Hitachi ZX470-5A, 470LC-5A, 490H-5A, 490LCH-5A, 530LCH-5A - Service Manual - Wiring Diagrams

HITACHI ZX470-5A, 470LC-5A, 490H-5A, 490LCH-5A, 530LCH-5A - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS

- English Service Manual and Wiring Diagrams, for Hitachi ZX470-5A, 470LC-5A, 490H-5A, 490LCH-5A, 530LCH-5A.
 

CONTENTS:


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 DIAGRAMS

- 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