Technical Manual Hitachi ZX220LC-GI Hydraulic Excavator | TTDCR-EN-00

Technical Manual Hitachi ZX220LC-GI Hydraulic Excavator TTDCR-EN-00 (Preview)

TTDCR-EN-00
INTRODUCTION
To The Reader
Additional References
Manual Composition
Page Number
Safety Alert Symbol and Headline Notations
Units Used
SYMBOL AND ABBREVIATION
SAFETY
Recognize Safety Information
Understand Signal Words
Follow Safety Instructions
Prepare for Emergencies
Wear Protective Clothing
Protect Against Noise
Inspect Machine
General Precautions for Cab
Use Handholds and Steps
Adjust the Operator’s Seat
Ensure Safety Before Rising from or Leaving Operator’s Seat
Fasten Your Seat Belt
Move and Operate Machine Safely
Operate Only from Operator’s Seat
Jump Starting
Keep Riders off Machine
Precautions for Operations
Investigate Job Site Beforehand
Install OPG Guard
Provide Signals for Jobs Involving Multiple Machines
Confirm Direction of Machine to Be Driven
Drive Machine Safely
Avoid Injury from Rollaway Accidents
Avoid Injury from Back-Over and Swing Accidents
Keep Person Clear from Working Area
Never Position Bucket Over Anyone
Avoid Undercutting
Avoid Tipping
Never Undercut a High Bank
Dig with Caution
Operate with Caution
Avoid Power Lines
Precautions for Lightning
Object Handling
Protect Against Flying Debris
Park Machine Safely
Handle Fluids Safely−Avoid Fires
Transport Safely
Practice Safe Maintenance
Warn Others of Service Work
Support Machine Properly
Stay Clear of Moving Parts
Prevent Parts from Flying
Store Attachments Safely
Prevent Burns
Replace Rubber Hoses Periodically
Avoid High-Pressure Fluids
Prevent Fires
Evacuating in Case of Fire
Beware of Exhaust Fumes
Precautions for Welding and Grinding
Avoid Heating Near Pressurized Fluid Lines
Avoid Applying Heat to Lines Containing Flammable Fluids
Precautions for Handling Accumulator and Gas Damper
Remove Paint Before Welding or Heating
Beware of Asbestos and Silicon Dust and Other Contamination
Prevent Battery Explosions
Service Air Conditioning System Safely
Handle Chemical Products Safely
Dispose of Waste Properly
Never Ride Attachment
Precautions for Communication Terminal
Precaution for Communication Terminal Equipment
Before Returning the Machine to the Customer
SECTION AND GROUP CONTENTS
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction
Operational Performance Tests
Preparation for Performance Tests
Group 2 Standard
Operational Performance Standard Table
Main Pump P-Q Diagram
Sensor Activating Range
MPDr. Monitor Indicating Values
Group 3 Engine Test
Engine Speed
Engine Compression Pressure
Valve Clearance
Nozzle
Injection Timing
Lubricant Consumption
Group 4 Machine Performance Test
Travel Speed
Track Revolution Speed
Mistrack Check
Travel Parking Leakage
Swing Speed
Swing Function Drift Check
Swing Motor Leakage
Maximum Swingable Slant Angle
Swing Bearing Play
Hydraulic Cylinder Cycle Time
Dig Function Drift Check
Control Lever Operating Force
Control Lever Stroke
Combined Operation of Boom Raise / Swing Function Check
Combined Operation of Boom Raise / Arm Roll-In Function Check
Group 5 Component Test
Primary Pilot Pressure
Secondary Pilot Pressure
Solenoid Valve Set Pressure
Main Pump Delivery Pressure
Main Relief Set Pressure
Relief pressure (when relieving swing)
Overload Relief Valve Set Pressure
Main Pump Flow Rate Measurement
Swing Motor Drainage
Travel Motor Drainage
Group 6 Adjustment
Engine Speed Adjustment and EngineLearning
Governor Lever and Fuel Cut Lever Position
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Introduction
Diagnosis Procedure
Electric System Inspection
Precautions for Inspection and Maintenance
Instructions for Disconnecting Connectors
Fuse Inspection
Fusible Link Inspection
Battery Voltage Check
Alternator Check
Continuity Check
Voltage and Current Measurement
Check by False Signal
Test Harness
Group 2 Monitor
Outline
Built-In Diagnosing System Operation
Built-In Diagnosing Function Display List
Inspection of Hour Meter and Fuel Gauge
Fuel Gauge and Coolant Temperature Gauge
Group 3 e-Service
Outline
List of Operation Data
Snapshot Data
Communication System
Group 4 Component Layout
Main Component
Electrical System (Overview)
Engine
Electrical System (In Cab)
Electrical System (Rear Tray)
Electrical System (Monitors)
Electrical System (Switch Panel)
Electrical System (Around Air Cleaner)
Electrical System (Relays)
Pump Device
Control Valve
Signal Control Valve
Swing Device
Travel Device
3-Spool Solenoid Valve Unit
Layout of Attachment Spec. Parts
Pilot Port
Group 5 Troubleshooting A
Troubleshooting A (Base Machine DiagnosisBy Using Fault Codes) Procedure
MC Fault Code List
ECF Fault Code List
Monitor Fault Code List
Information Controller Fault Code List
Communication Terminal Fault Code List
MC Fault Codes 11000 to 11002
MC Fault Code 11003
ECF Fault Code 16603
MC Fault Codes 11006, 11007,11009
ECF Fault Code 16604
Monitor Fault Codes 14212, 14213, 14215
CAN Harness Check
MC Fault Code 11100
MC Fault Code 11101
MC Fault Codes 11200, 11202
MC Fault Codes 11206, 11208
MC Fault Codes 11301 to 11303
MC Fault Codes 11304, 11307
MC Fault Code 11400
MC Fault Code 11401
MC Fault Code 11402
MC Fault Code 11403
MC Fault Code 11407
MC Fault Code 11901
ECF Fault Codes 16600 to 16602
ECF Fault Code 16605
ECF Fault Code 16606
Monitor Fault Codes 14224, 14230
Monitor Fault Code 14231
Monitor Fault Codes 20100 to 20114
Group 6 Troubleshooting B
Troubleshooting B (Machine Diagnosis byUsing Troubleshooting Symptom) Procedure
Relationship between Machine Trouble Symptoms and Related Parts
Correlation between Trouble Symptoms and Part Failures
Engine System Troubleshooting
All Actuator System Troubleshooting
Front Attachment System Troubleshooting
Swing System Troubleshooting
Travel System Troubleshooting
Other System Troubleshooting
Exchange Inspection
How to Lowering Boom in Case of Emergency and When Engine Stops
Group 7 Troubleshooting C
Troubleshooting C (Monitor Diagnosis)Procedure
Malfunction of Monitor Buzzer
Malfunction of Coolant Temperature Gauge
Malfunction of Fuel Gauge
Malfunction of Hour Meter
Malfunction of Light Bulb Check System
Malfunction of Fuel Level Indicator
Malfunction of Air Filter Restriction Indicator
Malfunction of Overheat Indicator
Malfunction of Engine Oil Pressure Indicator
Malfunction of Alternator Indicator
Malfunction of Engine Warning Indicator
Malfunction of Pilot Control Shut-Off Lever Indicator
Malfunction of Preheat Indicator
Malfunction of Hydraulic Oil Filter Restriction Indicator
Malfunction of LCD
Malfunction of Auto-Idle Indicator
Malfunction of ECO Mode Indicator
Malfunction of PWR Mode Indicator
Malfunction of Digging Mode Indicator
Malfunction of Attachment Mode Indicator
Group 8 Air Conditioner
Outline
Functions of Main Parts
Troubleshooting
Air Conditioner Controller Fault Code List
Air Conditioner Controller Fault Codes E11 to E22
Air Conditioner Controller Fault Codes E43 to E57
Work after Replacing Components
Refill Compressor Oil
Charge Air Conditioner with Refrigerant
Hose and Pipe Tightening Torque