Hitachi ZX470-6 ZX470LC-6 ZX490H-6 ZX490LCH-6 ZX490R-6 ZX490LCR-6 ZX530LCH-6 Excavator Workshop Repair Service Manual PDF - MHITZX470ZX530JAG.zip
A full factory-level service and repair guide, complete with electrical wiring schematics, covering the Hitachi ZX470-6, ZX470LC-6, ZX490H-6, ZX490LCH-6, ZX490R-6, ZX490LCR-6, and ZX530LCH-6 Excavators — providing every bit of shop data needed to maintain, troubleshoot, fix, and service these machines just like expert technicians.
The workshop service repair manual for Hitachi ZX470-6, ZX470LC-6, ZX490H-6, ZX490LCH-6, ZX490R-6, ZX490LCR-6, and ZX530LCH-6 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: 1,729 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English
MANUAL LIST:
TOJAG50-EN-00 - Hitachi ZX470-6, ZX470LC-6, ZX490H-6, ZX490LCH-6, ZX490R-6, ZX490LCR-6, ZX530LCH-6 Hydraulic Excavator Technical Manual (Operational Principle).pdf
TTJAG50-EN-00 (attach to) - Hitachi ZX470-6, ZX470LC-6, ZX490H-6, ZX490LCH-6, ZX490R-6, ZX490LCR-6, ZX530LCH-6 Hydraulic Excavator Electrical Circuit Diagram.pdf
TTJAG50-EN-00 - Hitachi ZX470-6, ZX470LC-6, ZX490H-6, ZX490LCH-6, ZX490R-6, ZX490LCR-6, ZX530LCH-6 Hydraulic Excavator Technical Manual (Troubleshooting).pdf
WAG50-EN-00 - Hitachi ZX470-6, ZX470LC-6, ZX490H-6, ZX490LCH-6, ZX490R-6, ZX490LCR-6, ZX530LCH-6 Hydraulic Excavator Workshop Manual.pdf
MAIN SECTIONS
TOJAG50-EN-00 - Hitachi ZX470-6, ZX470LC-6, ZX490H-6, ZX490LCH-6, ZX490R-6, ZX490LCR-6, ZX530LCH-6 Hydraulic Excavator Technical Manual (Operational Principle).....1
TOJAG50-EN-00.....1
CONTENTS.....3
INTRODUCTION.....9
SYMBOL AND ABBREVIATION.....11
SECTION AND GROUP CONTENTS.....13
SECTION 1GENERAL.....15
Group 1 Specifications.....17
Specifications ZX470-6, 470LC-6.....17
Working Ranges ZX470-6, 470LC-6.....18
Specifications ZX490H-6, 490LCH-6.....19
Working Ranges ZX490H-6, 490LCH-6.....20
Specifications ZX530LCH-6.....21
Working Ranges ZX530LCH-6.....22
Group 2 Component Layout.....23
Main Component.....23
Electrical System (Overview).....25
Electrical System (Rear Tray).....26
Electrical System (Switch Panel).....27
Electrical System (Cab Behind Side).....28
Engine 1.....30
Engine 2.....31
Aftertreatment Device.....32
Pump Device.....33
Control Valve.....34
DEF Tank.....35
Expansion Tank.....35
Check Valve.....36
Signal Control Valve.....36
4-Spool Solenoid Valve Unit.....39
2-Spool Solenoid Valve Unit.....39
Fan Valve.....39
Layout of Attachment Spec. Parts (Hydraulic System).....40
Group 3 Component Specifications.....45
Engine.....45
Engine Accessories.....49
Hydraulic Component.....51
Electrical Component.....55
SECTION 2SYSTEM.....59
Group 1 Controller.....61
Outline.....61
CAN Circuit.....62
Group 2 Control System.....65
Outline.....65
Engine Control.....68
Pump Control.....98
Valve Control (Standard).....126
Other Control.....158
Group 3 Engine System.....171
Outline.....171
ECM System.....172
Fuel Injection Control.....174
Fuel Injection Amount Correction Control.....182
EGR Control.....184
Preheating Control.....186
Variable Turbocharger Control.....187
Alarm Control.....188
Urea SCR System.....189
Engine Output Restriction Control (INDUCEMENT).....200
Aftertreatment Device.....204
Aftertreatment Device Regeneration Control.....206
Group 4 Hydraulic System.....209
Outline.....209
Pilot Circuit.....210
Main Circuit.....226
Breaker/Pulverizer/Crusher Circuit (Optional).....252
Group 5 Electrical System.....261
Outline.....261
Main Circuit.....262
Electric Power Circuit (Key Switch: OFF).....264
CAN Circuit.....266
Accessory Circuit (Key Switch: ACC).....268
Starting Circuit (Key Switch: START).....270
Charging Circuit (Key Switch: ON).....272
Surge Voltage Prevention Circuit.....276
Pilot Shut-Off Circuit (Key Switch: ON).....278
Auto Shut-Down Circuit/Automatic Engine Stop Circuit at Low Temperature.....280
Engine Stop Circuit.....282
Monitor Circuit.....285
Security Circuit.....286
Radio Circuit.....288
Air Conditioner Circuit.....288
Accessory Circuit.....291
Work Light Circuit.....292
Wiper/Washer Circuit.....294
Cab Light Circuit.....296
SECTION 3COMPONENT OPERATION.....301
Group 1 Pump Device.....303
Outline.....303
Main Pump.....304
Regulator.....306
Pump Control Solenoid Valve.....314
Fan Pump.....316
Fan Pump Flow Rate Control.....318
Pilot Pump.....320
Pump Delivery Pressure Sensor.....320
Pump Control Pressure Sensor.....320
Group 2 Swing Device.....321
Outline.....321
Swing Reduction Gear.....322
Swing Motor.....323
Swing Parking Brake.....324
Valve Unit.....326
Group 3 Control Valve.....329
Outline.....329
Hydraulic Circuit.....346
Flow Combiner Valve.....352
Main Relief valve.....354
Overload Relief Valve (with Make-Up Function).....358
Boom Overload Relief Valve (Low Pressure).....364
Regenerative Valve.....366
Anti-Drift Valve.....370
Flow Rate Control Valve.....374
Boom Lower Meter-In Cut Valve.....382
Bypass Shut-Out Valve.....384
Auxiliary Flow Combiner Valve.....388
Group 4 Pilot Valve.....391
Outline.....391
Operation (Front Attachment/Swing and Travel Pilot Valves).....393
Operation (Auxiliary, Counterweight Removal/Installation Pilot Valves).....401
Shockless Function (Only for Travel Pilot Valve).....406
Group 5 Travel Device.....407
Outline.....407
Travel Reduction Gear.....408
Travel Motor.....410
Parking Brake.....412
Travel Brake Valve.....414
Overload Relief Valve.....418
Travel Mode Control.....420
Group 6 Signal Control Valve.....425
Outline.....425
Pilot Port.....426
Shuttle Valve.....430
Shockless Valve.....434
Pump 1 and Pump 2 Flow Rate Control Valves.....438
Arm Flow Rate Control Valve Control Spool, Flow Combiner Valve Control Spool, Swing Parking Brake Release Spool.....440
Group 7 Others (Upperstructure).....441
Pilot Shut-Off Solenoid Valve.....441
Solenoid Valve.....443
Hose Rupture Valve (Optional).....446
Fan Motor.....450
Fan Valve.....451
Pilot Relief Valve.....457
Shockless Valve.....458
Accumulator (Pilot Circuit).....460
Accumulator (Attachment Circuit) (Optional).....461
Selector Valve (Optional).....462
Distribution Valve.....464
Group 8 Others (Undercarriage).....467
Swing Bearing.....467
Centerjoint.....468
Track Adjuster.....469
SERVICE MANUAL REVISION REQUEST FORM.....473
TTJAG50-EN-00 (attach to) - Hitachi ZX470-6, ZX470LC-6, ZX490H-6, ZX490LCH-6, ZX490R-6, ZX490LCR-6, ZX530LCH-6 Hydraulic Excavator Electrical Circuit Diagram.....475
ELECTRICAL CIRCUIT DIAGRAM.....475
AIR CONDITIONER CIRCUIT DIAGRAM.....476
CONNECTORS.....477
CAB HARNESS.....478
MAIN HARNESS.....479
ENGINE HARNESS.....480
PUMP HARNESS.....481
CONTROL VALVE HARNESS.....482
NOx HARNESS.....483
EXPANSION TANK SUB HARNESS.....484
DEF SENSOR UNIT HARNESS.....485
MONITOR HARNESS.....486
KEY SWITCH HARNESS.....487
MANUAL REGENERATION SWITCH HARNESS.....488
OIL COOLER FAN REVERSE ROTATION SWITCH HARNESS.....489
ENGINE STOP SWITCH HARNESS.....490
FLOOR EARTH HARNESS.....491
PILOT SHUT-OFF SOLENOID VALVE HARNESS.....492
STARTER HARNESS.....493
GSM (MOBILE COMMUNICATION TERMINAL) HARNESS.....494
SATELLITE COMMUNICATION HARNESS.....495
AUTO LUBRICATION HARNESS.....496
AUTO LUBRICATION ON/OFF SWITCH HARNESS.....497
REARVIEW CAMERA HARNESS.....498
COUNTERWEIGHT REMOVAL SWITCH HARNESS (OPTION).....499
BOOM MODE SWITCH AND SEAT HEATER SWITCH HARNESS (OPTION).....500
BREAKER HARNESS (OPTION).....501
WORK LIGHT (ON THE CAB ROOF) HARNESS 1 (OPTION).....502
WORK LIGHT (ON THE CAB ROOF) HARNESS 2 (OPTION).....503
ADDITIONAL WORK LIGHT (ON THE CAB ROOF) HARNESS (OPTION).....504
HYDRAULIC CIRCUIT DIAGRAM (STANDARD).....505
HYDRAULIC CIRCUIT DIAGRAM (OPTIONAL).....506
HYDRAULIC CIRCUIT DIAGRAM (WITH HOSE RUPTURE VALVE)(OPTIONAL.....507
HYDRAULIC CIRCUIT DIAGRAM (WITH COUNTERWEIGHT REMOVAL AND INSTALLATION DEVICE)(OPTIONAL).....508
TTJAG50-EN-00 - Hitachi ZX470-6, ZX470LC-6, ZX490H-6, ZX490LCH-6, ZX490R-6, ZX490LCR-6, ZX530LCH-6 Hydraulic Excavator Technical Manual (Troubleshooting).....509
TTJAG50-EN-00.....509
CONTENTS.....511
INTRODUCTION.....515
SYMBOL AND ABBREVIATION.....517
SAFETY.....519
SECTION AND GROUP CONTENTS.....561
SECTION 4 OPERATIONAL PERFORMANCE TEST.....563
Group 1 Introduction.....565
Operational Performance Tests.....565
Preparation for Performance Tests.....566
Group 2 Standard.....567
Operational Performance Standard Table.....567
Main Pump P-Q Diagram.....571
Fan Pump P-Q Diagram.....572
Sensor Activating Range.....573
MPDR. Monitor Indicating Values (MC).....574
MPDr. Monitor Indicating Values (ECM).....580
Group 3 Engine Test.....581
Engine Speed.....581
Lubricant Consumption.....584
Group 4 Machine Performance Test.....585
Travel Speed.....585
Track Revolution Speed.....586
Mistrack Check.....587
Travel Parking Leakage.....588
Swing Speed.....589
Swing Function Drift Check.....590
Swing Motor Leakage.....592
Maximum Swingable Slant Angle.....594
Swing Bearing Play.....596
Hydraulic Cylinder Cycle Time.....598
Dig Function Drift Check.....600
Control Lever Operating Force.....603
Control Lever Stroke.....604
Combined Operation of Boom Raise and Swing Function Check.....605
Group 5 Component Test.....607
Primary Pilot Pressure.....607
Secondary Pilot Pressure.....609
4-Spool Solenoid Valve Set Pressure.....610
2-Spool Solenoid Valve Set Pressure.....611
Main Pump Delivery Pressure.....613
Fan Pump Delivery Pressure.....614
Main Relief Valve Set Pressure.....615
Overload Relief Valve Set Pressure.....621
Main Pump Flow Rate Measurement.....624
Fan Pump Flow Rate Measurement.....630
Swing Motor Drainage.....636
Travel Motor Drainage.....638
Group 6 Adjustment.....641
Pump Learning.....641
Torque Adjustment.....642
Connection.....643
Rewrite of Aftertreatment Device Serial No.....645
How to Clear Fault Code.....646
Procedure after Replacing DCU and ECM.....647
Air Bleeding from the Diesel Exhaust Fluid Defrosting Piping.....648
How to Check Manual Regeneration Switch.....649
Remedy at DEF Pressure Decrease.....650
Remedy at DEF Abnormal Quality.....652
Clean DEF Tank.....654
Remedy When Mixing Oil DEF Tank.....655
SECTION 5 TROUBLESHOOTING.....659
Group 1 Diagnosing Procedure.....661
Introduction.....661
Diagnosis Procedure.....662
Electrical System Inspection.....665
Precautions for Inspection and Maintenance.....666
Instructions for Disconnecting Connectors.....668
Fuse Inspection.....670
Fusible Link Inspection.....673
Battery Voltage Check.....674
Alternator Check.....675
Continuity Check.....676
Voltage and Current Measurement.....678
Check by False Signal.....685
Test Wire Harness.....686
Group 2 Monitor.....689
Outline.....689
Operating Procedures of Service Menu.....690
Setting Menu.....659
Inspection of Engine Oil Level, Coolant Level,Hour Meter, and Fuel Gauge.....728
Fuel Gauge, Coolant Temperature Gauge,DEF/AdBlue Gauge.....729
Group 3 e-Service.....731
Outline.....731
List of Operation Data.....732
Communication System.....734
Group 4 Component Layout.....735
Main Component.....735
Electrical System (Overview).....737
Electrical System (Rear Tray).....738
Electrical System (Switch Panel).....739
Electrical System (Cab Behind Side).....740