accident.................................. 44
		Prevent Burns.................................................................. 44
		Replace Rubber Hoses Periodically.............................................. 45
		Avoid High-Pressure Fluids..................................................... 45
		Prevent Fires.................................................................. 46
		Evacuating in Case of Fire..................................................... 48
		Beware of Exhaust Fumes........................................................ 48
		Precautions for Welding and Grinding........................................... 49
		Avoid Heating Near Pressurized Fluid Lines..................................... 50
		Avoid Applying Heat to Lines Containing Flammable Fluids....................... 50
		Precautions for Handling Accumulator and Gas Damper............................ 50
		Remove Paint Before Welding or Heating......................................... 51
		Beware of Asbestos and Silica Dust and Other Contamination..................... 51
		Prevent Battery Explosions..................................................... 52
		Service Air Conditioning System Safely......................................... 52
		Handle Chemical Products Safely................................................ 53
		Dispose of Waste Properly...................................................... 53
		Never Ride Attachment.......................................................... 54
		Notes on Aftertreatment Device................................................. 54
		Precautions for Communication Terminal......................................... 54
		Precautions for Communication Terminal Equipment............................... 55
		Notes on Protection of Operator’s Station when the Machine Rolls Over.......... 57
		Before Returning the Machine to the Customer................................... 58
	SECTION AND GROUP CONTENTS......................................................... 59
	SECTION 1 GENERAL.................................................................. 63
		Group 1 Precautions for Disassembling and Assembling........................... 65
			Precautions for Disassembling and Assembling............................... 65
		Group 2 Tightening............................................................. 71
			Tightening Bolts and Nuts.................................................. 71
			Piping Joint............................................................... 74
		Group 3 Painting............................................................... 81
			Painting................................................................... 81
		Group 4 Bleeding Air........................................................... 83
			Bleeding Air from Hydraulic System......................................... 83
			Bleeding Air from Fuel System.............................................. 84
			Air Bleeding from the Diesel Exhaust Fluid Defrosting Piping............... 86
		Group 5 Preparation............................................................ 87
			Preparation before Inspection and Maintenance.............................. 87
			Hydraulic Circuit Pressure Release Procedure............................... 89
			Pressure Release from Hydraulic Oil Tank................................... 90
			Pressure Release from Expansion Tank....................................... 91
	SECTION 2 MAINTENANCE STANDARD..................................................... 95
		Group 1 Upperstructure......................................................... 97
			Pump Device................................................................ 97
			Swing Motor................................................................101
		Group 2 Undercarriage..........................................................105
			Travel Motor...............................................................105
			Sprocket...................................................................107
			Front Idler................................................................109
			Upper Roller...............................................................111
			Lower Roller...............................................................112
			Track......................................................................113
		Group 3 Front Attachment.......................................................117
			Pin and Bushing............................................................117
			Side Cutter (2014503, 2014504).............................................119
			Point (4427919)............................................................120
			Standard Dimensions for Arm and Bucket Connection..........................121
			Standard Dimensions for Arm and Boom Connection............................122
			Cylinder...................................................................123
	SECTION 3 UPPERSTRUCTURE...........................................................127
		Group 1 Cab....................................................................129
			Removal and Installation of Cab............................................129
			Dimensions of Cab Glass....................................................171
		Group 2 Counterweight..........................................................191
			Removal and Installation of Counterweight (ZX225USLC-6)....................191
			Removal and Installation of Counterweight (ZX225USRLC-6)...................195
		Group 3 Main Frame.............................................................199
			Removal and Installation of Main Frame.....................................199
		Group 4 Engine.................................................................219
			Removal and Installation of Engine.........................................219
		Group 8 Pump Device............................................................259
			Removal and Installation of Pump Device....................................259
			Removal and Installation of Coupling.......................................277
			Disassembly of Pump Device.................................................281
			Assembly of Pump Device....................................................289
			Disassembly of Regulator...................................................301
			Assembly of Regulator......................................................303
			Disassembly of Solenoid Valve Unit.........................................305
			Assembly of Solenoid Valve Unit............................................307
			Structure of Pilot Pump....................................................309
		Group 9 Control Valve..........................................................311
			Removal and Installation of Control Valve..................................311
			Removal and Installation of Blade Control Valve............................335
			Disassembly of Housing.....................................................339
			Assembly of Housing........................................................341
			Disassembly of Control Valve (A Side)......................................343
			Assembly of Control Valve (A Side).........................................351
			Disassembly of Control Valve (B Side)......................................363
			Assembly of Control Valve (B Side).........................................372
			Disassembly of Blade Control Valve.........................................385
			Assembly of Blade Control Valve............................................387
		Group 10 Swing Device..........................................................389
			Removal and Installation of Swing Device...................................389
			Disassembly of Swing Reduction Gear........................................395
			Assembly of Swing Reduction Gear...........................................401
			Disassembly of Swing Motor.................................................409
			Assembly of Swing Motor....................................................412
		Group 11 Pilot Valve...........................................................415
			Removal and Installation of Pilot Valve (Left).............................415
			Removal and Installation of Pilot Valve (Right)............................427
			Removal and Installation of Travel Pilot Valve.............................443
			Removal and Installation of Blade Pilot Valve..............................447
			Disassembly of Pilot Valves (Right and Left)...............................461
			Assembly of Pilot Valves (Right and Left)..................................464
			Disassembly of Travel Pilot Valve..........................................467
			Assembly of Travel Pilot Valve.............................................471
			Disassembly of Blade Pilot Valve...........................................477
			Assembly of Blade Pilot Valve..............................................480
		Group 12 Solenoid Valve........................................................483
			Removal and Installation of Pilot Shut-Off Solenoid Valve..................483
			Removal and Installation of 5-Spool Solenoid Valve Unit....................487
			Removal and Installation of 2-Spool Solenoid Valve Unit....................495
			Disassembly of Pilot Shut-Off Solenoid Valve...............................499
			Assembly of Pilot Shut-Off Solenoid Valve..................................501
			Structure of 5-Spool Solenoid Valve Unit...................................503
			Structure of 2-Spool Solenoid Valve Unit...................................505
		Group 13 Signal Control Valve..................................................507
			Removal and Installation of Signal Control Valve...........................507
			Structure of Signal Control Valve..........................................517
		Group 14 Aftertreatment Device.................................................521
			Removal and Installation of Aftertreatment Device (ZX225USLC-6)............521
			Removal and Installation of Aftertreatment Device (ZX225USRLC-6)...........547
		Group 15 DEF Tank..............................................................575
			Removal and Installation of DEF Tank (ZX225USLC-6).........................575
			Removal and Installation of DEF Tank (ZX225USRLC-6)........................601
		Group 16 Coolant Control Valve.................................................617
			Removal and Installation of Coolant Control Valve..........................617
		Group 17 DEF Supply Module.....................................................621
			Removal and Installation of DEF Supply Module..............................621
	SECTION 4 UNDERCARRIAGE............................................................631
		Group 1 Swing Bearing..........................................................633
			Removal and Installation of Swing Bearing..................................633
			Disassembly of Swing Bearing...............................................639
			Assembly of Swing Bearing..................................................642
		Group 2 Travel Device..........................................................645
			Removal and Installation of Travel Device..................................645
			Disassembly of Travel Device...............................................649
			Assembly of Travel Device..................................................653
			Disassembly of Travel Motor................................................661
			Assembly of Travel Motor...................................................664
			Disassembly of Brake Valve.................................................669
			Assembly of Brake Valve....................................................671
			Precautions for Using Floating Seal........................................673
		Group 3 Center Joint...........................................................675
			Removal and Installation of Center Joint (Without Blade)...................675
			Removal and Installation of Center Joint (With Blade)......................683
			Disassembly of Center Joint (without Blade)................................691
			Assembly of Center Joint (without Blade)...................................693
			Replacement of Body and Spindle............................................696
			Disassembly of Center Joint (with Blade)...................................697
			Assembly of Center Joint (with Blade)......................................699
			Replacement of Body and Spindle............................................702
		Group 4 Track Adjuster.........................................................703
			Removal and Installation of Track Adjuster.................................703
			Disassembly of Front Idler.................................................707
			Assembly of Front Idler....................................................710
			Disassembly of Track Adjuster..............................................713
			Assembly of Track Adjuster.................................................717
			Precautions for Using Floating Seal........................................721
		Group 6 Upper and Lower Rollers................................................723
			Removal and Installation of Upper Roller...................................723
			Removal and Installation of Lower Roller...................................729
			Disassembly of Lower Roller................................................735
			Assembly of Lower Roller...................................................737
			Precautions for Using Floating Seal........................................739
		Group 7 Track..................................................................741
			Removal and Installation of Track..........................................741
		Group 8 Blade Cylinder.........................................................749
			Removal and Installation of Blade Cylinder.................................749
			Disassembly of Blade Cylinder..............................................755
			Assembly of Blade Cylinder.................................................758
	SECTION 5 FRONT ATTACHMENT.........................................................763
		Group 1 Front Attachment.......................................................765
			Removal and Installation of Front Attachment...............................765
		Group 2 Cylinder...............................................................779
			Removal and Installation of Boom Cylinder..................................779
			Removal and Installation of Arm Cylinder...................................787
			Removal and Installation of Bucket Cylinder................................795
			Removal and Installation of Positioning Cylinder...........................799
			Disassembly of Boom, Arm, and Bucket Cylinders.............................805
			Assembly of Boom, Arm, and Bucket Cylinders................................811
			Disassembly of Positioning Cylinder........................................817
			Assembly of Positioning Cylinder...........................................820
		Group 3 Hose Rupture Valve.....................................................823
			Removal and Installation of Hose Rupture Valve for Boom Cylinder...........823
			Removal and Installation of Hose Rupture Valve for Arm Cylinder............827
			Removal and Installation of Hose Rupture Valve for Positioning Cylinder....831
			Structure of Hose Rupture Valve for Boom Cylinder (Right)..................835
			Structure of Hose Rupture Valve for Boom Cylinder (Left)...................837
			Structure of Hose Rupture Valve for Arm Cylinder...........................839
			Structure of Hose Rupture Valve for Positioning Cylinder...................841
	SERVICE MANUAL REVISION REQUEST FORM...............................................845

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]