Zaxis 470 pdf

Never use highly flammable oil such as fuel oil and gasoline to clean parts or surfaces. Disconnect battery ground cable - before making adjustments to electrical systems or before performing welding on the machine. Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the machine. Always use a work light protected with a guard.

In case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire. This tag is available from your authorized dealer. Do not support the machine on cinder blocks, hollow tires, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack.

Failure to follow the precautions below may result in serious injury, blindness, or death. Inadvertent disassembling of the track adjuster may cause the parts such as a spring to fly off, possibly resulting in severe personal injury or death. Keep children and bystanders away from storage areas. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns. DO NOT remove the radiator cap until the engine is cool.

When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap. Again, be sure to release all pressure before removing the cap. The engine, hoses, lines and other parts become hot as well.

It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone. Wear a face shield or goggles for eye protection. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

Always check key switch function before operating the machine every day: 1. Start the engine and run it at slow idle. Turn the key switch to the OFF position to confirm that the engine stops. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.

Store flammable objects in a safe place before starting welding. Never allow an unqualified person to perform welding. Store flammable objects in a safe place before starting grinding.

Install temporary fire-resistant guards to protect hoses or other materials before engaging in welding, soldering, etc.. If inhaled, these fumes may cause sickness. Dispose of paint and solvent properly. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding.

Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. Inhalation of asbestos fibers may be the cause of lung cancer. Spray water to prevent asbestos from becoming airborne. Use only genuine Hitachi Parts. Use a voltmeter or hydrometer. There is fear of explosion. If battery electrolyte is frozen, wait until it is liquefied completely in an atmospheric temperature room.

Explosion of the battery may result. Securely tighten all terminals. If the battery should explode, battery electrolyte may be splashed into eyes, possibly resulting in blindness.

Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paints, and adhesives. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and use recommended equipment. Do not use food or beverage containers that may mislead someone into drinking from them. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.

All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice. Track Revolution Speed T Mistrack Check Operational Performance Standard Table T Dr.

T Sensor Activating Range Swing Speed T Swing Function Drift Check T Swing Motor Leakage T Maximum Swingable Slant Angle T Swing Bearing Play T Hydraulic Cylinder Cycle Time T Dig Function Drift Check T Control Lever Operating Force T Control Lever Stroke Engine Compression Pressure T Valve Clearance T Lubricant Consumption T Secondary Pilot Pressure T Solenoid Valve Set Pressure T Main Pump Delivery Pressure T Fan Pump Delivery Pressure T Swing Motor Drainage T Travel Motor Drainage Group 6 Adjustment Pump Learning T Torque Adjustment Purpose of Performance Tests 1.

To comprehensively evaluate each operational function by comparing the performance test data with the standard values. To economically operate the machine under optimal conditions.

The machine performance does not always deteriorate as the working hours increase. However, the machine performance is normally considered to reduce in proportion to the increase of the operation hours. Operation speed values and dimensions of the new machine. Operational performance of new components adjusted to specifications. Allowable errors will be indicated as necessary. Kinds of Tests 1. Base machine performance test is to check the operational performance of each system such as engine, travel, swing, and hydraulic cylinders.

Hydraulic component unit test is to check the operational performance of each component such as hydraulic pump, motor, and various kinds of valves. Precautions for Evaluation of Test Data 1. To evaluate not only that the test data are correct, but also in what range the test data are. Be sure to evaluate the test data based on the machine operation hours, kinds and state of work loads, and machine maintenance conditions.

Observe the following rules in order to carry out performance tests accurately and safely. Repair any defects and damage found, such as oil or water leaks, loose bolts, cracks and so on, before starting to test. Select a hard and flat surface. Secure enough space to allow the machine to run straight more than 20 m 65 ft 7 in , and to make a full swing with the front attachment extended. If required, rope off the test area and provide signboards to keep unauthorized personnel away.

Before starting to test, agree upon the signals to be employed for communication among coworkers. Once the test is started, be sure to communicate with each other using these signals, and to follow them without fail.

Operate the machine carefully and always give first priority to safety. While testing, always take care to avoid accidents due to landslides or contact with high-voltage power lines.

Always confirm that there is sufficient space for full swings. Avoid polluting the machine and the ground with leaking oil. Use oil pans to catch escaping oil. Pay special attention to this when removing hydraulic pipings. Accurately calibrate test instruments in advance to obtain correct data. Carry out tests under the exact test conditions prescribed for each test item. Repeat the same test and confirm that the test data obtained can be produced repeatedly.

Use mean values of measurements if necessary. The standard performance values are listed in the table below. Refer to the group T to T for performance test procedures. Values indicated in parentheses are reference values. Remarks When boom raise relieving When boom raise relieving When boom raise relieving When boom raise relieving, When Neutral: kPa When boom raise relieving When boom raise relieving When boom raise relieving.

Measure the engine speed by using the monitor unit or Dr. Measure the engine speeds in each mode. NOTE: If the engine speed is not adjusted correctly, all other performance data will be unreliable.

Consequently, measure the engine speed before performing all other tests in order to check that the engine speed meets specification. Preparation: 1. Select the service menu of monitor unit In case of Dr. ZX, install Dr. ZX first. Measurement: 1. Measure the items as shown in the table below. When measuring, set the switch and test condition as shown in the table below in response to the engine speed to be measured.

Digging Mode Check in the Dr. Measure engine speed with the lever in neutral. Measure engine speed while Digging Mode relieving the boom raise circuit. Measure engine speed while relieving the boom raise circuit.

Check engine speed 4 secDigging Mode onds after returning all control levers to neutral. Measure compression pressure in the cylinders and check for a decline in engine power. Check exhaust gas color. Keep track of engine oil consumption. Check for abnormalities in the intake system, including the air filter. Confirm that valve clearances are correct. Confirm that the batteries are charged properly. Run the engine until the coolant temperature gauge reaches the operating range.

Remove the negative terminal of battery. Remove all the glow plugs from each cylinder. Therefore, ECM judges that the fuel system is faulty and the fault code is displayed. After measurement, delete the displayed fault code. Disconnect the connector of injector which is installed to the lower head cover. Install the negative terminal of battery. Turn the starter. Exhaust foreign subjects from the cylinder. Install a pressure gauge Isuzu and an adaptor Isuzu to the glow plug mounting part.

Sufficiently install them in order to prevent air leakage. Turn the starter and measure compression pressure of each cylinder. Repeat the measurement three times and calculate the mean values. Remedy: Refer to the engine workshop manual. Perform the measurement when the engine is cold.

Before starting any work, clean the head cover mounting area and avoid contamination in the engine. Remove the head cover. Remove the terminal nut which secures the harness to the injector. Remove the bolts 2 used. Remove the harness assembly from the injector. Remove the leak off pipe. Rotate the crank pulley. NOTE: When rotating the crank pulley, remove the fan guard. Then, rotate the fan while holding the fan belt. If it is difficult to rotate, remove all glow plugs and release compression pressure.

Check if piston No. If any clearances on the both ends of the push rods are found, piston No. If the exhaust valve of cylinder No. Start measurement from the cylinder No. Insert a thickness gauge into the clearance between rocker arm and cam, and measure the valve clearance. Injection Order: 2. When measurement is started from No. Cylinder No. Valve locations When the measurement is started from No.

Continue measurement of other valves in the same way. Loosen the lock nuts 12 used and adjusting screws 12 used , which secure the bridge and rocker arm. Insert a thickness gauge into the clearance between rocker arm and cam. Tighten the adjusting screw of rocker arm until condition for the thickness gauge is proper. Tighten the lock nut of rocker arm. Tighten the adjusting screw of bridge until the thickness gauge does not move 6.

Tighten the adjusting screw of bridge until condition for the thickness gauge is proper. Tighten the lock nut of bridge. Check the valve clearance after the lock nuts are tightened. Place the machine on level firm ground and leave the machine for at least one hour in order to let the lubricant lower to the oil pan when the engine stops.

At this time, confirm that the machine is level by using a leveler. Record read-out A unit: hour of the hour meter. Replenish the lubricant up to the high-level. Operate the machine for at least hours or until the oil level lowers to the low-level. Record read-out B unit: hour of the hour meter. Replenish the lubricant up to the high-level gauge while measuring the oil-replenishing volume C. NOTE: When measuring, use a high-precision measuring cylinder or the like.

Adjust the track sag on both side tracks equally. Prepare a flat and solid test track 20 m Hold the bucket 0. Measure both the slow and fast speeds of the machine. Measurement conditions are as below. Start traveling the machine in the acceleration zone with the travel levers to full stroke. Measure the time required to travel 20 m Perform the measurement three times and calculate the average values. Adjust the track sag of both side tracks to be equal. Put the mark on the track to be measured, by using a piece of chalk.

Place blocks under the machine frame. Measure the both tracks on forward and reverse directions at each travel mode. Operate the travel control lever of the raised track to full stroke. Measure the time required for 3 revolutions in both directions after a constant track revolution speed is obtained. NOTE: The measurement data obtained through the raised track revolution test may have wide variations. Therefore, the evaluation based on the results obtained from the 20 m travel speed check described before is more recommendable.

Allow the machine to travel 20 m Measure the maximum tread deviation from the tread chord line drawn between the travel start and end points to check the performance equilibrium between both sides of the travel device systems from the main pump to the travel motor. If measured on a concrete surface, the tread deviation has a trend to decrease.

Adjust the track sag of both tracks to be equal. Provide a flat, solid test yard 20 m Measure the amount of mistracking in both fast, and slow travel speeds.

Start traveling the machine in the acceleration zone with the travel levers at full stroke. Measure the maximum distance between a straight 20 m Measure the travel parking brake slip amount while parked.

Climb the slope and place the travel levers in neutral. Stop the engine. After the machine stops, put the matching marks on a track link or shoe, and the track side frame. After 5 minutes, measure the distance between the marks on the track link or shoe and the track side frame.

Alignment marks on the track side frame and shoe when the machine comes to a stop. Displacement measured after 5 minutes. Check the lubrication of the swing gear and swing bearing. Place the machine on flat, solid ground with ample space for swinging. Do not conduct this test on slopes. With the bucket empty, position the front attachment as follows: Backhoe: With the arm cylinder fully retracted, and the bucket cylinder fully extended, raise the boom so that the arm tip pin height is flush with the boom foot pin height.

Loading Shovel: With the arm cylinder and the bucket cylinder fully extended, raise the boom so that the arm tip pin height is flush with the boom foot pin height.

NOTE: In case of no place to be measured, measure with the boom raised and the arm rolled-in. Always make sure that the area is clear and that co-workers are out of the swing area before starting the measurement. Operate swing control lever fully. Measure the time required to swing 3 turns in one direction.

Operate swing control lever fully in the opposite direction and measure the time required for 3 turns. Do not conduct this test on a slope. Loading shovel: With the arm cylinder and the bucket cylinder fully extended, raise the boom so that the arm tip pin height is flush with the boom foot pin height.

Put the matching marks on the swing bearing and on the track frame by using a tape, as illustrated. Measure the distance between the two marks. Load bucket fully. In lieu of loading the bucket, weight W of the following specification can be used. Position the front attachment as follows: Backhoe: With the arm cylinder fully retracted, and the bucket cylinder fully extended, raise the boom so that the arm tip pin height is flush with the boom foot pin height.

Park the machine on a smooth slope with a gradient of Put the matching marks on the swing bearing periphery and track frame by using a tape, as illustrated. Maintain the engine at slow idle. After five minutes, measure the difference between the marks along the swing bearing periphery and the track frame. Perform the measurement in both right and left swing directions.

Check that the swing gear and bearing are well lubricated. Position the front attachment as follows: Backhoe: With the arm cylinder fully retracted and the bucket cylinders fully extended. Loading shovel: With the arm cylinder fully extended and the bucket cylinders fully extended. Hold the arm tip pin to the position flush with the boom foot pin height. Operate the swing lever to full stroke to swing the upperstructure to the uphill side.

If the machine can swing, measure the cab floor slant angle. Increase the slope angle and repeat the measurement.

Check both clockwise and counterclockwise. Check swing bearing mounting bolts for looseness. Check the lubrication of the swing bearing. Confirm that bearing rotation is smooth and without noise. Install a dial gauge on the track frame as shown by using a magnetic base.

Position the upperstructure so that the boom aligns with the tracks facing towards the front idlers. Position the dial gauge so that its needle point comes into contact with the bottom face of the bearing outer race. Bucket should be empty. NOTE: The measured value will vary depending on where the magnet base is secured. Secure the magnet base onto the round trunk or in a position as close to the round trunk as possible. Position the front attachment as follows: Backhoe: With the arm cylinders fully retracted and the bucket cylinders fully extended, position the arm tip pin height is flush with the boom foot pin height.

Loading shovel: With the arm cylinder fully extended and the bucket cylinders fully extended, position the arm top pin height is flush with the boom foot pin height.

Lower the bucket to the ground and use it to raise the front idler 0. Record the dial gauge reading h2. Position the front attachment as described in the following. Then, measure the operating time until the cylinder reaches the stroke end by fully moving the control lever. Arm Cylinder: Retract the bucket cylinder so that the arm and bucket teeth are vertical to the ground.

Adjust the boom cylinder stroke so that the bucket bottom height is 0. Set the arm so that the center of arm operation is vertical. Bucket Cylinder: Adjust the boom and arm cylinder so that the center of full stroke movement of the bucket is positioned vertically. Boom Cylinder: With the bucket cylinder and the arm cylinder fully extended, lower the bucket to the ground. Arm Cylinder: With the arm fully retracted, position the bucket so that the rear bucket does not come in contact with the arm stopper.

Then, adjust the boom cylinder stroke to position the bucket bottom 1 m 39 in above the ground. Bucket Cylinder: With the bucket closed and held in a load dump position, adjust the boom cylinder stroke so that bucket bottom height is approx. Bucket Open-Close Cylinder: With the bucket cylinder and arm cylinder fully extended, adjust the boom cylinder stroke so that the bucket bottom height approx. NOTE: When testing the dig function drift just after cylinder replacement, slowly operate each cylinder to its stroke end to release air.

Position the front attachment as follows: Backhoe: With the arm cylinder fully retracted and the bucket cylinder fully extended.

Loading shovel: With the arm cylinder and the bucket cylinder fully extended. Raise the boom so that the arm tip pin height is flush with the boom foot pin height concerning backhoe and loading shovel. With the arm rolled out and the bucket rolled in, hold the bucket so that the height of the bucket pin is the same as the boom foot pin. Five minutes after the engine has been stopped, measure the change in the position of the bottom of the bucket, as well as the boom, arm and bucket cylinders.

Measure each lever operating force using a spring scale 2. Measure the maximum lever operating force at the grip center of each control lever. Check the control lever condition.

Measure each control lever. Operate each boom raise arm and bucket lever to the fully and measure the maximum operating force for each with each actuator relieved. Operate boom lower lever and measure the maximum operating force with the boom lower relieved by jacking up the machine in a safe area. Operate swing lever and measure the maximum operating force with swing relieved after securing the front attachment to prevent swinging.

Lower the bucket to the ground to raise one track off the ground. Operate the travel lever to full stroke and measure the maximum operating force required. When finished, lower the track and then jack-up the other track. Check the lever stroke play and the lever operating condition. Measure each lever stroke at the lever top using a ruler. Measure the lever stroke at the grip center of each control lever. NOTE: When the lever has play, take a half of this value and add it to the measured stroke.

Measure each lever stroke at the lever top from neutral to the stroke end using a ruler. Summary: Check boom raise and swing movement speeds while operating both functions simultaneously. Start the engine and run it at fast idle. Operate the boom raise function and check to be sure that the cylinder movement is smooth, with out sticking. Position the machine with front attachment positioned as illustrated and with the bucket empty.

Always make sure that the area is clear and that coworkers are out of the swing area before starting the measurement. Raise the boom and swing simultaneously. Push the air bleed valve on top of the hydraulic oil tank and release any remaining pressure. Remove the plug from the pilot filter.

Install adapter ST and pressure gauge ST to the pressure check port. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connection. Measure pilot pressure in each specified setting above without load. Repeat the measurement three times and calculate the average values. Remove plug 1 from the relief valve.

Install the estimated number of shims 2. After adjustment, tighten plug 1. After adjustment, check the set pressure. Measure pressure at the location between pilot valve and signal control valve.

Remove the pilot hose from the circuit to be measured. Measure pilot pressure by using a pressure gauge with the corresponding control lever operated to full stroke.

Connect Dr. ZX and select the monitoring function. When Dr. ZX is not available, use the pressure gauge. Remove the line from the solenoid valve to be measured. Solenoid Valve SF: Combined operation of boom lower and arm, or boom lower and bucket. Operate the front and swing operation. Read the values on both Dr. ZX and the pressure gauge. Do not loosen adjusting screw 8 more than 2 turns. Loosen lock nut 7.

Turn adjusting screw 8 and adjust the set pressure. After adjustment, tighten lock nut 7. Remove the plug of pressure check port from the main pump delivery port. Measurement Conditions are below. Measure pressure with the control levers in neutral without load. Remove the plug of pressure check port from the fun pump delivery port. First, slowly operate the bucket, arm and boom control levers to the stroke end and relieve each function. As for the swing function, secure the upperstructure so it is immovable.

Slowly operate the swing lever and relieve the swing function. As for the travel function, secure the tracks against an immovable object. For lifting capacities, subtract bucket and quick hitch weight from lifting capacities without bucket. Standard and optional equipment may vary by country, so please consult your Hitachi dealer for details. If not so, please make modifications accordingly.

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