Hitachi ZX470-6 ZX470LC-6 ZX490H-6 ZX490LCH-6 ZX490R-6 ZX490LCR-6 ZX530LCH-6 Hydraulic Excavator Technical Workshop Manual – PDF Download

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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

HITACHI ZX470-6 ZX470LC-6 ZX490H-6 ZX490LCH-6 ZX490R-6 ZX490LCR-6 ZX530LCH-6 HYDRAULIC EXCAVATOR TECHNICAL WORKSHOP MANUAL – PDF DOWNLOAD:

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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]