Hitachi ZX470-5G ZX470LC-5G ZX470H-5G ZX470LCH-5G ZX470R-5G ZX470LCR-5G Hydraulic Excavator Technical Workshop Manual
File Details:
Hitachi ZX470-5G ZX470LC-5G ZX470H-5G ZX470LCH-5G ZX470R-5G ZX470LCR-5G Hydraulic Excavator Technical Workshop Manual
- Manual Language:English
- Downloadable:Yes
- Pages: 2500+
- Size: 117 MB
- Format:PDF
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Description:
Hitachi ZX470-5G ZX470LC-5G ZX470H-5G ZX470LCH-5G ZX470R-5G ZX470LCR-5G 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.
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 ZX470-5G ZX470LC-5G ZX470H-5G ZX470LCH-5G ZX470R-5G ZX470LCR-5G Hydraulic Excavator Technical Workshop Manual
WJAC-E-00............................................................ 1 INTRODUCTION......................................................... 3 SYMBOL AND ABBREVIATION.............................................. 5 SAFETY............................................................... 7 SECTION AND GROUP CONTENTS........................................... 49 SECTION 1 GENERAL.................................................... 51 Group 1 Precautions for Disassembling and Assembling............. 53 Precautions for Disassembling and Assembling................. 53 Group 2 Tightening............................................... 59 Tightening Bolts and Nuts.................................... 59 Piping Joint................................................. 62 Group 3 Painting................................................. 67 Painting Specification....................................... 67 Final Painted Color.......................................... 67 Group 4 Bleeding Air............................................. 69 Bleeding Air from Hydraulic Oil Tank......................... 69 Bleeding Air from Hydraulic System........................... 70 Bleeding Air from Fuel System................................ 71 Bleeding Air from Radiator................................... 72 Group 5 Pressure Release Procedure............................... 73 Hydraulic Circuit Pressure Release Procedure................. 73 Group 6 Preparation.............................................. 75 Preparation before Inspection and Maintenance................ 75 SECTION 2 MAINTENANCE STANDARD....................................... 79 Group 1 Upperstructure........................................... 81 Main Pump.................................................... 81 Swing Motor.................................................. 83 Group 2 Undercarriage............................................ 85 Travel Motor................................................. 85 Sprocket..................................................... 86 Center Joint................................................. 87 Front Idler.................................................. 89 Upper Roller................................................. 91 Lower Roller................................................. 92 Track........................................................ 93 Group 3 Front Attachment......................................... 97 Remove and Install Bushing................................... 97 Pin and Bushing.............................................. 99 Side Cutter..................................................101 Point........................................................101 Standard Dimensions for Arm and Bucket Connection............102 Standard Dimensions for Arm and Boom Connection..............104 Cylinder.....................................................105 SECTION 3 UPPERSTRUCTURE.............................................109 Group 1 Cab......................................................111 Removal and Installation of Cab..............................111 Dimensions of Cab Glass (Standard Cab).......................127 Dimensions of Cab Glass (H Cab)..............................146 Group 2 Counterweight............................................149 Removal and Installation of Counterweight....................153 Group 3 Main Frame...............................................153 Removal and Installation of Main Frame.......................153 Group 4 Engine...................................................161 Removal and Installation of Engine...........................161 Group 5 Radiator Assembly........................................203 Replacement of Radiator and Oil Cooler.......................203 Group 6 Hydraulic Oil Tank.......................................227 Removal and Installation of Hydraulic Oil Tank...............227 Group 7 Fuel Tank................................................245 Removal and Installation of Fuel Tank........................245 Group 8 Pump Device..............................................263 Removal and Installation of Pump Device......................263 Disassembly of Main Pump.....................................287 Assembly of Main Pump........................................294 Disassembly of Regulator for Main Pump.......................303 Assembly of Regulator for Main Pump..........................305 Structure of Pilot Pump......................................309 Structure of A Sensor........................................311 Group 9 Control Valve............................................313 Removal and Installation of Control Valve....................313 Disassembly and Assembly of Valve Unit.......................339 Disassembly of Control Valve (4-Spool Side)..................345 Assembly of Control Valve (4-Spool Side).....................353 Disassembly of Control Valve (5-Spool Side)..................361 Assembly of Control Valve (5-Spool Side).....................368 Group 10 Swing Device............................................375 Removal and Installation of Swing Device.....................375 Disassembly of Swing Device..................................379 Assembly of Swing Device.....................................385 Disassembly of Swing Motor...................................391 Assembly of Swing Motor......................................394 Group 11 Pilot Valve.............................................399 Removal and Installation of Pilot Valve (Left)...............399 Removal and Installation of Pilot Valve (Right)..............405 Removal and Installation of Travel Pilot Valve...............413 Disassembly of Pilot Valves (Right and Left).................417 Assembly of Pilot Valves (Right and Left)....................420 Disassembly of Travel Pilot Valve............................423 Assembly of Travel Pilot Valve...............................427 Group 12 Solenoid Valve..........................................433 Removal and Installation of Pilot Shut-Off Solenoid Valve....433 Removal and Installation of 4-Spool Solenoid Valve Unit......437 Removal and Installation of 2-Spool Solenoid Valve Unit......441 Disassembly of Pilot Shut-Off Solenoid Valve.................445 Assembly of Pilot Shut-Off Solenoid Valve....................447 Structure of 4-Spool Solenoid Valve Unit.....................449 Structure of 2-Spool Solenoid Valve Unit.....................451 Group 13 Signal Control Valve....................................453 Removal and Installation of Signal Control Valve.............453 Structure of Signal Control Valve............................459 Group 14 Shockless Valve.........................................461 Removal and Installation of Shockless Valve..................461 Structure of Shockless Valve.................................463 SECTION 4 UNDERCARRIAGE..............................................467 Group 1 Swing Bearing............................................469 Removal and Installation of Swing Bearing....................469 Disassembly of Swing Bearing.................................473 Assembly of Swing Bearing....................................476 Group 2 Travel Device............................................479 Removal and Installation of Travel Device....................479 Disassembly of Travel Device.................................483 Assembly of Travel Device....................................490 Disassembly of Travel Motor..................................499 Assembly of Travel Motor.....................................503 Disassembly of Brake Valve...................................509 Assembly of Brake Valve......................................512 Group 3 Center Joint.............................................517 Removal and Installation of Center Joint.....................517 Disassembly of Center Joint..................................521 Assembly of Center Joint.....................................523 Replacement of Body and Spindle..............................526 Group 4 Track Adjuster...........................................527 Removal and Installation of Track Adjuster...................527 Disassembly of Track Adjuster................................529 Assembly of Track Adjuster...................................534 Group 5 Front Idler..............................................539 Removal and Installation of Front Idler......................539 Disassembly of Front Idler...................................541 Assembly of Front Idler......................................544 Group 6 Upper and Lower Rollers..................................549 Removal and Installation of Upper Roller.....................549 Removal and Installation of Lower Roller.....................553 Disassembly of Lower Roller..................................557 Assembly of Lower Roller.....................................559 Group 7 Track....................................................565 Removal and Installation of Track............................565 SECTION 5 FRONT ATTACHMENT...........................................581 Group 1 Front Attachment.........................................583 Removal and Installation of Front Attachment.................583 Removal and Installation of Bushing..........................591 Group 2 Cylinder.................................................593 Removal and Installation of Boom Cylinder....................593 Removal and Installation of Arm Cylinder.....................597 Removal and Installation of Bucket Cylinder..................601 Disassembly of Boom Cylinder.................................605 Assembly of Boom Cylinder....................................608 Disassembly of Arm Cylinder..................................611 Assembly of Arm Cylinder.....................................614 Disassembly of Bucket Cylinder...............................617 Assembly of Bucket Cylinder..................................620 SECTION 6 ENGINE AND ACCESSORY.......................................625 General Information..............................................627 General Repair Instruction...................................627 Illustration Arrows..........................................628 Abbreviations Charts.........................................629 Nut and Bolt Angular Tightening Method.......................630 Standard Bolt Torque Specifications..........................632 Recommended Thread Locking Agents............................634 Main Data and Specification..................................635 Performance Curve............................................637 Engine External Drawing......................................638 Service Standard.............................................639 Torque Specifications........................................645 Special Tools................................................653 Troubleshooting..............................................655 Lubricant Application........................................665 Sealant Application..........................................665 Service Information..............................................667 Identification...............................................667 Lubrication System...........................................668 Fuel System..................................................668 Cooling System...............................................672 Valve Clearance Adjustment...................................673 Compression Pressure Measurement.............................675 Recommended Lubricants.......................................676 Engine Oil Viscosity Chart...................................676 Engine Mechanical................................................677 Service Precautions..........................................678 General Description..........................................678 Fan Center...................................................680 Turbocharger.................................................683 Exhaust Manifold.............................................685 Inlet Manifold...............................................686 Water Pump...................................................689 Alternator...................................................691 Oil Cooler...................................................694 Injection Pump...............................................696 Coupling Assembly............................................700 Cylinder Head................................................703 Rocker Arm and Shaft Assembly................................723 Camshaft.....................................................728 Timing Gears.................................................733 Flywheel Housing.............................................742 Oil Pan......................................................745 Piston.......................................................749 Crankshaft...................................................764 Crank Pulley.................................................775 Flywheel.....................................................778 Cylinder Block...............................................780 Engine Cooling...................................................789 Service Precautions..........................................789 General Description..........................................790 Water Pump...................................................791 Thermostat...................................................796 Engine Fuel......................................................799 Service Precautions..........................................799 General Description..........................................800 Fuel Filter..................................................803 Injection Nozzle Holder......................................805 Injection Pump...............................................811 Injection Nozzle Holder-Tow-Stage Injection Type.............815 Starting and Charging............................................827 Service Precautions..........................................827 Alternator...................................................828 Starter Motor................................................837 Engine Lubrication...............................................849 Service Precaution...........................................849 General Description..........................................850 Oil Pump.....................................................852 Oil Cooler...................................................860 Engine Induction.................................................865 Service Precaution...........................................865 Turbocharger.................................................866 SERVICE MANUAL REVISION REQUEST FORM.................................877
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