Complete workshop repair service manual with electrical wiring diagrams for Hitachi ZAXIS 220LC-GI Excavator. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

Hitachi ZX220LC-GI Excavator service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

TODCR-EN-00 - Hitachi ZX220LC-GI Hydraulic Excavator Technical Manual (Operational Principle).pdf
TTDCR-EN-00 (attach to) - Hitachi ZX220LC-GI Hydraulic Excavator Electrical Circuit Diagram.pdf
TTDCR-EN-00 - Hitachi ZX220LC-GI Hydraulic Excavator Technical Manual (Troubleshooting).pdf
WDCR-EN-00 - Hitachi ZX220LC-GI Hydraulic Excavator Workshop Manual.pdf

FORMAT: PDF
LANGUAGE: ENGLISH
PAGES: 1,277
...
TODCR-EN-00 - Hitachi ZX220LC-GI Hydraulic Excavator Technical Manual (Operational Principle)...2
  TODCR-EN-00...2
    INTRODUCTION...4
      To The Reader...4
      Additional References...4
      Manual Composition...4
      Page Number...4
      Safety Alert Symbol and Headline Notations...5
      Units Used...5
    SYMBOL AND ABBREVIATION...6
    SECTION AND GROUP CONTENTS...8
    SECTION 1 GENERAL...10
      Group 1 Specification...12
        Specifications...12
        Working Ranges (Grouser shoe)...13
      Group 2 Component Layout...14
        Main Component...14
        Electrical System (Overview)...15
        Engine...16
        Electrical System (In Cab)...16
        Electrical System (Rear Tray)...17
        Electrical System (Monitors)...18
        Electrical System (Switch Panel)...19
        Electrical System (Around Air Cleaner)...20
        Electrical System (Relays)...21
        Pump Device...22
        Control Valve...23
        Signal Control Valve...23
        Swing Device...25
        Travel Device...25
        3-Spool Solenoid Valve Unit...26
        Layout of Attachment Spec. Parts...27
      Group 3 Component Specifications...30
        Engine...30
        Engine Accessories...34
        Hydraulic Component...35
        Electrical Component...39
    SECTION 2 SYSTEM...42
      Group 1 Controller...44
        Outline...44
        CAN (Network Provided for Machine)...45
      Group 2 Control System...48
        Outline...48
        Engine Control...51
        Pump Control...73
        Valve Control...83
        Other Control...95
      Group 3 Hydraulic System...100
        Outline...100
        Pilot Circuit...101
        Main Circuit...111
      Group 4 Electrical System...124
        Outline...124
        Main Circuit...125
        Electric Power Circuit (Key Switch: OFF)...127
        CAN Circuit...129
        Accessory Circuit...131
        Preheating Circuit (Key Switch: ON, START)...133
        Starting Circuit (Key Switch: START)...135
        Charging Circuit (Key Switch: ON)...139
        Surge Voltage Prevention Circuit...143
        Pilot Shut-Off Circuit (Key switch: ON)...145
        Engine Stop Circuit...147
        Accessory Circuit...150
        Work Light Circuit...151
        Wiper/Washer Circuit...153
        Cab Light Circuit...155
    SECTION 3 COMPONENT OPERATION...160
      Group 1 Pump Device...162
        Outline...162
        Main Pump...163
        Regulator...167
        Solenoid Valve...185
        Pilot Pump...187
        Pump Delivery Pressure Sensor...187
        Pump Control Pressure Sensor...187
        N Sensor (Engine Speed Sensor)...188
      Group 2 Swing Device...190
        Outline...190
        Swing Reduction Gear...191
        Swing Motor...192
        Swing Parking Brake...193
        Valve Unit...195
      Group 3 Control Valve...198
        Outline...198
        Hydraulic Circuit...219
        Flow Combiner Valve...225
        Main Relief Valve...227
        Overload Relief Valve (with Make-Up Function)...231
        Regenerative Valve...235
        Anti-Drift Valve...239
        Flow Rate Control Valve...243
        Digging Regenerative Valve...247
        Boom Lower Meter-In Cut Valve...249
        Bypass Shut-Out Valve...251
      Group 4 Pilot Valve...254
        Outline...254
        Operation (Front Attachment / Swing and Travel Pilot Valves)...256
        Operation (Auxiliary Pilot Valve)...264
        Shockless Function (Only for Travel Pilot Valve)...269
      Group 5 Travel Device...270
        Outline...270
        Travel Reduction Gear...271
        Travel Motor...273
        Parking Brake...275
        Travel Brake Valve...277
        Overload Relief Valve...281
        Travel Mode Control...283
      Group 6 Signal Control Valve...288
        Outline...288
        Pilot Port...289
        Shuttle Valve...294
        Shockless Valve...297
        Pump 1 and 2 Flow Rate Control Valve...301
        Bucket Flow Rate Control Valve Control Spool, Flow Combiner Valve Control Spool, Swing Parking Brake Release Spool, Arm 1 Flow Rate Control Valve Control Spool...303
      Group 7 Others (Upperstructure)...306
        Pilot Shut-Off Solenoid Valve...306
        Solenoid Valve...308
        Pilot Relief Valve...311
        EC Motor...311
      Group 8 Others (Undercarriage)...312
        Swing Bearing...312
        Center Joint...313
        Track Adjuster (Front Idler Integrated Type)...314
TTDCR-EN-00 (attach to) - Hitachi ZX220LC-GI Hydraulic Excavator Electrical Circuit Diagram...319
  01-1_ZX220LC-GI_ELE...319
  01-2_ZX220LC-GI_CON...320
  02-1_ZX220LC-GI_CAB...321
  02-2_ZX220LC-GI_ENG...322
  03-1_ZX220LC-GI_PUMP...323
  04-1_ZX220LC-GI_MON...324
  04-2_ZX220LC-GI_KEY-SW...325
  05-1_ZX220LC-GI_GSM...326
  05-2_ZX220LC-GI_SATELLITE...327
  06-1_ZX220LC-GI_LOCK-SOL...328
  07-1_ZX220LC-GI_HYD_STD...329
  07-2_ZX220LC-GI_HYD_OPT...330
TTDCR-EN-00 - Hitachi ZX220LC-GI Hydraulic Excavator Technical Manual (Troubleshooting)...331
  TTDCR-EN-00...331
    INTRODUCTION...333
      To The Reader...333
      Additional References...333
      Manual Composition...333
      Page Number...333
      Safety Alert Symbol and Headline Notations...334
      Units Used...334
    SYMBOL AND ABBREVIATION...335
    SAFETY...337
      Recognize Safety Information...337
      Understand Signal Words...337
      Follow Safety Instructions...338
      Prepare for Emergencies...339
      Wear Protective Clothing...339
      Protect Against Noise...340
      Inspect Machine...340
      General Precautions for Cab...341
      Use Handholds and Steps...342
      Adjust the Operator's Seat...342
      Ensure Safety Before Rising from or Leaving Operator’s Seat...343
      Fasten Your Seat Belt...343
      Move and Operate Machine Safely...344
      Operate Only from Operator's Seat...344
      Jump Starting...345
      Keep Riders off Machine...345
      Precautions for Operations...346
      Investigate Job Site Beforehand...347
      Install OPG Guard...348
      Provide Signals for Jobs Involving Multiple Machines...349
      Confirm Direction of Machine to Be Driven...349
      Drive Machine Safely...350
      Avoid Injury from Rollaway Accidents...352
      Avoid Injury from Back-Over and Swing Accidents...353
      Keep Person Clear from Working Area...354
      Never Position Bucket Over Anyone...354
      Avoid Undercutting...355
      Avoid Tipping...355
      Never Undercut a High Bank...356
      Dig with Caution...356
      Operate with Caution...356
      Avoid Power Lines...357
      Precautions for Lightning...357
      Object Handling...358
      Protect Against Flying Debris...358
      Park Machine Safely...359
      Handle Fluids Safely−Avoid Fires...359
      Transport Safely...360
      Practice Safe Maintenance...361
      Warn Others of Service Work...362
      Support Machine Properly...362
      Stay Clear of Moving Parts...363
      Prevent Parts from Flying...363
      Store Attachments Safely...364
      Prevent Burns...364
      Replace Rubber Hoses Periodically...365
      Avoid High-Pressure Fluids...365
      Prevent Fires...366
      Evacuating in Case of Fire...368
      Beware of Exhaust Fumes...368
      Precautions for Welding and Grinding...369
      Avoid Heating Near Pressurized Fluid Lines...370
      Avoid Applying Heat to Lines Containing Flammable Fluids...370
      Precautions for Handling Accumulator and Gas Damper...370
      Remove Paint Before Welding or Heating...371
      Beware of Asbestos and Silicon Dust and Other Contamination...371
      Prevent Battery Explosions...372
      Service Air Conditioning System Safely...372
      Handle Chemical Products Safely...373
      Dispose of Waste Properly...373
      Never Ride Attachment...374
      Precautions for Communication Terminal...374
      Precaution for Communication Terminal Equipment...375
      Before Returning the Machine to the Customer...376
    SECTION AND GROUP CONTENTS...377
    SECTION 4 OPERATIONAL PERFORMANCE TEST...379
      Group 1 Introduction...381
        Operational Performance Tests...381
        Preparation for Performance Tests...382
      Group 2 Standard...383
        Operational Performance Standard Table...383
        Main Pump P-Q Diagram...389
        Sensor Activating Range...391
        MPDr. Monitor Indicating Values...392
      Group 3 Engine Test...401
        Engine Speed...401
        Engine Compression Pressure...404
        Valve Clearance...406
        Nozzle...408
        Injection Timing...410
        Lubricant Consumption...412
      Group 4 Machine Performance Test...413
        Travel Speed...413
        Track Revolution Speed...414
        Mistrack Check...415
        Travel Parking Leakage...416
        Swing Speed...417
        Swing Function Drift Check...418
        Swing Motor Leakage...420
        Maximum Swingable Slant Angle...422
        Swing Bearing Play...424
        Hydraulic Cylinder Cycle Time...426
        Dig Function Drift Check...428
        Control Lever Operating Force...431
        Control Lever Stroke...432
        Combined Operation of Boom Raise / Swing Function Check...433
        Combined Operation of Boom Raise / Arm Roll-In Function Check...434
      Group 5 Component Test...435
        Primary Pilot Pressure...435
        Secondary Pilot Pressure...437
        Solenoid Valve Set Pressure...438
        Main Pump Delivery Pressure...440
        Main Relief Set Pressure...442
        Relief pressure (when relieving swing)...446
        Overload Relief Valve Set Pressure...448
        Main Pump Flow Rate Measurement...450
        Swing Motor Drainage...458
        Travel Motor Drainage...460
      Group 6 Adjustment...463
        Engine Speed Adjustment and EngineLearning...463
        Governor Lever and Fuel Cut Lever Position...468
    SECTION 5 TROUBLESHOOTING...473
      Group 1 Diagnosing Procedure...475
        Introduction...475
        Diagnosis Procedure...476
        Electric System Inspection...479
        Precautions for Inspection and Maintenance...480
        Instructions for Disconnecting Connectors...482
        Fuse Inspection...484
        Fusible Link Inspection...486
        Battery Voltage Check...487
        Alternator Check...488
        Continuity Check...489
        Voltage and Current Measurement...490
        Check by False Signal...497
        Test Harness...498
      Group 2 Monitor...501
        Outline...501
        Built-In Diagnosing System Operation...502
        Built-In Diagnosing Function Display List...503
        Inspection of Hour Meter and Fuel Gauge...505
        Fuel Gauge and Coolant Temperature Gauge...506
      Group 3 e-Service...507
        Outline...507
        List of Operation Data...508
        Snapshot Data...512
        Communication System...513
      Group 4 Component Layout...515
        Main Component...515
        Electrical System (Overview)...516
        Engine...517
        Electrical System (In Cab)...517
        Electrical System (Rear Tray)...518
        Electrical System (Monitors)...519
        Electrical System (Switch Panel)...520
        Electrical System (Around Air Cleaner)...521
        Electrical System (Relays)...522
        Pump Device...523
        Control Valve...524
        Signal Control Valve...524
        Swing Device...526
        Travel Device...526
        3-Spool Solenoid Valve Unit...527
        Layout of Attachment Spec. Parts...528
        Pilot Port...552
      Group 5 Troubleshooting A...557
        Troubleshooting A (Base Machine DiagnosisBy Using Fault Codes) Procedure...557
        MC Fault Code List...559
        ECF Fault Code List...569
        Monitor Fault Code List...570
        Information Controller Fault Code List...574
        Communication Terminal Fault Code List...575
        MC Fault Codes 11000 to 11002...577
        MC Fault Code 11003...578
        ECF Fault Code 16603...578
        MC Fault Codes 11006, 11007,11009...581
        ECF Fault Code 16604...581
        Monitor Fault Codes 14212, 14213, 14215...581
        CAN Harness Check...582
        MC Fault Code 11100...585
        MC Fault Code 11101...586
        MC Fault Codes 11200, 11202...587
        MC Fault Codes 11206, 11208...588
        MC Fault Codes 11301 to 11303...589
        MC Fault Codes 11304, 11307...590
        MC Fault Code 11400...591
        MC Fault Code 11401...592
        MC Fault Code 11402...593
        MC Fault Code 11403...594
        MC Fault Code 11407...595
        MC Fault Code 11901...596
        ECF Fault Codes 16600 to 16602...597
        ECF Fault Code 16605...598
        ECF Fault Code 16606...599
        Monitor Fault Codes 14224, 14230...600
        Monitor Fault Code 14231...601
        Monitor Fault Codes 20100 to 20114...602
      Group 6 Troubleshooting B...603
        Troubleshooting B (Machine Diagnosis byUsing Troubleshooting Symptom) Procedure...603
        Relationship between Machine Trouble Symptoms and Related Parts...605
        Correlation between Trouble Symptoms and Part Failures...624
        Engine System Troubleshooting...638
        All Actuator System Troubleshooting...652
        Front Attachment System Troubleshooting...659
        Swing System Troubleshooting...671
        Travel System Troubleshooting...673
        Other System Troubleshooting...678
        Exchange Inspection...679
        How to Lowering Boom in Case of Emergency and When Engine Stops...682
      Group 7 Troubleshooting C...683
        Troubleshooting C (Monitor Diagnosis)Procedure...683
        Malfunction of Monitor Buzzer...686
        Malfunction of Coolant Temperature Gauge...688
        Malfunction of Fuel Gauge...690
        Malfunction of Hour Meter...691
        Malfunction of Light Bulb Check System...692
        Malfunction of Fuel Level Indicator...693
        Malfunction of Air Filter Restriction Indicator...694
        Malfunction of Overheat Indicator...695
        Malfunction of Engine Oil Pressure Indicator...696
        Malfunction of Alternator Indicator...697
        Malfunction of Engine Warning Indicator...698
        Malfunction of Pilot Control Shut-Off Lever Indicator...699
        Malfunction of Preheat Indicator...700
        Malfunction of Hydraulic Oil Filter Restriction Indicator...702
        Malfunction of LCD...703
        Malfunction of Auto-Idle Indicator...704
        Malfunction of ECO Mode Indicator...705
        Malfunction of PWR Mode Indicator...706
        Malfunction of Digging Mode Indicator...708
        Malfunction of Attachment Mode Indicator...710
      Group 8 Air Conditioner...713
        Outline...713
        Functions of Main Parts...716
        Troubleshooting...721
        Air Conditioner Controller Fault Code List...722
        Air Conditioner Controller Fault Codes E11 to E22...723
        Air Conditioner Controller Fault Codes E43 to E57...724
        Work after Replacing Components...746
        Refill Compressor Oil...747
        Charge Air Conditioner with Refrigerant...748
        Hose and Pipe Tightening Torque...756
WDCR-EN-00 - Hitachi ZX220LC-GI Hydraulic Excavator Workshop Manual...761
  WDCR-EN-00...761
  INTRODUCTION...763
  SYMBOL AND ABBREVIATION...765
  SAFETY...767
  SECTION AND GROUP CONTENTS...807
  SECTION 1 GENERAL...809
    Group 1 Precautions for Disassembling and Assembling...811
      Precautions for Disassembling and Assembling...811
    Group 2 Tightening...817
      Tightening Bolts and Nuts...817
      Piping Joint...821
    Group 3 Painting...827
      Painting...827
    Group 4 Bleeding Air...829
      Bleeding Air from Hydraulic Oil Tank...829
      Bleeding Air from Hydraulic System...830
      Bleeding Air from Fuel System...831
      Bleeding Air from Radiator...833
    Group 5 Pressure Release Procedure...835
      Hydraulic Circuit Pressure Release Procedure...835
    Group 6 Preparation...837
      Preparation before Inspection and Maintenance...837
  SECTION 2 MAINTENANCE STANDARD...841
    Group 1 Upperstructure...843
      Pump Device...843
      Swing Motor...847
    Group 2 Undercarriage...851
      Travel Motor...851
      Sprocket...853
      Front Idler...855
      Upper Roller...857
      Lower Roller...858
      Track...859
    Group 3 Front Attachment...863
      Pin and Bushing...863
      Side Cutter (ZC00000040, ZC00000041)...865
      Point (ZC00000042)...866
      Standard Dimensions for Arm and Bucket Connection...867
      Standard Dimensions for Arm and Boom Connection...868
      Cylinder...869
  SECTION 3 UPPERSTRUCTURE...873
    Group 1 Cab...875
      Removal and Installation of Cab...875
      Dimensions of Cab Glass...895
    Group 2 Counterweight...915
      Removal and Installation of Counterweight...915
    Group 3 Main Frame...917
      Removal and Installation of Main Frame...917
    Group 4 Engine...925
      Removal and Installation of Engine...925
    Group 5 Radiator Assembly...943
      Replacement of Radiator, Oil Cooler, and Intercooler...943
    Group 6 Hydraulic Oil Tank...955
      Removal and Installation of Hydraulic Oil Tank...955
    Group 7 Fuel Tank...963
      Removal and Installation of Fuel Tank...963
    Group 8 Pump Device...971
      Removal and Installation of Pump Device...971
      Removal and Installation of Coupling...979
      Disassembly of Pump Device...981
      Assembly of Pump Device...988
      Disassembly of Regulator...999
      Assembly of Regulator...1001
      Disassembly of Solenoid Valve...1003
      Assembly of Solenoid Valve...1005
      Structure of Pilot Pump...1007
    Group 9 Control Valve...1009
      Removal and Installation Control Valve...1009
      Disassembly of Housing...1025
      Assembly of Housing...1027
      Disassembly of Control Valve (4-Spool Side)...1029
      Assembly of Control Valve (4-Spool Side)...1036
      Disassembly of Control Valve (5-Spool Side)...1047
      Assembly of Control Valve (5-Spool Side)...1054
    Group 10 Swing Device...1063
      Removal and Installation of Swing Device...1063
      Disassembly of Swing Device...1069
      Assembly of Swing Device...1074
      Disassembly of Swing Motor...1081
      Assembly of Swing Motor...1084
    Group 11 Pilot Valve...1087
      Removal and Installation of Pilot Valve (Left)...1087
      Removal and Installation of Pilot Valve (Right)...1093
      Removal and Installation of Travel Pilot Valve...1101
      Disassembly of Pilot Valves (Right and Left)...1105
      Assembly of Pilot Valves (Right and Left)...1108
      Disassembly of Travel Pilot Valve...1111
      Assembly of Travel Pilot Valve...1115
    Group 12 Solenoid Valve...1121
      Removal and Installation of Pilot Shut-Off Solenoid Valve...1121
      Removal and Installation of 3-Spool Solenoid Valve Unit...1125
      Disassembly of Pilot Shut-Off Solenoid Valve...1129
      Assembly of Pilot Shut-Off Solenoid Valve...1131
      Structure of 3-Spool Solenoid Valve Unit...1133
    Group 13 Signal Control Valve...1135
      Removal and Installation of Signal ControlValve...1135
      Structure of Signal Control Valve...1141
  SECTION 4 UNDERCARRIAGE...1145
    Group 1 Swing Bearing...1147
      Removal and Installation of Swing Bearing...1147
      Disassembly of Swing Bearing...1151
      Assembly of Swing Bearing...1154
    Group 2 Travel Device...1157
      Removal and Installation of Travel Device...1157
      Disassembly of Travel Device...1161
      Assembly of Travel Device...1165
      Disassembly of Travel Motor...1173
      Assembly of Travel Motor...1176
      Disassembly of Brake Valve...1181
      Assembly of Brake Valve...1183
      Precautions for Using Floating Seal...1185
    Group 3 Center Joint...1187
      Removal and Installation of Center Joint...1187
      Disassembly of Center Joint...1191
      Assembly of Center Joint...1193
    Group 4 Track Adjuster...1197
      Removal and Installation of Track Adjuster...1197
      Disassembly of Track Adjuster...1199
      Assembly of Track Adjuster...1204
      Precautions for Using Floating Seal...1207
    Group 5 Front Idler...1209
      Removal and Installation of Front Idler...1209
      Disassembly of Front Idler...1211
      Assembly of Front Idler...1214
      Precautions for Using Floating Seal...1217
    Group 6 Upper and Lower Rollers...1219
      Removal and Installation of Upper Roller...1219
      Removal and Installation of Lower Roller...1223
      Disassembly of Lower Roller...1227
      Assembly of Lower Roller...1229
      Precautions for Using Floating Seal...1231
    Group 7 Track...1233
      Removal and Installation of Track...1233
  SECTION 5 FRONT ATTACHMENT...1241
    Group 1 Front Attachment...1243
      Removal and Installation of Front Attachment...1243
    Group 2 Cylinder...1249
      Removal and Installation of Boom Cylinder...1249
      Removal and Installation of Arm Cylinder...1253
      Removal and Installation of Bucket Cylinder...1259
      Disassembly of Boom, Arm, Bucket Cylinder...1263
      Assembly of Boom, Arm, Bucket Cylinder...1270
  SERVICE MANUAL REVISION REQUEST FORM...1277

Hitachi ZX220LC-GI Excavator Factory Service & Shop Manual