Hitachi ZX470-5A 470LC-5A 490H-5A 490LCH-5A 530LCH-5A Excavator Workshop Manual PDF - MHITZX470JAE.zip

Full factory-level service and repair documentation, complete with electrical wiring schematics, covering the Hitachi ZX470-5A, 470LC-5A, 490H-5A, 490LCH-5A and 530LCH-5A Excavators — everything a professional technician needs to service, troubleshoot, fix, and overhaul these machines like a seasoned pro.

This workshop service & repair manual for Hitachi ZX470-5A, 470LC-5A, 490H-5A, 490LCH-5A and 530LCH-5A Excavators contains:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

Total Pages: 1,472 pages

File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)

Language: English

MANUAL LIST:

TOJAE-EN-00 - Hitachi ZX470-5A, 470LC-5A, 490H-5A, 490LCH-5A, 530LCH-5A Hydraulic Excavator Technical Manual (Operational Principle).pdf

TTJAE-EN-00 (attach to) - Hitachi ZX470-5A, 470LC-5A, 490H-5A, 490LCH-5A, 530LCH-5A Hydraulic Excavator Electrical Circuit Diagram.pdf

TTJAE-EN-00 - Hitachi ZX470-5A, 470LC-5A, 490H-5A, 490LCH-5A, 530LCH-5A Hydraulic Excavator Technical Manual (Troubleshooting).pdf

WJAE-EN-00 - Hitachi ZX470-5A, 470LC-5A, 490H-5A, 490LCH-5A, 530LCH-5A Hydraulic Excavator Workshop Manual.pdf

TABLE OF CONTENTS

TECHNICAL MANUAL (Operational Principle)

SECTION 1 GENERAL

Group 1 Specification

CONTENTS

Group 2 Component Layout

Group 3 Component Specifications

SECTION 2 SYSTEM

Group 1 Controller

Group 2 Control System

Group 3 ECM System

Group 4 Hydraulic System

Group 5 Electrical System

SECTION 3 COMPONENT OPERATION

Group 1 Pump Device

Group 2 Swing Device

Group 3 Control Valve

Group 4 Pilot Valve

Group 5 Travel Device

Group 6 Signal Control Valve

Group 7 Others (Upperstructure)

Group 8 Others (Undercarriage)

MAIN SECTIONS

TOJAE-EN-00......1

INTRODUCTION......3

SYMBOL AND ABBREVIATION......5

SECTION AND GROUP CONTENTS......7

SECTION 1 GENERAL......9

Group 1 Specifications......11

Specifications ZX470-5A, 470LC-5A......11

Working Ranges ZX470-5A, 470LC-5A......12

Specifications ZX490H-5A, 490LCH-5A, 490LCH-5A (Bolt-joint Track)......13

Working Ranges ZX490H-5A, 490LCH-5A, 490LCH-5A (Bolt-joint Track)......14

Specifications ZX530LCH-5A......15

Working Ranges ZX530LCH-5A......16

Group 2 Component Layout......17

Main Component......17

Electrical System (Overview)......19

Electrical System (Rear Tray)......20

Electrical System (Switch Panel)......21

Electrical System (Utility Space)......22

Engine......24

Pump Device......25

Around Pump Device......26

Control Valve......27

Check Valve/Accumlator......28

Signal Control Valve......28

Swing Device......30

Travel Device......30

4-Spool Solenoid Valve Unit......31

Fan Valve (Option)......31

2-Spool Solenoid Valve Unit......31

Group 3 Component Specifications......33

Engine......33

Engine Accessories......37

Hydraulic Component......38

Electrical Component......42

SECTION 2 SYSTEM......45

Group 1 Controller......47

Outline......47

CAN Circuit......48

Group 2 Control System......51

Outline......51

Engine Control......54

Pump Control......76

Valve Control......100

Other Control......118

Group 3 ECM System......131

Outline......131

Fuel Injection Control......132

Fuel Injection Amount Correction Control......140

EGR Control......142

Preheating Control......144

Alarm Control......145

Fuel Bleeding Air Control......146

Group 4 Hydraulic System......147

Outline......147

Pilot Circuit......148

Main Circuit......160

Oil Cooler Fan Reverse Rotation Control Circuit (Option)......182

Group 5 Electrical System......183

Outline......183

Main Circuit......184

Electric Power Circuit (Key Switch: OFF)......186

CAN Circuit......188

Accessory Related Circuit (Key Switch: ACC)......190

Starting Circuit (Key Switch: START)......192

Charging Circuit (Key Switch: ON)......194

Surge Voltage Prevention Circuit......198

Pilot Shut-Off Circuit (Key Switch: ON)......200

Auto Shut-Down Circuit......202

Engine Stop Circuit......204

Monitor Circuit......207

Security Circuit......208

Radio Circuit......210

Air Conditioner Circuit......210

Accessory Circuit......213

Work Light Circuit......214

Wiper/Washer Circuit......218

Cab Light Circuit......220

SECTION 3 COMPONENT OPERATION......225

Group 1 Pump Device......227

Outline......227

Main Pump......228

Regulator......230

Pump Control Solenoid Valve......238

Fan Pump......240

Fan Pump Flow Rate Control......242

Pilot Pump......244

Pump Delivery Pressure Sensor......244

Pump Control Pressure Sensor......244

Group 2 Swing Device......245

Outline......245

Swing Reduction Gear......246

Swing Motor......247

Swing Parking Brake......248

Valve Unit......250

Group 3 Control Valve......253

Outline......253

Hydraulic Circuit......270

Flow Combiner Valve......276

Main Relief valve......278

Overload Relief Valve (with Make-Up Function)......282

Boom Overload Relief Valve (Low Pressure)......288

Regenerative Valve......290

Anti-Drift Valve......294

Flow Rate Control Valve......298

Boom Lower Meter-In Cut Valve......306

Bypass Shut-Out Valve......308

Auxiliary Flow Combiner Valve......312

Group 4 Pilot Valve......315

Outline......315

Operation (Front Attachment/Swing and Travel Pilot Valves)......317

Shockless Function (Only for Travel Pilot Valve)......325

Group 5 Travel Device......327

Outline......327

Travel Reduction Gear......328

Travel Motor......330

Parking Brake......332

Travel Brake Valve......334

Overload Relief Valve......338

Travel Mode Control......340

Group 6 Signal Control Valve......345

Outline......345

Pilot Port......346

Shuttle Valve......350

Shockless Valve......354

Pump 1 and Pump 2 Flow Rate Control Valves......358

Arm Flow Rate Control Valve Control Spool, Flow Combiner Valve Control Spool, Swing Parking Brake Release Spool......360

Group 7 Others (Upperstructure)......361

Pilot Shut-Off Solenoid Valve......361

Solenoid Valve......363

Fan Motor......366

Fan Valve (Option)......367

Pilot Relief Valve......373

Shockless Valve......374

Accumulator (Pilot Circuit)......376

Distribution Valve......377

Group 8 Others (Undercarriage)......381

Swing Bearing......381

Centerjoint......382

Track Adjuster......383

SERVICE MANUAL REVISION REQUEST FORM......387

TTJAE-EN-00 (attach to) - Hitachi ZX470-5A, 470LC-5A, 490H-5A, 490LCH-5A, 530LCH-5A Hydraulic Excavator Electrical Circuit Diagram......389

ELECTRICAL DIAGRAM......389

AIR CONDITIONER CIRCUIT DIAGRAM......390

CONNECTORS......391

CAB HARNESS......392

MAIN HARNESS......393

ENGINE HARNESS......394

PUMP HARNESS......395

CONTROL VALVE HARNESS......396

MONITOR HARNESS......397

KEY SWITCH HARNESS......398

OIL COOLER FAN REVERSE ROTATION SWITCH HARNESS......399

ENGINE STOP SWITCH HARNESS......400

PILOT SHUT-OFF SOLENOID VALVE HARNESS......401

GSM (MOBILE COMMUNICATION TERMINAL) HARNESS......402

SATELLITE COMMUNICATION HARNESS......403

AUTO LUBRICATION ON/OFF SWITCH HARNESS......404

CAMERA HARNESS......405

BOOM MODE SWITCH AND SEAT HEATER SWITCH HARNESS (OPTION)......406

WORK LIGHT (ON THE CAB ROOF) HARNESS 1 (OPTION)......407

WORK LIGHT (ON THE CAB ROOF) HARNESS 2 (OPTION)......408

HYDRAULIC CIRCUIT DIAGRAM......409

TTJAE-EN-00 - Hitachi ZX470-5A, 470LC-5A, 490H-5A, 490LCH-5A, 530LCH-5A Hydraulic Excavator Technical Manual (Troubleshooting)......410

TTJAE-EN-00......410

INTRODUCTION......412

SYMBOL AND ABBREVIATION......414

SAFETY......416

SECTION AND GROUP CONTENTS......456

SECTION 4......458

Group 1 Introduction......460

Operational Performance Tests......460

Preparation for Performance Tests......461

Group 2 Standard......462

Operational Performance Standard Table......462

Main Pump P-Q Diagram......466

Fan Pump P-Q Diagram......467

Sensor Activating Range......468

Monitor Indicating Values (MC)......469

Monitor Indicating Values (ECM)......475

Group 3 Engine Test......476

Engine Speed......476

Lubricant Consumption......479

Group 4 Machine Performance Test......480

Travel Speed......480

Track Revolution Speed......481

Mistrack Check......482

Travel Parking Leakage......483

Swing Speed......484

Swing Function Drift Check......485

Swing Motor Leakage......487

Maximum Swingable Slant Angle......489

Swing Bearing Play......491

Hydraulic Cylinder Cycle Time......493

Dig Function Drift Check......495

Control Lever Operating Force......498

Control Lever Stroke......499

Combined Operation of Boom Raise and Swing Function Check......500

Group 5 Component Test......502

Primary Pilot Pressure......502

Secondary Pilot Pressure......504

4-Spool Solenoid Valve Set Pressure......505

2-Spool Solenoid Valve Set Pressure......506

Main Pump Delivery Pressure......508

Fan Pump Delivery Pressure......509

Main Relief Set Pressure......510

Overload Relief Set Pressure......516

Main Pump Flow Rate Measurement......519

Fan Pump Flow Rate Measurement......521

Swing Motor Drainage......525

Travel Motor Drainage......527

Group 6 Adjustment......530

PUMP LEARNING......530

TORQUE ADJUSTMENT......531

CONNECTION......532

SECTION 5......536

Group 1 Diagnosing Procedure......538

Introduction......538

Diagnosis Procedure......539

Electrical System Inspection......542

Precautions for Inspection and Maintenance......543

Instructions for Disconnecting Connectors......545

Fuse Inspection......547

Fusible Link Inspection......550

Battery Voltage Check......551

Alternator Check......552

Continuity Check......553

Voltage and Current Measurement......555

Check by False Signal......562

Test Wire Harness......563

Group 2 Monitor......566

Outline......566

Operating Procedures of Service Menu......567

Setting Menu......604

Inspection of Engine Oil Level, Coolant Level, Hour Meter, and Fuel Gauge......606

Fuel Gauge and Coolant Temperature Gauge......607

Group 3 e-Service......608

Outline......608

List of Operation Data......609

Snapshot Data......613

Communication System......614

Group 4 Component Layout......616

Main Component......616

Electrical System (Overview)......618

Electrical System (Rear Tray)......619

Electrical System (Switch Panel)......620

Electrical System (Utility Space)......621

Engine......623

Pump Device......624

Around Pump Device......625

Control Valve......626

Check Valve/Accumlator......627

Signal Control Valve......627

Swing Device......629

Travel Device......629

4-Spool Solenoid Valve Unit......630

2-Spool Solenoid Valve Unit......630

Fan Valve (Option)......630

Layout of Control Valve......631

Pilot Port (Signal Control Valve)......647