Hitachi ZX470-5B ZX470LC-5B ZX470H-5B ZX470LCH-5B ZX470R-5B ZX470LCR-5B ZX520LCH-5B Hydraulic Excavator Technical Troubleshooting Manual (TTJAA-EN-01)
File Details:
Hitachi ZX470-5B ZX470LC-5B ZX470H-5B ZX470LCH-5B ZX470R-5B ZX470LCR-5B ZX520LCH-5B Hydraulic Excavator Technical Troubleshooting Manual (TTJAA-EN-01)
- Manual Language:English
- Pages: 518
- Size: 4.59 MB
- Format:PDF
- Downloadable:Yes
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Description:
Hitachi ZX470-5B ZX470LC-5B ZX470H-5B ZX470LCH-5B ZX470R-5B ZX470LCR-5B ZX520LCH-5B Hydraulic Excavator Technical Troubleshooting Manual (TTJAA-EN-01)
TO THE READER
• This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
• 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 ZX470-5B ZX470LC-5B ZX470H-5B ZX470LCH-5B ZX470R-5B ZX470LCR-5B ZX520LCH-5B Hydraulic Excavator Technical Troubleshooting Manual (TTJAA-EN-01)
TTJAA-EN-01................................................................................. 1 INTRODUCTION................................................................................ 3 SYMBOL AND ABBREVIATION..................................................................... 5 SAFETY...................................................................................... 7 SECTION AND GROUP CONTENTS.................................................................. 47 SECTION 4 OPERATIONAL PERFORMANCE TEST...................................................... 49 Group 1 Introduction.................................................................... 51 Operational Performance Tests....................................................... 51 Preparation for Performance Tests................................................... 52 Group 2 Standard........................................................................ 53 Operational Performance Standard Table.............................................. 53 Main Pump P-Q Diagram............................................................... 57 Fan Pump P-Q Diagram................................................................ 58 MPDR. Monitor Indicating Values (MC)................................................ 60 MPDr. Monitor Indicating Values (ECM)............................................... 66 Sensor Activating Range............................................................. 67 Group 3 Engine Test..................................................................... 69 Engine Speed........................................................................ 69 Lubricant Consumption............................................................... 72 Group 4 Machine Performance Test........................................................ 73 Travel Speed........................................................................ 73 Mistrack Check...................................................................... 75 Travel Motor Leakage................................................................ 76 Swing Speed......................................................................... 77 Swing Function Drift Check.......................................................... 78 Swing Motor Leakage................................................................. 79 Maximum Swingable Slant Angle....................................................... 80 Swing Bearing Play.................................................................. 82 Hydraulic Cylinder Cycle Time....................................................... 84 Dig Function Drift Check............................................................ 86 Control Lever Operating Force....................................................... 87 Control Lever Stroke................................................................ 88 Boom Raise/Swing Combined Operation Check........................................... 89 Group 5 Component Test.................................................................. 91 Primary Pilot Pressure.............................................................. 91 Secondary Pilot Pressure............................................................ 93 4-Spool Solenoid Valve Set Pressure................................................. 94 2-Spool Solenoid Valve Set Pressure................................................. 95 Main Pump Delivery Pressure......................................................... 97 Fan Pump Delivery Pressure.......................................................... 98 Main Relief Valve Set Pressure...................................................... 99 Overload Relief Valve Set Pressure..................................................105 Main Pump Flow Rate Measurement.....................................................110 Fan Pump Flow Rate Measurement......................................................116 Swing Motor Drainage................................................................122 Travel Motor Drainage...............................................................124 Group 6 Adjustment......................................................................127 Pump Learning.......................................................................127 Torque Adjustment...................................................................128 Connection..........................................................................129 Measuring Method of No-Load-Max Differential Pressure...............................130 Muffler Filter Differential Pressure Sensor Learning................................132 Rewrite of Muffler Filter Serial No.................................................133 Maintenance of Muffler Filter.......................................................134 SECTION 5 TROUBLESHOOTING...................................................................137 Group 1 Diagnosing Procedure............................................................139 Introduction........................................................................139 Diagnosis Procedure.................................................................140 Electric System Inspection..........................................................143 Precautions for Inspection and Maintenance..........................................144 Instructions for Disconnecting Connectors...........................................146 Fuse Inspection.....................................................................148 Fusible Link Inspection.............................................................151 Battery Voltage Check...............................................................152 Alternator Check....................................................................153 Continuity Check....................................................................154 Voltage and Current Measurement.....................................................156 Check by False Signal...............................................................163 Test Harness........................................................................164 Group 2 Monitor.........................................................................167 Outline.............................................................................167 Operating Procedures of Service Menu (Built-In Diagnosing System)...................168 Inspection of Engine Oil Level, Hour Meter and Fuel Gauge...........................200 Fuel Gauge and Coolant Temperature Gauge............................................201 Group 3 e-Service.......................................................................203 Outline.............................................................................203 List of Operation Data..............................................................204 Snapshot Data.......................................................................208 Communication System................................................................209 Group 4 Component Layout................................................................211 Main Component......................................................................211 Electrical System (Overview)........................................................213 Electrical System (Rear Tray).......................................................214 Electrical System (Switch Panel)....................................................215 Electrical System (Cab Behind Side).................................................216 Engine 1............................................................................218 Engine 2............................................................................219 Muffler Filter......................................................................220 Pump Device.........................................................................221 Control Valve.......................................................................222 Check Valve.........................................................................224 Signal Control Valve................................................................224 4-Spool Solenoid Valve Unit.........................................................227 2-Spool Solenoid Valve Unit.........................................................227 Layout of Attachment Spec. Parts (Hydraulic System).................................228 Layout of Control Valve.............................................................232 Pilot Port (Signal Control Valve)...................................................248 Group 5 Troubleshooting A...............................................................253 Troubleshooting A (Base Machine Diagnosis by Using Fault Codes) Procedure...........253 MC Fault Code List..................................................................255 ECM Fault Code List.................................................................278 Monitor Controller (Information) Fault Code List....................................310 Communication Terminal Fault Code List..............................................312 Electrical Lever (Optional) Fault Code List.........................................313 MC Fault Codes 11000 to 11002.......................................................318 MC Fault Code 11003.................................................................320 MC Fault Codes 11004, 11006, 11007, 11009...........................................322 CAN0 Harness Check..................................................................323 CAN0 (Engine) Harness Check.........................................................326 MC Fault Codes 11005, 11008, 11010..................................................328 CAN1 Harness Check..................................................................329 MC Fault Code 11100.................................................................332 MC Fault Code 11101.................................................................333 MC Fault Codes 11200, 11202.........................................................334 MC Fault Codes 11301, 11302.........................................................335 MC Fault Code 11303.................................................................336 MC Fault Codes 11304, 11325.........................................................337 MC Fault Code 11405.................................................................338 MC Fault Code 11408.................................................................339 MC Fault Code 11412.................................................................340 MC Fault Code 11428.................................................................341 MC Fault Code 11802.................................................................342 MC Fault Code 11901.................................................................343 MC Fault Codes 11910, 11911, 11914, 11918, 11920....................................344 MC Fault Codes 11942, 11943.........................................................345 MC Fault Codes 11944, 11945.........................................................346 MC Fault Code 11946.................................................................347 CAN0 Harness Check..................................................................348 MC Fault Code 11947.................................................................351 CAN1 Harness Check..................................................................352 MC Fault Code 11948.................................................................355 MC Fault Code 11950.................................................................356 MC Fault Code 11951.................................................................357 MC Fault Code 11952 (670, 870)......................................................358 MC Fault Code 11953.................................................................359 MC Fault Codes 11971, 11972.........................................................360 MC Fault Codes 11974, 11975.........................................................361 MC Fault Codes 11978, 11979.........................................................362 MC Fault Code 11981.................................................................363 MC Fault Code 11982.................................................................364 MC Fault Codes 11983, 11984.........................................................365 MC Fault Codes 11985, 11986.........................................................366 MC Fault Code 11989.................................................................367 MC Fault Codes 11992, 11994.........................................................368 MC Fault Codes 11995, 11997.........................................................369 MC Fault Code 11998.................................................................370 MC Fault Codes 20000, 20003, 20005, 20006, 20008....................................371 MC Fault Codes 20009, 20010, 20062..................................................372 Monitor Controller (Monitor) Fault Codes 20100 to 20106.............................373 Monitor Controller (Monitor) Fault Codes 20109 to 20149.............................374 Group 6 Troubleshooting B...............................................................375 Troubleshooting B (Machine Diagnosis by Using Troubleshooting Symptom) Procedure....375 Relationship Between Machine Trouble Symptoms and Related Parts.....................377 Correlation Between Trouble Symptoms and Part Failures..............................404 Engine System Troubleshooting.......................................................423 All Actuator System Troubleshooting.................................................431 Front Attachment System Troubleshooting.............................................440 Swing System Troubleshooting........................................................453 Travel System Troubleshooting.......................................................456 Other System Troubleshooting........................................................460 Exchange Inspection.................................................................467 How to Lowering Boom in Case of Emergency and When Engine Stops.....................470 Group 7 Air Conditioner.................................................................471 Outline.............................................................................471 Functions of Main Parts.............................................................474 Troubleshooting.....................................................................479 Air Conditioner Controller Fault Code List..........................................480 Air Conditioner Controller Fault Codes 11 to 22.....................................481 Air Conditioner Controller Fault Codes 43 to 92.....................................482 Work after Replacing Components.....................................................504 Refill Compressor Oil...............................................................505 Charge Air Conditioner with Refrigerant.............................................506 Hose and Pipe Tightening Torque.....................................................514 SERVICE MANUAL REVISION REQUEST FORM........................................................517 The Attached Diagram List...................................................................518
Please Note:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
Ishaan Neil –
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