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