Hitachi ZAXIS ZX470-5 class, ZX670-5 class, ZX870-5 class Assembly Procedure Manual KO-493-02

Foreword
Assembly work is the final touch that gives the machine life. The quality of a machine's
assembly affects its operative performance and service life of the machine.
Because a machine's value is determined by its assembly, those who do this work are
required to have sufficient know-how about assembly.
This manual basically contains assembly know-how such as methods and useful hints for
assembling the ZX470-5 class, ZX670LC-5 class, ZX870-5 class hydraulic shovels. Please
read this manual carefully and try to keep it for reference before you engage in assembly
or while you work.

Table of Contents

1. Precautions …………………………………………………………………………………………………………… 1
1-1. Safety precautions for servicemen …………………………………………………………………………… 1
1-2. How to use a power wrench ………………………………………………………………………………… 19
1-3. Work precaution ……………………………………………………………………………………………… 23
2. Work Plan and Preparations ……………………………………………………………………………………… 33
2-1. Work plan (backhoe front) …………………………………………………………………………………… 33
2-2. Transport………………………………………………………………………………………………………… 35
2-3. Transport arrangements ……………………………………………………………………………………… 45
3. Parts Check …………………………………………………………………………………………………………… 49
3-1. Check …………………………………………………………………………………………………………… 49
4. Preparation …………………………………………………………………………………………………………… 51
4-1. Preparation for ZX470-5 class (backhoe front) …………………………………………………………… 51
4-2. Preparation for ZX670LC-5 class (backhoe front) ………………………………………………………… 53
4-3. Preparation for ZX870-5 class (backhoe front) …………………………………………………………… 53
5. Machines, Apparatuses, Tools and Materials necessary for Assembly …………………………………… 55
6. Assembly of Undercarriage and Superstructure ……………………………………………………………… 63
6-1. Preparation ……………………………………………………………………………………………………… 63
6-2. Connection of undercarriage and superstructure ………………………………………………………… 65
6-2-1. Connecting the superstructure (with track cente frame) and side frame ………………………………… 67
6-2-2. Connecting the track center frame and side frame ………………………………………………………… 79
6-2-3. Connecting the undercarriage and superstructure ………………………………………………………… 91
6-3. Connection of travel hoses and installation of steps, handrails ………………………………………… 109
6-4. Greasing of swing bearing ………………………………………………………………………………… 119
6-5. Final check of superstructure ……………………………………………………………………………… 121
6-6. Releasing the air from the main pump …………………………………………………………………… 131
6-7. Trial operation of superstructure …………………………………………………………………………… 133
7. Assembly Procedure for Backhoe Front ……………………………………………………………………… 137
7-1. Preparation …………………………………………………………………………………………………… 137
7-2. Preparing to assemble the backhoe front ………………………………………………………………… 139
7-3. Installing the boom ………………………………………………………………………………………… 149
7-4. Installing the arm …………………………………………………………………………………………… 161
7-5. Installing the bucket ………………………………………………………………………………………… 175
7-5'. Installing the bucket ………………………………………………………………………………………… 183
7-6. Installing the counterweight ………………………………………………………………………………… 197
7-7. Bleeding the all cylinders and checking for hoses interference ………………………………………… 205
7-8. Adjusting the track link tension …………………………………………………………………………… 209
7-9. Final check of trial operation ……………………………………………………………………………… 211
7-10. Applying grease to the backhoe front …………………………………………………………………… 213
7-11. Disassembly procedure for shipment ……………………………………………………………………… 215
8. Side Frame Extension and Retraction Method ……………………………………………………………… 241
9. Post-assembly Inspection ……………………………………………………………………………………… 253
10. Checking Machine Performance ……………………………………………………………………………… 259
11. Appendix (drawings of lifting parts) …………………………………………………………………………… 267
11-1. ZX470-5 class superstructure lifting parts ……………………………………………………………… 269
11-2. ZX670LC-5 superstructure lifting parts …………………………………………………………………… 273
11-3. ZX870-5 class superstructure lifting parts ……………………………………………………………… 277
11-4. Instructions for lifting the base machine assembly ……………………………………………………… 281
ASSEMBLY CHECK SHEET ……………………………………………………………………………………… 285