Hitachi ZX470-5G, ZX470LC-5G, ZX470H-5G, ZX470LCH-5G, ZX470R-5G, ZX470LCR-5G Excavator Factory Service & Shop Manual
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Complete workshop repair service manual with electrical wiring diagrams for Hitachi ZX470-5G, ZX470LC-5G, ZX470H-5G, ZX470LCH-5G, ZX470R-5G, ZX470LCR-5G Excavator. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.
Hitachi ZX470-5G, ZX470LC-5G, ZX470H-5G, ZX470LCH-5G, ZX470R-5G, ZX470LCR-5G Excavator service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.
TOJAC-EN-00 - Hitachi ZX470-5G, ZX470LC-5G, ZX470H-5G, ZX470LCH-5G, ZX470R-5G, ZX470LCR-5G Hydraulic Excavator Technical Manual (Operational Principle).pdf
TTJAC-EN-00 (attach to) - Hitachi ZX470-5G, ZX470LC-5G, ZX470H-5G, ZX470LCH-5G, ZX470R-5G, ZX470LCR-5G Hydraulic Excavator Electrical Circuit Diagram.pdf
TTJAC-EN-00 - Hitachi ZX470-5G, ZX470LC-5G, ZX470H-5G, ZX470LCH-5G, ZX470R-5G, ZX470LCR-5G Hydraulic Excavator Technical Manual (Troubleshooting).pdf
WJAC-EN-00 - Hitachi ZX470-5G, ZX470LC-5G, ZX470H-5G, ZX470LCH-5G, ZX470R-5G, ZX470LCR-5G Hydraulic Excavator Workshop Manual.pdf
TOTAL PAGES: 1,747
LANGUAGE: ENGLISH
FORMAT: PDF
EXCERPT:
SECTION 3 UPPERSTRUCTURE
Group 9 Control Valve
Disassembly of Load Check Valve (p)
45. Remove cap (71) from housing (1).
l: 14 mm
46. Remove check valve (72), spring (48), and check valve (49) from housing (1).
47. Remove O-ring (19) and backup ring (47) from cap
(71).
Disassembly of Bypass Shut-Out Valve (q)
48. Remove cap (65) from housing (1).
j: 46 mm
49. Remove spool (69) and spring (68) from housing (1).
50. Remove piston (64), cap (66), and O-ring (67) from cap (65).
j: 46 mm
51. Remove O-ring (67) from cap (66).
52. Remove cap (44) from housing (1).
j: 46 mm
53. Remove O-ring (45) from cap (44).
54. Remove socket bolts (38) (12 used).
l: 12 mm
55. Remove flanges (36) (3 used) from housing (1).
Remove O-rings
...
TOJAC-EN-00 - Hitachi ZX470-5G, ZX470LC-5G, ZX470H-5G, ZX470LCH-5G, ZX470R -5G, ZX470LCR -5G Hydraulic Excavator Technical Manual (Operational Principle)...2
TOJAC-EN-00...2
INTRODUCTION...4
Symbol and Abbreviation...6
SECTION AND GROUP CONTENTS...8
SECTION 1 GENERAL...10
Group 1 Specifications...12
Specifications...12
Working Ranges...15
Group 2 Component Layout...18
Main Component...18
Electrical System (Overview)...20
Electrical System (Rear Tray)...21
Electrical System (Switch Panel)...22
Electrical System (Cab Behind Side)...23
Isolation Switch (Optional)...25
Engine...27
Pump Device...28
Control Valve...29
Check Valve / Accumulator...31
Signal Control Valve...31
4-Spool Solenoid Valve Unit...34
2-Spool Solenoid Valve Unit...34
Layout of Attachment Spec. Parts (Hydraulic System)...35
Group 3 Component Specifications...40
Engine...40
Engine Accessories...44
Hydraulic Component...45
Electrical Component...49
SECTION 2 SYSTEM...52
Group 1 Controller...54
Outline...54
CAN Circuit...55
Group 2 Control System...58
Outline...58
Engine Control...61
Pump Control...85
Valve Control (Standard)...103
Other Control...129
Group 3 Hydraulic System...138
Outline...138
Pilot Circuit...139
Main Circuit...153
Breaker/Pulverizer/Crusher Circuit (Optional)...175
Group 4 Electrical System...184
Outline...184
Main Circuit...185
Electric Power Circuit (Key Switch: OFF)...187
CAN Circuit...189
Accessory Circuit...191
Preheating Circuit (Key Switch: ON, START)...193
Starting Circuit (Key Switch: START)...195
Charging Circuit (Key Switch: ON)...199
Surge Voltage Prevention Circuit...203
Pilot Shut-Off Circuit (Key switch: ON)...205
Engine Stop Circuit...207
Monitor Circuit...210
Security Circuit...211
Radio Circuit...213
Air Conditioner Circuit...213
Accessory Circuit...216
Work Light Circuit...217
Wiper/Washer Circuit...219
Cab Light Circuit...221
SECTION 3 COMPONENT OPERATION...226
Group 1 Pump Device...228
Outline...228
Main Pump...229
Regulators...231
Pilot Pump...239
N Sensor (Engine Speed Sensor)...239
Pump Delivery Pressure Sensor...239
Pump Displacement Angle Sensor...239
Group 2 Swing Device...240
Outline...240
Swing Reduction Gear...241
Swing Motor...242
Swing Parking Brake...243
Valve Unit...245
Group 3 Control Valve...248
Outline...248
Hydraulic Circuit...265
Flow Combiner Valve...271
Main Relief Valve...273
Overload Relief Valve (with Make-Up Function)...277
Boom Overload Relief Valve (Low Pressure)...283
Regenerative Valve...285
Anti-Drift Valve...289
Flow Rate Control Valve...293
Boom Lower Meter-In Cut Valve...301
Bypass Shut-Out Valve...303
Auxiliary Flow Combiner Valve...305
Group 4 Pilot Valve...308
Outline...308
Operation (Front Attachment / Swing and Travel Pilot Valves)...310
Operation (Auxiliary / Counterweight Removaland Installation Pilot Valve)...318
Shockless Function (Only for Travel Pilot Valve)...323
Group 5 Travel Device...324
Outline...324
Travel Reduction Gear...325
Travel Motor...327
Parking Brake...329
Travel Brake Valve...331
Overload Relief Valve...335
Travel Mode Control...337
Group 6 Signal Control Valve...342
Outline...342
Pilot Port...343
Shuttle Valve...348
Shockless Valve...351
Pump 1 Flow Rate Control Valve, Pump 2Flow Rate Control Valve...355
Arm Flow Rate Control Valve Control Spool, Flow Combiner Valve Control Spool, Swing Parking Brake Release Spool...357
Group 7 Others (Upperstructure)...358
Pilot Shut-Off Solenoid Valve...358
Solenoid Valve...360
Fan Motor...363
Fan Valve...364
Pilot Relief Valve...367
Shockless Valve...368
Accumulator...369
Distribution Valve...370
Group 8 Others (Undercarriage)...374
Swing Bearing...374
Center Joint...375
Track Adjuster...376
SERVICE MANUAL REVISION REQUEST FORM...380
TTJAC-EN-00 (attach to) - Hitachi ZX470-5G, ZX470LC-5G, ZX470H-5G, ZX470LCH-5G, ZX470R -5G, ZX470LCR -5G Hydraulic Excavator Electrical Circuit Diagram...382
ZX470-5G/470LC-5G/470H-5G/470LCH-5G/470R-5G/470LCR-5G ELECTRICAL CIRCUIT DIAGRAM...382
ZX470-5G/470LC-5G/470H-5G/470LCH-5G/470R-5G/470LCR-5G CONNECTORS...383
ZX470-5G/470LC-5G/470H-5G/470LCH-5G/470R-5G/470LCR-5G CAB HARNESS...384
ZX470-5G/470LC-5G/470H-5G/470LCH-5G/470R-5G/470LCR-5G MAIN HARNESS...385
ZX470-5G/470LC-5G/470H-5G/470LCH-5G/470R-5G/470LCR-5G ENGINE HARNESS...386
ZX470-5G/470LC-5G/470H-5G/470LCH-5G/470R-5G/470LCR-5G OIL COOLER SUB HARNESS...387
ZX470-5G/470LC-5G/470H-5G/470LCH-5G/470R-5G/470LCR-5G CNTROL VALVE HARNESS...388
ZX470-5G/470LC-5G/470H-5G/470LCH-5G/470R-5G/470LCR-5G PUMP HARNESS...389
ZX470-5G/470LC-5G/470H-5G/470LCH-5G/470R-5G/470LCR-5G CAMERA HARNESS...390
ZX470-5G/470LC-5G/470H-5G/470LCH-5G/470R-5G/470LCR-5G FUSE BOX HARNESS...391
ZX470-5G/470LC-5G/470H-5G/470LCH-5G/470R-5G/470LCR-5G HYDRAULIC CIRCUIT DIAGRAM (STANDARD)...392
TTJAC-EN-00 - Hitachi ZX470-5G, ZX470LC-5G, ZX470H-5G, ZX470LCH-5G, ZX470R -5G, ZX470LCR -5G Hydraulic Excavator Technical Manual (Troubleshooting)...393
TTJAC-EN-00...393
INTRODUCTION...395
Symbol and Abbreviation...397
SAFETY...399
SECTION AND GROUP CONTENTS...441
SECTION 4 OPERATIONAL PERFORMANCE TEST...443
Group 1 Introduction...445
Operational Performance Tests...445
Preparation for Performance Tests...446
Group 2 Standard...447
Operational Performance Standard Table...447
Main Pump P-Q Diagram...451
MPDR. Monitor Indicating Values (MC)...452
MPDr. Monitor Indicating Values (ECF)...457
Sensor Activating Range...458
Group 3 Engine Test...459
Engine Speed...459
Engine Compression Pressure...462
Valve Clearance...464
Nozzle...468
Injection Timing...470
Lubricant Consumption...471
Group 4 Machine Performance Test...473
Travel Speed...473
Mistrack Check...475
Travel Motor Leakage...476
Swing Speed...477
Swing Function Drift Check...478
Swing Motor Leakage...479
Maximum Swingable Slant Angle...480
Swing Bearing Play...482
Hydraulic Cylinder Cycle Time...484
Dig Function Drift Check...486
Control Lever Operating Force...487
Control Lever Stroke...488
Boom Raise/Swing Combined Operation Check...489
Group 5 Component Test...491
Primary Pilot Pressure...491
Secondary Pilot Pressure...493
4-Spool Solenoid Valve Set Pressure...494
2-Spool Solenoid Valve Set Pressure...495
Main Pump Delivery Pressure...497
Main Relief Valve Set Pressure...498
Overload Relief Valve Set Pressure...504
Main Pump Flow Rate Measurement...508
Swing Motor Drainage...516
Travel Motor Drainage...518
Group 6 Adjustment...521
Installation and Adjustment of Pump Displacement Angle Sensor...521
Engine Speed Adjustment and Engine Learning...526
Positions of Governor Lever and Fuel Cut Lever...528
SECTION 5 TROUBLESHOOTING...533
Group 1 Diagnosing Procedure...535
Introduction...535
Diagnosis Procedure...536
Electric System Inspection...539
Precautions for Inspection and Maintenance...540
Instructions for Disconnecting Connectors...542
Fuse Inspection...544
Fusible Link Inspection...547
Battery Voltage Check...548
Alternator Check...549
Continuity Check...550
Voltage and Current Measurement...552
Check by False Signal...559
Test Harness...560
Group 2 Monitor...563
Outline...563
Operating Procedures of Service Menu(Built-In Diagnosing System)...564
Setting Menu...601
Inspection of Hour Meter and Fuel Gauge...603
Fuel Gauge and Coolant Temperature Gauge...604
Group 3 e-Service...605
Outline...605
List of Operation Data...606
Snapshot Data...610
Communication System...611
Group 4 Component Layout...613
Main Component...613
Electrical System (Overview)...615
Electrical System (Rear Tray)...616
Electrical System (Switch Panel)...617
Electrical System (Cab Behind Side)...618
Isolation Switch (Optional)...620
Engine...622
Pump Device...623
Control Valve...624
Check Valve / Accumulator...626
Signal Control Valve...626
4-Spool Solenoid Valve Unit...629
2-Spool Solenoid Valve Unit...629
Layout of Attachment Spec. Parts(Hydraulic System)...630
Layout of Control Valve...634
Pilot Port (Signal Control Valve)...650
Group 5 Troubleshooting A...655
Troubleshooting A (Base Machine Diagnosis by Using Fault Codes) Procedure...655
MC Fault Code List...657
ECF Fault Code List...677
Monitor Controller (Monitor) Fault Code List...678
Monitor Controller (Information) Fault Code List...679
Air Conditioner Controller Fault Code List...682
Communication Terminal Fault Code List...683
MC Fault Codes 11000 to 11002...685
MC Fault Code 11003...686
ECF Fault Code 16603...686
MC Fault Codes 11006, 11007,11009...689
ECF Fault Code 16604...689
Monitor Controller (Monitor) Fault Codes 13002, 13003, 13005...689
CAN0 Harness Check...690
MC Fault Codes 11008, 11010...693
Monitor Controller (Monitor) Fault Codes 13004, 13006, 13007...693
CAN1 Harness Check...694
MC Fault Code 11101...697
MC Fault Codes 11200, 11202...698
MC Fault Codes 11301, 11302...699
MC Fault Code 11303...700
MC Fault Codes 11304, 11325...701
MC Fault Code 11405...702
MC Fault Code 11408...703
MC Fault Code 11428...704
MC Fault Code 11901...705
MC Fault Code 11940...706
MC Fault Code 11941...707
MC Fault Codes 11942, 11944...708
MC Fault Code 11945...709
MC Fault Code 11948...710
MC Fault Code 11950...711
MC Fault Code 11951...712
MC Fault Code 11953...713
MC Fault Codes 11955, 11956...714
MC Fault Codes 11978, 11979...715
MC Fault Code 11980...716
MC Fault Code 11989...717
MC Fault Codes 11995, 11997...718
MC Fault Code 11998...719
MC Fault Codes 20062...720
ECF Fault Codes 16600 to 16602...721
ECF Fault Code 16605...722
ECF Fault Code 16606...723
Air Conditioner Controller Fault Codes 11 to 22...724
Air Conditioner Controller Fault Codes 43 to 92...725
Monitor Controller (Information) Fault Codes 13304, 13310...726
Monitor Controller (Information) Fault Code 13311...727
Monitor Controller (Information) Fault Codes 20100 to 20114...728
Group 6 Troubleshooting B...729
Troubleshooting B (Machine Diagnosis by Using Troubleshooting Symptom) Procedure...729
Relationship Between Machine Trouble Symptoms and Related Parts...731
Correlation Between Trouble Symptoms and Part Failures...755
Engine System Troubleshooting...774
All Actuator System Troubleshooting...787
Front Attachment System Troubleshooting...792
Swing System Troubleshooting...805
Travel System Troubleshooting...808
Other System Troubleshooting...812
Exchange Inspection...819
How to Lowering Boom in Case of Emergencyand When Engine Stops...822
Group 7 Air Conditioner...823
Outline...823
Functions of Main Parts...826
Troubleshooting...831
Air Conditioner Controller Fault Code List...832
Air Conditioner Controller Fault Codes 11 to 22...833
Air Conditioner Controller Fault Codes 43 to 92...834
Work after Replacing Components...856
Refill Compressor Oil...857
Charge Air Conditioner with Refrigerant...858
Hose and Pipe Tightening Torque...866
SERVICE MANUAL REVISION REQUEST FORM...869
The Attached Diagram List...870
WJAC-EN-00 - Hitachi ZX470-5G, ZX470LC-5G, ZX470H-5G, ZX470LCH-5G, ZX470R -5G, ZX470LCR -5G Hydraulic Excavator Workshop Manual...871
WJAC-E-00...871
INTRODUCTION...873
SYMBOL AND ABBREVIATION...875
SAFETY...877
SECTION AND GROUP CONTENTS...919
SECTION 1 GENERAL...921
Group 1 Precautions for Disassembling and Assembling...923
Precautions for Disassembling and Assembling...923
Group 2 Tightening...929
Tightening Bolts and Nuts...929
Piping Joint...932
Group 3 Painting...937
Painting Specification...937
Final Painted Color...937
Group 4 Bleeding Air...939
Bleeding Air from Hydraulic Oil Tank...939
Bleeding Air from Hydraulic System...940
Bleeding Air from Fuel System...941
Bleeding Air from Radiator...942
Group 5 Pressure Release Procedure...943
Hydraulic Circuit Pressure Release Procedure...943
Group 6 Preparation...945
Preparation before Inspection and Maintenance...945
SECTION 2 MAINTENANCE STANDARD...949
Group 1 Upperstructure...951
Main Pump...951
Swing Motor...953
Group 2 Undercarriage...955
Travel Motor...955
Sprocket...956
Center Joint...957
Front Idler...959
Upper Roller...961
Lower Roller...962
Track...963
Group 3 Front Attachment...967
Remove and Install Bushing...967
Pin and Bushing...969
Side Cutter...971
Point...971
Standard Dimensions for Arm and Bucket Connection...972
Standard Dimensions for Arm and Boom Connection...974
Cylinder...975
SECTION 3 UPPERSTRUCTURE...979
Group 1 Cab...981
Removal and Installation of Cab...981
Dimensions of Cab Glass (Standard Cab)...997
Dimensions of Cab Glass (H Cab)...1016
Group 2 Counterweight...1019
Removal and Installation of Counterweight...1023
Group 3 Main Frame...1023
Removal and Installation of Main Frame...1023
Group 4 Engine...1031
Removal and Installation of Engine...1031
Group 5 Radiator Assembly...1073
Replacement of Radiator and Oil Cooler...1073
Group 6 Hydraulic Oil Tank...1097
Removal and Installation of Hydraulic Oil Tank...1097
Group 7 Fuel Tank...1115
Removal and Installation of Fuel Tank...1115
Group 8 Pump Device...1133
Removal and Installation of Pump Device...1133
Disassembly of Main Pump...1157
Assembly of Main Pump...1164
Disassembly of Regulator for Main Pump...1173
Assembly of Regulator for Main Pump...1175
Structure of Pilot Pump...1179
Structure of A Sensor...1181
Group 9 Control Valve...1183
Removal and Installation of Control Valve...1183
Disassembly and Assembly of Valve Unit...1209
Disassembly of Control Valve (4-Spool Side)...1215
Assembly of Control Valve (4-Spool Side)...1223
Disassembly of Control Valve (5-Spool Side)...1231
Assembly of Control Valve (5-Spool Side)...1238
Group 10 Swing Device...1245
Removal and Installation of Swing Device...1245
Disassembly of Swing Device...1249
Assembly of Swing Device...1255
Disassembly of Swing Motor...1261
Assembly of Swing Motor...1264
Group 11 Pilot Valve...1269
Removal and Installation of Pilot Valve (Left)...1269
Removal and Installation of Pilot Valve (Right)...1275
Removal and Installation of Travel Pilot Valve...1283
Disassembly of Pilot Valves (Right and Left)...1287
Assembly of Pilot Valves (Right and Left)...1290
Disassembly of Travel Pilot Valve...1293
Assembly of Travel Pilot Valve...1297
Group 12 Solenoid Valve...1303
Removal and Installation of Pilot Shut-Off Solenoid Valve...1303
Removal and Installation of 4-Spool Solenoid Valve Unit...1307
Removal and Installation of 2-Spool Solenoid Valve Unit...1311
Disassembly of Pilot Shut-Off Solenoid Valve...1315
Assembly of Pilot Shut-Off Solenoid Valve...1317
Structure of 4-Spool Solenoid Valve Unit...1319
Structure of 2-Spool Solenoid Valve Unit...1321
Group 13 Signal Control Valve...1323
Removal and Installation of Signal Control Valve...1323
Structure of Signal Control Valve...1329
Group 14 Shockless Valve...1331
Removal and Installation of Shockless Valve...1331
Structure of Shockless Valve...1333
SECTION 4 UNDERCARRIAGE...1337
Group 1 Swing Bearing...1339
Removal and Installation of Swing Bearing...1339
Disassembly of Swing Bearing...1343
Assembly of Swing Bearing...1346
Group 2 Travel Device...1349
Removal and Installation of Travel Device...1349
Disassembly of Travel Device...1353
Assembly of Travel Device...1360
Disassembly of Travel Motor...1369
Assembly of Travel Motor...1373
Disassembly of Brake Valve...1379
Assembly of Brake Valve...1382
Group 3 Center Joint...1387
Removal and Installation of Center Joint...1387
Disassembly of Center Joint...1391
Assembly of Center Joint...1393
Replacement of Body and Spindle...1396
Group 4 Track Adjuster...1397
Removal and Installation of Track Adjuster...1397
Disassembly of Track Adjuster...1399
Assembly of Track Adjuster...1404
Group 5 Front Idler...1409
Removal and Installation of Front Idler...1409
Disassembly of Front Idler...1411
Assembly of Front Idler...1414
Group 6 Upper and Lower Rollers...1419
Removal and Installation of Upper Roller...1419
Removal and Installation of Lower Roller...1423
Disassembly of Lower Roller...1427
Assembly of Lower Roller...1429
Group 7 Track...1435
Removal and Installation of Track...1435
SECTION 5 FRONT ATTACHMENT...1451
Group 1 Front Attachment...1453
Removal and Installation of Front Attachment...1453
Removal and Installation of Bushing...1461
Group 2 Cylinder...1463
Removal and Installation of Boom Cylinder...1463
Removal and Installation of Arm Cylinder...1467
Removal and Installation of Bucket Cylinder...1471
Disassembly of Boom Cylinder...1475
Assembly of Boom Cylinder...1478
Disassembly of Arm Cylinder...1481
Assembly of Arm Cylinder...1484
Disassembly of Bucket Cylinder...1487
Assembly of Bucket Cylinder...1490
SECTION 6 ENGINE AND ACCESSORY...1495
General Information...1497
General Repair Instruction...1497
Illustration Arrows...1498
Abbreviations Charts...1499
Nut and Bolt Angular Tightening Method...1500
Standard Bolt Torque Specifications...1502
Recommended Thread Locking Agents...1504
Main Data and Specification...1505
Performance Curve...1507
Engine External Drawing...1508
Service Standard...1509
Torque Specifications...1515
Special Tools...1523
Troubleshooting...1525
Lubricant Application...1535
Sealant Application...1535
Service Information...1537
Identification...1537
Lubrication System...1538
Fuel System...1538
Cooling System...1542
Valve Clearance Adjustment...1543
Compression Pressure Measurement...1545
Recommended Lubricants...1546
Engine Oil Viscosity Chart...1546
Engine Mechanical...1547
Service Precautions...1548
General Description...1548
Fan Center...1550
Turbocharger...1553
Exhaust Manifold...1555
Inlet Manifold...1556
Water Pump...1559
Alternator...1561
Oil Cooler...1564
Injection Pump...1566
Coupling Assembly...1570
Cylinder Head...1573
Rocker Arm and Shaft Assembly...1593
Camshaft...1598
Timing Gears...1603
Flywheel Housing...1612
Oil Pan...1615
Piston...1619
Crankshaft...1634
Crank Pulley...1645
Flywheel...1648
Cylinder Block...1650
Engine Cooling...1659
Service Precautions...1659
General Description...1660
Water Pump...1661
Thermostat...1666
Engine Fuel...1669
Service Precautions...1669
General Description...1670
Fuel Filter...1673
Injection Nozzle Holder...1675
Injection Pump...1681
Injection Nozzle Holder-Tow-Stage Injection Type...1685
Starting and Charging...1697
Service Precautions...1697
Alternator...1698
Starter Motor...1707
Engine Lubrication...1719
Service Precaution...1719
General Description...1720
Oil Pump...1722
Oil Cooler...1730
Engine Induction...1735
Service Precaution...1735
Turbocharger...1736
SERVICE MANUAL REVISION REQUEST FORM...1747
Hitachi ZX470-5G, ZX470LC-5G, ZX470H-5G, ZX470LCH-5G, ZX470R-5G, ZX470LCR-5G Excavator Factory Service & Shop Manual