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Hitachi ZX450-3/ZX450LC-3/ZX470H-3/ZX470LCH-3/ZX500LC-3/ZX520LCH-3 Excavator Technical Manual

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Hitachi ZX450-3 / ZX450LC-3 / ZX470H-3 / ZX470LCH-3 / ZX500LC-3 / ZX520LCH-3 Hydraulic Excavator Technical Manual
Hitachi ZX450-3/ZX450LC-3/ZX470H-3/ZX470LCH-3/ZX500LC-3/ZX520LCH-3 Excavator Technical Manual

Information included in this Technical Manual: technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures for the ZX450-3 / ZX450LC-3 / ZX470H-3 / ZX470LCH-3 / ZX500LC-3 / ZX520LCH-3 Hitachi Hydraulic Excavator.

APPLICABLE MODELS :

Hitachi Zaxis 450-3 / Hitachi ZX-450-3
Hitachi Zaxis 450LC-3 / Hitachi ZX-450LC-3
Hitachi Zaxis 470H-3 / Hitachi Zx-470H-3
Hitachi Zaxis 470LCH-3 / Hitachi ZX-470LCH-3
Hitachi Zaxis 500LC-3 / Hitachi ZX-500LC-3
Hitachi Zaxis 520LCH-3 / Hitachi ZX-520LCH-3

TABLE OF CONTENTS :

Operational Principle – TO1J1-E-00

SECTION 1 GENERAL
Group 1 Specification
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)

Troubleshooting – TT1J1-E-00

SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction
Group 2 Standard
Group 3 Engine Test
Group 4 Excavator Test
Group 5 Component Test
Group 6 Adjustment

SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Group 2 Monitor Unit
Group 3 Dr. ZX
Group 4 ICF
Group 5 Component Layout
Group 6 Troubleshooting A
Group 7 Troubleshooting B
Group 8 Electrical System Inspection

ZX450_circuit
ZX450-3(1)
ZX450-3_500LC-3_520LCH-3(8)
ZX450-3_500LC-3_520LCH-3(9)
ZX450-3_500LC-3_520LCH-3(10)

MANUAL SPECIFICATION :

File Format : PDF in Zip
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Total Pages : 340+615+38=993

This complete technical manual PDF download for the Hitachi ZAXIS 450-3 / 450LC-3 / 470H-3 / 470LCH-3 / 500LC-3 / 520LCH-3 Hydraulic Excavator has easy to read text sections with top quality diagrams, pictures and illustrations.

• Information included in the Technical Manual (Operational Principle): technical information needed for redeliver and delivery, operation and activation of all devices and systems.

• Information included in the Technical Manual (Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures.

This service repair workshop technical manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

SECTION 1 GENERAL
Specifications
SPECIFICATIONS
WORKING RANGES
Component Layout
MAIN COMPONENT LAYOUT
ELECTRICAL COMPONENT LAYOUT
ENGINE
PUMP DEVICE
SWING DEVICE
TRAVEL DEVICE
CONTROL VALVE
Component Specifications
ENGINE
ENGINE ACCESSORIES
HYDRAULIC COMPONENT
ELECTRICAL COMPONENT

SECTION 2 SYSTEM
Controller
OUTLINE
CAN: CONTROLLER AREA NETWORK (NETWORK PROVIDED FOR MACHINE)
MC: MAIN CONTROLLER
ECM: ENGINE CONTROL MODULE
ICF: INFORMATION CONTROLLER
MONITOR UNIT
Control System
OUTLINE
ENGINE CONTROL
PUMP CONTROL
VALVE CONTROL
OTHER CONTROLS
ECM System
OUTLINE
FUEL INJECTION CONTROL
FUEL INJECTION AMOUNT CORRECTION CONTROL
PREHEATING CONTROL
EGR (EXHAUST GAS RECIRCULATION) CONTROL
ENGINE STOP CONTROL
Hydraulic System
OUTLINE
PILOT CIRCUIT
MAIN CIRCUIT
COUNTERWEIGHT REMOVAL / INSTALLATION CIRCUIT (OPTIONAL)
Electrical System
OUTLINE
MAIN CIRCUIT
ELECTRIC POWER CIRCUIT (KEY SWITCH: OFF)
ACCESSORY CIRCUIT
STARTING CIRCUIT (KEY SWITCH: START)
CHARGING CIRCUIT (KEY SWITCH: ON)
SERGE VOLTAGE PREVENTION CIRCUIT
PILOT SHUT-OFF CIRCUIT (KEY SWITCH: ON)
SECURITY LOCK CIRCUIT
ENGINE STOP CIRCUIT (KEY SWITCH: OFF)
SECURITY HORN CIRCUIT
WORKING LIGHT CIRCUIT
WIPER / WASHER CIRCUIT

SECTION 3 COMPONENT OPERATION
Pump Device
OUTLINE
MAIN PUMP, FAN PUMP
REGULATOR FOR MAIN PUMP
REGULATOR FOR FAN PUMP
PUMPS 1, 2 CONTROL SOLENOID VALVE, FAN PUMP CONTROL SOLENOID VALVE
PILOT PUMP
PUMP DELIVERY PRESSURE SENSOR
PUMP REGULATOR PRESSURE (FLOW RATE CONTROL PRESSURE) SENSOR
Swing Device
OUTLINE
SWING REDUCTION GEAR
SWING MOTOR
SWING PARKING BRAKE
VALVE UNIT
Control Valve
OUTLINE
HYDRAULIC CIRCUIT
MAIN RELIEF VALVE
OVERLOAD RELIEF VALVE (WITH MAKE-UP FUNCTION)
BOOM OVERLOAD RELIEF CONTROL VALVE
FLOW COMBINER VALVE
ANTI-DRIFT VALVE
REGENERATIVE VALVE
FLOW RATE CONTROL VALVE
BYPASS SHUT-OUT VALVE
Pilot Valve
OUTLINE
OPERATION
SHOCKLESS FUNCTION (ONLY FOR TRAVEL PILOT VALVE)
Travel Device
OUTLINE
TRAVEL REDUCTION GEAR
TRAVEL MOTOR
TRAVEL BRAKE VALVE
PARKING BRAKE
Signal Control Valve
OUTLINE
PILOT PORT
SHUTTLE VALVE
SHOCKLESS VALVE
ARM FLOW RATE CONTROL VALVE CONTROL SPOOL, FLOW COMBINER VALVE CONTROL SPOOL, SWING PARKING BRAKE RELEASE SPOOL
Others (Upperstructure)
PILOT SHUT-OFF SOLENOID VALVE
4-SPOOL SOLENOID VALVE UNIT
PILOT RELIEF VALVE
FAN MOTOR
FAN VALVE
SHOCKLESS VALVE
ACCUMULATOR
DISTRIBUTION VALVE (OPTIONAL)
Others (Undercarriage)
SWING BEARING
CENTER JOINT
TRACK ADJUSTER

SECTION 4 OPERATIONAL 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
Fan Pump I-Q Diagram
Dr.ZX Monitor Indicating Values (MC)
Dr.ZX Monitor Indicating Values (ECM)
Sensor Activating Range
Group 3 Engine Test
Engine Speed
Engine Compression Pressure
Valve Clearance
Lubricant Consumption
Group 4 Excavator Test
Travel Speed
Track Revolution Speed
Mistrack Check
Travel Motor 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
Boom Raise/Swing Combined Operation Check
Group 5 Component Test
Primary Pilot Pressure
Secondary Pilot Pressure
Solenoid Valve Set Pressure
Main Pump Delivery Pressure
Fan Pump Delivery Pressure
Main Relief Valve Set Pressure
Overload Relief Valve 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

SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Introduction
Diagnosing Procedure
Group 2 Monitor Unit
Outline
How to Use Screens
Screen Display When An Alarm is Issued
Contents of Alarms
Troubleshooting
Controller Version
Monitoring
Displaying Operating Conditions
Pump 2 Flow Rate Adjustment
Attachment Selection
Time Set
Fuel Rate Display/No Display
Back Monitor Settings
Maintenance Settings
Language Settings
Mail (Optional)
Group 3 Dr. ZX
Outline
Self-Diagnostic Results
Select Controller
Main Controller
Main Menu Monitor Display (MC)
Special Functions
Setup
Adjustment Data List
Attachment Adjustment Data List
Engine Controller
Main Menu Monitor Display (ECM)
Record Data Display
Password Change
ICF Controller
Main Menu Information C/U Various Setup
Information C/U: Initialize
Enter Model and Serial No.
Enter Date and Time
Control Data: Initialize
Satellite Terminal: Initialize
Satellite Terminal No. Confirmation
Communicating State Check
Enter Satellite Comm. Start / Stop Set
Data Download
Save Data Check
Password Change
Monitor Controller
Monitoring
Various Settings
Option Function Allocate
Overload Warning Enable / Disable Selection
Back Monitor Setup
Operational Condition Enable / Disable Selection
Time Set Function Enable / Disable Selection
Maintenance Setup Maintenance Operation Allow / Not Allow Selection
Notification Function Enable / Disable Selection
Maintenance Display Items On/Off Selection
Internal Hour Meter Synchronization
Fuel Cost Meter Display Enable / Disable Selection
Password Change
Group 4 ICF
Outline
List of Daily Report Data
List of Frequency Distribution Data
List of Total Operating Hours
How to Download and Upload Data of ICF
Various Setup of ICF and Satellite Communication Terminal by Using Dr. ZX
List of Fault Code
Satellite Communication System
Group 5 Component Layout
Main Component Layout
Electrical Component Layout
Engine
Pump Device
Swing Device
Travel Device
Control Valve
Components in Control Valve
Pilot Port
Group 6 Troubleshooting A
Troubleshooting A Procedure
MC Fault Code List
ECM Fault Code List
ICF Fault Code List
Satellite Terminal Fault Code List (Optional)
Monitor Unit Fault Code List
MC Fault Code 11000 to 11002
MC Fault Code 11003
MC Fault Code 11004
CAN Harness Check
MC Fault Code 11101
MC Fault Code 11200
MC Fault Code 11202
MC Fault Code 11301
MC Fault Code 11302
MC Fault Code 11303
MC Fault Code 11400
MC Fault Code 11402
MC Fault Code 11404
MC Fault Code 11405
MC Fault Code 11410
MC Fault Code 11412
MC Fault Code 11802
MC Fault Code 11901
MC Fault Codes 11910, 11911, 11914, 11918, 11920, 11983, 11984
MC Fault Codes 11910, 11911, 11914, 11918, 11920, 11983, 11984 CAN Harness Check
MC Fault Code 11989
MC Fault Code 11991
MC Fault Code 11992
MC Fault Code 11993
MC Fault Code 11994
MC Fault Code 11995
MC Fault Code 11997
MC Fault Code 11998
MC Fault Code 11999
ICF Fault Codes 14000 to 14003
Information C/U: Initialize
Control Data: Initialize
Enter Model and Serial No
ICF Fault Codes 14006, 14008
Satellite Terminal (Optional) Fault Codes 14100 to 14106
Monitor Unit Fault Code 13303
Monitor Unit Fault Code 13304
Monitor Unit Fault Codes 13306, 13308
Monitor Unit Fault Code 13310
Monitor Unit Fault Code 13311
Pilot Shut-Off Lever Alarm
Group 7 Troubleshooting B
Troubleshooting B 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
Work After Replacing Components
Charge Air Conditioner with Refrigerant
Exchange Inspection
Group 8 Electrical System Inspection
Precautions for Inspection and Maintenance
Instructions for Disconnecting Connectors
Fuse Inspection
Fusible Link Inspection and Replacement
Battery Voltage Check
How to Troubleshoot Alternator Malfunctions
Continuity Check
Voltage and Current Measurement
Check by False Signal
Test Harness

SERVICE MANUAL REVISION REQUEST FORM
THE ATTACHED DIAGRAM LIST

CIRCUIT DIAGRAM
ATT Sensor Harness

TT1J1-E-00_circuit
ZX450_cir
ZX450-3(1)
ZX450-3_500LC-3_520LCH-3(8)
ZX450-3_500LC-3_520LCH-3(9)
ZX450-3_500LC-3_520LCH-3(10)

 

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Hitachi ZX450-3/ZX450LC-3/ZX470H-3/ZX470LCH-3/ZX500LC-3/ZX520LCH-3 Excavator Technical Manual.pdf

Source : Sitelux.com

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