Hitachi ZX470
WORKSHOP, SERVICE, REPAIR MANUAL - WIRING SCHEMATICS
HITACHI ZX470-5A, 470LC-5A, 490H-5A, 490LCH-5A, 530LCH-5A - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING SCHEMATICS - English Workshop Manual and Wiring Schematics, for Hitachi ZX470-5A, 470LC-5A, 490H-5A, 490LCH-5A, 530LCH-5A. INDEX: WORKSHOP MANUAL - WJAE-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 - Restriction of Attachment Installation - 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 - Avoid Injury from Attachment Falling Accident - 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 - Precautions for Communication Terminal Equipment - Before Returning the Machine to the Customer - SECTION AND GROUP CONTENTS - SECTION 1 GENERAL - Group 1 Precautions for Disassembling and Assembling - Precautions for Disassembling and Assembling - Group 2 Tightening - Tightening Bolts and Nuts - Piping Joint - Group 3 Painting - Painting specification - Final painted color - Group 4 Bleeding Air - Bleeding Air from Hydraulic Oil Tank (Pressure Release) - Bleeding Air from Hydraulic System - Bleeding Air from Fuel System - Bleeding Air from Expansion Tank (Radiator) (Pressure Release) - Group 5 Pressure Release Procedure - Hydraulic Circuit Pressure Release Procedure - Group 6 Preparation - Preparation before Inspection and Maintenance - SECTION 2 MAINTENANCE STANDARD - Group 1 Upperstructure - Main Pump - Fan Pump - Swing Motor - Group 2 Undercarriage - Travel Motor - Sprocket - Center Joint - Front Idler - Upper Roller - Lower Roller - Track - Group 3 Front Attachment - Remove and Install Bushing - Pin and Bushing - Side Cutter - Point - Standard Dimensions for Arm and Bucket Connection - Standard Dimensions for Arm and Boom Connection - Cylinder - SECTION 3 UPPERSTRUCTURE - Group 1 Cab - Removal and Installation of Cab - Dimensions of Cab Glass (Standard Cab) - Dimensions of Cab Glass (H Cab) - Group 2 Counterweight - Removal and Installation of Counterweight - Group 3 Main Frame - Removal and Installation of Main Frame - Group 4 Engine - Removal and Installation of Engine - Group 8 Pump Device - Removal and Installation of Pump Device - Disassembly of Main Pump - Assembly of Main Pump - Disassembly of Regulator for Main Pump - Assembly of Regulator for Main Pump - Disassembly of Fan Pump - Assembly of Fan Pump - Structure of Pilot Pump - Group 9 Control Valve - Removal and Installation of Control Valve - Disassembly and Assembly of Valve Unit - Disassembly of Control Valve (4-Spool Side) - Assembly of Control Valve (4-Spool Side) - Disassembly of Control Valve (5-Spool Side) - Assembly of Control Valve (5-Spool Side) - Group 10 Swing Device - Removal and Installation of Swing Device - Disassembly of Swing Device - Assembly of Swing Device - Disassembly of Swing Motor - Assembly of Swing Motor - Group 11 Pilot Valve - Removal and Installation of Pilot Valve (Left) - Removal and Installation of Pilot Valve (Right) - Removal and Installation of Travel Pilot Valve - Disassembly of Pilot Valves (Right and Left) - Assembly of Pilot Valves (Right and Left) - Disassembly of Travel Pilot Valve - Assembly of Travel Pilot Valve - Group 12 Solenoid Valve - Removal and Installation of Pilot Shut-Off Solenoid Valve - Removal and Installation of 4-Spool Solenoid Valve Unit - Removal and Installation of 2-Spool Solenoid Valve Unit - Removal and Installation of Fan Pump Control Solenoid Valve - Disassembly of Pilot Shut-Off Solenoid Valve - Assembly of Pilot Shut-Off Solenoid Valve - Structure of 4-Spool Solenoid Valve Unit - Structure of 2-Spool Solenoid Valve Unit - Structure of Fan Pump Solenoid Valve - Group 13 Signal Control Valve - Removal and Installation of Signal Control Valve - Structure of Signal Control Valve - Group 14 Shockless Valve - Removal and Installation of Shockless Valve - Structure of Shockless Valve - Group 15 Fan Valve - Removal and Installation of Fan Valve - Structure of Fan Valve - Group 16 Fan Motor - Removal and Installation of Fan Motor - Structure of Fan Motor - SECTION 4 UNDERCARRIAGE - Group 1 Swing Bearing - Removal and Installation of Swing Bearing - Disassembly of Swing Bearing - Assembly of Swing Bearing - Group 2 Travel Device - Removal and Installation of Travel Device - Disassembly of Travel Device - Assembly of Travel Device - Disassembly of Travel Motor - Assembly of Travel Motor - Disassembly of Brake Valve - Assembly of Brake Valve - Group 3 Center Joint - Removal and Installation of Center Joint - Disassembly of Center Joint - Assembly of Center Joint - Replacement of Body and Spindle - Group 4 Track Adjuster - Removal and Installation of Track Adjuster - Disassembly of Track Adjuster - Assembly of Track Adjuster - Group 5 Front Idler - Removal and Installation of Front Idler - Disassembly of Front Idler - Assembly of Front Idler - Group 6 Upper and Lower Rollers - Removal and Installation of Upper Roller - Removal and Installation of Lower Roller - Disassembly of Lower Roller - Assembly of Lower Roller - Group 7 Track - Removal and Installation of Track - SECTION 5 FRONT ATTACHMENT - Group 1 Front Attachment - Removal and Installation of Front Attachment - Removal and Installation of Bushing - Group 2 Cylinder - Removal and Installation of Boom Cylinder - Removal and Installation of Arm Cylinder - Removal and Installation of Bucket Cylinder - Disassembly of Boom Cylinder - Assembly of Boom Cylinder - Disassembly of Arm Cylinder - Assembly of Arm Cylinder - Disassembly of Bucket Cylinder - Assembly of Bucket Cylinder - SERVICE MANUAL REVISION REQUEST FORM TROUBLESHOOTING - TTJAE-EN-00 - INTRODUCTION - SYMBOL AND ABBREVIATION - SAFETY - SECTION AND GROUP CONTENTS - SECTION 4OPERATIONAL PERFORMANCE TEST - Group 1 Introduction - Operational Performance Tests - Preparation for Performance Tests - Group 2 Standard - Operational Performance Standard Table - Main Pump P-Q Diagram - Fan Pump P-Q Diagram - Sensor Activating Range - Monitor Indicating Values (MC) - Monitor Indicating Values (ECM) - Group 3 Engine Test - Engine Speed - 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 and Swing Function Check - Group 5 Component Test - Primary Pilot Pressure - Secondary Pilot Pressure - 4-Spool Solenoid Valve Set Pressure - 2-Spool Solenoid Valve Set Pressure - Main Pump Delivery Pressure - Fan Pump Delivery Pressure - Main Relief Set Pressure - Overload Relief Set Pressure - Main Pump Flow Rate Measurement - Fan Pump Flow Rate Measurement - Swing Motor Drainage - Travel Motor Drainage - Group 6 Adjustment - PUMP LEARNING - TORQUE ADJUSTMENT - CONNECTION - SECTION 5TROUBLESHOOTING - Group 1 Diagnosing Procedure - Introduction - Diagnosis Procedure - Electrical 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 Wire Harness - Group 2 Monitor - Outline - Operating Procedures of Service Menu - Setting Menu - Inspection of Engine Oil Level, Coolant Level, 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) - Electrical System (Rear Tray) - Electrical System (Switch Panel) - Electrical System (Utility Space) - Engine - Pump Device - Around Pump Device - Control Valve - Check Valve/Accumlator - Signal Control Valve - Swing Device - Travel Device - 4-Spool Solenoid Valve Unit - 2-Spool Solenoid Valve Unit - Fan Valve (Option) - Layout of Control Valve - Pilot Port (Signal Control Valve) - Group 5 Troubleshooting A - Troubleshooting A (Base Machine DiagnosisBy Using Fault Codes) Procedure - MC Fault Code List - ECM Fault Code List - Monitor Controller (Monitor) Fault Code List - Monitor Controller (Information) Fault Code List - Air Conditioner Controller Fault Code List - Communication Terminal Fault Code List - MC Fault Codes 11000 to 11002 - MC Fault Code 11003 - MC Fault Codes 11006, 11007,11009 - Monitor Controller (Monitor) Fault Codes 13002, 13003, 13005 - CAN0 Harness Check - MC Fault Codes 11008, 11010 - Monitor Controller (Monitor) Fault Codes 13004, 13006, 13007 - CAN1 Harness Check - MC Fault Code 11100 - MC Fault Code 11101 - MC Fault Codes 11200, 11202 - MC Fault Codes 11301, 11302 - MC Fault Code 11303 - MC Fault Codes 11304, 11325 - MC Fault Code 11405 - MC Fault Code 11408 - MC Fault Code 11412 - MC Fault Code 11428 - MC Fault Code 11802 - MC Fault Code 11901 - MC Fault Codes 11942, 11944 - MC Fault Codes 11945 - MC Fault Code 11948 - MC Fault Code 11950 - MC Fault Code 11951 - MC Fault Code 11953 - MC Fault Codes 11978, 11979 - MC Fault Code 11982 - MC Fault Codes 11985, 11986 - MC Fault Code 11989 - MC Fault Codes 11992, 11994 - MC Fault Codes 11995, 11997 - MC Fault Code 11998 - MC Fault Codes 20062 - Monitor Controller (Information) Fault Codes 13304, 13310 - Monitor Controller (Information) Fault Code 13311 - Monitor Controller (Information) Fault Codes 20100 to 20104, 20106 - Monitor Controller (Information) Fault Codes 20107, 20109, 20110, 20114, 20146, 20149 - Air Conditioner Controller Fault Codes 11 to 22 - Air Conditioner Controller Fault Codes 43 to 92 - Group 6 Troubleshooting B - Troubleshooting B (Machine Diagnosis byUsing Trouble 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 When Emergency and When Engine Stops - Group 7 Air Conditioner - Outline - Functions of Main Parts - Troubleshooting - Air Conditioner Controller Fault Code List - Air Conditioner Controller Fault Codes 11 to 22 - Air Conditioner Controller Fault Codes 43 to 92 - Work after Replacing Components - Refill Compressor Oil - Charge Air Conditioner with Refrigerant - Hose and Pipe Tightening Torque - SERVICE MANUAL REVISION REQUEST FORM - The Attached Diagram List OPERATIONAL PRINCIPLE - TOJAE-EN-00 - INTRODUCTION - SYMBOL AND ABBREVIATION - SECTION AND GROUP CONTENTS - SECTION 1 GENERAL - Group 1 Specifications - Specifications ZX470-5A, 470LC-5A - Working Ranges ZX470-5A, 470LC-5A - Specifications ZX490H-5A, 490LCH-5A, 490LCH-5A (Bolt-joint Track) - Working Ranges ZX490H-5A, 490LCH-5A, 490LCH-5A (Bolt-joint Track) - Specifications ZX530LCH-5A - Working Ranges ZX530LCH-5A - Group 2 Component Layout - Main Component - Electrical System (Overview) - Electrical System (Rear Tray) - Electrical System (Switch Panel) - Electrical System (Utility Space) - Engine - Pump Device - Around Pump Device - Control Valve - Check Valve/Accumlator - Signal Control Valve - Swing Device - Travel Device - 4-Spool Solenoid Valve Unit - Fan Valve (Option) - 2-Spool Solenoid Valve Unit - Group 3 Component Specifications - Engine - Engine Accessories - Hydraulic Component - Electrical Component - SECTION 2 SYSTEM - Group 1 Controller - Outline - CAN Circuit - Group 2 Control System - Outline - Engine Control - Pump Control - Valve Control - Other Control - Group 3 ECM System - Outline - Fuel Injection Control - Fuel Injection Amount Correction Control - EGR Control - Preheating Control - Alarm Control - Fuel Bleeding Air Control - Group 4 Hydraulic System - Outline - Pilot Circuit - Main Circuit - Oil Cooler Fan Reverse Rotation Control Circuit (Option) - Group 5 Electrical System - Outline - Main Circuit - Electric Power Circuit (Key Switch: OFF) - CAN Circuit - Accessory Related Circuit (Key Switch: ACC) - Starting Circuit (Key Switch: START) - Charging Circuit (Key Switch: ON) - Surge Voltage Prevention Circuit - Pilot Shut-Off Circuit (Key Switch: ON) - Auto Shut-Down Circuit - Engine Stop Circuit - Monitor Circuit - Security Circuit - Radio Circuit - Air Conditioner Circuit - Accessory Circuit - Work Light Circuit - Wiper/Washer Circuit - Cab Light Circuit - SECTION 3 COMPONENT OPERATION - Group 1 Pump Device - Outline - Main Pump - Regulator - Pump Control Solenoid Valve - Fan Pump - Fan Pump Flow Rate Control - Pilot Pump - Pump Delivery Pressure Sensor - Pump Control Pressure Sensor - Group 2 Swing Device - Outline - Swing Reduction Gear - Swing Motor - Swing Parking Brake - Valve Unit - Group 3 Control Valve - Outline - Hydraulic Circuit - Flow Combiner Valve - Main Relief valve - Overload Relief Valve (with Make-Up Function) - Boom Overload Relief Valve (Low Pressure) - Regenerative Valve - Anti-Drift Valve - Flow Rate Control Valve - Boom Lower Meter-In Cut Valve - Bypass Shut-Out Valve - Auxiliary Flow Combiner Valve - Group 4 Pilot Valve - Outline - Operation (Front Attachment/Swing and Travel Pilot Valves) - Shockless Function (Only for Travel Pilot Valve) - Group 5 Travel Device - Outline - Travel Reduction Gear - Travel Motor - Parking Brake - Travel Brake Valve - Overload Relief Valve - Travel Mode Control - Group 6 Signal Control Valve - Outline - Pilot Port - Shuttle Valve - Shockless Valve - Pump 1 and Pump 2 Flow Rate Control Valves - Arm Flow Rate Control Valve Control Spool, Flow Combiner Valve Control Spool, Swing Parking Brake Release Spool - Group 7 Others (Upperstructure) - Pilot Shut-Off Solenoid Valve - Solenoid Valve - Fan Motor - Fan Valve (Option) - Pilot Relief Valve - Shockless Valve - Accumulator (Pilot Circuit) - Distribution Valve - Group 8 Others (Undercarriage) - Swing Bearing - Centerjoint - Track Adjuster - SERVICE MANUAL REVISION REQUEST FORM WIRING SCHEMATICS - ELECTRICAL DIAGRAM - AIR CONDITIONER CIRCUIT DIAGRAM - CONNECTORS - CAB HARNESS - MAIN HARNESS - ENGINE HARNESS - PUMP HARNESS - CONTROL VALVE HARNESS - MONITOR HARNESS - KEY SWITCH HARNESS - OIL COOLER FAN REVERSE ROTATION SWITCH HARNESS - ENGINE STOP SWITCH HARNESS - PILOT SHUT-OFF SOLENOID VALVE HARNESS - GSM (MOBILE COMMUNICATION TERMINAL) HARNESS - SATELLITE COMMUNICATION HARNESS - AUTO LUBRICATION ON/OFF SWITCH HARNESS - CAMERA HARNESS - BOOM MODE SWITCH AND SEAT HEATER SWITCH HARNESS (OPTION) - WORK LIGHT (ON THE CAB ROOF) HARNESS 1 (OPTION) - WORK LIGHT (ON THE CAB ROOF) HARNESS 2 (OPTION) - HYDRAULIC CIRCUIT DIAGRAM
Hitachi ZX470-5A, 470LC-5A, 490H-5A, 490LCH-5A, 530LCH-5A - Workshop Manual - Wiring Schematics
inicio - index
coche - car
moto
4x4
quad - buggy
camión - truck
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