Hitachi Zx470 hướng dẫn sửa chữa

4705G 470LC5G 470H5G 470LCH5G 470R5G 470LCR5G 4705G 470LC5G 470H5G 470LCH5G 470R5G 470LCR5G Hitachi Zx470 hướng dẫn sửa chữaHitachi Zx470 hướng dẫn sửa chữaHitachi Zx470 hướng dẫn sửa chữaHitachi Zx470 hướng dẫn sửa chữaHitachi Zx470 hướng dẫn sửa chữaHitachi Zx470 hướng dẫn sửa chữaHitachi Zx470 hướng dẫn sửa chữav

PART NO ZX470-5G • 470LC-5G • 470H-5G • 470LCH-5G • 470R-5G • 470LCR-5G HYDRAULIC EXCAVATOR WORKSHOP MANUAL URL:http://www.hitachi-c-m.com WJAC-EN-00 Workshop Manual ZX 470-5G 470LC-5G 470H-5G 470LCH-5G 470R-5G 470LCR-5G Hydraulic Excavator WJAC-EN-00 PRINTED IN JAPAN (K) 2012, 02 Service Manual consists of the following separate Part No Technical Manual (Operational Principle) : Vol No.TOJAC-EN Technical Manual (Troubleshooting) : Vol No.TTJAC-EN Workshop Manual : Vol No.WJAC-EN INTRODUCTION To The Reader This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine  If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual (Note: Do not tear off the form Copy it for usage.):  Publications Marketing & Product Support Hitachi Construction Machinery Co Ltd  TEL: 81-29-832-7084  FAX: 81-29-831-1162  E-mail: dc@hitachi-kenki.com  Be sure to thoroughly read this manual for correct product information and service procedures Additional References Please refer to the other materials (operator’s manual, parts catalog, engine technical material and Hitachi training material etc.) in addition to this manual Manual Composition  Information included in the Workshop Manual: Technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and assemble / disassemble procedures This manual consists the Technical Manual, the Workshop Manual and the Engine Manual  Information included in the Technical Manual: Technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures  Information included in the Engine Manual: Technical information needed for redelivery and delivery and maintenance and repair of the machine, operation and activation of all devices and systems, troubleshooting and assemble / disassemble procedures Page Number Each page has a number, located on the center lower part of the page, and each number contains the following information: Example:  Technical Manual: T 1-3-5 T  Workshop Manual: W 1-3-2-5 W Technical Manual Section Number Group Number Consecutive Page Number for Each Group IN-01 Workshop Manual Section Number Group Number Sub Group Number Consecutive Page Number for Each Group INTRODUCTION Safety Alert Symbol and Headline Notations In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage d CAUTION: Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death d This is the safety alert symbol When you see this IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine symbol, be alert to the potential for personal injury Never fail to follow the safety instructions prescribed along with the safety alert symbol The safety alert symbol is also used to draw attention to component/part weights To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts f NOTE: Indicates supplementary technical information or knowhow Units Used Example: 24.5 MPa (250 kgf/cm2, 3560 psi) SI Units (International System of Units) are used in this manual MKSA system units and English units are also indicated in parentheses just behind SI units A table for conversion from SI units to other system units is shown below for reference purposes Quantity To Convert From Into Multiply By Length mm in 0.03937 mm ft 0.003281 L US gal 0.2642 L US qt 1.057 m3 yd3 1.308 Weight kg lb 2.205 Force N kgf 0.10197 N lbf 0.2248 Torque N·m kgf·m Pressure MPa kgf/cm MPa psi 145.0 kW PS 1.360 kW HP 1.341 Temperature °C °F °C×1.8+32 Velocity km/h mph 0.6214 rpm 1.0 L/min US gpm 0.2642 mL/rev cc/rev 1.0 Volume Power Flow rate -1 fNOTE: The numerical value in this manual might be different from the above-mentioned table IN-02 0.10197 10.197 SYMBOL AND ABBREVIATION Symbol / Abbreviation TO TT T/M W, W/M MC ECM VGS GSM GPS CAN A/C OP, OPT MPDr A/I WU Li ATT HI, Hi LO, Lo Name Explanation Technical manual (Operational principle) Technical manual (Troubleshooting) Technical manual Workshop manual Technical manual (Operational Principle) Technical manual (Troubleshooting) Technical manual Workshop manual (Removal and Installation, Disassembly and Assembly) Main Controller Main controller MC controls the engine, pump, and valve according to the machine operating condition Engine Control Module Engine controller ECM controls fuel injection amount according to the machine operating condition Variable Geometry System controller Variable turbo controller VGS is an exhaust turbo charged system to supercharge the exhaust energy while running the engine at slow idle speed VGS optimizes the turbine rotation, improves the performance at slow-speed torque and the acceleration, reduces fuel consumption, and reduces particulate matter (PM) by adjusting the nozzle opening of turbine housing Global System for Mobile communications Communication controller GSM is a type of wireless controller communication system, is used in more than on 100 countries around Europe and Asia, and becomes the factual global standards of the mobile telephone Global Positioning System Global positioning system Controller Area Network CAN communication CAN is a serial communications protocol internationally-standardized by ISO (International Organization for Standardization) Air Conditioner Air conditioner Option Optional component Maintenance Pro Dr MPDr is software that troubleshooting, monitoring, and adjustment Auto-Idle Auto-idle Warming-Up Warming-up Low (Slow) Idle Slow idle engine speed Attachment Attachment Attachment is optional parts such as breaker, crusher, and pulverizer in this manual High Travel fast position Low Travel slow position SY-1 SYMBOL AND ABBREVIATION Symbol / Name Abbreviation DPF Diesel Particulate Filter DPD Diesel Particulate Diffuser DOC Diesel Oxidation Catalyst CSF Catalyzed Soot Filter PM EGR Particulate Matter Exhaust Gas Recirculation Explanation DPF is a filter which removes particulate matter (PM) including the toxic substance of exhaust gas of the diesel engine Exhaust particulate removal equipment DPD is an exhaust emission control system, a type of DPF, which cleans up particulate matter (PM) of diesel engine exhaust gas DPD is a ceramic filter which traps and filters PM of exhaust gas DPD burns up accumulated PM when PM increases and regenerates the filter Oxidation catalyst for the diesel engine Diesel oxidation catalyst oxidizes unburnt fuel and raises exhaust temperature Filter The filter traps, burns, and remove particulate matter (PM) by using high-temperature-exhaust gas with diesel oxidation catalyst Catalyst is applied onto the filter This advances PM burning Particulate matter The EGR control re-circulates a part of exhaust gas in the intake manifold and combines it with intake-air Therefore, combustion temperature is lowered and generation of oxide of nitrogen (NOx) is controlled SY-2 SAFETY Recognize Safety Information  These are the SAFETY ALERT SYMBOLS  When you see these symbols on your machine or in this manual, be alert to the potential for personal injury  Follow recommended precautions and safe operating practices SA-688 Understand Signal Words  On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol  DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury  WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury  CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury  DANGER or WARNING safety signs are located near specific hazards General precautions are listed on CAUTION safety signs  Some safety signs not use any of the designated signal words above after the safety alert symbol are occasionally used on this machine  CAUTION also calls attention to safety message in this manual  To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine  NOTE: indicates an additional explanation for an element of information SA-1 SA-1223 SAFETY Follow Safety Instructions  Carefully read and follow all safety signs on the machine and all safety messages in the operator's manual  Safety signs should be installed, maintained and replaced when necessary  If a safety sign or the operator's manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering)  Learn how to operate the machine and its controls correctly and safely  Allow only trained, qualified, authorized personnel to operate the machine  Keep your machine in proper working condition  Unauthorized modifications of the machine may impair its function and/or safety and affect machine life  Do not modify any machine parts without authorization Failure to so may deteriorate the part safety, function, and/or service life In addition, personal accident, machine trouble, and/or damage to material caused by unauthorized modifications will void Hitachi Warranty Policy  Do not use attachments and/or optional parts or equipment not authorized by Hitachi Failure to so may deteriorate the safety, function, and/or service life of the machine In addition, personal accident, machine trouble, and/or damage to material caused by using unauthorized attachments and/or optional parts or equipment will void Hitachi Warranty Policy  The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines However it is impossible for these safety messages to cover every hazardous situation you may encounter If you have any questions, you should first consult your supervisor and/ or your authorized dealer before operating or performing maintenance work on the machine SA-2 SA-003 SAFETY Prepare for Emergencies  Be prepared if a fire starts or if an accident occurs  Keep a first aid kit and fire extinguisher on hand  Thoroughly read and understand the label attached on the fire extinguisher to use it properly  To ensure that a fire extinguisher can be always used when necessary, check and service the fire extinguisher at the recommended intervals as specified in the fire extinguisher manual  Establish emergency procedure guidelines to cope with fires and accidents  Keep emergency numbers for doctors, ambulance service, hospital, and fire department posted near your telephone SA-437 Wear Protective Clothing  Wear close fitting clothing and safety equipment appropriate to the job You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask Be sure to wear the correct equipment and clothing for the job Do not take any chances  Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine  Operating equipment safely requires the full attention of the operator Do not wear radio or music headphones while operating the machine SA-3 SA-438 SAFETY Protect Against Noise  Prolonged exposure to loud noise can cause impairment or loss of hearing  Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises SA-434 Inspect Machine  Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury  In the walk-around inspection be sure to cover all points described in the "Inspect Machine Daily Before Starting" section in the operator’s manual SA-435 SA-4 69697_ESS-172A_SEC6G 2011.8.2 3:54 PM ページ 16 MEMO 69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ ENGINE INDUCTION 6J–1 ENGINE INDUCTION CONTENTS Service Precaution 6J-1 Turbocharger 6J-2 General Description 6J-2 Service precaution CAUTION: Always use the correct fastener in the proper location When you replace a fastener, use ONLY the exact part number for that application ISUZU will call out those fasteners that require a replacement after removal ISUZU will also call out the fasteners that require thread lockers or thread sealant UNLESS OTHERWISE SPECIFIED, not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener When you install fasteners, use the correct tightening sequence and specifications Following these instructions can help you avoid damage to parts and systems Disassembly 6J-4 Inspection and Repair 6J-5 Reassembly 6J-7 69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ 6J–2 ENGINE INDUCTION Turbocharger General Description 037EY00003 Major turbocharger components consist of the Center Housing and Rotating Assembly (CHRA), the compressor housing, and the turbine housing Rotating parts include the turbine shaft, the compressor wheel, the shaft bearings, the thrust bearings and the oil seal ring There parts are supported by the center housing The turbocharger increases air intake efficiency, the results in increased engine power, reduced fuel consumption and minimal engine noise Turbocharger rotating parts operate at very high speeds and temperatures The parts materials have been carefully selected and machined to extremely high precision 69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ ENGINE INDUCTION Identification 6J–3 Turbocharger Servicing The turbocharger name plate gives the date of manufacturer and other important information required to identify the unit when service inquiries are made The turbocharger name plate has the following information stamped on it Refer to the illustration (1) Turbocharger specification, production year and production month Example: VIBU (2) Production date, serial number and production line name Example: RHC92 (3) Part number assigned is ISUZU MOTORS LIMITED Example: 1144003281 Part numbers (3) indicate specific designs or configurations Refer to TROUBLESHOOTING in this Manual to determine whether or not turbocharger repair or overhaul is required The following procedures should also be performed (either with the turbocharger on the equipment or removed form the equipment but not disassembled) to determine whether or not turbocharger repair or overhaul is required * Visual checks * Clearance measurements * End play measurements Refer to INSPECTION AND REPAIR The turbocharger compressor and turbine housing may be removed from the center housing and rotating assembly (CHRA) for further visual inspection Refer to DISASSEMBLY and REASSEMBLY Precaution Turbocharger servicing requires great care and expertise Faulty turbocharger servicing procedures can result in serious damage to pistons, valves, cylinder liners, and other important engine parts ISUZU does not recommended the performance of any servicing procedure not specified described in this Manual Contact your nearest IHI service facility to have the turbocharger assembly repaired or overhauled The identification plate and assembly number will be required by the service facility A list of IHI Turbocharger Service Network locations is given at the end of this Section Name plate example Turbo Spec Serial No.RHC9 Parts No 037EY00010 69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ 6J–4 ENGINE INDUCTION Disassembly 036HT001 Legend (1) Lock plate and bolt (2) Turbine housing (3) Lock plate and bolt (4) Compressor housing (5) Center housing and rotating assembly 69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ ENGINE INDUCTION Remove the lock plate and bolt Apply a setting mark across the center housing and rotating assembly (1), the turbine housing (2), and the compressor housing (3) 6J–5 Take care not to allow foreign material to enter the center housing NOTE: Disassembly and servicing of the center housing and rotating assembly is not recommended Inspection and Repair Make the necessary adjustment, repairs, and part replacements if excessive wear or damage is discovered during inspection Minor servicing operations are described in this Section Contact the nearest IHI SERVICE FACILITY for major repairs and maintenance Refer to IHI SERVICE NETWORK at the end of this Section for the location of your area’s IHI SERVICE FACILITY Turbine shaft End Play 037EY00005 Set a dial indictor to the turbine shaft end Apply a force of 11.7 N (1.2 kg/2.6 lb) alternately to the compressor wheel end and the the turbine wheel end Read the dial indicator Turbine shaft end play Standard: 0.075 – 0.110 mm (0.0030 – 0.0043 in.) Limit: 0.12 mm (0.0047 in.) 037EY00006 Remove the turbine housing Remove the lock plate and bolt Remove the compressor housing Remove the center housing and rotating assembly • Loosen the lock plate bolts • Disassembly the parts Handle the parts with extreme care Be particularly careful not to damage the turbine wheel blades and the compressor wheel blades Turbine Shaft Bearing Clearance Due to the unique location of the center housing casting internal opening, access to the shaft wheel is difficult To check the turbine shaft and bearing clearance, a special gauge arm assembly must be fabricated for use with a dial gauge The assembly can be constructed from any conveniently available material However, it must conform to the dimensions shown in the illustration 69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ 6J–6 ENGINE INDUCTION Pass the gauge arm assembly through the oil outlet port and the casting internal opening The curved end of the gauge arm assembly must make contact with the wheel shaft 037EY00007 Set the dial gauge to “0” Grasp both ends of the shaft at the wheel hubs Move the shaft gently back and forth in a motion that is parallel to the plane of the oil drain flange face Note the dial gauge reading If the dial gauge reading is above or below the standard range, the center housing and rotating assembly must be replaced Standard: 0.130 – 0.235 mm (0.0051 – 0.0093 in.) Limit: 0.275 mm (0.0108 in.) 69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ ENGINE INDUCTION 6J–7 Reassembly 036HT001 Legend (1) Lock plate and bolt (2) Turbine housing (3) Lock plate and bolt (4) Compressor housing (5) Center housing and rotating assembly 69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ 6J–8 ENGINE INDUCTION Install the center housing and rotating assembly to the compressor housing • Apply Threebond 1215 or equivalent to the flange surface of compressor houisng shown in the illustration 037EY00006 037EY00008 • Align the setting marks (applied at disassembly) on the center housing and rotating assembly and the compressor housing Handle the parts with extreme care to avoid damaging the compressor wheel blades • Apply an anti-seizing agent (LOCTITE ANTISEIZE LUBRICANT or equivalent) to the new bolt threads or the V-band threads • Install the new lock plate and bolts to the compressor housing • Tighten the bolts to the specified torque Torque: 23 N·m (2.3 kgm) Install the turbine housing • Align the setting marks (applied at disassembly) on the center housing and rotating assembly and the turbine housing Handle the parts with extreme care to avoid damaging the turbine shaft wheel blades • Apply an anti-seizing agent (LOCTITE ANTISEIZE LUBRICANT or equivalent) to the bolt • Tighten the bolt to the specified torque Torque: 28 N·m (2.85 kgm) • Check that the rotating assembly turns smoothly 037EY00005 69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ ENGINE INDUCTION 6J–9 IHI SERVICE NETWORK For inquiries relating to turbochargers, please contact you ISUZU distributor or the nearest IHI Turbocharger Service Facility HEADQUARTERS ISHIKAWAJIMA HARIMA HEAVY INDUSTRIES CO., LTD (IHI) General Machinery Division Tokyo Chuo Building 1-6-2 Marunouchi Chiyoda-ku Tokyo 100-0005 JAPAN TEL: 81-(3)-3286-2405 to 2407 (3 lines) FAX: 81-(3)-3286-2430 CHINA IHI BEIJING OFFICE Room 705, China World Trade Center, No Jian Guo Men Wai Avenue Beijing, People’s Republic of CHINA TEL: 86-(1)-505-4997, 0408 FAX: 86-(1)-505-4350 TLX: 210343 IHIPK CN TAIWAN IHI TAIPEI OFFICE Room 1202, Chia Hsin Building, No 96 Chung Shan North Road, Section 2, Taipei, TAIWAN TEL: 886-(3)-542-5520, 5521, 5523 FAX: 886-(2)-542-4362 TLX: 11320 IHICO THAILAND IHI BANGKOK OFFICE 8th Floor, Thaniya Building, 62 Silom Road, Bangkok, THAILAND TEL: 66-(2)-236-2390, 7356, 9099 FAX: 66-(2)-236-7340 TLX: 82375 IHICO TH MALAYSIA IHI KUALA LUMPUR OFFICE Letter Box No 52, 22nd Floor, UBN Tower, 10 Jin P Ramlee 50250 Kuala Lumpur, MALYASIA TEL: 60-(3)-232-1255, 1271 FAX: 60-(3)-232-1418 TLX: IHI KLMA 20257 INDONESIA IHI JAKARTA OFFICE 9th Floor, Skyline Building JI, M.H Thamrin, No 9, Jakarta, INDONESIA TEL: 62-(21)-32-2147, 390-2211 FAX: 62-(21)-32-3273 TLX: 44175 IHIJKT 69697_ESS-172A_SEC6J 11.8.4 3:29 PM ページ 10 MEMO MEMO MEMO Hitachi Construction Machinery Co Ltd Attn: Publications, Marketing & Product Support Tel: 81-29-982-7084 Fax: 81-29-831-1162 E-mail: dc@hitachi-kenki.com Hitachi Ref No SERVICE MANUAL REVISION REQUEST FORM COMPANY NAME: YOUR NAME: DATE: FAX: E-mail: MODEL: PUBLICATION PART NO.: (Located at the left top corner in the cover page) PAGE NO.: (Located at the bottom center in the page If two or more revisions are requested, use the comment column) YOUR COMMENTS / SUGGESTIONS: Attach photo or sketch if required If your need more space, please use another sheet REPLY: (Copy this form for usage)