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

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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.

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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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