Hitachi ZX470-5G ZX470LC-5G ZX470H-5G ZX470LCH-5G ZX470R-5G ZX470LCR-5G Hydraulic Excavator Troubleshooting Technical Manual (TTJAC-EN-00) – PDF Download

Description

Hitachi ZX470-5G ZX470LC-5G ZX470H-5G ZX470LCH-5G ZX470R-5G ZX470LCR-5G Hydraulic Excavator Troubleshooting Technical Manual (TTJAC-EN-00)

File Details:

Hitachi ZX470-5G ZX470LC-5G ZX470H-5G ZX470LCH-5G ZX470R-5G ZX470LCR-5G Hydraulic Excavator Troubleshooting Technical Manual (TTJAC-EN-00)

• Manual Language:English
• Downloadable:Yes
• Pages: 478
• Size: 5.16 MB
• Format:PDF

HITACHI ZX470-5G ZX470LC-5G ZX470H-5G ZX470LCH-5G ZX470R-5G ZX470LCR-5G HYDRAULIC EXCAVATOR TROUBLESHOOTING TECHNICAL MANUAL (TTJAC-EN-00) – PDF DOWNLOAD:

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Description:

Hitachi ZX470-5G ZX470LC-5G ZX470H-5G ZX470LCH-5G ZX470R-5G ZX470LCR-5G Hydraulic Excavator Troubleshooting Technical Manual (TTJAC-EN-00)

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, the Workshop Manual and the Engine 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.
 Information included in the Engine Manual: Technical information needed for redelivery and delivery and maintenance and repair of the machine, operation and activation of all devices and systems, troubleshooting and assemble / disassemble procedures.

Table Of Content:

Hitachi ZX470-5G ZX470LC-5G ZX470H-5G ZX470LCH-5G ZX470R-5G ZX470LCR-5G Hydraulic Excavator Troubleshooting Technical Manual (TTJAC-EN-00)

TTJAC-EN-00.....................................................................................  1
	INTRODUCTION................................................................................  3
	Symbol and Abbreviation.....................................................................  5
	SAFETY......................................................................................  7
	SECTION AND GROUP CONTENTS.................................................................. 49
	SECTION 4 OPERATIONAL PERFORMANCE TEST...................................................... 51
		Group 1 Introduction.................................................................... 53
			Operational Performance Tests....................................................... 53
			Preparation for Performance Tests................................................... 54
		Group 2 Standard........................................................................ 55
			Operational Performance Standard Table.............................................. 55
			Main Pump P-Q Diagram............................................................... 59
			MPDR. Monitor Indicating Values (MC)................................................ 60
			MPDr. Monitor Indicating Values (ECF)............................................... 65
			Sensor Activating Range............................................................. 66
		Group 3 Engine Test..................................................................... 67
			Engine Speed........................................................................ 67
			Engine Compression Pressure......................................................... 70
			Valve Clearance..................................................................... 72
			Nozzle.............................................................................. 76
			Injection Timing.................................................................... 78
			Lubricant Consumption............................................................... 79
		Group 4 Machine Performance Test........................................................ 81
			Travel Speed........................................................................ 81
			Mistrack Check...................................................................... 83
			Travel Motor Leakage................................................................ 84
			Swing Speed......................................................................... 85
			Swing Function Drift Check.......................................................... 86
			Swing Motor Leakage................................................................. 87
			Maximum Swingable Slant Angle....................................................... 88
			Swing Bearing Play.................................................................. 90
			Hydraulic Cylinder Cycle Time....................................................... 92
			Dig Function Drift Check............................................................ 94
			Control Lever Operating Force....................................................... 95
			Control Lever Stroke................................................................ 96
			Boom Raise/Swing Combined Operation Check........................................... 97
		Group 5 Component Test.................................................................. 99
			Primary Pilot Pressure.............................................................. 99
			Secondary Pilot Pressure............................................................101
			4-Spool Solenoid Valve Set Pressure.................................................102
			2-Spool Solenoid Valve Set Pressure.................................................103
			Main Pump Delivery Pressure.........................................................105
			Main Relief Valve Set Pressure......................................................106
			Overload Relief Valve Set Pressure..................................................112
			Main Pump Flow Rate Measurement.....................................................116
			Swing Motor Drainage................................................................124
			Travel Motor Drainage...............................................................126
		Group 6 Adjustment......................................................................129
			Installation and Adjustment of Pump Displacement Angle Sensor.......................129
			Engine Speed Adjustment and Engine Learning.........................................134
			Positions of Governor Lever and Fuel Cut Lever......................................136
	SECTION 5 TROUBLESHOOTING...................................................................141
		Group 1 Diagnosing Procedure............................................................143
			Introduction........................................................................143
			Diagnosis Procedure.................................................................144
			Electric System Inspection..........................................................147
			Precautions for Inspection and Maintenance..........................................148
			Instructions for Disconnecting Connectors...........................................150
			Fuse Inspection.....................................................................152
			Fusible Link Inspection.............................................................155
			Battery Voltage Check...............................................................156
			Alternator Check....................................................................157
			Continuity Check....................................................................158
			Voltage and Current Measurement.....................................................160
			Check by False Signal...............................................................167
			Test Harness........................................................................168
		Group 2 Monitor.........................................................................171
			Outline.............................................................................171
			Operating Procedures of Service Menu(Built-In Diagnosing System)....................172
			Setting Menu........................................................................209
			Inspection of Hour Meter and Fuel Gauge.............................................211
			Fuel Gauge and Coolant Temperature Gauge............................................212
		Group 3 e-Service.......................................................................213
			Outline.............................................................................213
			List of Operation Data..............................................................214
			Snapshot Data.......................................................................218
			Communication System................................................................219
		Group 4 Component Layout................................................................221
			Main Component......................................................................221
			Electrical System (Overview)........................................................223
			Electrical System (Rear Tray).......................................................224
			Electrical System (Switch Panel)....................................................225
			Electrical System (Cab Behind Side).................................................226
			Isolation Switch (Optional).........................................................228
			Engine..............................................................................230
			Pump Device.........................................................................231
			Control Valve.......................................................................232
			Check Valve / Accumulator...........................................................234
			Signal Control Valve................................................................234
			4-Spool Solenoid Valve Unit.........................................................237
			2-Spool Solenoid Valve Unit.........................................................237
			Layout of Attachment Spec. Parts(Hydraulic System)..................................238
			Layout of Control Valve.............................................................242
			Pilot Port (Signal Control Valve)...................................................258
		Group 5 Troubleshooting A...............................................................263
			Troubleshooting A (Base Machine Diagnosis by Using Fault Codes) Procedure...........263
			MC Fault Code List..................................................................265
			ECF Fault Code List.................................................................285
			Monitor Controller (Monitor) Fault Code List........................................286
			Monitor Controller (Information) Fault Code List....................................287
			Air Conditioner Controller Fault Code List..........................................290
			Communication Terminal Fault Code List..............................................291
			MC Fault Codes 11000 to 11002.......................................................293
			MC Fault Code 11003.................................................................294
			ECF Fault Code 16603................................................................294
			MC Fault Codes 11006, 11007,11009...................................................297
			ECF Fault Code 16604................................................................297
			Monitor Controller (Monitor) Fault Codes 13002, 13003, 13005........................297
			CAN0 Harness Check..................................................................298
			MC Fault Codes 11008, 11010.........................................................301
			Monitor Controller (Monitor) Fault Codes 13004, 13006, 13007........................301
			CAN1 Harness Check..................................................................302
			MC Fault Code 11101.................................................................305
			MC Fault Codes 11200, 11202.........................................................306
			MC Fault Codes 11301, 11302.........................................................307
			MC Fault Code 11303.................................................................308
			MC Fault Codes 11304, 11325.........................................................309
			MC Fault Code 11405.................................................................310
			MC Fault Code 11408.................................................................311
			MC Fault Code 11428.................................................................312
			MC Fault Code 11901.................................................................313
			MC Fault Code 11940.................................................................314
			MC Fault Code 11941.................................................................315
			MC Fault Codes 11942, 11944.........................................................316
			MC Fault Code 11945.................................................................317
			MC Fault Code 11948.................................................................318
			MC Fault Code 11950.................................................................319
			MC Fault Code 11951.................................................................320
			MC Fault Code 11953.................................................................321
			MC Fault Codes 11955, 11956.........................................................322
			MC Fault Codes 11978, 11979.........................................................323
			MC Fault Code 11980.................................................................324
			MC Fault Code 11989.................................................................325
			MC Fault Codes 11995, 11997.........................................................326
			MC Fault Code 11998.................................................................327
			MC Fault Codes 20062................................................................328
			ECF Fault Codes 16600 to 16602......................................................329
			ECF Fault Code 16605................................................................330
			ECF Fault Code 16606................................................................331
			Air Conditioner Controller Fault Codes 11 to 22.....................................332
			Air Conditioner Controller Fault Codes 43 to 92.....................................333
			Monitor Controller (Information) Fault Codes 13304, 13310...........................334
			Monitor Controller (Information) Fault Code 13311...................................335
			Monitor Controller (Information) Fault Codes 20100 to 20114.........................336
		Group 6 Troubleshooting B...............................................................337
			Troubleshooting B (Machine Diagnosis by Using Troubleshooting Symptom) Procedure....337
			Relationship Between Machine Trouble Symptoms and Related Parts.....................339
			Correlation Between Trouble Symptoms and Part Failures..............................363
			Engine System Troubleshooting.......................................................382
			All Actuator System Troubleshooting.................................................395
			Front Attachment System Troubleshooting.............................................400
			Swing System Troubleshooting........................................................413
			Travel System Troubleshooting.......................................................416
			Other System Troubleshooting........................................................420
			Exchange Inspection.................................................................427
			How to Lowering Boom in Case of Emergencyand When Engine Stops......................430
		Group 7 Air Conditioner.................................................................431
			Outline.............................................................................431
			Functions of Main Parts.............................................................434
			Troubleshooting.....................................................................439
			Air Conditioner Controller Fault Code List..........................................440
			Air Conditioner Controller Fault Codes 11 to 22.....................................441
			Air Conditioner Controller Fault Codes 43 to 92.....................................442
			Work after Replacing Components.....................................................464
			Refill Compressor Oil...............................................................465
			Charge Air Conditioner with Refrigerant.............................................466
			Hose and Pipe Tightening Torque.....................................................474
	SERVICE MANUAL REVISION REQUEST FORM........................................................477
	The Attached Diagram List...................................................................478

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