Technical Manual Hitachi ZX60USB-5N Excavator | TAFC60-EN-01 (2023.12.26)

Technical Manual Hitachi ZX60USB-5N Excavator TAFC60-EN-01 (2023.12.26) (Preview)

TAFC60-EN-01
INTRODUCTION
To The Reader
Additional References
Manual Composition
Page Number
Safety Alert Symbol and Headline Notations
Units Used
SYMBOL AND ABBREVIATION
Symbols and abbreviations
CONTRASTING LIST OF PART NAME
Contrasting List of Part Name between Technical Manual and Parts Catalog
SAFETY
Recognize Safety Information
Understand Signal Words
Follow Safety Instructions
Prepare for Emergencies
Wear Appropriate Clothing
Protect Against Noise
Inspect Machine
General Precautions for the Cab
Use Handholds and Steps
Adjust the Operator’s Seat
Ensure Safety Before Leaving or Standing up from Operator’s Seat
Fasten Your Seat Belt
Move and Operate Machine Safely
Operate Only from Operator’s Seat
Jump Starting
Checking Battery Level and Supplementary Charging
Keep Riders off Machine
Precautions for Operations
Investigate Job Site Beforehand
Install OPG (Operator Protective 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 People Clear from Working Area
Never Position the Bucket Over Anyone
Avoid Undercutting
Avoid Tipping
Never Undercut a High Bank
Dig with Caution
Operate with Caution
Avoid Power Lines
Precautions for Lightning
Lifting Application
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
Hot spraying fluids:
Replace Rubber Hoses Periodically
Avoid High-Pressure Fluids
Prevent Fires
Check for Oil Leaks:
Check for Shorts:
Clean up Flammable Materials:
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
Warnings about the Muffler Filter
Muffler Filter
Warnings about the ECU (Engine Control Unit)
ECU (Engine Control Unit)
Precautions for Communication Terminal
Precautions for Communication Terminal Equipment
Compliance with FCC and IC Rules and Regulations (USA and Canada)
Precautions about Operator’s Seat Protections when Overturned (4-pillar Canopy or Cab Models)
Before Returning the Machine to the Customer
SECTION AND GROUP CONTENTS
CONTENTS
GENERAL
Specifications
Specifications of ZX60USB-5N
Working Ranges of ZX60USB-5N
Component Layout
Main Component
Electrical System (Overview)
Electrical System (Relays)
Electrical System (Relays) (Air Conditioner)
Electrical System (Monitor, Switches)
Electrical System (Battery Chamber)
Engine
Muffler Filter
Swing Device
Travel Device
Revolution Sensing Valve
Pilot Filter
Auxiliary Flow Rate Selector Valve (Option)
Blade Float Solenoid Valve (Only Machine with Blade Float Attached)
Quick Coupler Solenoid Valve (Only Machine with Air Conditioner (Option) Attached)
AUX Function Solenoid Valve
Control Valve
2-Spool Solenoid Valve Unit
Port Layout of Control Valve (Main Circuit)
Port Layout of Control Valve (Pilot Circuit)
Floor Harness (Up to Serial No. 297534)
Floor Harness (Serial No. 297535 and Up)
Main Wire Harness (Up to Serial No. 297534)
Main Wire Harness (Serial No. 297535 and Up)
Light Harness (Halogen) (Up to Serial No. 297534)
Light Harness (LED) (Serial No. 297535 and Up)
Air Conditioner Floor Harness
Auto Shut-Down Harness (Up to Serial No. 297534)
Quick Coupler Harness (Serial No. 297535 and Up)
Angle Blade Harness (Serial No. 297535 and Up)
Blade Float Harness (Serial No. 297535 and Up)
Component Specifications
Specifications of Engine
Specifications of Engine Accessories
Specifications of Hydraulic Component
Specifications of Electrical Component
SYSTEM
Control System
Outline of Control System
Engine Control
Fuel Injection Control
Fuel Injection Amount Control
Fuel Injection Timing Control
Fuel Injection Rate Control
Fuel Injection Pressure Control
Engine Control Dial Control
Auto-Idle Control
Idle Speed-Up Control
ECO Mode Control
EGR Control
Starter Restraining Control
Preheating Control
Outline of Muffler Filter
Operation of Muffler Filter
Muffler Filter Regeneration Control
Pump Control
LS Cut Control (ZX50U-5N: Up to Serial No. 300172, ZX60USB-5N: Up to Serial No. 297534)
Power Decrease Control (Only Machine with Air Conditioner)
Valve control
Auxiliary Flow Rate Selection Control (Option)
AUX Function Lever (AFL) Control
Blade Float Control (ZX50U-5N: Serial No. 300173 and Up, ZX60USB-5N: Serial No. 297535 and Up)
Quick Coupler Control (Option) (ZX50U-5N: Serial No. 300173 and up, ZX60USB-5N: Serial No. 297535 and up)
Other Control
Travel Alarm Control
Interlock Control
Hydraulic System
Outline of Hydraulic System
Pilot Circuit of Hydraulic System
Operation Control Circuit
Pump Control Circuit (Flow Rate Control Circuit)
Travel Motor Displacement Angle Control Circuit
Swing Parking Brake Release Circuit
Neutral Circuit (When Control Lever in Neutral)
Single Operation Control Circuit (Other Than Boom Operation)
Single Operation Circuit (Boom Raise Operation)
Single Operation Circuit (Boom Lower Operation)
Combined Operation Circuit (Combined Operation of Swing and Boom Raise)
Operation of Differential Reducing Valve (Hydraulic System)
Operation of Pressure Compensator (Hydraulic System)
Electrical System
Outline of Electrical System
Main Circuit of Electrical System
Electric Power Circuit (Key Switch: OFF)
CAN Circuit
Electric Power Circuit (Key Switch: ON)
Preheating Circuit (Key Switch: ON)
Starting Circuit (Key Switch: START)
Charging Circuit (Key Switch: ON)
Pilot Shut-Off Circuit (Key Switch: ON)
Engine Stop Circuit (Key Switch: OFF)
Auto Shut-Down Circuit
COMPONENT OPERATION
Pump device
Outline of Pump Device
Components in Pump Device
Outline of Main Pump P1
Increasing and Decreasing Flow Rate of Main Pump
Outline of Regulator
Flow Rate Control
Flow Rate Control by Signal Pressure (Delivery Flow Rate of Main Pump is Minimum When the Control Lever is in Neutral)
Flow Rate Control by Signal Pressure (Delivery Flow Rate of Main Pump Increases)
Flow Rate Control by Signal Pressure (Delivery Flow Rate of Main Pump Decreases)
LS Cut Control (Pump Device) (Up to Serial No. 297534)
Flow Rate Control by Own Pump Pressure
Outline of Revolution Sensing Valve
Outline of Revolution Sensing Valve
Component in Revolution Sensing Valve
Operation of Revolution Sensing Valve (When Engine Stops)
Operation of Revolution Sensing Valve (While Engine is Running (Output Curve: A to B)
Operation of Revolution Sensing Valve (While Engine is Running (Output Curve: B to C))
Swing Device
Outline of Swing Device
Outline of Swing Reduction Gear
Outline of Swing Motor
Outline of Swing Parking Brake
Operation of Swing Parking Brake (When Brake is Released)
Operation of Swing Parking Brake (When Brake is Applied)
Outline of Valve Unit
Operation of Make-Up Valve
Outline of Swing Relief Valve
Low-Pressure Relief Operation (Shockless Function) of Swing Relief Valve
High-Pressure Relief Operation (Overload Prevention) of Swing Relief Valve
Relief Operation of Swing Relief Valve (Piston Quick Return)
Control Valve
Outline of Control Valve (Up to Serial No. 294685)
Components in Control Valve (Up to Serial No. 294685)
Outline of Control Valve (From Serial No. 294686 to Serial No. 297534)
Components in Control Valve (From Serial No. 294686 to Serial No. 297534)
Outline of Control Valve (Serial No. 297535 and Up)
Components in Control Valve (Serial No. 297535 and Up)
Main Circuit of Control Valve
Pilot Operation Control Circuit of Control Valve
Outline of Main Relief Valve
Operation of Main Relief Valve
Pressure Increasing Operation of Main Relief Valve
Outline of Overload Relief Valve (With Make-Up Function)
Relief Operation of Overload Relief Valve
Make-Up Operation of Overload Relief Valve
Outline of Make-Up Valve
Operation of Make-Up Valve
Outline of Boom Anti-Drift Valve
Operation of Boom Anti-Drift Valve (When Boom Spool is in Neutral)
Operation of Boom Anti-Drift Valve (When Operating Boom Raise)
Operation of Boom Anti-Drift Valve (When Operating Boom Lower)
Flow Rate Control Circuit of Control Valve
Outline of Unload Valve
Operation of Unload Valve (Neutral State)
Operation of Unload Valve (When Pressure P1 Increases)
Outline of Differential Reducing Valve
Operation of Differential Reducing Valve (When the Force to Push to the Left is Stronger)
Operation of Differential Reducing Valve (When the Force to Push to the Left is Weaker)
Outline of Pressure Compensator
Operation of Pressure Compensator (When the Differential Pressure between Pressure PIN and Pressure PL is Higher Than Pressure PLS)
Operation of Pressure Compensator (When the Differential Pressure between Pressure PIN and Pressure PL is Lower Than Pressure PLS)
Pilot Valve
Outline of Pilot Valve
Outline of Front Attachment/Swing Pilot Valve
Outline of Travel Pilot Valve
Outline of Boom Swing, Blade and Auxiliary Pilot Valves
Operation of Front Attachment/Swing and Travel Pilot Valve
When Front Attachment/Swing and Travel Pilot Valves are in Neutral (Output Curve: A to B)
During Metering or Decompressing of Front Attachment/Swing and Travel Pilot Valves (Output Curve: C to D)
Full Stroke of Travel Pilot Valve (Output Curve: E to F)
Operation of Boom Swing, Blade and Auxiliary Pilot Valves
When Boom Swing, Blade and Auxiliary Pilot Valves in Neutral (Output Curve: A to B)
During Metering or Decompressing of Boom Swing, Blade and Auxiliary Pilot Valves (Output Curve: C to D)
Outline of Shockless Function (Only Travel Pilot Valve)
Operation of Shockless Function
Outline of Shuttle Valve
Travel Device
Outline of Travel Device
Outline of Travel Reduction Gear
Outline of Travel Motor
Operation of Travel Motor
Outline of Parking Brake
Operation of Parking Brake (When Brake is Released)
Operation of Parking Brake (When Brake is Applied)
Outline of Travel Brake Valve
Operation of Counterbalance Valve (During Travel)
Operation of Counterbalance Valve (When Descending a Slope)
Outine of Anti-Cavitation Valve
Operation of Anti-Cavitation Valve (During Travel)
Operation of Anti-Cavitation Valve (When Traveling is Stopped)
Operation of Travel Mode Selector Valve (Slow Speed Operation)
Operation of Travel Mode Selector Valve (Fast Speed Operation)
Operation of Travel Mode Selector Valve (When Engine Stops)
Auto Swash Angle Control
Others (Upperstructure)
Outline of 2-Spool Solenoid Valve Unit
Operation of Pilot Shut-Off Solenoid Valve (Pilot Shut-Off Lever: LOCK Position)
Operation of Pilot Shut-Off Solenoid Valve (Pilot Shut-Off Lever: UNLOCK Position)
Operation of Travel Mode Selector Solenoid Valve (Slow Speed Position)
Operation of Travel Mode Selector Solenoid Valve (Fast Speed Position)
Operation of Pilot Relief Valve
Outline of Operate Check Valve (Up to Serial No. 294685)
Operation of Operate Check Valve (Up to Serial No. 294685)
Outline of Back Pressure Valve
Outline of Slow Return Valve
Outline of LS Cut Solenoid Valve (ZX50U-5N: Up to Serial No. 300172, ZX60USB-5N: Up to Serial No. 297534)
Operation of LS Cut Solenoid Valve (During Muffler Filter Regeneration) (ZX50U-5N: Up to Serial No. 300172, ZX60USB-5N: Up to Serial No. 297534)
Operation of LS Cut Solenoid Valve (Normal Operation) (ZX50U-5N: Up to Serial No. 300172, ZX60USB-5N: Up to Serial No. 297534)
Outline of Quick Coupler Solenoid Valve (Only for Quick Coupler (Option) Models) (ZX50U-5N: Serial No. 300173 and Up, ZX60USB-5N: Serial No. 297535 and Up)
Operation of Quick Coupler Solenoid Valve (Only for Quick Coupler (Option) Models) (When in Neutral) (ZX50U-5N: Serial No. 300173 and Up, ZX60USB-5N: Serial No. 297535 and Up)
Operation of Quick Coupler Solenoid Valve (Only for Quick Coupler (Option) Models) (When Excited) (ZX50U-5N: Serial No. 300173 and Up, ZX60USB-5N: Serial No. 297535 and Up)
Outline of Blade Float Solenoid Valve (Only for Blade Float Models) (ZX50U-5N: Serial No. 300173 and Up, ZX60USB-5N: Serial No. 297535 and Up)
Operation of Blade Float Solenoid Valve (Only for Blade Float Models) (When in Neutral) (ZX50U-5N: Serial No. 300173 and Up, ZX60USB-5N: Serial No. 297535 and Up)
Operation of Blade Float Solenoid Valve (Only for Blade Float Models) (When Excited) (ZX50U-5N: Serial No. 300173 and Up, ZX60USB-5N: Serial No. 297535 and Up)
Others (Undercarriage)
Outline of Swing Bearing
Outline of Center Joint
Outline of Track Adjuster
OPERATIONAL PERFORMANCE TEST
Performance Test
Operational Performance Tests
Preparation for Performance Tests
Standard
Operational Performance Standard Table
Engine System Performance Standards
Travel System Performance Standards
Swing System Performance Standards
Front Attachment System Performance Standards
Lever System Performance Standards
Combined Operation System Performance Standards
Hydraulic Component Performance Standards
Main Pump P-Q Diagram
Engine Control Dial Activating Range
Low Pressure Sensor Activating Range
Engine Test
Engine Speed
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
Clearance of Front Attachment Connecting Part
Component Test
Primary Pilot Pressure
Secondary Pilot Pressure
Main relief set pressure
Relief Pressure (When Relieving Swing)
Overload Relief Valve Set Pressure
Pump Driving Torque
Swing Motor Drainage
Travel Motor Drainage
Revolution Sensing Valve Output Pressure (Pressure PGR)
Pump Delivery Pressure
Adjustment
Rewrite of Muffler Filter Serial No.
Maintenance of Muffler Filter
TROUBLESHOOTING
Diagnosing Procedure
Introduction
Diagnosis Procedure
Electrical System Inspection
Precautions for Inspection and Maintenance
Instructions for Disconnecting Connectors
Fuse Inspection
Fuse Connection Destination
Slow Blow Fuse Inspection
Battery Voltage Check
Alternator Check
Continuity Check
Voltage Inspection Method
Voltage and Current Measurement of 5-Volt Circuit
Check by False Signal
Removal of Monitor Controller
Installation of Monitor Controller
Removal of ECU
Installation of ECU
Mounting Position of Fuel Sensor
Mounting Position of Auto-Idle Pressure Sensor
Monitor
Basic Screen of Monitor
Operating Procedures of Service Menu
How to Display Service Menu
Monitoring
Monitoring List
Setting
List of Setting Items
Issued Warning Record
List of Alarm
Engine Fault Code List
Inspection of Fuel Gauge, Battery Voltage, Hour Meter, and Destination Number
Fuel Gauge
Coolant Temperature Gauge
Factory Setting
e-Service
Overview of e-Service
List of Operation Data
Communication System
Troubleshooting A
Troubleshooting A (Base Machine Diagnosis By Using Fault Codes) Procedure
Contents of Troubleshooting A
Fault Code List
Fault Code W: 1304
Fault Code W: 1310, *W: 6301
Fault Code W: 2312, W: 2315, W: 2318, W: 2321
Fault Code W: 2313, W: 2316, W: 2319, W: 2322
Fault Code W: 2304
Fault Code W: 2307
Troubleshooting B
Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure
Contents of Troubleshooting B
Identification Symbol of Troubleshooting B
E-1 Starter does not rotate.
E-2 Even if starter rotates, engine does not start.
E-3 Auto-idle system is faulty.
E-4 Engine is difficult to start at low temperature. (During cold weather or in cold districts, engine is difficult to start or does not start even if pre-heated.)
E-5 ECO mode is faulty.
A-1 All actuator speeds are slow or power is weak.
A-2 All actuators do not work.
A-3 Actuator does not stop even if control lever is set to neutral.
A-4 Actuator does not stop even if control lever is set to neutral. (Amount of drift is large.)
A-5 Auto or manual regeneration of muffler filter cannot be performed.
F-1 All front attachment actuator power are weak.
F-2 Some cylinders are not operated or speeds are slow.
F-3 Only boom is not operated or its speed is slow.
F-4 Front attachment drifts remarkably.
F-5 When boom raise or arm roll-out is operated, boom or arm starts to move after moving slightly down.
F-6 Boom swing is not operated or moves slowly.
S-1 Swing speed is slow or is not operated.
S-2 Swing drifts remarkably when swinging is stopped.
T-1 Machine does not travel, travel slowly, or power is weak.
T-2 Fast travel can not be selected. Travel mode does not change from slow speed mode to fast speed mode.
T-3 Slow travel cannot be selected. Travel mode does not change from fast mode to slow mode.
T-4 One side travel is not operated or travel speed is slow. Machine mistracks.
BL-1 Blade is not operated or moves slowly.
How to Lower Boom in Case of Emergency and When Engine Stops
Air Conditioner
Outline of Air Conditioner
Troubleshooting of Air Conditioner
Faulty cooling
Air conditioner is not operated. Air conditioner control panel does not light at all.
Air vent air temperature control is impossible.
Compressor clutch is not turned ON.
Blower motor does not rotate.
Air flow volume is not shifted. (Air flow volume at all stages are the same.)
Air flow volume is changed into only two stages
Air flow volume is changed into only three stages
Air vent cannot be shifted.
Air vent selection is impossible.
Work after Replacing Components
Necessity of Purging
Procedures for charging air conditioner with refrigerant
Warm-up Operation
AIR CONDITIONER TROUBLE REPORT
SERVICE MANUAL REVISION REQUEST FORM
The Attached Diagram List