Hitachi ZX670LC-5G Instruction manual

WJBF90-EN-00
ZX670-5G HYDRAULIC EXCAVATOR WORKSHOP MANUAL
PRINTED IN JAPAN (K) 2013, 04
URL:http://www.hitachi-c-m.com
Service Manual consists of the following separate Part No.
Technical Manual (Operational Principle) : Vol. No.TOJBF90-EN
Technical Manual (Troubleshooting) : Vol. No.TTJBF90-EN
Workshop Manual : Vol. No.WJBF90-EN
WJBF90-EN-00
PART NO.
Workshop Manual
ZX670LC-5G
Hydraulic Excavator

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INTRODUCTION
IN-01
To The Reader
Additional References
Manual Composition
Page Number
This manual is written for an experienced technician to
provide technical information needed to maintain and
repair this machine.
yBe sure to thoroughly read this manual for correct
product information and service procedures.
Please refer to the other materials (operator’s manual,
parts catalog, engine technical material and Hitachi
training material etc.) in addition to this manual.
This manual consists the Technical Manual, the Workshop
Manual and the Engine Manual.
yInformation 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.
Each page has a number, located on the center lower part
of the page, and each number contains the following
information:
Example:
yTechnical Manual: T 1-3-5
T Technical Manual
1 Section Number
3 Group Number
5 Consecutive Page Number for Each Group
yIf 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.):
xPublications Marketing & Product Support Hitachi
Construction Machinery Co. Ltd.
xTEL: 81-29-832-7084
xFAX: 81-29-831-1162
xE-mail: [email protected]
yInformation 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.
yInformation 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.
yWorkshop Manual: W 1-3-2-5
W Workshop Manual
1 Section Number
3 Group Number
2 Sub Group Number
5 Consecutive Page Number for Each Group
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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.
dThis 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 appropriate
lifting techniques and equipment when lifting heavy
parts.
dCAUTION:
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.
fNOTE:
Indicates supplementary technical information or know-
how.
Units Used
Quantity To Convert From Into Multiply By
Length mm in 0.03937
mm ft 0.003281
Volume L US gal 0.2642
L US qt 1.057
m3yd31.308
Weight kg lb 2.205
Force N kgf 0.10197
N lbf 0.2248
Torque N·m kgf·m 0.10197
Pressure MPa kgf/cm210.197
MPa psi 145.0
Power kW PS 1.360
kW HP 1.341
Temperature °C °F °C×1.8+32
Velocity km/h mph 0.6214
min-1 rpm 1.0
Flow rate L/min US gpm 0.2642
mL/rev cc/rev 1.0
fNOTE: The numerical value in this manual might be
different from the above-mentioned table.
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.
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 purposes.
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Symbol and Abbreviation
SY-1
Symbol and Abbreviation
Symbol /
Abbreviation
Name Explanation
TO Technical manual (Operational principle) Technical manual (Operational Principle).
TT Technical manual (Troubleshooting) Technical manual (Troubleshooting).
T/M Technical manual Technical manual.
W, W/M Workshop manual Workshop manual (Removal and Installation, Disassembly
and Assembly).
MC Main Controller Main controller. MC controls the engine, pump, and valve
according to the machine operating condition.
ECF Engine Controller Engine controller. ECF controls EC motor according to the
machine operating condition.
VGS 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.
GSM Global System for Mobile communications
controller
Communication controller. GSM is a type of wireless
communication system, is used in more than on 100
countries around Europe and Asia, and becomes the factual
global standards of the mobile telephone.
GPS Global Positioning System Global positioning system.
CAN Controller Area Network CAN communication. CAN is a serial communications
protocol internationally-standardized by ISO (International
Organization for Standardization).
A/C Air Conditioner Air conditioner.
OP, OPT Option Optional component.
MPDr. Maintenance Pro Dr. MPDr. is software that troubleshooting, monitoring, and
adjustment.
A/I Auto-Idle Auto-idle.
WU Warming-Up Warming-up.
Li Low (Slow) Idle Slow idle engine speed.
ATT Attachment Attachment. Attachment is optional parts such as breaker,
crusher, and pulverizer in this manual.
HI, Hi High Travel fast position.
LO, Lo Low Travel slow position.
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Symbol and Abbreviation
SY-2
Symbol /
Abbreviation
Name Explanation
DPF Diesel Particulate Filter 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 Diesel Particulate Diffuser 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.
DOC Diesel Oxidation Catalyst Oxidation catalyst for the diesel engine. Diesel oxidation
catalyst oxidizes unburnt fuel and raises exhaust
temperature.
CSF Catalyzed Soot Filter 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.
PM Particulate Matter Particulate matter.
EGR Exhaust Gas Recirculation 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.
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Recognize Safety Information
yThese are the SAFETY ALERT SYMBOLS.
xWhen you see these symbols on your machine or in this
manual, be alert to the potential for personal injury.
xFollow recommended precautions and safe operating
practices.
Understand Signal Words
yOn machine safety signs, signal words designating the
degree or level of hazard - DANGER, WARNING, or CAUTION
- are used with the safety alert symbol.
xDANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
xWARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
xCAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
xDANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on
CAUTION safety signs.
xSome safety signs do not use any of the designated signal
words above after the safety alert symbol are occasionally
used on this machine.
yCAUTION also calls attention to safety message in this
manual.
yTo 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.
yNOTE: indicates an additional explanation for an
element of information.
SA-1
SAFETY
SA-688
SA-1223
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Follow Safety Instructions
yCarefully read and follow all safety signs on the machine
and all safety messages in the operator's manual.
ySafety signs should be installed, maintained and replaced
when necessary.
xIf 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).
yLearn how to operate the machine and its controls correctly
and safely.
yAllow only trained, qualified, authorized personnel to
operate the machine.
yKeep your machine in proper working condition.
xUnauthorized modifications of the machine may impair
its function and/or safety and affect machine life.
xDo not modify any machine parts without authorization.
Failure to do 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.
xDo 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 attachments and/or optional parts or
equipment will void Hitachi Warranty Policy.
yThe 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.
SAFETY
SA-2
SA-003
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Prepare for Emergencies
yBe prepared if a fire starts or if an accident occurs.
xKeep a first aid kit and fire extinguisher on hand.
xThoroughly read and understand the label attached on
the fire extinguisher to use it properly.
xTo 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.
xEstablish emergency procedure guidelines to cope with
fires and accidents.
xKeep emergency numbers for doctors, ambulance
service, hospital, and fire department posted near your
telephone.
Wear Protective Clothing
yWear 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.
xAvoid wearing loose clothing, jewelry, or other items that
can catch on control levers or other parts of the machine.
yOperating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones while
operating the machine.
SAFETY
SA-3
SA-437
SA-438
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Protect Against Noise
yProlonged exposure to loud noise can cause impairment or
loss of hearing.
xWear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortably loud noises.
Inspect Machine
yInspect your machine carefully each day or shift by walking
around it before you start it to avoid personal injury.
xIn 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-434
SAFETY
SA-4
SA-435
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SAFETY
SA-5
General Precautions for Cab
xBefore entering the cab, thoroughly remove all dirt and/or
oil such as mud, grease, soil or stones that may mess up
the cab 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.
xDo not mess up around the operator's seat with parts,
tools, soil, stones, obstacles that may fold up or turn
over, cans or lunch box. The levers or pedals become
inoperable if obstacle jams in operation stroke of the
travel levers/pedals, pilot control shut-off lever or control
levers, which may result in serious injury or death.
xAvoid storing transparent bottles in the cab. Do not
attach any transparent type window decorations on
the windowpanes as they may focus sunlight, possibly
starting a fire.
xRefrain from listening to the radio, or using music
headphones or mobile telephones in the cab while
operating the machine.
xKeep all flammable objects and/or explosives away from
the machine.
xAfter using the ashtray, always cover it to extinguish the
match and/or tobacco.
xDo not leave cigarette lighters in the cab. When the
temperature in the cab increases, the lighter may
explode.
xUse proper floor mat dedicated to the machine. If another
floor mat is used, it may be displaced and contact with
the travel pedals during operation, resulting in serious
injury or death.

Use Handholds and Steps
yFalling is one of the major causes of personal injury.
xWhen you get on and off the machine, always face the
machine and maintain a three-point contact with the
steps and handrails.
xDo not use any controls as hand-holds.
xNever jump on or off the machine. Never mount or
dismount a moving machine.
xBe careful of slippery conditions on platforms, steps, and
handrails when leaving the machine.
xNever get on and off the machine with tools in your
hands.
Adjust the Operator's Seat
yA poorly adjusted seat for either the operator or for the
work at hand may quickly fatigue the operator leading to
misoperations.
xThe seat should be adjusted whenever changing the
operator for the machine.
xThe operator should be able to fully depress the pedals
and to correctly operate the control levers with his back
against the seat back.
xIf not, move the seat forward or backward, and check
again.
xAdjust 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.
SAFETY
SA-6
SA-439
SA-378

Ensure Safety Before Rising from or Leaving
Operator’s Seat
yBefore rising from the operator’s seat to open/close either
side window or to adjust the seat position, be sure to first
lower the front attachment to the ground and then move
the pilot control shut-off lever to the LOCK position. Failure
to do so may allow the machine to unexpectedly move
when a body part unintentionally comes in contact with
a control lever and/or pedal, possibly resulting in serious
personal injury or death.
yBefore leaving the machine, be sure to first lower the front
attachment to the ground and then move the pilot control
shut-off lever to the LOCK position. Turn the key switch OFF
to stop the engine.
yBefore leaving the machine, close all windows, doors, and
access covers and lock them up.
Fasten Your Seat Belt
yIf the machine should overturn, the operator may become
injured and/or thrown from the cab. Additionally the
operator may be crushed by the overturning machine,
resulting in serious injury or death.
xPrior to operating the machine, thoroughly examine
webbing, buckle and attaching hardware. If any item is
damaged or worn, replace the seat belt or component
before operating the machine.
xBe sure to remain seated with the seat belt securely
fastened at all times when the machine is in operation to
minimize the chance of injury from an accident.
xWe recommend that the seat belt be replaced every three
years regardless of its apparent condition.
SA-237
SAFETY
SA-7

Move and Operate Machine Safely
yBystanders can be run over.
xTake extra care not to run over bystanders. Confirm the
location of bystanders before moving, swinging, or
operating the machine.
xAlways keep the travel alarm and horn in working
condition (if equipped). It warns people when the
machine starts to move.
xUse a signal person when moving, swinging, or operating
the machine in congested areas. Coordinate hand signals
before starting the machine.
xUse appropriate illumination. Check that all lights are
operable before operating the machine. If any faulty
illumination is present, immediately repair it.
xEnsure the cab door, windows, doors and covers are
securely locked.
xCheck the mirrors and the monitor in the CAB for
problems.
If there is, replace the problem part(s) or clean the mirror,
camera and the monitor.
Refer to Rear View Monitor section on the cleaning of the
camera and the monitor in the operator's manual.
Operate Only from Operator's Seat
yInappropriate engine starting procedures may cause the
machine to runaway, possibly resulting in serious injury or
death.
xStart the engine only when seated in the operator's seat.
xNEVER start the engine while standing on the track or on
ground.
xDo not start engine by shorting across starter terminals.
xBefore starting the engine, confirm that all control levers
are in neutral.
xBefore starting the engine, confirm the safety around the
machine and sound the horn to alert bystanders. SA-444
SAFETY
SA-8
SA-426

Jump Starting
yBattery gas can explode, resulting in serious injury.
xIf the engine must be jump started, be sure to follow
the instructions shown in the “OPERATING THE ENGINE”
chapter in the operator’s manual.
xThe operator must be in the operator’s seat so that the
machine will be under control when the engine starts.
Jump starting is a two-person operation.
xNever use a frozen battery.
xFailure to follow correct jump starting procedures could
result in a battery explosion or a runaway machine.
Keep Riders off Machine
yRiders on machine are subject to injury such as being struck
by foreign objects and being thrown off the machine.
xOnly the operator should be on the machine. Keep riders
off.
xRiders also obstruct the operator’s view, resulting in the
machine being operated in an unsafe manner.
SA-379
SAFETY
SA-9
SA-032

Precautions for Operations
yInvestigate the work site before starting operations.
xBe sure to wear close fitting clothing and safety
equipment appropriate for the job, such as a hard hat,
etc. when operating the machine.
xClear all persons and obstacles from area of operation and
machine movement.
Always beware of the surroundings while operating.
When working in a small area surrounded by obstacles,
take care not to hit the upperstructure against obstacles.
xWhen loading onto trucks, bring the bucket over the truck
beds from the rear side. Take care not to swing the bucket
over the cab or over any person.
SAFETY
SA-10
M178-05-007

Investigate Job Site Beforehand
yWhen working at the edge of an excavation or on a road
shoulder, the machine could tip over, possibly resulting in
serious injury or death.
xInvestigate the configuration and ground conditions of
the job site beforehand to prevent the machine from
falling and to prevent the ground, stockpiles or banks
from collapsing.
xMake a work plan. Use machines appropriate to the work
and job site.
xReinforce ground, edges and road shoulders as
necessary. Keep the machine well back from the edges of
excavations and road shoulders.
xWhen working on an incline or on a road shoulder,
employ a signal person as required.
xConfirm that your machine is equipped with a FOPS cab
before working in areas where the possibility of falling
stones or debris exist.
xWhen the footing is weak, reinforce the ground before
starting work.
xWhen working on frozen ground, be extremely alert. As
ambient temperatures rise, footing becomes loose and
slippery.
xBeware the possibility of fire when operating the machine
near flammable objects such as dry grass.
SAFETY
SA-11
SA-380

yMake sure the worksite has sufficient strength to firmly
support the machine.
When working close to an excavation or at road
shoulders, operate the machine with the tracks positioned
perpendicular to the cliff face with travel motors at the rear,
so that the machine can more easily evacuate if the cliff face
collapses.
yIf working on the bottom of a cliff or a high bank is required,
be sure to investigate the area first and confirm that no
danger of the cliff or bank collapsing exists. If any possibility
of cliff or bank collapsing exists, do not work on the area.
ySoft ground may collapse when operating the machine on
it, possibly causing the machine to tip over. When working
on soft ground is required, be sure to reinforce the ground
first using large pieces of steel plates strong and firm
enough to easily support the machine.
yNote that there is always a possibility of machine tipping
over when working on rough terrain or on slopes. Prevent
machine tipping over from occurring. When operating on
rough terrain or on slopes:
xReduce the engine speed.
xSelect slow travel speed mode.
xOperate the machine slowly and be cautious with
machine movements.
Install OPG Guard
In case the machine is operated in areas where the possibilities
of falling stones or debris exist, equip Hitachi OPG guard.
Consult your authorized dealer for installing the OPG guard.
The guard can be compliant with ROPS standards depending
on the machine specifications.
In order not to impair operator protective structure:
Replace damaged ROPS or OPG guard. Never attempt to repair
or modify the guard.
ROPS: Roll Over Protective Structure
OPG: Operator Protective Guard
M104-05-016
SAFETY
SA-12
SA-490

Provide Signals for Jobs Involving Multiple
Machines
yFor jobs involving multiple machines, provide signals
commonly known by all personnel involved. Also, appoint
a signal person to coordinate the job site. Make sure that all
personnel obey the signal person’s directions.
Confirm Direction of Machine to Be Driven
yIncorrect travel pedal/lever operation may result in serious
injury or death.
xBefore driving the machine, confirm the position of the
undercarriage in relation to the operator’s position. If the
travel motors are located in front of the cab, the machine
will move in reverse when travel pedals/levers are
operated to the front.
SA-481
SA-491
SAFETY
SA-13

Drive Machine Safely
yBefore driving the machine, always confirm that the travel
levers/pedals direction corresponds to the direction you
wish to drive.
xBe sure to detour around any obstructions.
xAvoid traveling over obstructions. Soil, fragments of rocks,
and/or metal pieces may scatter around the machine. Do
not allow personnel to stay around the machine while
traveling.
yDriving on a slope may cause the machine to slip or
overturn, possibly resulting in serious injury or death.
xNever attempt to ascend or descend 35 degrees or
steeper slopes.
xBe sure to fasten the seat belt.
xWhen driving up or down a slope, keep the bucket facing
the direction of travel, approximately 0.2 to 0.3 m (A)
above the ground.
xIf the machine starts to skid or becomes unstable,
immediately lower the bucket to the ground and stop.
xDriving across the face of a slope or steering on a
slope may cause the machine to skid or turnover. If
the direction must be changed, move the machine to
level ground, then, change the direction to ensure safe
operation.
A
A
SA-657
SA-658
SA-441
SA-590
WRONG
SAFETY
SA-14