Hitachi ZX470-6 ZX470LC-6 ZX490H-6 ZX490LCH-6 ZX490R-6 ZX490LCR-6 ZX530LCH-6 Hydraulic Excavator Technical Workshop Manual
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Hitachi ZX470-6 ZX470LC-6 ZX490H-6 ZX490LCH-6 ZX490R-6 ZX490LCR-6 ZX530LCH-6 Hydraulic Excavator Technical Workshop Manual
- Manual Language:English
- Downloadable:Yes
- Pages: 691
- Size: 19.7 MB
- Format:PDF
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Description:
Hitachi ZX470-6 ZX470LC-6 ZX490H-6 ZX490LCH-6 ZX490R-6 ZX490LCR-6 ZX530LCH-6 Hydraulic Excavator Technical Workshop Manual
To The Reader
This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.The machine specification and description according to destination may be explained on this manual.
Be sure to thoroughly read this manual for correct product information and service procedures.
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.
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
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 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.
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.
Table Of Contents:
Hitachi ZX470-6 ZX470LC-6 ZX490H-6 ZX490LCH-6 ZX490R-6 ZX490LCR-6 ZX530LCH-6 Hydraulic Excavator Technical Workshop Manual
WJAG50-EN-00..................................................................... 1 CONTENTS .................................................................... 3 SECTION 1 GENERAL........................................................ 3 SECTION 2 MAINTENANCE STANDARD.......................................... 5 SECTION 3 UPPERSTRUCTURE................................................ 7 SECTION 4 UNDERCARRIAGE................................................. 9 SECTION 5 FRONT ATTACHMENT.............................................. 11 INTRODUCTION................................................................. 13 To The Reader............................................................ 13 Additional References.................................................... 13 Manual Composition....................................................... 13 Page Number.............................................................. 13 Trademark................................................................ 13 Safety Alert Symbol and Headline Notations............................... 14 Units Used............................................................... 14 SYMBOL AND ABBREVIATION...................................................... 15 SAFETY....................................................................... 17 Recognize Safety Information............................................. 17 Understand Signal Words.................................................. 17 Follow Safety Instructions............................................... 18 Prepare for Emergencies.................................................. 19 Wear Protective Clothing................................................. 19 Protect Against Noise.................................................... 20 Inspect Machine.......................................................... 20 General Precautions for the Cab.......................................... 21 Use Handholds and Steps.................................................. 22 Adjust the Operator's Seat............................................... 22 Ensure Safety Before Rising from or Leaving Operator’s Seat.............. 23 Fasten Your Seat Belt.................................................... 23 Move and Operate Machine Safely.......................................... 24 Operate Only from Operator's Seat........................................ 24 Jump Starting............................................................ 25 Keep Riders off Machine.................................................. 25 Precautions for Operations............................................... 26 Investigate Job Site Beforehand.......................................... 27 Install OPG Guard........................................................ 28 Restriction of Attachment Installation................................... 28 Provide Signals for Jobs Involving Multiple Machines..................... 29 Confirm Direction of Machine to Be Driven................................ 29 Drive Machine Safely..................................................... 30 Avoid Injury from Rollaway Accidents..................................... 32 Avoid Injury from Back-Over and Swing Accidents.......................... 33 Keep People Clear from Working Area...................................... 34 Never Position the Bucket Over Anyone.................................... 34 Avoid Undercutting....................................................... 35 Avoid Tipping............................................................ 35 Never Undercut a High Bank............................................... 36 Dig with Caution......................................................... 36 Operate with Caution..................................................... 36 Avoid Power Lines........................................................ 37 Precautions for Lightning................................................ 37 Object Handling.......................................................... 38 Protect Against Flying Debris............................................ 38 Park Machine Safely...................................................... 39 Handle Fluids Safely−Avoid Fires......................................... 39 Transport Safely......................................................... 40 Practice Safe Maintenance................................................ 41 Warn Others of Service Work.............................................. 42 Support Machine Properly................................................. 42 Stay Clear of Moving Parts............................................... 43 Prevent Parts from Flying................................................ 43 Avoid Injury from Attachment Falling Accident............................ 44 Prevent Burns............................................................ 44 Replace Rubber Hoses Periodically........................................ 45 Avoid High-Pressure Fluids............................................... 45 Prevent Fires............................................................ 46 Evacuating in Case of Fire............................................... 48 Beware of Exhaust Fumes.................................................. 48 Precautions for Welding and Grinding..................................... 49 Avoid Heating Near Pressurized Fluid Lines............................... 50 Avoid Applying Heat to Lines Containing Flammable Fluids................. 50 Precautions for Handling Accumulator and Gas Damper...................... 50 Remove Paint Before Welding or Heating................................... 51 Beware of Asbestos and Silica Dust and Other Contamination............... 51 Prevent Battery Explosions............................................... 52 Service Air Conditioning System Safely................................... 52 Handle Chemical Products Safely.......................................... 53 Dispose of Waste Properly................................................ 53 Never Ride Attachment.................................................... 54 Notes on Aftertreatment Device........................................... 54 Precautions for Communication Terminal................................... 54 Precautions for Communication Terminal Equipment......................... 55 Notes on Protection of Operator’s Station when the Machine Rolls Over.... 57 Before Returning the Machine to the Customer............................. 58 SECTION AND GROUP CONTENTS................................................... 59 SECTION 1 GENERAL............................................................ 63 Group 1 Precautions for Disassembling and Assembling..................... 65 Precautions for Disassembling and Assembling......................... 65 Group 2 Tightening....................................................... 71 Tightening Bolts and Nuts............................................ 71 Piping Joint......................................................... 74 Group 3 Painting......................................................... 81 Painting............................................................. 81 Group 4 Bleeding Air..................................................... 83 Bleeding Air from Hydraulic System................................... 83 Bleeding Air from Fuel System........................................ 84 Air Bleeding from the Diesel Exhaust Fluid Defrosting Piping......... 86 Group 5 Preparation...................................................... 87 Preparation before Inspection and Maintenance........................ 87 Hydraulic Circuit Pressure Release Procedure......................... 89 Pressure Release from Hydraulic Oil Tank............................. 90 Pressure Release from Expansion Tank................................. 91 SECTION 2 MAINTENANCE STANDARD............................................... 95 Group 1 Upperstructure................................................... 97 Pump Device.......................................................... 97 Swing Motor..........................................................101 Group 2 Undercarriage....................................................105 Travel Motor.........................................................105 Sprocket.............................................................107 Center Joint.........................................................109 Front Idler..........................................................111 Upper Roller.........................................................113 Lower Roller.........................................................114 Track................................................................115 Group 3 Front Attachment.................................................119 Pin and Bushing......................................................119 Side Cutter..........................................................121 Point (4512365)......................................................122 Standard Dimensions for Arm and Bucket Connection....................123 Standard Dimensions for Arm and Boom Connection......................124 Cylinder.............................................................125 SECTION 3 UPPERSTRUCTURE.....................................................129 Group 1 Cab..............................................................131 Removal and Installation of Cab......................................131 Dimensions of Cab Glass (Standard Cab)...............................159 Dimensions of Cab Glass (H Cab)......................................178 Group 2 Counterweight....................................................181 Removal and Installation of Counterweight............................181 Group 3 Main Frame.......................................................187 Removal and Installation of Main Frame...............................187 Group 4 Engine...........................................................197 Removal and Installation of Engine...................................197 Group 8 Pump Device......................................................229 Removal and Installation of Pump Device..............................229 Disassembly of Main Pump.............................................249 Assembly of Main Pump................................................254 Disassembly of Regulator for Main Pump...............................261 Assembly of Regulator for Main Pump..................................263 Disassembly of Fan Pump..............................................267 Assembly of Fan Pump.................................................271 Structure of Pilot Pump..............................................275 Group 9 Control Valve....................................................277 Removal and Installation of Control Valve............................277 Disassembly and Assembly of Housing..................................291 Disassembly of Control Valve 4-Spool Side............................295 Assembly of Control Valve 4-Spool Side...............................303 Disassembly of Control Valve 5-Spool Side............................311 Assembly of Control Valve 5-Spool Side...............................318 Group 10 Swing Device....................................................325 Removal and Installation of Swing Device.............................325 Disassembly of Swing Device..........................................329 Assembly of Swing Device.............................................335 Disassembly of Swing Motor...........................................341 Assembly of Swing Motor..............................................344 Group 11 Pilot Valve.....................................................349 Removal and Installation of Pilot Valve (Left).......................349 Removal and Installation of Pilot Valve (Right)......................361 Removal and Installation of Travel Pilot Valve.......................377 Disassembly of Pilot Valves (Right and Left).........................381 Assembly of Pilot Valves (Right and Left)............................384 Disassembly of Travel Pilot Valve....................................387 Assembly of Travel Pilot Valve.......................................391 Group 12 Solenoid Valve..................................................397 Removal and Installation of Pilot Shut-Off Solenoid Valve............397 Removal and Installation of 4-Spool Solenoid Valve Unit..............401 Removal and Installation of 2-Spool Solenoid Valve Unit..............405 Removal and Installation of Fan Pump Control Solenoid Valve..........409 Disassembly of Pilot Shut-Off Solenoid Valve.........................413 Assembly of Pilot Shut-Off Solenoid Valve............................415 Structure of 4-Spool Solenoid Valve Unit.............................417 Structure of 2-Spool Solenoid Valve Unit.............................419 Structure of Fan Pump Control Solenoid Valve.........................421 Group 13 Signal Control Valve............................................423 Removal and Installation of Signal Control Valve.....................423 Structure of Signal Control Valve....................................429 Group 14 Aftertreatment Device...........................................433 Removal and Installation of Aftertreatment Device....................433 Group 15 DEF Tank........................................................441 Removal and Installation of DEF Tank.................................441 Group 16 Coolant Control Valve...........................................457 Removal and Installation of Coolant Control Valve....................457 Group 17 DEF Supply Module...............................................463 Removal and Installation of DEF Supply Module........................463 Group 19 Fan Valve.......................................................467 Removal and Installation of Fan Valve................................467 Structure of Fan Valve...............................................501 Group 20 Fan Motor.......................................................503 Removal and Installation of Fan Motor................................503 Structure of Fan Motor...............................................511 Group 21 Shockless Valve.................................................513 Removal and Installation of Shockless Valve..........................513 Structure of Shockless Valve.........................................515 SECTION 4 UNDERCARRIAGE......................................................519 Group 1 Swing Bearing....................................................521 Removal and Installation of Swing Bearing............................521 Disassembly of Swing Bearing.........................................525 Assembly of Swing Bearing............................................528 Group 2 Travel Device....................................................531 Removal and Installation of Travel Device............................531 Disassembly of Travel Device.........................................535 Assembly of Travel Device............................................542 Disassembly of Travel Motor..........................................551 Assembly of Travel Motor.............................................555 Disassembly of Brake Valve...........................................561 Assembly of Brake Valve..............................................564 Group 3 Center Joint.....................................................569 Removal and Installation of Center Joint.............................569 Disassembly of Center Joint..........................................573 Assembly of Center Joint.............................................575 Replacement of Body and Spindle......................................578 Group 4 Track Adjuster...................................................579 Removal and Installation of Track Adjuster...........................579 Disassembly of Track Adjuster........................................581 Assembly of Track Adjuster...........................................586 Group 5 Front Idler......................................................591 Removal and Installation of Front Idler..............................591 Disassembly of Front Idler...........................................593 Assembly of Front Idler..............................................596 Group 6 Upper and Lower Rollers..........................................601 Removal and Installation of Upper Roller.............................601 Removal and Installation of Lower Roller.............................605 Disassembly of Lower Roller..........................................611 Assembly of Lower Roller.............................................613 Group 7 Track............................................................617 Removal and Installation of Track....................................617 SECTION 5 FRONT ATTACHMENT...................................................633 Group 1 Front Attachment.................................................635 Removal and Installation of Front Attachment.........................635 Removal and Installation of Bushing..................................641 Group 2 Cylinder.........................................................643 Removal and Installation of Boom Cylinder............................643 Removal and Installation of Arm Cylinder.............................651 Removal and Installation of Bucket Cylinder..........................659 Disassembly of Boom, Arm, and Bucket Cylinders.......................663 Assembly of Boom, Arm, and Bucket Cylinders..........................669 Group 3 Hose Rupture Valve...............................................675 Removal and Installation of Hose Rupture Valve for Boom Cylinder.....675 Removal and Installation of Hose Rupture Valve for Arm Cylinder......679 Structure of Hose Rupture Valve for Boom Cylinder....................683 Structure of Hose Rupture Valve for Arm Cylinder (Bottom Side).......685 Structure of Hose Rupture Valve for Arm Cylinder (Rod Side)..........687 SERVICE MANUAL REVISION REQUEST FORM.........................................691
Please Note:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]