Technical Manual Hitachi ZX17U-6, ZX19U-6 Excavator | TABK50-EN-01

Technical Manual Hitachi ZX17U-6, ZX19U-6 Excavator TABK50-EN-01 (Preview)

TABK50-EN-01
INTRODUCTION
To The Reader
Additional References
Manual Composition
Page Number
Trademark
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
Keep Riders off Machine
Precautions for Operations
Investigate Job Site Beforehand
Install OPG
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
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
Handle Chemical Products Safely
Dispose of Waste Properly
Never Ride Attachment
Precautions for Communication Terminal
Before Returning the Machine to the Customer
SECTION AND GROUP CONTENTS
CONTENTS
GENERAL
Specifications
Specifications of ZX17U-6
Specifications of ZX19U-6
Working Ranges of ZX17U-6
Working Ranges of ZX19U-6
Component Layout
Main Component
Electrical System (Overview)
Electrical System (Relays)
Electrical System (Monitor, Switches)
Engine
Swing Device
Travel Device
Control Valve
2-Spool Solenoid Valve Unit
Port Layout of Control Valve (Main Circuit)
Port Layout of Control Valve (Pilot Circuit)
FLOOR HARNESS
Main Harness
Light Harness (LED)
Solenoid Harness
Component Specifications
Specifications of Engine
Specifications of Engine Accessories
Specifications of Hydraulic Component
Specifications of Electrical Component
SYSTEM
Hydraulic System
Outline of Hydraulic System
Pilot Circuit of Hydraulic System
Operation Control Circuit
Travel Motor Displacement Angle Control Circuit
Swing Parking Brake Release Circuit
Main Circuit of Hydraulic System
Neutral Circuit
Flow Combiner Circuit
Relief Circuit
Single Operation Circuit
Combined Operation Circuit
Electrical System
Outline of Electrical System
Main Circuit of Electrical System
Electric Power Circuit (Key Switch: OFF)
Electric Power Circuit (Key Switch: ON)
Preheating Circuit (Key Switch: HEAT)
Starting Circuit (Key Switch: START)
Charging Circuit (Key Switch: ON)
Alternator Operation
Regulator Operation
Pilot Shut-Off Circuit (Key Switch: ON)
Engine Stop Circuit (Key Switch: OFF)
Monitor Circuit of Electrical System
Indicator Circuit (Except Preheat Indicator)
Indicator Circuit (Preheat Indicator)
Work Light and Monitor Internal Light Circuit
Instrument Circuit
Fuel Gauge
Hour meter
Coolant Temperature Indicator
COMPONENT OPERATION
Pump device
Outline of Pump Device
Outline of Main Pump P1 and Main Pump P2
Outline of Main Pump P3 and Pilot Pump
Output Power Control Operation
Swing Device
Outline of Swing Device
Outline of Swing Motor
Operation of Swing Motor
Outline of Swing Parking Brake
When Brake is Released of Swing Parking Brake
When Brake is Applied of Swing Parking Brake
Outline of Valve Unit
Operation of Make-Up Valve
Outline of Swing Relief Valve
Operation of Swing Relief Valve
Control Valve
Outline of Control Valve
Components in Control Valve
Hydraulic Circuit of Control Valve
Outline of Flow Combiner Valve
Outline of Main Relief Valve
Operation of Main Relief Valve
Outline of Overload Relief Valve
Relief Operation of Overload Relief Valve
Make-Up Operation of Overload Relief Valve
Operation of Make-Up Valve
Pilot Valve
Outline of Pilot Valve
Outline of Front Attachment/Swing Pilot Valve
Outline of Travel Pilot Valve
Outline of Boom Swing and Auxiliary Pilot Valves
Outline of Blade Pilot Valve
Operation of Front Attachment/Swing and Travel Pilot Valves
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 Valve (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
Travel Device
Outline of Travel Device
Outline of Travel Reduction Gear
Outline of Travel Motor
Operation of Travel Motor
Outline of Parking Brake
When Parking Brake is Released
When Parking Brake is Operated
Outline of Travel Brake Valve
Operation of Counterbalance Valve (During Travel)
Operation of Counterbalance Valve (When Descending a Slope)
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
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 (ZX17U-6)
Front Attachment System Performance Standards (ZX19U-6)
Lever System Performance Standards
Combined Operation System Performance Standards (ZX17U-6)
Combined Operation System Performance Standards (ZX19U-6)
Component System Performance Standards
Main Pump P1 and Main Pump P2 P-Q Diagram
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
Adjustment
Engine Control Lever Adjustment
TROUBLESHOOTING
Diagnosing Procedure
Introduction
Diagnosis Procedure
Electrical System Inspection
Precautions for Inspection and Maintenance
Instructions for Disconnecting Connectors
Instructions for Removing Relays
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
Removal of Monitor Controller
Installation of Monitor Controller
Mounting Position of Coolant Temperature Sensor
Mounting Position of Fuel Sensor
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 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 preheated.)
A-1 All actuator speeds are slow and power is weak. (Other than side frame extend/retract)
A-2 All actuators do not work. (Other than side frame extend/retract)
A-3 Actuator does not stop even if control lever is set to neutral. (Other than side frame extend/retract)
A-4 Actuator does not stop even if control lever is set to neutral. (Amount of drift is large) (Other than side frame extend/retract)
A-5 Boom raise speed is slow or power is weak during combined operation of front attachment and boom raise.
F-1 All front attachment actuator power are weak.
F-2 Some cylinders are not operated or speeds are slow.
F-3 Front attachment drifts remarkably.
F-4 When boom raise or arm roll-out is operated, boom or arm starts to move after moving slightly down.
F-5 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 is not 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.
SF-1 Side frame is not operated or moves slowly.
How to Lowering Boom in Case of Emergency and When Engine Stops
Troubleshooting C
Troubleshooting C (Monitor Diagnosis) Procedure
Contents of Troubleshooting C
The buzzer continues to sound even when the engine oil pressure indicator or overheat indicator goes OFF with the engine running.
The buzzer continues to sound even when the engine oil pressure indicator or overheat indicator goes OFF with the engine oil.
Malfunction of Coolant Temperature Indicator
The coolant temperature indicator is turned off.
The coolant temperature indicator does not light up.
Malfunction of Fuel Gauge
Even when fuel is sufficient, all segments in the fuel gauge do not light.
Even when fuel is reduced, all segments in the fuel gauge light.
The segments in fuel gauge unstably light.
The hour meter does not count with the engine running.
The hour meter counts operation hours while the key switch is ON (the engine is stopped.)
Indicator Operation Check
Even when the fuel tank is empty, the indicator does not light.
Even when fuel is sufficient, the indicator light.
Even when the engine overheats, the indicator does not light.
Even when coolant temperature is low, the indicator light.
Even when the engine oil pressure is insufficient, the indicator does not light.
Even when the engine runs, the indicator is not turned OFF.
Even when the engine runs, the alternator indicator is not turned OFF.
Even when charging is low, the alternator indicator does not light.
Malfunction of Preheat Indicator
SERVICE MANUAL REVISION REQUEST FORM
The Attached Diagram List