Hitachi ZAXIS 470LCH-3 ZAXIS 500LC-3 Instruction manual

PRINTED IN JAPAN (E) 2006, 02
ZAXIS450
-3
•
450LC
-3
•
470H
-3
•
470LCH
-3
•
500LC
-3
•
520LCH
-3
class HYDRAULIC EXCAVATOR WORKSHOP MANUAL
PART NO. W1J1-E-00
Workshop Manual
URL:http://www.hitachi-c-m.com
Hydraulic Excavator
Service Manual consists of the following separate Part No;
Technical Manual (Operational Principle) : Vol. No.TO1J1-E
Technical Manual (Troubleshooting) : Vol. No.TT1J1-E
Workshop Manual : Vol. No.W1J1-E
450-3
450LC-3
470H-3
470LCH-3
500LC-3
520LCH-3
W1J1-E-00 2006.2.20, 12:25Page 1 AdobePageMaker7.0J/PPC
Hitachi Zaxis 450 450lc 470h 470lch 500lc 520lch 3 Workshop Manual
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INTRODUCTION
IN-01
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.
(Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: [phone]
FAX: [phone]
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition
to this manual.
• The Operator’s Manual
• The Parts Catalog
• The Engine Manual
• Parts Catalog of the Engine
• Hitachi Training Material
MANUAL COMPOSITION
• This manual consists of three portions: the Techni-
cal Manual (Operational Principle), the Technical
Manual (Troubleshooting) and the Workshop Man-
ual.
• Information included in the Technical Manual
(Operational Principle):
technical information needed for redelivery and
delivery, operation and activation of all devices
and systems.
• Information included in the Technical Manual
(Troubleshooting):
technical information needed for operational per-
formance 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 assem-
ble/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 : T 1-3-5
Consecutive Page Number for Each Group
Group Number
Section Number
T: Technical Manual W: Workshop Manual

INTRODUCTION
IN-02
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.
This is the safety alert symbol. When you see this
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 appropri-
ate lifting techniques and equipment when lifting heavy
parts.
• CAUTION:
Indicated potentially hazardous situation which could,
if not avoided, result in personal injury or death.
• IMPORTANT:
Indicates a situation which, if not conformed to the
instructions, could result in damage to the machine.
• NOTE:
Indicates supplementary technical information or
know-how.
UNITS USED
• SI Units (International System of Units) are used in
this manual.
MKSA system units and English units are also
indicated in parenthheses just behind SI units.
Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
A table for conversion from SI units to other system
units is shown below for reference purposees.
Quantity To Convert
From Into Multiply By
MPa kgf/cm210.197Pressure
MPa psi 145.0
kW PS 1.360Power
kW HP 1.341
Temperature °C °F °C×1.8+32
km/h mph 0.6214Velocity
min-1 rpm 1.0
Flow rate L/min US gpm 0.2642
mL/rev cc/rev 1.0
Quantity To Convert
From Into Multiply By
mm in 0.03937Length
mm ft 0.003281
L US gal 0.2642
L US qt 1.057
Volume
m3yd31.308
Weight kg lb 2.205
N kgf 0.10197Force
N lbf 0.2248
N⋅m kgf⋅m 1.0197Torque
N⋅m lbf⋅ft 0.7375

SAFETY
SA-1
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 per-
sonal injury.
• Follow recommended precautions and safe oper-
ating practices.
001-E01A-0001
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 don't use any of the desig-
nated signal words above after the safety alert
symbol are occasionally used on this machine.
• To avoid confusing machine protection with personal
safety messages, a signal word IMPORTANT indi-
cates a situation which, if not avoided, could result in
damage to the machine.
• NOTE indicates an additional explanation for an
element of information.
002-E01A-1223
SA-1223

SAFETY
SA-2
FOLLOW SAFETY INSTRUCTIONS
• Carefully read and follow all safety signs on the
machine and all safety messages in this manual.
• Safety signs should be installed, maintained and
replaced when necessary.
• If a safety sign or this manual is damaged or
missing, order a replacement from your author-
ized dealer in the same way you order other re-
placement 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 ma-
chine life.
• Do not modify any machine parts without au-
thorization. Failure to do so may deteriorate the
part safety, function, and/or service life. In addi-
tion, 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 do
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 attach-
ments 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 au-
thorized dealer before operating or performing
maintenance work on the machine.
003-E01B-0003
SA-003

SAFETY
SA-3
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 at-
tached 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, ambu-
lance service, hospital, and fire department
posted near your telephone.
004-E01A-0437
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 atten-
tion of the operator. Do not wear radio or music
headphones while operating the machine.
005-E01A-0438
SA-428

SAFETY
SA-4
PROTECT AGAINST NOISE
• Prolonged exposure to loud noise can cause im-
pairment or loss of hearing.
• Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objec-
tionable or uncomfortably loud noises.
006-E01A-0434
SA-434
INSPECT MACHINE
• Inspect your machine carefully each day or shift by
walking around it before you start it to avoid per-
sonal injury.
• In the walk-around inspection be sure to cover all
points described in the "RE-START INSPEC-
TION" chapter in the operator's manual.
007-E01A-0435
SA-435

SAFETY
SA-5
GENERAL PRECAUTIONS FOR CAB
• Before entering the cab, thoroughly remove all dirt
and/or oil from the soles of your work boots. If any
controls such as a pedal is operated while with
dirt and/or oil on the soles of the operator's work
boots the operator's foot may slip off the pedal,
possibly resulting in a personal accident.
• Do not leave parts and/or tools lying around the
operator's seat. Store them in their specified loca-
tions.
• Avoid storing transparent bottles in the cab. Do
not attach any transparent type window decora-
tions on the windowpanes as they may focus
sunlight, possibly starting a fire.
• Refrain from listening to the radio, or using music
headphones or mobile telephones in the cab
while operating the machine.
• Keep all flammable objects and/or explosives
away from the machine.
• After using the ashtray, always cover it to extin-
guish the match and/or tobacco.
• Do not leave cigarette lighters in the cab. When
the temperature in the cab increases, the lighter
may explode.
524-E01A-0000

SAFETY
SA-6
USE HANDHOLDS AND STEPS
• Falling is one of the major causes of personal injury.
• When you get on and off the machine, always
face the machine and maintain a three-point
contact with the steps and handrails.
• Do not use any controls as hand-holds.
• Never jump on or off the machine. Never mount or
dismount a moving machine.
• Be careful of slippery conditions on platforms,
steps, and handrails when leaving the machine.
008-E01A-0439
SA-439
ADJUST THE OPERATOR'S SEAT
• A poorly adjusted seat for either the operator or for
the work at hand may quickly fatigue the operator
leading to mis-operations.
• The seat should be adjusted whenever changing
the operator for the machine.
• The operator should be able to fully depress the
pedals and to correctly operate the control levers
with his back against the seat back.
• If not, move the seat forward or backward, and
check again.
• Adjust the rear view mirror position so that the
best rear visibility is obtained from the operator's
seat. If the mirror is broken, immediately replace it
with a new one.
009-E01A-0462
SA-462