Zx-5 - Ko-493-01 Assemble Manual of Excavators Good

KO-493-01
ASSEMBLY
PROCEDURE
MANUAL
ZX470 -5 class ZX670-5 class ZX870-5 class

ZAXIS-5B series ZAXIS-5B series ZAXIS-5B series
470-5B 670LC-5B 870-5B
470LC-5B 670LCH-5B 870LC-5B
470H-5B 670LCR-5B 870H-5B
470LCH-5B ZAXIS-5G series 870LCH-5B
470R-5B 670LC-5G 870R-5B
470LCR-5B 670LCH-5G 870LCR-5B
ZAXIS-5G series 670LCR-5G ZAXIS-5G series
470-5G 870-5G
470LC-5G 870LC-5G
470H-5G 870H-5G
470LCH-5G 870LCH-5G
470R-5G 870R-5G
470LCR-5G 870LCR-5G
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.
This manual is a practical compilation of the following three viewpoints: "the improvement
of work safety", "the improvement of efficiency" and "the enhancement of product quality."
1) Safety: Some hints and information for safe work are provided, such as the
weight of the parts, their lifting points when raised with wire ropes or
nylon slings and their handling procedure.
Work safety is attained with this manual.
2) Quality: Procedures and hints are described for correct machine assembly. They
include the part numbers, tightening torque values of bolts, etc. Correct
assembly is essential to provide the machine with a longer service life at
maximum performance.
3) Efficiency: Tool jigs, the facilities necessary to do the work and the preparation
needed for each work stage are introduced to assure speedy and
effective completion.
We hope this manual will be helpful to you in assembling the machine without a hitch.
ZX-5B series ZX870-5B series
ZX670LC-5B series
ZX470-5B series
Fig. 1
i
ZX-5G series ZX870-5G series
ZX670LC-5G series
ZX470-5G series
Fig. 2
ii
Table of Contents
Page
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 ………………………………………………………………………127
6-7. Trial operation of superstructure ……………………………………………………………………………129
7. Assembly Procedure for Backhoe Front ………………………………………………………………………133
7-1. Preparation ……………………………………………………………………………………………………133
7-2. Preparing to assemble the backhoe front …………………………………………………………………135
7-3. Installing the boom ……………………………………………………………………………………………145
7-4. Installing the arm ………………………………………………………………………………………………157
7-5. Installing the bucket ……………………………………………………………………………………………171
7-5'. Installing the bucket ……………………………………………………………………………………………179
7-6. Installing the counterweight …………………………………………………………………………………193
7-7. Bleeding the all cylinders and checking for hoses interference …………………………………………201
7-8. Adjusting the track link tension ………………………………………………………………………………205
7-9. Final check of trial operation …………………………………………………………………………………207
7-10. Applying grease to the backhoe front ………………………………………………………………………209
7-11. Disassembly procedure for shipment ………………………………………………………………………211
8. Side Frame Extension and Retraction Method …………………………………………………………………225
9. Post-assembly Inspection …………………………………………………………………………………………237
10. Checking Machine Performance …………………………………………………………………………………241
11. Appendix (drawings of lifting parts) ……………………………………………………………………………249
11-1. ZX470-5 class superstructure lifting parts …………………………………………………………………251
11-2. ZX670LC-5 superstructure lifting parts………………………………………………………………………255
11-3. ZX870-5 class superstructure lifting parts …………………………………………………………………259
11-4. Instructions for lifting the base machine assembly …………………………………………………………263
■ ASSEMBLY CHECK SHEET ………………………………………………………………………………………267
iii
iv
ZX470-5B series assembly procedure chart
Backhoe front
Model Code: ZX470-5B / ZX470LC-5B / ZX470H-5B / ZX470LCH-5B / ZX470R-5B / ZX470LCR-5B

Engine Rated Power: 270 kW (362 HP)
Operating Weight: ZX470-5B: 4 600 kg / ZX470LC-5B: 46 900 kg
ZX470H-5B: 47 500 kg / ZX470LCH-5B: 48 500 kg
ZX470R-5B: 48 300 kg / ZX470LCR-5B: 49 300 kg
Backhoe Bucket: ISO Heaped: 1.15 - 2.30 m3
Fig. 1
ZX670LC-5B series assembly procedure chart

Backhoe front
Model Code: ZX670LCH-5B / ZX670LCR-5B

Operating Weight: ZX670LCH-5B: 68 300 - 69 800 kg
ZX670LCR-5B: 69 300 - 69 500 kg
Backhoe Bucket: ISO Heaped: ZX670LCH-5B: 1.80 - 3.30 m3
ZX670LCH-5B: 1.80 - 3.30 m3
Fig. 2
ZX870-5B series assembly procedure chart

Backhoe front
Model Code: ZX870-5B / ZX870LC-5B / ZX870H-5B / ZX870LCH-5B / ZX870R-5B / ZX870LCR-5B

Operating Weight: ZX870-5B / ZX870H-5B / ZX870R-5B: 80 700 kg
ZX870LC-5B / ZX870LCH-5B / ZX870LCR-5B: 82 400 kg
Backhoe Bucket: ISO Heaped: ZX870-5B 2.8 - 4.3 m3
ZX870LC-5B 2.9 - 4.5 m3
Fig. 3
v
ZX470-5G series assembly procedure chart
Backhoe front
Model Code: ZX470-5G / ZX470LC-5G / ZX470H-5G / ZX470LCH-5G

Operating Weight: ZX470-5G: 45 600 kg / ZX470LC-5G: 46 800 kg
ZX470H-5G: 46 700 kg / ZX470LCH-5G: 47 800 kg
Fig. 1
ZX670LC-5G series assembly procedure chart

Backhoe front
Model Code: ZX670LCR-5G / ZX670LCH-5G

Operating Weight: ZX670LC-5G: 66 800 kg
ZX670LCH-5G: 68 200 kg
Fig. 2
ZX870-5G series assembly procedure chart

Backhoe front
Model Code: ZX870-5G / ZX870LC-5G / ZX870H-5G / ZX870LCH-5G

Operating Weight: ZX870-5G: 80 800 kg / ZX870LC-5G: 82 600 kg
ZX870H-5G: 82 300 kg / ZX870LCH-5G: 84 200 kg
Fig. 3
vii
1. Precautions
1-1 Safety precautions for servicemen
1 RECOGNIZE SAFETY INFORMATION

This is the safety-alert symbol. When you see this
symbol on your machine or in this manual, be alert to
the potential for personal injury.
Follow recommended precautions and safe operating

practices.
Fig. 1-1
2 UNDERSTAND SIGNAL WORDS

Machine safety signs incorporate signal words -
DANGER, WARNING and CAUTION - to designate the
degree or level of hazard.
DANGER indicates an imminently hazardous situation

which, if not avoided, will potentially result in death or
serious injury.
WARNING indicates a potentially hazardous situation

which, if not avoided, could result in death or serious
injury.
CAUTION and NOTE provide cautionary remarks and

references on assembly.
They indicate a potentially hazardous situation which,
if not avoided, may result in minor or moderate injury.
DANGER and WARNING safety signs are located near

specific hazards.
General precautions are listed on CAUTION safety
signs. CAUTION also calls attention to safety items in
this manual. Fig. 1-2
To avoid confusing machine protection with personal

safety messages, IMPORTANT is used to indicate a
situation which, if not avoided, could result in damage
to the machine.
1
3 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 Hitachi dealer in the
same way as you order other replacement parts (be
sure to state the machine model and serial number
when ordering.) Fig. 1-3
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 to the machine may impair
its functions and safety, and affect machine life.
The safety messages in this chapter are intended to
illustrate basic safety procedures for hydraulic
excavators. 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 before operating or performing
maintenance work on the machine.
4 DESIGNATE ONE LEADER AND TWO

SUBLEADERS
In order to work with the greatest safety and ease,
designate a foreman and two subleaders as working
partners. When assembling the superstructure, station
the subleaders at the front and rear of the machine.
They should carry out and follow the leader's signals
with utmost care to avoid breakage of components and
personal injury.
• Briefing on work procedure
To ensure absolute safety, provide an explanation on Fig. 1-4
the work order, responsibilities of each worker,
cautionary remarks and such to all related staff.
• Decide in advance the signal method, signal
persons, supervisor, signal method between the
driver and signal person.
Only have one signal person for the work.
Everyone obeys the signals of the signal person to
proceed with the work.
To have several signal persons can confuse the
workers and lead to accidents.
5 CLEAN THE MACHINE REGULARLY

Remove any grease, oil or dirt build-up to avoid
possible injury or machine damage.
Do not spray water or steam inside the cab.

Fig. 1-5
2
6 Cautionary remarks for the slinging work
1 Deciding the signal method and supervisor
The signal method is decided by the driver and signal

person.
Only have one signal person for the work.
Everyone obeys the signals of the signal person.
To have several signal persons can confuse the
workers and lead to accidents.
Fig. 1-6
2 Use of a protector
To hang a wire rope over an angular material, put a

protector inside the material so that it doesn’t damage.
3 Cautionary remarks for load suspension
• Use a hook that comes with a stopper.
• Use a sling rope, suspension chain or nylon sling of

the mandated strength.
• Never pass a hanging load over someone’s head.
• Make sure that no one goes directly under the

suspending load. Fig. 1-7
4 Manual adjustment of the wire rope
After using the wire rope, correct the torsion, bend and
return to the designated place.
CAUTION:
A qualified worker undertakes crane work and sling
work.
Fig. 1-8
3
7 WEAR PROTECTIVE CLOTHING
Do not wear loose clothes and accessories. These can
get caught in the control lever or other machine parts.
Wear close fitting clothing and safety equipment

appropriate to the job.
You may need:

• A hard hat
• Safety shoes
• Safety glasses, goggles, or a face shield
• Heavy gloves
• Hearing protection
• Reflective clothing
• Wet weather gear
• Respirator or filter mask. Fig. 1-9
8 PREPARE FOR EMERGENCIES

Be prepared for the eventuality of a fire.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance

service, a hospital, and the fire department near your
telephone. Fig. 1-10
9 PREPARE SUITABLE LIFTING TOOLS

Work with this machine involves lifting heavy and bulky
items with a crane. Pay attention to the following
points:
a) Prepare suitable lifting tools.
b) To prevent unnecessary breakdowns due to broken
parts, do not use damaged chains or frayed cables,
nylon slings, or wire ropes.
Be sure to use a proper protector and patch.
c) Before proceeding with the work, agree on specific
signals with the crane operator and the designated
leader/subleader team.
d) Always keep the area directly below any load clear
of people during slinging work.
e) Service personnel and mechanics must check the
Fig. 1-11
weights given in this manual, and apply the proper
lifting procedures when removing any components.
f) When using hydraulic excavators for lifting
operations, be sure to comply with all local
regulations.
4
10 ENGINE SAFETY
a) No one should be allowed inside the hydraulic
excavator while it is being operated or during
assembly.
b) Keep hands away from moving parts.
c) Sound the horn as an alert to those nearby before
starting up the engine.
d) Start the engine from the operator's seat and never
while standing on the ground.
e) To avoid injury or possible machine damage, never
start the engine by shorting across the starter
terminals.
Fig. 1-12
11 SUPPORT RAISED EQUIPMENT

Never work under or near a raised bucket. Lower the
bucket to the ground or onto secure blocks.
12 SAFETY AT HEIGHT Fig. 1-13

Take adequate measures to avoid falling from high
spots during work. Clean any mud or debris from the
steps, walkways, or work platforms before work, and
use a safety belt during work.
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
handholds.
Before getting off, be sure to align the cab parallel with
the tracks.
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 getting off the machine.
Fig. 1-14
5
13 FUEL SAFETY AND FLAMMABLE
MATERIALS
a) Never smoke while refueling or handling flammable
materials.
b) Shut the engine off while refueling.
c) Exercise caution when refueling while the engine is
still hot.
d) Do not clean parts using opened cans of gasoline
or diesel fuel. Use good, commercial, non-
flammable solvents.
Fig. 1-15
14 PREVENT BATTERY EXPLOSIONS

Keep sparks, lighted matches, and flame away from
the top of the battery. Battery gas can explode.
Never check the battery charge by placing a metal

object across the posts. Use a voltmeter or hydrometer.
Do not charge a frozen battery - it may explode. Warm

the battery to 16°C (60.8°F).
Disconnect the negative ground cable before working

on the electrical system or making major repairs.
Fig. 1-16
Fig. 1-17
6
15 AVOID HIGH-PRESSURE FLUIDS
• Fluids such as diesel fuel or hydraulic oil under
pressure, can penetrate the skin or eyes causing
serious injury, blindness or death.
• Avoid this hazard by relieving pressure before

disconnecting hydraulic or other lines.
Relieve the pressure by moving the control levers
several times.
Tighten all connections before pressurizing the
hydraulic system.
• Search for leaks with a piece of cardboard, taking

care to protect your hands and body from high-
pressure fluids. Wear a face shield or safety goggles
for eye protection.
• If an accident occurs, see a doctor familiar with this Fig. 1-18

type of injury immediately.
Any fluid injected into the skin must be surgically
removed within a few hours, or gangrene may result.
Fig. 1-19 Fig. 1-20 Fig. 1-21
16 CHECK EQUIPMENT SAFETY

a) Use a piece of cardboard or paper to safely check
for leaks in all systems, including the following:
Hydraulic system
Fuel system
b) Use the correct testing gauge type when checking
the hydraulic pressure.
c) Check all protective parts on the machine (shields,
guards, pins, etc.). They should be in good
condition and securely fastened.
d) Inspect electrical wiring for worn or frayed
insulation, and install new wiring if damage has
occurred.
Fig. 1-22
7
17 PROTECT AGAINST NOISE
Prolonged exposure to loud noise can cause
impairment or loss of hearing.
Wear a suitable hearing protective device such as

earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.
Fig. 1-23
18 FASTEN YOUR SEAT BELT

Prior to operating the machine, thoroughly examine the
belt, buckle and attaching hardware. If any item is
damaged or worn, replace the seat belt or component
in question before operating the machine.
Be sure to remain seated with seat belt securely

fastened at all times when the machine is in operation.
Fig. 1-24
19 BEWARE OF EXHAUST FUMES

Prevent asphyxiation. Engine exhaust fumes can cause
sickness or death.
If you must operate in a building, be sure there is

adequate ventilation. Either use an exhaust pipe
extension to remove the exhaust fumes, or open doors
and windows to bring enough fresh air into the area.
Fig. 1-25
8
20 PRACTICE SAFE MAINTENANCE
Understand service procedures before performing any
work. Keep the work area clean and dry.
Never lubricate or service the machine while it is

moving.
Keep hands, feet and clothing away from power-driven
parts.
Before servicing the machine.
• Park the machine on a level surface.

• Lower the bucket to the ground.
Fig. 1-26
• Turn the auto-idle switch off.
• Run the engine at slow idle speed without load for 3
minutes.
• Turn the ignition OFF to stop the engines.
• Relieve the pressure in the hydraulic system by
moving the control levers several times.
• Remove the key from the ignition.
• Attach a "Do Not Operate" tag to the travel speed
select/pilot control shut-off lever
• Set the travel speed select/pilot control shut-off lever
to the P position.
• Allow the engine to cool.
If a maintenance procedure must be performed with the

engine running, do not leave the machine unattended.
If the machine must be raised, maintain a 90 to 110˚

angle between the boom and arm. To lift parts of the
machine for the servicing work, securely support with
90° ~ 110°
wooden blocks, etc. of satisfactory strength.
Never work under a machine raised by the boom.
Inspect certain parts periodically, and repair or replace

as necessary. Refer to the relevant section of the Wooden block
Operation Manual. Fig. 1-27
Keep all parts in good condition and properly installed.

Fix any damage immediately. Replace worn or broken
parts. Remove any buildup of grease, oil or debris.
Disconnect the battery ground cable (-) before making

adjustments to the electrical system or performing
welding work on the machine.
9
21 WARN OTHERS OF SERVICE WORK
Unexpected machine movement can cause serious
injury.
Before performing any work on the machine, attach a

"DO NOT OPERATE" tag to the travel speed
select/pilot control shut-off lever.
This tag is available from your authorized dealer.
Fig. 1-28
22 PEEL OFF THE PAINT BEFORE YOU

WELD OR HEAT
• To weld, solder or torch-heat without peeling off the
paint can generate toxic fumes, and this is
detrimental to the health.
• Peel off the paint before you begin to weld or heat.
• Avoid producing toxic fumes or dust.
• Work outside or in a well-ventilated location.
• After peeling off the paint, wait at least 15 minutes
before you weld or heat.
• To peel off the paint, be careful with the following.
1) To remove the paint using a grinder, wear a
mask to avoid inhaling any dust.
2) If you use a solvent, wash your hands with soap
and water before welding to wash away any
combustible substances of the solvent.
3) Don’t place the solvent near flammables.
Fig. 1-29
23 PROTECT AGAINST FLYING DEBRIS

Guard against injury from flying pieces of metal or
debris - wear goggles or safety glasses.
In order to avoid personal injury, keep bystanders away

from the working area when striking any object.
Fig. 1-30
10
24 PREVENT AGAINST FLYING PARTS
Grease in the track adjuster is under high pressure.
Do not attempt to remove a GREASE FITTING or
VALVE ASSEMBLY.
Be sure to keep your body and face away from any
valve, as pieces may fly off.
The travel reduction gears are under pressure.
So as to avoid injury from flying parts, be sure to keep
your body and face away from the AIR RELEASE
PLUG.
GEAR OIL is hot. Wait for the GEAR OIL to cool, then Fig. 1-31
gradually loosen the AIR RELEASE PLUG to release
pressure.
25 PREVENT BURNS
Hot spraying fluids:
• After operation, the engine coolant is hot and under
pressure. Also, hot water or steam is contained in the
engine, radiator and heater lines.
Prevent possible injury from hot spraying water.
DO NOT remove the radiator cap until the engine is
cool. When opening, turn the cap slowly to the stop
position.
Allow all pressure to release before removing the
cap. Fig. 1-32
• The hydraulic oil tank is pressurized. Again, be sure

to release all pressure before removing the cap.
Hot fluids and surfaces:

• Skin contact with escaping hot water or steam can
cause severe burns.
Be sure to stop the engine, and let the engine and
radiator cool. Once the system has cooled, slowly
loosen the radiator cap to release pressure, then
remove it.
• Engine oil, gear oil and hydraulic oil also become hot
during operation.
The engine, hoses, lines and other parts also
become hot. HotSurface Fig. 1-33
Wait for the oil and components to cool before
starting any maintenance or inspection work.
26 STORE ATTACHMENTS SAFELY

Stored attachments such as buckets, hydraulic
hammers, and blades can fall and cause serious injury
or death.
Securely store attachments and implements to prevent

them falling. Keep playing children and bystanders
away from the storage area.
Fig. 1-34
11
27 DISPOSE OF WASTE PROPERLY
Improper waste disposal can threaten the environment
and ecology. Potentially harmful waste used with
HITACHI equipment includes such items as oil, fuel,
coolant, brake fluid, filters, and batteries.
Use leakproof containers when draining fluids. Do not

use food or beverage containers that may mislead
someone into drinking from them.
Do not pour waste onto the ground, down a drain, or Fig. 1-35
into any water source.
Allowing air conditioning refrigerants to escape into the

air can damage the Earth's atmosphere. Government
regulations may require a certified air conditioning
service center to recover and recycle used air
conditioning refrigerants.
Inquire as to the proper way to recycle or dispose of

waste from your local environmental or recycling
center, or from your HITACHI dealer.
28 SERVICE THE AIR CONDITIONING

SYSTEM SAFELY
Refer to the outside of the freon container for proper
handling procedures when servicing the air
conditioning system.
Use a recovery and recycling system to avoid venting
freon into the atmosphere.
Never let the freon stream make contact with your skin.
Severe frost burns will result.
29 HANDLE CHEMICAL PRODUCTS SAFELY

Direct exposure to hazardous chemicals can cause
serious injury. Potentially hazardous chemicals used
with your machine include such items as lubricants,
coolants, paint, and adhesives.
Fig. 1-36
12
30 HANDLE POWER WRENCHES
CORRECTLY
Misuse of power wrenches (part nos. 4093800 and
4229414) may lead to their breakage or personal injury.
Please use power wrenches correctly and in
accordance with this manual.
1 For your safety, do not enter into the turning circle

of the wrench. After tightening is complete, a
torque acting in the opposite direction will be
applied to the wrench. Therefore, do not suddenly
let go of the handle, but let it gently rotate back in
the opposite direction until the torque is zero.
Fig. 1-37
2 Excessive input torque may cause the output end

or reaction lever to break, causing the wrench to
fall from the machine. The wrench may also fall if
it slips off the reaction member. Secure the
wrench so that it cannot drop, especially when
working on vertical surfaces.
Fig. 1-38 Fig. 1-39
3 It is sometimes difficult to remove the power

wrench from a nut or bolt after tightening.This is
generally due to elastic deformation (elastic force)
between the wrench and bolt. Try changing the
clutch direction to L to make the wrench easier to
remove. Release the torque on the ratchet handle
gradually, since a force will be acting in the
opposite direction after changing over the clutch. If
Fig. 1-40
it is not possible to change the clutch by hand, do
not attempt to use force (a hammer, etc.).
• Try turning the wrench handle slightly in the L

direction to make the clutch easier to change
over.
1
Switching of clutch
L (counterclockwise)
R (clockwise)
Fig. 1-41
2
Fig. 1-42
13
31 COMMUNICATION
1 When slinging work is performed on heavy loads,
a predetermined hand signalling method should
be used for trouble-free communication.
2 In order to facilitate remote teamwork during

assembly, workers should wear headsets for
reliable communication.
Fig. 1-43
32 -a COMPONENT NAMES (ZX470-5B series) 1 Bucket 8 Hydraulic Oil Tank

2 Bucket Cylinder 9 Engine
3 Arm 10 Counterweight
4 Arm Cylinder 11 Travel Device
3 5 Boom Cylinder 12 Track link
6 Boom 13 Front Idler
4
7 Fuel Tank 14 Cab
2
5
7
8
9
1
14
13 10
12
Fig. 1-44-a
14 11
32 -b COMPONENT NAMES (ZX670LC-5B series) 1 Bucket 8 Hydraulic Oil Tank
3 4 5 Boom Cylinder 12 Track link
2 6 Boom 13 Front Idler
7 Fuel Tank 14 Cab
6
7
9
1
14
13
10
12
11
Fig. 1-44-b
32 -c COMPONENT NAMES (ZX870-5B series)
1 Bucket 8 Hydraulic Oil Tank
3 3 Arm 10 Counterweight
4
7 Fuel Tank 14 Cab
6
7
8
9
14
13
10
12
11 Fig. 1-44-c
15
32 -d COMPONENT NAMES (ZX470-5G series) 1 Bucket 8 Hydraulic Oil Tank
3 4 Arm Cylinder 11 Travel Device
2
7 Fuel Tank 14 Cab
6
7
9
1
14
13 10
12
11 Fig. 1-44-d
32 -e COMPONENT NAMES (ZX670LC-5G series)
1 Bucket 8 Hydraulic Oil Tank
3 3 Arm 10 Counterweight
4
5 Boom Cylinder 12 Track link
2
7 Fuel Tank 14 Cab
5
6
7 8
9
14
13 10
12
11 Fig. 1-44-e
16
32 -f COMPONENT NAMES (ZX870-5G series) 1 Bucket 8 Hydraulic Oil Tank
3 4 Arm Cylinder 11 Travel Device
4
5 Boom Cylinder 12 Track link
2 6 Boom 13 Front Idler
7 Fuel Tank 14 Cab
6
7
14
13
10
12
11 Fig. 1-44-f
17
18
1-2 How to use a power wrench
This section describes the correct use of power wrenches. Please note however that, if available, a hydraulic wrench
should be preferred over a power wrench, for reasons of safety and overall quality.
1 METHOD OF USE 4. Input direction selection on the

ratchet handle.
1. Socket selection and mounting. The input direction is set by using
Select the socket which fits most the changeover lever on the
snugly onto the bolt, and mount the ratchet handle.
socket on the wrench. Secure the
socket to the wrench with a 38.1
Changeover lever
mm pin or 25.4 mm bolt.
Fig. 1-49
5. Changeover clutch.
Changeover
Select the input direction by setting clutch
Fig. 1-45
the changeover clutch as detailed
in the figure to right (Fig. 1-50).
2. When accurate torque control is
required.
Set the torque according to the
input/output diagram in Fig. 1-59
(page 21). (Output = input x gear
ratio x efficiency)
Fig. 1-50
Fig. 1-46
6. Completion of work.
On completion of tightening,
3. Check the positioning of the reaction lever.
remove the wrench from the nut or
Depending upon the wrench type the reaction lever usually acts 2
bolt. Elastic deformation (force)
radially. Due to the large reaction force applied to the reaction lever, the
between the wrench and bolt can
reaction lever should be positioned so that it is both secure and stable. 1
make it difficult to remove the
power wrench. In this case,
gradually release the torque on the
ratchet handle and change over
the clutch direction.
Fig. 1-51
Straight type
reaction lever
Fig. 1-47
When using an "L-type" torque wrench, make sure that the distance "L"
between the center of the bolt and support point is at least the figures
shown below. Failing to observe this minimum distance can damage or
break the bolt, or cause the output shaft to become jammed.
Switching of clutch
L (counterclockwise)
R (clockwise)
L type reaction lever
Model L
8-150P 110
8-300P 130
12-450P 145
12-600P 160
(Unit: mm) Fig. 1-52
Fig. 1-48
19
2 THE CORRECT HANDLING OF POWER WRENCHES
Misuse of power wrenches (part nos. 4093800 and 4229414) may lead to their breakage or personal injury. Please use
power wrenches correctly and in accordance with this manual.
CAUTION
1. Changing the clutch

· Set the base line of the dial to the R or L marker on the power wrench main body.
Clutch of selection
(Select R for clockwise, L for counterclockwise movement.)
L (counterclockwise) A tightening torque is applied with R and a loosening torque with L. Note that reverse
R (clockwise) operation may damage the clutch.
· The changeover clutch is intended to prevent reverse rotation when the force is released
during a tightening or loosening operation, and is not designed to transmit torque in the
manner of the ratchet handle.
Fig. 1-53
2. Stay away from the ratchet handle

turning circle.
For your safety, do not enter into the turning circle of the wrench. After
tightening is complete, a torque acting in the opposite direction will be
applied to the wrench. Therefore, do not suddenly let go of the handle,
but let it gently rotate back in the opposite direction until the torque is
zero.
Fig. 1-54
3. Don' t drop the wrench.

Excessive input torque may cause the output end or reaction
lever to break, causing the wrench to become removed from
the component. The wrench may also become removed if it
slips off the reaction member. Secure the wrench so that it
cannot fall, especially when working on vertical surfaces.
Fig. 1-55 Fig. 1-56
4. After tightening.
It is sometimes difficult to remove the power wrench from a nut or bolt
after tightening.This is generally due to elastic deformation (elastic
force) between the wrench and bolt. Try changing the clutch direction
to L to make the wrench easier to remove. Release the torque on the
1
ratchet handle gradually since a force will be acting in the opposite
direction after changeover of the clutch. If it is not possible to change
over the clutch by hand, do not attempt to use force (a hammer, etc.).
· Try turning the wrench handle slightly in the L

direction to make the clutch easier to change over.
Fig. 1-57
Fig. 1-58
2
20
(2548)
5. Power Wrench Input/Output Diagram
Input/Output Diagram (2254)
[Output=input x gear ratio x efficiency]
(1960)
(1666)
Output kgf·m (lbf·ft)

(N.m)
(1372)
(1078)
In selecting a power wrench, give due consideration of the
differences in power performance between the different
(784)
wrench types.
(490)
Input kgf·m
(lbf·ft)
Bolt Power Wrench (N.m) (98) (196) (294) (392) (490) (588) (686) (784) (882)
(6860)
(5880)
Fig. 1-59 (4900)
(3920)
Output kgf·m (lbf·ft)
(N.m)
(2940)
(1960)
Input kgf·m
(lbf·ft)
(N.m) (137) (176) (216) (255) (294) (333) (372) (412) (451)
6. Torque Specifications
Wrench Tightening Torque

Bolt Dia Size
No. Descriptions (mm) (mm) N·m kgf·m lbf·ft
ZX470-5B M33 50 1750 175 1291

1 Side frame mounting bolt ZX520-5B M33 50 2200 220 1623
ZX670-5B, -5G/ZX870-5B, -5G M36 55 2800 280 2065
ZX470-5B, -5G M45 65 2400 240 1770
2 Counterweight mounting bolt
ZX670-5B, -5G/ZX870-5B, -5G M45 65 2800 280 2065
Counterweight lock plate ZX470-5B, -5G M24 36 450 45 332

3 securing bolt
ZX670-5B, -5G/ZX870-5B, -5G M24 36 700 70 516
1-3/16-12UNF 36 180 18 133
4 Hydraulic hose mounting bolt
1-7/16-12UNF 41 210 21 155
Pin retaining bolt M20 30 400 40 295
5
Pin retaining nut M20 30 400 40 295
21
22
1-3 Work precautions
1 APPLYING LUBRICANT
1 Be sure to apply a suitable lubricant to mounting
bolts before tightening. Use lubricant made by
mixing white zinc jelly and spindle oil in 1: 1
White zinc jelly
proportions.
Spindle oil
In the case that these materials are not available,
make up the lubricant from materials of the same
composition:
1:1
Material Composition
White zinc jelly Composition list given on page 31
Spindle oil Composition list given on page 31
2 Lubricant should be applied to both the bolt and

spacer, in the positions marked ＊ in the diagram Lubricant
below. Spacer
Bolt
Fig. 1-60
＊＊＊＊ Base
Face area Face area Thread of the head
Fig. 1-61
2 HANDLING SEALS
High Tack Adhesive/
1 Remove the seal fitted to the ports and pipes of Sealant #98D
hydraulic components just before assembly, to
prevent the ingress of dust.
2 Oil will come out when removing the seals from Fig. 1-62
the hydraulic ports. Collect it with a suitable oil

container.
3 Lightly apply High Tack Adhesive/Sealant #98D to
the O-ring before hose connection.
Note:
Obtain high tack adhesive/sealant #98D through the
manufacturer detailed on page 31.
Fig. 1-63
3 CONNECTING HOSES.
1 Be careful not to damage the joining surfaces of
the hydraulic components.
2 Make sure that no dust has adhered to the seat
faces of the hoses and adaptors. Remove cables here
3 When connecting hoses, do not twist them or their Battery

service life will be shortened.
4 When connecting the hoses, avoid contact with
other parts.
CAUTION:
Hydraulic ports are sealed with plugs on shipment from
the factory. On removal of these plugs, hydraulic oil will
escape due to the internal hydraulic pressure built up
through transportation, etc.
4 POST-WIRING
Be sure to remove the battery cables from the
grounded (-) battery clamp before commencing electric
wiring.
This will help avoid short circuits during electric wiring Fig. 1-64
work.
23
5 TIGHTENING LARGE-DIAMETER BOLTS
DURING ASSEMBLY
1 It is vital that large-diameter bolts be tightened to
Marking
the specified tightening torque during assembly. If
torque specifications are not followed, the Bolt
operation of the machine will be affected, with
machine failure, lowering of functionality and
Spacer
shortening of machine life potentially resulting. Be
careful, therefore, to note the correct tightening
torque at each stage of assembly.
This manual describes use of a power wrench to Fig. 1-65
achieve the required torque, but a hydraulic
wrench will allow for even more accurate and
efficient tightening work.
2 Be sure to tighten each bolt to the specified torque

using a torque wrench, power wrench, or hydraulic
wrench.
Torque wrench
1) After tightening a bolt to the specified torque,
mark the alignment of the bolt head, spacer Fig. 1-66
and bolted part. (See Fig. 1-65.)

2) Use only genuine Hitachi bolts.
CAUTION:
i) If a bolt is too long, you will not be able to fully
tighten it.
ii) If a bolt is too short, you will not be able to be
tighten it sufficiently to secure the parts, possibly
resulting in a serious accident. Pin
Moly coat spray
Fig. 1-67
6 NOTES ON INSERTING PINS WHEN
AFFIXING THE FRONT-END ATTACHMENT
1 When attaching the front-end attachment,
thoroughly clean away the anticorrosive applied to
the pins and pin holes before inserting the pins,
Pin
then regrease them and spray them with Moly
coat.
2 Be sure to check the alignment of pin holes when
joining parts. Do not use unreasonable force to
insert pins, and attempt to insert all pins manually.
If this is insufficient, use a medium-sized hammer
to ease the pin in place.
The use of forklift prongs to force in pins is
Fig. 1-68
absolutely forbidden. Any other unreasonable
force can lead to a pin being misformed and
rendered unusable, and should be avoided.
(Fig. 1-68)
7 APPLYING SEALING TAPE

Wrap sealing tape around the bolt in the opposite
direction to the thread direction.
Do not cover the first two threads, as indicated in Fig.
1-69. Fig. 1-69
24
8 PRECAUTIONS FOR CONNECTING THE PILOT HOSES
Be sure to observe the following points when connecting the pilot hoses. If the hoses are connected without paying
attention to the precautions described below, contaminants may enter the pilot circuit. If this happens, the contaminants
may cause the pilot valve to malfunction.
Plug
Plug
Step 1 The ends of both the valve and hose to be

connected will be sealed with plugs.
Detail A
Fig. 1-70
Adaptor
Step 2 1) Remove the plugs. Fitting

2) Thoroughly clean the hose fitting and
adaptor, then connect them, taking care Remove
the plugs
to prevent the ingression of any
contaminants.
Detail B
Fig. 1-71
Step 3 Connect the adaptor and hose fitting. Adaptor
Notes: Fitting
i) When connecting hoses, do not twist
them, or their service life will be
shortened.
ii) Connect the hoses so as to avoid
contact with other parts.
iii) Make sure that no dust has adhered to Detail C
the seat face of the hoses. Fig. 1-72
iv) Be careful to not damage the joining
surfaces of the hoses.
25
9 Standards for Hydraulic Joint Work
A ORS joint
Work procedure
1 Check that the O-ring, adapter, hose seat surfaces are free of scars or dirt.
Note:
Visually check their conditions. Wipe off dirt, if any. Do not use any scarred parts.
Check for dirt and scars
Adapter Hose, union part
O-ring Fig. 1-73
2 Apply bond to the groove in the adapter, install the O-ring, and apply spray grease High Tack Adhesive/Sealand
98D (Loctite, Ltd) to the screw part of the hose union.
Notes:
i) Remember to handle the O-ring with your bare hands.
ii) Press the entire O-ring with your fingers and install it properly.
iii) Apply the bond uniformly to the groove. Do not overapply. (Otherwise, the bond will seep into the hydraulic
circuit, causing a breakdown.)
Handle the O-ring with your bare hands!
Apply spray grease here. Fig. 1-74
3 Screw the hose and union into the adapter.
Notes:
i) To prevent the O-ring from falling out of place, place the O-ring surface of the adapter and seat surface of the
hose horizontal to each other to keep them immobile.
ii) Tighten the union nut fully with your hands.
iii) If the O-ring is jammed, it will feel differently from when you've tightened it fully with your hands (the torque will
not develop instantaneously and you will feel as though there is something stuck). If you sense any abnormality,
loosen the union nut and make sure to verify the O-ring.
Tighten the union nut fully with your hands
Fig. 1-75
4 Tightening the union.

• To tighten the union, use a spanner-style torque wrench and control the torque properly.
• Use a specified torque wrench.
Note:
After the work, carry out a check using a white pen.
26
B Union joint
Work procedure
1 Check that the adapter and hose union seat surfaces are free of scars or dirt.
Note:
Visually check their conditions. Wipe off dirt, if any. Do not use any scarred parts.
Adapter seat surfaces Hose union seat surface
Fig. 1-76
Fig. 1-77
Apply spray grease here
2 Apply spray grease to the screw parts of the hose and union.
Note:
Do not overapply.
(When the temperature of the base machine goes up, grease will flow out and this may be mistaken as an oil leak.)
3 Screw the hose into the adapter.
Note:
Tighten fully using your hands.
(If there are no scars on the thread, you will be able to screw it fully with your hands.)
Tighten the union nut fully with

your hands
Fig. 1-78
4 Tightening the union.

• To tighten the union, use a spanner-style torque wrench and control the torque properly.
• Use a specified torque wrench.
Notes:
i) After tightening, loosen the union by turning the wrench 2 - 3 times to adapt the seat surface to it.
ii) After the work, carry out a check using a white pen.
27
C Split flange joint
Work procedure
1 Check that the O-ring and hose-seat surfaces are free of scars or dirt.
Notes:
i) Visually check their conditions. Wipe off dirt, if any. Do not use any scarred parts.
ii) Check also the seat surfaces of opposite parts (C/V, pump, etc.) for scars and dirt.
Check for scars and dirt Fig. 1-79
O-ring Hose, flange
2 Apply bond to the O-ring groove in the hose and flange and install the O-ring High Tack Adhesive/Sealand 98D
(Loctite, Ltd).
Notes:
i) Remember to handle the O-ring with your bare hands.
ii) Apply the bond uniformly to the groove. Do not overapply.
(Otherwise, the bond will seep into the hydraulic circuit, causing a breakdown.)
iii) Press the entire O-ring with your fingers and install it properly.
Handle the O-ring with your bare

hands. Do not overapply the bond. Fig. 1-80
3 Installing the split flange.

1) Temporarily install one side of the split flange 2) Confirm the O-ring and set the hose onto the
using the socket bolts. split flange.
Note: Notes:
Using your hands, screw in the bolt to about half its i) Make sure to insert the hose horizontally to the
length. installation surface.
ii) Take care so that the O-ring does not fall out of
place.
Screw in the bolt to

about half its length.
Pay attention to
the O-ring
Fig. 1-81 Fig. 1-82
Split flange Socket bolts
28
3) After setting the hose, install the other split flange.
Notes:
i) If the bolt has not been screwed in adequately, the instability of the hose seat surface will increase and the O-
ring may fall off.
ii) After setting the hose, pay attention to the hose installation angle to avoid the hose from being turned.
Install other split flange

If the bolt has not been
screwed in adequately,
the instability of the hose
seat surface will increase,
Fig. 1-83
causing the O-ring to fall
off
Fig. 1-84
4 Tightening the socket bolt.

1) Temporary tightening, hose angle adjustment. 2) Tightening the bolts.
• Make sure to tighten the bolts in the correct • Tighten the bolts using a crisscross
order to avoid lopsided tightening. sequence in the same way as for temporary
• The bolts should be tightened using a tightening.
crisscross sequence. • Be careful not to tighten the bolts lopsidedly.
• The hose should still have movement even • Be careful not to overtighten the bolts with
after the bolts have been tightened. an impact wrench.
• Adjust the hose angle.
3) Checking the torque.
1 4 • Use a torque wrench to check that the bolts
are properly tightened.
• Check the bolts in the same crisscross
Bolt tightening sequence sequence as for tightening.
• After the work, carry out a check using a
white pen.
3 2
Fig. 1-85
No gap on one
side and too
much gap on the In the case of Should be tightened so that
other side lopsided tightening the gaps are uniform
Fig. 1-86 Fig. 1-87
29
10 ADJUSTING LIFTING ANGLE
Example of usage of a chain block or lever block.
By adjusting length “L” on the chain block (or lever block)
connecting the wire ropes, the lifted angle of the load can
easily be adjusted.
Wire rope
L'
Wire rope
L
Chain block
(Lever block)
Chain block
Wire rope
Lever block
Fig. 1-88
Work
Example
The angle of the workpiece in Fig. 1-89 can be
adjusted using chain blocks A .
Workpiece
Chain block
A
Chain block
A
a<b a=b
b
b
a a
Fig. 1-89
30
11 For reference
1 Ingredients of the white zinc jelly and spindle oil.
White zinc jelly
This stiff paste consists primarily of extender pigment and is prepared with specially processed fatty oil.
Ingredients: Extender pigment (calcium carbonate): 84.0%
Color pigment (titanium oxide): 0.5%
Fatty oil (polymerized oil): 14.0%
Solvent (mineral turpentine): 1.5%
Spindle oil
Physical and chemical properties of this oil are as follows. (grade C machine oil)
Appearance: Light brown
Flash point (COC): Above 160°C (320°F)
Density: 0.89 ~ 0.95 g/cm3
Fluid point: Below 10°C (50°F)
Mixture: None
Chemical name and composition: Petroleum system hydrocarbon 100%
2 Purchase high tack adhesive/sealant #98D from the following company:

Company Name: Loctite, Ltd.
Part Name: High Tack Adhesive/Sealant #98D
Part No.: 80063 (Loctite Part No.)
12 Read the operation manual

Read the operation manual and this assembly
procedure manual thoroughly to familiarize yourself
with the work procedure.
Fig. 1-90
31
13 Safety remarks to move the machine
1 General cautionary remarks to move the machine
• Sit down in the driver’s seat, and then, start the

machine.
• To start the engine or drive forward/backward, look

around carefully.
Sound a warning or signal in one way or another.
• If the visibility is poor, place a signal person or a

guide. This person is always visible to the driver.
• All workers should know the meanings of all signal

lights and signals.
Decide the signal and guide supervisor.
• The confines of machine movements should be free

of all persons and obstacles.
2 Travel safety
• When you travel, be very careful with the

surrounding safety.
• Before starting to travel, confirm the relationship of

the travel direction of the travel lever and the actual
travel direction. Then, enable the travel lever.
3 Prevention of accidents during swinging,

reversing
Swinging and reversing are particularly dangerous

because the angle of the vision is narrow. If the
visibility is poor, place a signal person or a guide.
• Before you start to swing or reverse, confirm that

there is no one around.
• Horn or signal as a warning to make sure that no

one enters the machine confines.
32
2. Work Plan and Preparations
2-1 Work Plan (Backhoe Front)
The field assembly system facilitates easy machine assembly, without welding. Factors such as the workplace setting,
working conditions, equipment and tool quality, and worker experience can lead to variation in the assembly schedule
detailed below.
day day
Days
1 2
Fine weather
30 t x 0.5 day
Crane (With operator and assistant)
30t or 50t
High-lift work machine 25t auxiliary crane 25 t x 0.5 day
Tool inspection
Unloading
Unpacking major
Preparation Workers
components
Part inspection Supervisor 1

Workers 2
x 1 day
Cleaning parts
Undercarriage and
superstructure assembly
Assembly work
Backhoe front assembly
Bucket assembly
Counterweight assembly
Lubrication
Track link adjustment
Adjustments Operation
Touch-up painting
Final assembly check
33
34
Transport
2-2 Transport
Unloading
CAUTION:
When the machine travels on a ramp, the back of the
bed can suddenly jolt. Drive carefully on the ramp.
Slowly unload the machine onto the ramp from the

back of the trailer.
Fig. 1
Transport packaging
ZX470-5B series
ZX670LC-5B series ZX870-5B series
ZX470-5G series ZX670LC-5G series ZX870-5G series
<Type 1> <Type 2> <Type 3>
Front attachment-less
Front attachment-less superstructure and side frames Front attachment-less
Base machine (with track center frame) superstructure and side frames
Track center frame
2 side steps 2 side steps 3 side steps
Counterweight Counterweight Counterweight
Boom Boom Boom
Arm Arm Arm
Bucket Bucket Bucket
2 boom cylinders 2 boom cylinders 2 boom cylinders
4 hydraulic hoses 4 hydraulic hoses 4 hydraulic hoses
2 track side steps x 4 2 track side steps x 4 2 track side steps x 4
Sub-unit assembly parts group

The sub-unit assembly kit is shipped out in
disassembled form as stated below.
It needs to be reconnected and reinstalled.
ZX470-5B series
ZX670LC-5B series ZX870-5B series
Type 1 Type 2 Type 3
Parts group Weight Weight Weight
kg (lb) kg (lb) kg (lb)
Counterweight mounting parts 35 (77) 35 (77) 35 (77)
Track frame mounting parts 95 (209) 95 (209) 95 (209)
Travel hydraulic pipe cover and its related parts 100 (220) 100 (220) 100 (220)
Handrail and its related parts 125 (275) 125 (275) 125 (275)
J833314 ~ 37 pcs.
Swing bearing mounting bolts - (-) - (-) 62 (136)
J833319 ~ 4 pcs.
35
Transport
Model Shipment form
ZX470-5 class
ZX-5B series
Side frame
ZX470-5B
Superstructure
ZX470LC-5B
ZX470H-5B
ZX470LCH-5B Side frame
ZX470R-5B
ZX470LCR-5B
ZX520LCH-5B
Boom Arm Bucket Counterweight
ZX-5G series
ZX470-5G
ZX470LC-5G
ZX470H-5G
ZX470LCH-5G
ZX470R-5G Base machine Boom Arm Bucket Counterweight
(no attachment)
ZX470LCR-5G
Fig. 2
36
Transport
Model Shipment form
ZX670LC-5 class
ZX-5B series
Side frame
ZX670LC-5B
Superstructure
ZX670LCH-5B
ZX670LCR-5B
Side frame
ZX-5G series
Side frame
ZX670LC-5G
Superstructure
ZX670LCH-5G
ZX670LCR-5G
Side frame
Fig. 3
37
Transport
Model Shipment form
ZX870-5 class
ZX-5B series
Side frame
ZX870-5B
Track center Superstructure
ZX870LC-5B frame
ZX870H-5B
ZX870LCH-5B Side frame
ZX870R-5B
ZX870LCR-5B
ZX-5G series
Side frame
ZX870-5G
Track center Superstructure
ZX870LC-5G frame
ZX870H-5G
ZX870LCH-5G Side frame
ZX870R-5G
ZX870LCR-5G
Fig. 4
38
Transport
ZX470-5 class
Shipment form ZX470-5B series Shipment form ZX470-5G series
Superstructure (no front attachment, A (mm) B (mm) C (mm) Weight (kg) Attachment-less base machine (no front Shoe width (mm) A (mm) B (mm) C (mm) D (mm) Weight (kg)
no side frames, no hydraulic oil tank attachment, no hydraulic oil tank steps,
ZX470-5B ZX470-5G 3200 3010 5460 26900
steps, no handrails) 4700 2560 2985 15200 no handrails)
ZX470LC-5B ZX470LC-5G 3240 3010 5680 28100
ZX470H-5B ZX470H-5G 600G 3320 3010 5460 27500
4700 2670 2985 15400
ZX470LCH-5B ZX470LCH-5G (3340) 3360 3010 5680 28700
ZX470R-5G 3320 3010 5460 27700
Base machine (the numerical values for no front attachment, no side
A ZX470LCR-5G 3360 3010 5680 28800
frames, no catwalk. no ladder to the side of oil tank)
ZX470-5G 3200 3010 5460 27700
ZX470LC-5G 750G 3240 3010 5680 28900
4960 ZX470H-5G (3490) 3320 3010 5460 28200
4690
B ZX470LCH-5G 3360 3010 5680 29500
ZX-5B series A B
C = width
D
Side frame Shoe width (mm) A (mm) B (mm) C (mm) Weight (kg)
600 5040 1220 950 6200 × 2
ZX470-5B
750 5040 1220 1020 6600 × 2 C
600 5470 1220 940 6650 × 2
ZX470LC-5B 750 5470 1220 1010 7000 × 2
900 5470 1220 1090 7350 × 2
B ZX470H-5B 600 5040 1220 950 6400 × 2
ZX470LCH-5B 600 5470 1220 940 6850 × 2
A
Side frames (no mounting bolt, no travel pipe, no step)
3340 (for 600G shoe)
C = width 3490 (for 750G shoe)
ZX-5G series
Counterweight P/No. A (mm) B (mm) C (mm) Weight (kg) Counterweight P/No. A (mm) B (mm) C (mm) Weight (kg)
A STD 5011325 2950 754 1340 9080 STD 5011325 2950 754 1340 9080
For removal/installation 5013279 2950 754 1340 8400
ZX520LCH-5B YA40013789 2950 754 1340 9780 A
B
Standard B
A
B
C = height
Removal/installation
C = height
39
Transport
Shipment form ZX670LC-5 class Shipment form ZX870-5 class
Superstructure (no front attachment, ZX670LC-5B Superstructure (no front attachment, no ZX870-5B
no side frames, no hydraulic oil tank A (mm) B (mm) C (mm) Weight (kg) side frames, no hydraulic oil tank steps, A (mm) B (mm) C (mm) Weight (kg)
steps, no handrails) no handrails)
STD 5220 2640 3420 20100 STD 6065 2385 3420 19580
HD 5060 2750 3420 20300 A HD 6065 2385 3420 19800
A
B
B
ZX-5B series C = width
ZX-5B series A
C = width
ZX670LC-5G ZX870-5G
A
A (mm) B (mm) C (mm) Weight (kg) B A (mm) B (mm) C (mm) Weight (kg)
STD 5220 2640 3510 20000 STD 6065 2270 3420 19580
HD 2750 3510 20200 HD 6065 2270 3420 19800
B ZX-5G series C = width
Track center frame A (mm) B (mm) C (mm) Weight (kg)

STD/HD 3480 910 2460 7830
ZX-5G series A
C = width
Side frame
B
Shoe width A (mm) B (mm) C (mm) Weight (kg)

(mm) STD track guard Full track guard C = width
B
650G shoe 5850 1450 650 10300 × 2 10500 × 2
750G shoe 5850 1450 750 10600 × 2 10800 × 2
Side frame x 2 Weight (kg)
A 900G shoe 5850 1450 900 11100 × 2 11400 × 2 Shoe width
(mm) A (mm) B (mm) C (mm) Side frame, STD Side frame, LC
STD track guard Full track guard STD track guard Full track guard
650G shoe 5840 1500 650 11190 × 2 11430 × 2 12070 × 2 12370 × 2
B
750G shoe 5840 1500 750 11520 × 2 11750 × 2 12420 × 2 12720 × 2
900G shoe 6360 1500 900 11950 × 2 12180 × 2 12890 × 2 13190 × 2
A
C = width 1020G shoe 6360 1500 1020 12340 × 2 12570 × 2 13320 × 2 13620 × 2
C = width
Counterweight P/No. A (mm) B (mm) C (mm) Weight (kg)
STD 5013038 3360 610 1520 10400
Counterweight P/No. A (mm) B (mm) C (mm) Weight (kg)
For removal/installation YA40001178 3360 610 1520 9800
STD 5012286 3360 720 1670 13300
B For removal/installation YA40001179 3360 720 1830 12400
B
A
A
C = height
C = height
41
Transport
Shipment form ZX470-5 class ZX670LC-5 class ZX870-5 class
Boom A (mm) B (mm) C (mm) Weight (kg) A (mm) B (mm) C (mm) Weight (kg) A (mm) B (mm) C (mm) Weight (kg)
H 7300 1780 1100 4370 STD boom 8130 2330 1390 6560 STD boom 8760 2510 1440 8210
BE 6570 2020 1100 4450 H boom 8130 2330 1390 6580 H boom 8760 2510 1440 8210
BE boom 7130 2550 1390 6130 BE boom 7470 2680 1440 7680
R boom 8760 2510 1440 8280
BER boom 7470 2680 1440 7690
C = width
Arm A (mm) B (mm) C (mm) Weight (kg) A (mm) B (mm) C (mm) Weight (kg) A (mm) B (mm) C (mm) Weight (kg)
Semi-long 5140 1100 740 2640 STD arm 5110 1390 790 3620 STD arm 5260 1400 810 4310
H 4630 1090 740 2540 H arm 5110 1430 790 3720 H arm 5260 1460 810 4490
BE (2.5m) 3940 1330 740 2650 Semi-long arm 5700 1390 790 3930 R arm 5260 1460 820 4610
BE (2.9m) 4230 1220 740 2540 BE arm 4370 1680 790 3820 BE arm 4430 1700 840 4630
BER arm 4430 1700 840 4760
B Semi-long arm 5870 1400 810 4640
Long arm 6830 1480 760 4950
A
C = width
Bucket A (mm) B (mm) C (mm) Weight (kg) A (mm) B (mm) C (mm) Weight (kg) A (mm) B (mm) C (mm) Weight (kg)
3 2.9GP 2220 1810 1830 2200 3
1.9 (1.7)m BK 1960 1570 1540 1590 3.5m BK 2260 1910 2040 2980
3 2.9ROCK 2290 1770 1690 2850 3
2.1 (1.8)m BK 1960 1570 1630 1650 3.5m ROCK 2270 1920 1880 3790
2.3 (2.0)m3 BK 1930 1660 1660 1810 3.5m3 ROCK, reinforced 2240 1960 1890 4830
3 3
1.9 (1.7)m ROCK 2020 1480 1490 2070 3.7m ROCK 2270 1920 1970 3900
1.6 (1.4)m3 BK 1960 1570 1360 1480 3.7m3 ROCK, reinforced 2240 1960 1970 4970
3 3
2.65 (2.3)m BK 1950 1660 1860 1930 4.3m ROCK BE 2360 2020 2110 4270
B
2.1 (1.8)m3 ROCK 1950 1650 1580 2170 4.3m3 ROCK, reinforced 2360 2050 2110 5690
3 3
2.3 (2.0)m ROCK 1950 1650 1700 2260 4.5m BE 2350 2020 2190 3980
2.5 (2.2)m3 ROCK 1950 1650 1820 2360 4.5m3 ROCK BE 2360 2020 2190 4400
C = width
43
2-3 Transport arrangements
1 Transport of ZX470-5 class

1 Transport of ZX470-5B series (backhoe front) 2 Transport of ZX470-5G series (backhoe front)
E E
A
B B
C C
D D
F
F
H G
ZX470-5B series backhoe front (Unit: metric tonne) ZX470-5G series backhoe front (Unit: metric tonne)
A B Handrails, · Boom B Handrails,

· Boom A
Superstructure · Arm C Counter- Ladders, · Arm C Counter- Ladders,
Side frame F X 2 Base machine
with track · Bucket D weight G Steps, · Bucket D weight F Steps,
(no attachment)
center frame · Cylinder EX2 etc. H · Cylinder E X2 etc. G
28-tonne 28t 30-tonne 30t

trailer trailer
Trailers/trucks
16-tonne 16t 10-tonne 10t 10t
Trailers/trucks
trailer truck
10-tonne 10t 10t 8-tonne 8t

truck truck
8-tonne 8t
truck
45
2 Transport of ZX670LC-5 class 3 Transport of ZX870-5 class
Transport of ZX670LC-5B series/ZX670LC-5G series (backhoe front) Transport of ZX870-5B series/ZX870-5G series (backhoe front)
E E A -1
A
B
B
A -2
C
C
G
D D
H F H F
F F
ZX670LC-5 class backhoe front (Unit: metric tonne) ZX870-5 class backhoe front (Unit: metric tonne)
Base machine A
A -1 A -2 · Boom B
A · Boom B Handrails, Handrails,
· Arm C
Superstructure · Arm C Counter- Ladders, Superstructure Track center Side Counter- Ladders,
Side frame F X 2 · Bucket D
with track · Bucket D weight G Steps, frame frame F X 2 weight G Steps,
· Cylinder E
center frame · Cylinder EX2 etc. H etc. H
X2
23-tonne 23t 28-tonne 28t

trailer trailer
21-tonne 21t
trailer 21-tonne 21t 21t
Trailers/trucks
Trailers/trucks
trailer
15-tonne 15t
truck
14-tonne 14t
11-tonne 11t truck
truck
8-tonne 8t 8-tonne 8t 8t
truck
truck
47
3. Parts Check
3-1 Check
1 Unpack the major component parts.
2 Check their quantity against that shown on the packing

list.
3 Check the parts for any damage during transportation.

If there are any missing or damaged parts, take
pictures of the damage and then contact Hitachi or your
Hitachi distributor as soon as possible.
Fig. 3-1
49
50
4. Preparations
4-1 Preparation of ZX470-5 class (backhoe front)
4-1-1 ZX470-5B series 4-1-2 ZX470-5G series

Work site: Select level, firm ground. Work site: Select level, firm ground.
Work site area: 10m × 10m or larger Work site area: 10m × 10m or larger
Have ready one 30t or 50t crane and one 25t auxiliary crane. Have ready one 30t or 50t crane and one 25t auxiliary crane.
Have ready two high-lift work machines. Have ready two high-lift work machines.
Arrange major components according to the diagram below. Arrange the parts delivered from the Hitachi factory as shown below.
Arrange the parts delivered from the Hitachi factory as shown below. Arrange the parts delivered from the Hitachi factory as shown below.
1 Superstructure (with track center frame) 14 Track frame mounting bolts 1 Base machine (no attachment) 14 Track frame mounting bolts
2 Boom (with arm cylinder) 15 Wiper assembly 2 Boom (with arm cylinder) 15 Wiper assembly
3 Arm (with bucket cylinder and link) 16 Headlight 3 Arm (with bucket cylinder and link) 16 Headlight
4 Boom cylinder (L) 17 Tool set 4 Boom cylinder (L) 17 Tool set
5 Boom cylinder (R) 18 Spare parts 5 Boom cylinder (R) 18 Spare parts
6 Hydraulic hoses (for bucket cylinder) 19 Key, O-rings, washers, part list, manual, etc. 6 Hydraulic hoses (for bucket cylinder) 19 Key, O-rings, washers, part list, manual, etc.
7 Hydraulic hoses (for boom cylinder) 20 Exhaust piping (ZX-5B series only) 7 Hydraulic hoses (for boom cylinder) 20 Backhoe bucket
8 Counterweight 21 Backhoe bucket 8 Counterweight
9 Side step 22 Side frame (L) 9 Side step
10 Handrails 23 Side frame (R) 10 Handrails
11 Steps 11 Steps
12 Track frame steps 12 Track frame steps
13 Travel piping covers 13 Travel piping covers
17
7 20 7 19
6 19 14 6 18 14
18 17
13 13
12 16 11 12 16 11
15 10 15 10
9 9
21 20
2 5 2 5
4 4
1 1
3 23 3
10 m 10 8 m
m 22 10 m 10
8
Fig. 1 Fig. 2
51
4-2 Preparation of ZX670LC-5 class (backhoe front) 4-3 Preparation of ZX870-5 class (backhoe front)
4-2-1 ZX670LC-5B series/ZX670LC-5G series 4-3-1 ZX870-5B series/ZX870-5G series

Work site: Select level, firm ground. Work site: Select level, firm ground.
Work site area: 10m × 10m or larger Work site area: 10m × 10m or larger
Have ready one 30t or 50t crane and one 25t auxiliary crane. Have ready one 30t or 50t crane and one 25t auxiliary crane.
Have ready two high-lift work machines. Have ready two high-lift work machines.
Arrange major components according to the diagram below. Arrange major components according to the diagram below.
Arrange the parts delivered from the Hitachi factory as shown below. Arrange the parts delivered from the Hitachi factory as shown below.
1 Superstructure (with track center frame) 14 Track frame mounting bolts 1 Superstructure 14 Travel piping covers
2 Boom (with arm cylinder) 15 Wiper assembly 2 Track center frame 15 Track frame mounting bolts
3 Arm (with bucket cylinder and link) 16 Headlight 3 Boom (with arm cylinder) 16 Wiper assembly
4 Boom cylinder (L) 17 Tool set 4 Arm (with bucket cylinder and link) 17 Headlight
5 Boom cylinder (R) 18 Spare parts 5 Boom cylinder (L) 18 Tool set
6 Hydraulic hoses (for bucket cylinder) 19 Key, O-rings, washers, part list, manual, etc. 6 Boom cylinder (R) 19 Spare parts
7 Hydraulic hoses (for boom cylinder) 20 Exhaust piping (ZX-5B series only) 7 Hydraulic hoses (for bucket cylinder) 20 Key, O-rings, washers, part list, manual, etc.
8 Counterweight 21 Backhoe bucket 8 Hydraulic hoses (for boom cylinder) 21 Exhaust piping (ZX-5B series only)
9 Side step 22 Side frame (L) 9 Counterweight 22 Backhoe bucket
10 Handrails 23 Side frame (R) 10 Side step 23 Side frame (L)
11 Steps 11 Handrails 24 Side frame (R)
12 Track frame steps 12 Steps
13 Travel piping covers 13 Track frame steps
17 9 21
7 20 8 20
6 19 14 7 19 15
18 18 14
13
12 16 11 13 17 12
15 10 16 11
9 10
2
21 22
5 3 6
2
4 5
1 1
3 23 4
24
10 m 10
m 22 8 10 m 23 9 m
10
Fig. 1 Fig. 2
53
5. Machines, Apparatuses, Tools, and Materials necessary for Assembly
Assembly work is dangerous. Prepare in advance and have the necessary tools listed below.
1 Crane
By referring to the mass table on the disassembly page, choose the crane and prep.
· 35t or 50t crane to suspend the base machine – 1
· 25t auxiliary crane for suspension – 1
2 Wire ropes
34mmø × 10 000 mm (L) × 2
(1.3 inø) (390 in L)
34mmø × 3 000 mm (L) × 4
(1.3 inø) (117 in L)
26 mmø × 10 000 mm (L) × 1
(1.0 inø) (390 in L)
26 mmø × 8 000 mm (L) × 2
(1.0 inø) (312 in L)
26 mmø × 3 000 mm (L) × 2
(1.0 inø) (117 in L)
24 mmø × 10 000 mm (L) × 2
(0.95 inø) (390 in L)
24 mmø × 5 000 mm (L) × 2
(0.95 inø) (195 in L)
18 mmø × 10 000 mm (L) × 1
(0.7 inø) (390 in L)
18 mmø × 3 000 mm (L) × 2
(0.7 inø) (117 in L)
14 mmø × 10 000 mm (L) × 2
(0.55 inø) (390 in L)
14 mmø × 3 000 mm (L) × 4
(0.55 inø) (117 in L)
12 mmø × 5 000 mm (L) × 2
(0.5 inø) (195 in L)
10 mmø × 3 000 mm (L) × 5
(0.4 inø) (117 in L)
3 Guide rope
8 mmø × 5 000 mm (L) × 1
(0.3 inø) (195 in L)
4 Nylon sling belts
100 mm (W) × 2 000 mm (L) × 2
(4.0 in) (78 in)
20 mm (W) × 4 000 mm (L) × 2
(0.8 in) (156 in)
5 Shackles
For 2.5 kg lond × 4 For 5 t load × 2 For 6 t load × 2 For 8 t load × 2
6 Chain blocks/lever blocks
· Chain blocks · Lever blocks
For 6 t load × 2 sets For 1.0 t load × 2 sets
For 2.5 t load × 2 sets
A description of chain/lever block use in keeping the load level is described in item 10 on page 30.
55
7 Wooden blocks
1 200 mm (L) × 800 mm (W) × 1 000 mm (H) × 4
(47 in) (30 in) (40 in)
100 mm (L) × 800 mm (W) × 50 mm (H) × 1
(4 in) (30 in) (2 in)
50 mm (L) × 50 mm (W) × 500 mm (H) × 4
(2 in) (2 in) (20 in)
For 1 000 kg (2 200 lb) load × 2
8 Cylinder support
Height: 1 800 mm (70 in) × 1
9 V-block
V-block × 2 sets
10 Oil containers
20 liter capacity × 4
10 liter capacity × 2
11 Standard tool kits
Have ready 2 or more sets.
12 Large hammer (10 lb.)
13 Grease
14 Touch-up paint
Have ready 2 or more sets.
15 Pneumatic wrench (with compressor)
30 000 N·m (3 000 kgf·m/22 127 lbf·ft) capacity × 1 set
16 Hydraulic jack
For 20 t load × 2 Protector Used tire
17 Protector and patch

Refer to Fig. 1 for an example of an protector.
Protector × 5
18 Hand tachometer or digital tachometer
Fig. 1
Pulsemeter, Adapter
Engine speed sensor
19 Torque wrench
600 N·m (60 kgf·m/443 lbf·ft) capacity
20 Safety belt × 4
21 Grinder
22 Halogen torch or charge detector
For detecting refrigerant leaks.
56
23 Thermometer probe
For measuring the refrigerant temperature.
−10˚C to 100˚C × 1
24 Pressure gauge
For measuring the pressure in the track link tension adjusting cylinder.
1960 Pa (200 kg/m2) capacity × 1
25 Tap (Refer to p. 58)
ZX470-5 class: M33 × P3.0
ZX670LC-5 class: M36 × P3.0
ZX870-5 class: M36 × P3.0
26 Track center frame lifting jig (Refer to p. 59) × 1 set
27 High lift work machine × 2 (Fig. 2)
28 Miscellaneous
Rags, cleaning agent, lubricant, light and cord reel, grease,
Molykote spray
Fig. 2
57
Note:
If you are unable to procure the tools locally,
SPECIAL TOOLS order them in advance from Hitachi.
Item Illustration Tool name Q'ty Usage
M33×P3.0
Tap
Use to tap screw
ZX470-5 class
holes of the
1 1 track frame and
M36×P3.0 side frame
Tap mounting bolts.
ZX670LC-5 class
ZX870-5 class
Fig. 3
4093798
Torque wrench
100 ~ 410 N·m Used to tighten
2 1
10 ~ 41 kgf·m the bolts.
74 ~ 302 lbf·ft
capacity
Fig. 4
4093800 Use to tighten the

Power wrench track frame and
3 With wrench, socket 1 side frame
P/No. 4298389 mounting bolts.
Max. output torque

4 410 N·m (450 kgf·m/3 253 lbf·ft) Fig. 5
4229414 Use to tighten the

4 Power wrench 1 track frame and
With wrench, socket side frame
P/No. 4298388 mounting bolts.
Fig. 6
Bolt P/No. J901670 2 Use to release the

Washer P/No. A590116 2 swing lock.
5 Adapter P/No. A852122 2
R
M16×2.0
Hose P/No. 4331737 1 ZX870-5 class only
70
Fig. 7
58
Note:
If you are unable to procure the tools locally,
SPECIAL TOOLS (others) order them in advance from Hitachi.
Item Illustration Tool name Q'ty Usage
Lifting jig (right) Right side Left side

ZX470
-5 class 8123248 8123249 1
Lifting jig (left) ZX670LC 1
-5 class 8102865 8102864
ZX870 1
-5 class 8102726 8102725 Base machine
lifting jig
Fig. 8 For details of

6 lifting jigs, refer to
24 the appendix on
pages 249 to 265.
19 130
Spacer P/No. 4241784 4

Bolt P/No. J833006 2
Nut P/No. J953039 2
t=16 M30x3
Spacer Bolt Nut
Fig. 9
Vacuum pump
assembly ST6905
Use to create a
7 Vacuum pump ST6440 1 vacuum in the
Hose ST6326 hydraulic oil tank.
NipplePT 1/8 ST6066
NipplePT 3/8 ST6068
Fig. 10
Nut, eye
Lifting jig
(nut, eye)
4
P/No. 9772243
Track center lifting jig

Fig. 11
8
Flat washer
ZX870-5 class only
60 5
34
Lifting jig
(flat washer) 4
P/No. A590133
Fig. 12
59
NOTES
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60
UNDERCARRIAGE/SUPERSTRUCTURE
ASSEMBLY PROCEDURE
FOR
UNDERCARRIAGE AND SUPERSTRUCTURE
61
62
6. Assembly of Undercarriage and Superstructure
6-1 Preparation
ZX470-5 class/ZX670LC-5 class ZX870-5 class
Note:
The track frame is welded to the side
frame on ZX470-5G series. Shown below
are the types other than ZX470-5G series.
Assembly chart of undercarriage

and superstructure
Fig. 1 Fig. 2
Step 1
Preparing the necessary parts

Item Model
Part Name Qty Remarks
No. ZX470-5 class ZX670LC-5 class ZX870-5 class
00 (✽✽✽✽✽✽✽) (✽✽✽✽✽✽✽) (✽✽✽✽✽✽✽) Superstructure 1
01 ――― ――― 5010084 Track center frame 1 ZX870-5 class only
02
03
Item Model
04 (✽✽✽✽✽✽✽) (✽✽✽✽✽✽✽) (✽✽✽✽✽✽✽) Side frame (right) 1
05 (✽✽✽✽✽✽✽) (✽✽✽✽✽✽✽) (✽✽✽✽✽✽✽) Side frame (left) 1
06 YA00003325 8127205 8127205 Step (upper) 4 For ZX470-5 class (H) : P/No.8069333
07 YA40002172 8068378 8068378 Step (lower) 4
08 ――― ――― 4205476 Cover; rubber 1
09 ――― ――― 8039014 Stopper 1
10 ――― ――― A852332 Adapter 1
ZX870-5 class only
11 ――― ――― A852144 Adapter 1
12 ――― ――― 4114404 Washer 4
13 ――― ――― J901435 Bolt 2
Legend
(✽✽✽✽✽✽✽): No part number is given
63
Item Model
14 6028301 6024183 6024183 Step 1
15 6028300 6028198 6024192 Step 1
16 ――― ――― 6024198 Step 1
17
18 J833310 4218943 4639684 Bolt ＊1) ＊1) ZX470-5 ∼36 pcs.
ZX670LC-5 ∼44 pcs.
ZX870-5 ∼44 pcs.
19 4320218 4218944 4218944 Spacer ＊2) ＊2) ZX470-5 ∼36 pcs.
ZX670LC-5 ∼44 pcs.
ZX870-5 ∼44 pcs.
20 J833306 J833008 J833010 Bolt 8
21 4083438 4114408 4114408 Washer 8
22 4269566 4207766 4207766 Plate lock 4
23 4269567 4643263 4639597 Spacer 8
24
25 4650572 4650572 4650572 Wiper blade ＊3) ＊3) ZX470-5/ZX670LC-5 ∼1 pc.
ZX870LC-5 ∼2 pcs.
26 4675257 4675257 4675257 Mirror (right) 1
27 4675257 4675257 4675257 Mirror (left) 1
28 4326800 4326800 4326800 Headlight 2
29 7060123 7060238 7060238 Muffler 1 ZX-5B Series only
30
ZX470-5 class ZX670LC-5 class ZX870-5 class

Item Part Name Qty Remarks
ZX470-5B ZX470-5G ZX670LC-5B ZX670LC-5G ZX870-5B ZX870-5G
31 4465368 4465366 Pre-cleaner ＊4）＊4）ZX470-5 ∼1 pc.
ZX670LC-5 ∼1 pc.
32 ZX870-5 class
ZX870-5B ∼2 pcs.
33 ZX870-5G ∼1 pc.
Handrail at the right
34 YA40004147 1
forefront of the superstructure
35 YA40003436 YA40004521 Ladder 1
YA40004519 YA40004145 Handrail at the top of 1
36
YA40004520 YA40004146 the lubricator box 1
YA40003168 YA40004523 YA40006925 YA40004150 YA40005315 1
Handrail at the top
37 YA40003435 YA40004151 YA40006924 YA40004151 1
of the fuel tank
YA40004152 1
Handrail at the top of
38 8124297 1
the pump room
64
6-2 Connection of undercarriage and superstructure
Note:
The undercarriage - superstructure connection methods are different for the ZX470-5 class, ZX670LC-5 class
and ZX870-5 class.
Case: A
ZX470-5 class/ZX670LC-5 class
The ZX470-5 class/ZX670LC-5 class are shipped out with the track center frame connected to the superstructure.
Thus, the side frame (right side) and side frame (left side) are later connected to the superstructure.
Note:
The track frame is welded to the side frame on ZX470-5G series. Shown below are the types other than ZX470-5G series.
Prepare the Connect the Connect the

Assembled main body
superstructure right side frame left side frame
Fig. 1
Case: B
ZX870-5 class
The ZX870-5 class is shipped out in four parts: track center frame, left side frame, right side frame and superstructure.
Connect the left and right side frames to the track center frame to assemble them into an undercarriage.
Next, connect the undercarriage to the superstructure.
Connect the left and right side Assembled Connect the undercarriage Assembled main body
frames to the track center frame undercarriage to the superstructure
Fig. 2
65
66
Case A : In the case of ZX470-5 class/ZX670LC-5 class
6-2-1 Connecting the superstructure (with track center frame) and side frames
Note:
The part number and quantity for track center frame and side frame connection mechanism are different for
each model. Refer to the construction by model stated on page 78 to assemble.
Step 1
Preparing the side frame (right) Hold
1 Slinging the side frame (right)
1 Sling a wire rope over side frame (right) 04 as

Wire rope
shown in Fig. 1. 26 mmø × 8 000 mm
Note:
Use protectors in 4 locations designated in 04
Fig. 1 so that the wire rope doesn’t damage.
Weight of side frame assembly 04 :

For ZX470-5 class, refer to the chart on page 41. Protector
For ZX670LC-5 class, refer to the chart on page 43.
Wire rope used:

26 mmø × 8 000 mm (L) : 2 pcs.
(1.0 inø) (312 in L)
Protector: 4 pcs.
*About 1 800 mm
2 Lift side frame (right) 04 as shown in Fig. 1.

Fig. 1
CAUTIONS:
i) The work is dangerous, so make sure that there Front side
Side frame (right) 04
is no one under the lifting side frame.
ii) A qualified worker undertakes sling work and
lifting work. a
2 Installing the side frame (right), cleaning and finish b

1 Install side frame (right) 04 to the designated
position. Install the travel device so that it is
positioned at the back (refer to Fig. 2).
2 Using a tap, tap all the screw holes noted at a
and b on the surface of side frame (right) 04 on
which the track center frame is installed.
Travel device
Fig. 2
(ZX470-5 class)
Tap size: M33 × P3.0
(ZX670LC-5 class) Detail A
3 Clean the surface on which side frame (right) 04 is
installed. Check the surface for any damage. Tap
Note: 04
Repair or re-finish any damage.
Fig. 3
67
Step 2
Slinging the superstructure
CAUTIONS:
i) Use a lifting wire rope and lifting sling that are not damaged or worn and that are sufficiently strong.
ii) Contact the nearest Hitachi branch or sales office to learn the correct way to lift, the size and types of lifting wire
rope and lifting sling.
iii) To lift, bring the lock lever to “Lock” position so that the machine will not move involuntarily.
iv) Any errors in the lifting method or rope sling method can cause the machine to move during lifting work and lead
to fatalities and injuries or machine damage.
v) Do not apply load suddenly to the lifting wire rope and lifting sling.
vi) While lifting a load, never go under the machine or stand/walk nearby.
vii) A qualified worker undertakes sling work and lifting work.
1 Slinging the superstructure

00 Superstructure
1 Prepare superstructure 00 .
2 Use chain blocks, exclusive lifting slings and wire

ropes to sling superstructure 00 as shown in Fig. 2.
Notes:
i) Use lifting slings to install the counterweight side
by tightening bolt.
A detailed explanation on how to use the lifting
sling is found on the appendices (pages 259 to
262). Fig. 1
ii) Use protectors in two locations: to the right
forefront of the main frame/left forefront of the
Hold
main frame. See Fig. 2-a. Wire rope
34 mmø × 3 000 mm Wire rope
Chain block for 34 mmø ×
Weight of superstructure 00 : 10 000 mm
6t load
ZX470-5
15 200 kg (33 440 lb) Wire rope
ZX470LC-5
ZX470H-5 34 mmø × 3 000 mm
15 400 kg (33 880 lb) Shackle
ZX470LCH-5
ZX520LCH-5 15 400 kg (33 880 lb)
ZX670LC-5 STD 20 100 kg (44 220 lb)
ZX670LC-5 HD 20 300 kg (44 660 lb)
Wire rope used: 6 pcs. Bolt

34 mmø × 10 000 mm (L) : 2 pcs.
(1.3 inø) (390 in L)
34 mmø × 3 000 mm (L) : 4 pcs.
(1.3 inø) (117 in L) Protector
Exclusive
lifting sling
Chain block for 5.0t load: 2 pcs.
Wire rope
00 Fig. 2
Protector: 2 pcs.
Shackle for 5.0t load: 2 pcs. Protector
Exclusive lifting sling: 1 set
Fig. 2-a
68
2 Cleaning the track center frame Hold
CAUTION:
Before working under the superstructure, place
supports under the front, back, left and right of the
superstructure so that the load doesn’t drop.
00
Support for 5t load: 4 pcs.
Height: 1 000 mm (40 in)
1 Clean the front bottom, back bottom, left bottom and

right bottom at a - d (4 locations) of the track center
frame of superstructure 00
2 Finish the all spot-face bolt holes of the track
center frame neatly. a : left/front Support
3 Check the surface for any damage. b : right/front
Fig. 3
c : Left/back
Note: d : Right/back Track center frame
4 Clean all spot-facing surfaces of the track center Detail A

frame.
Detail B
Spot-facing
Fig. 4
Fig. 5
3 Confirming the superstructure and side frame locations Hold
1 Lift superstructure 00 horizontally.

Chain block
Note:
Adjust the chain blocks to make the superstructure
00
level.
CAUTION:
The work is dangerous, so make sure that there is no
one under the lifting superstructure.
2 Check the direction of the track center frame of

superstructure 00 . Check that the track center Track center frame
frame is facing the direction as shown in A in A
Fig. 6. Fig. 6
69
Step 3
Connecting the superstructure and side frame (right)
1 Connecting the superstructure and side frame (right) Lift
1 Bring the travel duct side of the track center frame

to the position relative to the lifting superstructure
00
00 as shown in Fig. 1.
04
2 Move it slowly towards the side of the side frame
(right) 04 that was placed in Step 1 .
Note:
Check that the travel duct side of the superstructure
track center frame is positioned so that it faces the
same direction as the travel device of the side
frame.
Travel device
Travel duct side Fig. 1

Track center frame
Lift
Move
00
04
Fig. 2
3 Match the height of the side frame installation
surface of the superstructure (track center frame)
with that of the side frame surface on which the Lift
track center frame is installed. Move
4 Bring the track center frame of the superstructure
towards side frame (right) 04 .
Track center frame

04
Fig. 3
70
Lift
2 Installing the side frame (right) Move
1 Bring the lifted superstructure 00 towards side

frame (right) 04 . Align the centers of the track
00
center frame and side frame by moving Track center frame
superstructure 00 horizontally in the direction of
the arrow.
2 Align the bolt holes of the track center frame and

04
side frame.
3 Apply lubricant to bolt 18 and spacer 19 .

Before installing the bolt, apply lubricant to the bolt
Fig. 4
screws and back of bolt heads.
Notes:
i) Use a lubricant that is a 1:1 mix of jell-form zinc Hold
white and spindle oil.

ii) Before inserting bolt 18 , apply lubricant to the
back of bolt heads and screws (at ＊) as shown
in Fig. 7.
iii) In the same way, apply lubricant to both the top
and bottom surfaces of spacer 19 .
4 Insert spacer 19 into bolt 18 . Use your hand to

screw all of the bolts into the screw holes.
ZX470-5 class : 18 sets
ZX670LC-5 class : 22 sets Fig. 5
Notes:
i) Install the spacer to the bolt by facing the
chamfered surface to the bolt head.
ii) Do not forcibly screw in the bolts. Doing that can
damage the screws. 18
19
5 Use a ratchet wrench to temporarily tighten bolts
18 that were screwed in step 4
Notes:
i) Tighten all the bolts until the surface is
completely tight.
ii) Check that there is no space between the
contact surfaces. Fig. 6
Detail A Detail B
Ratchet wrench
Chamfered surface ＊ 18
19 19
18
＊ a
Section a
Fig. 7 Fig. 8
71
6 Use bolt 20 , washer 21 and spacer 23 to install
lock plate 22 . 20
7 Before installing the bolt, apply lubricant to the bolt 21
22
Notes: 23
i) Use a lubricant that is a 1:1 mix of jell-form zinc
in Fig. 10.
and bottom surfaces of washer 21 .
8 Use your hand to screw all bolts 20 into the screw
holes.
Notes:
Fig. 9
i) Install the washer to the bolt by facing the
damage the screws.
9 Temporarily tighten the bolt with a ratchet wrench.
Notes:
completely tight.
contact surfaces.
Detail C Detail D
20
×4
20
21
＊
Chamfered surface a 22
×2
23
×4
＊ Section a 21 60
Fig. 10 Fig. 11
10 Using a power wrench, tighten bolt 18 completely. Detail E
Note:
Tighten lock plates 22 using ratchet wrench. Keep in 22
this state.
M33 bolt tightening torque:
ZX470-5 class 1 750 N·m

(175 kgf·m/1 291 lbf·ft)
Width across flats: 50 mm
Power wrench
ZX520LCH-5 2 200 N·m
(220 kgf·m/1 623 lbf·ft) 18 Fig. 12
M36 tightening torque:
ZX670LC-5 class 2 800 N·m CAUTION:

(280 kgf·m/2 065 lbf·ft)
Work carefully so that you don’t hit your hand with
reaction force bar of the power wrench.
72
Step 4
Connecting the superstructure and side frame (left)
1 Installing the side frame (left), cleaning and finish Side frame (left) 05
1 Install side frame (left) 05 to the designated

position. Install the travel device so that it is a
positioned at the back (refer to Fig. 1).
b
For ZX470-5 class, refer to the chart on page 39.
For ZX670LC-5 class, refer to the chart on page 41.
2 Using a tap, tap all the screw holes noted at a

and b on the surface of side frame (left) 05 on
Travel device Fig. 1
(ZX470-5 class)
(ZX670LC-5 class) Detail A
3 Clean the surface on which side frame (left) 05 is
installed. Check the surface for any damage. Tap
05
Note:
Fig. 2
73
05
2 Slinging the side frame (left)
1 Confirm that the travel device of side frame (left)

05 is assembled as shown in Fig. 3.
2 Sling a wire ropes over side frame (left) 05 as
shown in Fig. 4.
Note:
Use protectors in 4 locations designated in Fig. 4 so
that the wire rope doesn’t damage.
Travel device
Fig. 3
For ZX670LC-5 class, refer to the chart on page 41. Hold
Wire rope used:

26 mmø × 8 000 mm (L) : 2 pcs.
(1.0 inø) (312 in L)
Wire rope
26 mmø × 8 000 mm
Protector: 4 pcs.
3 Lift side frame (left) 05 as shown in Fig. 5. 05
CAUTION: Protector
one under the lifting side frame
Notes:
i) To lift the side frame (left), narrow the width of ＊
About 1 500 mm
the wire rope so that it doesn’t touch the frame
of the superstructure or the cab. Fig. 4
Travel device
ii) The travel motor side is heavy. Align carefully
and lift so that the front and back are horizontal
to each other.
iii) As shown below, tilt the side frame slightly so
that it is parallel to the contact surface of the
track center frame.
Detail B
Lift Lower Lift
Hook wire Lower Lay a block. Lift again. Then, the

rope to the vertically. Hook the block side frame will tilt as
side frame. to the outside shown here.
of the side
frame and
bring down to
the ground. In this state, you will
05 be able to connect it
Outside Inside smoothly with the
track center frame.
Block (2 pcs.)
Fig. 5
Block: 2 pcs.
1 000 kg (2 200 lb)
74
3 Installing the side frame (left)
1 Bring the lifted side frame (left) 05 towards Lift Hold

superstructure 00 slowly.
2 Align the bolt holes of the track center frame and Move
side frame. 00
Before using the bolt, apply lubricant to the bolt
Notes:
i) Use a lubricant that is a 1:1 mix of jell-form zinc 05 Track center
white and spindle oil. frame
Fig. 6
in Fig. 9. Hold Hold
and bottom surfaces of spacer 19 .
4 Insert spacer 19 into bolt 18 . Use your hand to

screw all of the bolts into the screw holes.
ZX470-5 class : 18 sets
ZX670LC-5 class : 22 sets
Notes:
i) Install the spacer to the bolt by facing the Fig. 7
damage the screws. 18
19
Detail C
Chamfered surface
＊ 18
19 19
Fig. 8
＊ a
Section a Ratchet wrench
Fig. 9
5 Using a ratchet wrench, temporarily tighten bolts

18 that were screwed in step 4 .
Notes:
completely tight.
contact surfaces.
18
Fig. 10
75
6 Use bolt 20 , washer 21 and spacer 23 to install 20
lock plate 22 .
7 Before using the bolt, apply lubricant to the bolt 21
22 23
Notes:
in Fig. 12.
Fig. 11
holes.
Notes:
damage the screws.
Notes:
completely tight.
contact surfaces.
Detail D Detail E
20
×4
20
21
＊ 22
Chamfered surface a
×2
23
×4
＊ Section a 21 60
Fig. 12 Fig. 13
10 Using a power wrench, tighten bolt 18 completely.
Note:
Tighten lock plates 22 using ratchet wrench. Keep in
this state. Power
wrench
ZX470-5 class 1 750 N·m

(175 kgf·m/1 291 lbf·ft)
22
ZX520LCH-5 2 200 N·m
(220 kgf·m/1 623 lbf·ft)
M36 tightening torque: 18
Fig. 14
ZX670LC-5 class 2 800 N·m CAUTION:
(280 kgf·m/2 065 lbf·ft)
76
Step 5
Removing the lifting sling Hold
1 Remove the wire ropes that was used to lift side frame
(left) 05 .
Hold
Wire rope
05
Fig. 1
Lift
2 Remove the wire ropes, chain blocks, exclusive lifting

sling that were used to lift superstructure 00 .
Wire rope
Wire rope
Chain block
Exclusive
lifting sling
Wire rope
00
Fig. 2
77
20 Bolt (J833306) 18 Bolt (J833310) Bolt (J833306) 20
ZX470-5 class 21 Washer (4083438) 19 Spacer (4320218) Washer (4083438) 21
22 Plate lock (4269566) Plate lock (4269566) 22
23 Spacer (4269567) Spacer (4269567) 23
Front 18 Bolt (J833310)
Bolt (J833306) 20
Washer (4083438) 21
Bolt (J833310) 18
Plate lock (4269566) 22
Rear Spacer (4320218) 19

Spacer (4269567) 23
19 Spacer (4320218)
20 Bolt (J833306)
21 Washer (4083438)
22 Plate lock (4269566) Bolt (J833310) 18
23 Spacer (4269567) Spacer (4320218) 19
Fig. 3
Bolt (4218943) 18
ZX670LC-5 class Spacer (4218944) 19
Rear
Front
20 Bolt (J833008)
21 Washer (4114408)
Plate lock (4207766) 22
Spacer (4643263) 23
Fig. 4
78
Lift
Case B : In the case of ZX870-5 class
6-2-2 Connecting the track center frame and side frames
Step 1 Wire rope

26 mmø × 8 000 mm
Preparing the side frame (right)
1 Slinging the side frame (right) a
1 Sling wire ropes over side frame (right) 04 as

shown in Fig. 1. b
04
Note: c
Use protectors in 4 locations a , b , c , d shown by
＊ d
so that the wire rope doesn’t damage. About 1 800 mm
Weight of side frame assembly 04 : Fig. 1

Refer to the chart on page 43. Front
Wire rope used:

26 mmø × 8 000 mm (L) : 2 pcs.
(1.0 inø) (312 in L)
Protector: 8 pcs.
2 Lift side frame (right) 04 as shown in Fig. 1.
CAUTIONS:
Travel device
i) The work is dangerous, so make sure that there
Rear
is no one under the lifting side frame.
ii) A qualified worker undertakes sling work and Fig. 2
lifting work.
04 Side frame (right)
2 Place the side frame on ground and set the travel
device so that it is positioned at the back. e
3 Cleaning the side frame (right) and finish
1 Using a tap, tap all the screw holes noted at e

and f on the surface of side frame (right) 04 on
Fig. 3
ZX870-5 class
Detail A
04
2 Clean the surface on which side frame (right) 04 is
installed.
Tap
Check the surface for any damage.
Note:
15
Fig. 4
79
Step 2 a
Preparing the track center frame 01
b
＊ Cleaning the track center frame and finish
1 Prepare track center frame 01 .
2 Clean the all surfaces of the track center frame

c
that is connected to the side frame (at a - d
shown by ).
d Fig. 1
Detail A
3 Check the surface for any damage.
Note:
4 Clean all spot-facing surfaces of Detail B

the track center frame. Spot-facing
Fig. 2
Fig. 3
Step 3
Hold
Slinging the track center frame
＊ 1 Use eyebolts and wire ropes to sling track center Wire rope
frame 01 as shown in Fig. 1. 30 mmø × 5 000 mm
2 Lift track center frame 01 as shown in Fig. 1.
01
Weight of track center frame 01 :
ZX870-5 class only 7 830 kg (17 225 lb)
Wire rope used:

30 mmø × 5 000 mm (L) : 4 pcs.
(1.2 inø) × (195 in L)
Eyebolt: 4 pcs.
For 5t load Fig. 1
CAUTIONS: Detail A
Hold
i) Make sure that no one goes directly under the
Rope L3
lifting track center frame. Rope L1
01 Rope L4
ii) A qualified worker undertakes sling work and
Rope L2
lifting work. Eyebolt
Fig. 2
80
Step 4
Connecting the track center frame and side frame (right)
Lift and move
1 1 Move track center frame 01 horizontally in the
Side frame (right) 04
direction of .
Note:
Position the travel device side of the side frame so
that it faces the same direction as the travel duct
side of the track center frame (refer to Fig. 1). 01
Travel device
Travel duct side

Fig. 1
2 Match the height of the installation surface of track
center frame 01 with that of the side frame (right) Detail A
04 surface on which the track frame is installed.
3 Align the centers of the side frame and track

center frame by moving track center frame 01 Lift and move
horizontally in the direction of the arrow.
Track center
frame 01
04
Side frame (right)
4 Connect the side frame to the track center frame.
Fig. 2
Hold
Fig. 3
81
2 Installing the side frame (right)
Hold
1 Align the bolt holes of the side frame and track

center frame.

screws and back of bolt heads. Track center Side frame (right)
frame
Notes:
in Fig. 6.
and bottom surfaces of spacer 19 . Fig. 4
3 Insert 22 sets of spacers 19 into bolts 18 and use

your hand to screw all of the bolts into the screw
holes.
Notes:
ii) Do not forcibly screw in the bolts. Doing that can 18
damage the screws.
19
4 Using a ratchet wrench, tighten bolts 18 that were
screwed in step 3 .
Notes:
completely tight.
Fig. 5
contact surfaces.
Detail B Detail C
Ratchet wrench
Chamfered surface
＊ 18
19 19
18
＊ a
Section a
Fig. 6 Fig. 7
82
lock plate 22 .
21
6 Before using the bolt, apply lubricant to the bolt
screws and back of bolt heads. 22
23
Notes:
in Fig. 9.

holes. Fig. 8
Notes:
damage the screws.
Notes:
completely tight.
contact surfaces.
Detail D Detail E
20
×4
20
21
＊
Chamfered surface a 22
×2
23
×4
＊ Section a 21 60
Fig. 9 Fig. 10
9 Using a power wrench, tighten bolt 18 completely. Detail F
Note:
Tighten lock plates 22 using a ratchet wrench. Keep in
22
this state.
ZX870-5 class 2 800 N·m

(280 kgf·m/2 065 lbf·ft)
Power wrench
18 Fig. 11
CAUTION:
83
Step 5
Connecting the side frame (left) and track center frame
Side frame (left) 05

1 Installing the side frame (left), cleaning and finish
1 Prepare side frame (left) 05 . a
2 Using a tap, tap all the screw holes noted at a b

and b on the surface of side frame (left) 05 on
(ZX870-5 class)
3 Clean the surface on which side frame (left) 05 is

installed. Fig. 1
Check the surface for any damage.
Detail A
05
Note:
Tap
Fig. 2
84
2 Slinging the side frame (left) 05
1 Confirm that the travel device of side frame (left)

05 is assembled as shown in Fig. 3.
2 Sling a wire ropes over side frame (left) 05 as
shown in Fig. 4.
Note:
Use protectors in 4 locations designated in Fig. 4 so
that the wire rope doesn’t damage.
Travel device Fig. 3
Wire rope used: Hold

26 mmø × 8 000 mm (L) : 2 pcs.
(1.0 inø) (312 in L)
Protector: 4 pcs.
Wire rope
26 mmø × 8 000 mm
3 Lift side frame (left) 05 as shown in Fig. 5.
05
CAUTION:
one under the lifting side frame. Protector
Notes:
i) The travel motor side is heavy. Align carefully
and lift so that the front and back are horizontal
to each other. ＊
About 1 800 mm
ii) As shown in Fig. 4, tilt the side frame slightly so
that it is parallel to the contact surface of the Fig. 4
Travel device
track center frame.
Detail B
Lift Lower Lift
Hook wire Lower Lay a block. Lift again. Then, the

rope to the vertically. Hook the side frame will tilt as
side frame. block to the shown here.
outside of the
side frame
and bring
down to the In this state, you will
ground. be able to connect it
05 Outside Inside smoothly with the
track center frame.
Block (2 pcs.)
Fig. 5
Block: 2 pcs.
1 000 kg (2 200 lb)
85
Lift and move
3 1 Align the centers of the side frame and track
center frame by moving track frame 05
Hold
horizontally in the direction of the arrow.
Side frame (left)

05
Track center frame
Fig. 6
2 Bring side frame (left) 05 towards the track center Lift and move
Hold
frame slowly.
Track center
frame
05
Fig. 7
86
Hold
4 Installing the side frame (left) Hold
1 Align the bolt holes of the track center frame and

side frame.
Track center
screws and back of bolt heads. frame
Notes:
i) Use a lubricant that is a 1:1 mix of jell-form zinc 05
in Fig. 10.
and bottom surfaces of spacer 19 . Fig. 8
3 Insert 22 sets of spacers 19 into bolts 18 and use

your hand to screw all of the bolts into the screw
holes.
Notes:
damage the screws.
Fig. 9
18
Detail C 19
Chamfered ＊ 18
surface
19
19
Fig. 11
＊ Section a a
Fig. 10 Ratchet wrench
4 Using a ratchet wrench, tighten bolts 18 that were

screwed in step 3 .
Notes:
completely tight.
contact surfaces.
18
Fig. 12
87
lock plate 22 .
21
6 Before using the bolt, apply lubricant to the bolt
screws and back of bolt heads. 22 23
Notes:
in Fig. 14.
and bottom surfaces of washer 21 . Fig. 13

holes.
Notes:
damage the screws.
Notes:
completely tight.
contact surfaces.
Detail D Detail E
20
×4
20
21
＊ 22
Chamfered
surface a
×2
23
×4
＊ Section a 21 60
Fig. 14 Fig. 15
9 Using a power wrench, tighten bolt 18 completely.
Note:
Tighten lock plates 22 using ratchet wrench. Keep in
this state.
Power wrench
ZX870-5 class 2 800 N·m

(280 kgf·m/2 065 lbf·ft)
22
CAUTION:
18
reaction force bar of the power wrench. Fig. 16
88
Step 6
Removing the wire rope
1 1 Lower the crane that was used to lift side frame

(left) 05 , and land the side frame on the ground. Hold
2 Remove the wire ropes that was used to lift side

Lower
frame (left) 05 . Remove
05
Fig. 1
2 1 Lower the crane that was used to lift track center

frame 00 .
2 From the swing bearing, remove the wire ropes Lower

and eyebolts that were used to lift track center Remove
frame 00 .
00
Fig. 2
3 This completes the undercarriage assembly work.
Fig. 3
89
ZX870-5 class
Front
Bolt (J833010) 20
Rear
Washer (4114408) 21
Plate lock (4207766) 22
Spacer (4639597) 23
Bolt (4639684) 18
Spacer (4218944) 19
Fig. 4
90
6-2-3 Connecting of undercarriage and superstructure
Step 1 Detail A The grease bath is covered with

plastic sheet so that it is not
Preparing the track center frame, cleaning and finish exposed to wind and rain. There is a
plywood board inside so that water
doesn’t collect on the plastic sheet.
1 1 The grease bath of the track center frame is
The bolts are held in
covered with plastic sheet so that it is not exposed place with wire, etc.
so that they don’t drop.
to wind and rain.
There is a plywood board inside so that water
doesn’t collect on the plastic sheet.
Remove the sheet and board.
2 The bolts used to install the swing bearing are
held in place with wire, etc. so that they don’t
drop. Fig. 1
Remove these swing bearing mounting bolts.
Detail B
Knock pin
2 1 Clean the surface (at a shown by ) of the
swing bearing that is attached to the track center
frame as shown in Fig. 2.
a
2 Check the surface of the swing bearing for any
damage and nick.
Note:
If there are damages, repair or re-finish.
<<Reference>>
3 Hammer knock pins into the knock pinholes in 2
locations (*1). Hammer two knock pins into the swing bearing. Fig. 2
Knock pinhole diameter

Detail C
ZX870-5 class ~ φ 34.5 mm Swing bearing
Soft zone
Front
Knock pin c
Right side
ZX870-5 class: 4293389 ~ 2pcs.
3 Check to make sure that there are no foreign

substances and water inside the grease bath that is
found inside the internal gear box of the swing bearing
(at b shown by ) as shown in Fig. 4.
Drain out any water, if mixed.
4 Turn the bearing so that the “soft zone” (at c shown

Left side
by ) of the outer race of the swing bearing is Fig. 3
positioned to the right of the truck center frame as
shown in Fig. 3. Detail D
5 Pour grease inside the grease bath (at b shown by

) as shown in Fig. 4.
6 Clean the contact surface of the bolt under the swing

bearing. b
Pour grease inside the grease bath. Fig. 4
91
7 Apply Three Bond 1102 to the upper surface of the Detail E
swing bearing as outlined below.
1 Check that the upper surface of the swing bearing

has been thoroughly cleaned.
(*1) Grease guide ring Fig. 5
2 Apply sealant evenly inside the outer race only by Detail F

making sure that it won’t run off the edge during Apply carefully so that the sealant
doesn’t run off the edge.
the connection process.
Fig. 6
3 Apply Three Bond 1102. Detail G

Apply Three Bond inside
the hole from where the
Apply Three Bond 1102 also inside the hole on taper pin is extracted.
the soft zone from where the taper pin is
extracted.
Fig. 7
4 After directly connecting the upper structure, Detail H

check so that there is no sealant running off the Work carefully so that no
sealant runs off the edge.
edge. If there is, wipe off thoroughly.
Fig. 8
92
Step 2
Slinging the superstructure
CAUTIONS:
i) Use a lifting wire rope and lifting sling that are not damaged or worn and that are sufficiently strong.
ii) Contact the nearest Hitachi branch or sales office to learn the correct way to lift, the size and types of lifting wire
rope and lifting sling.
iii) To lift, bring the lock lever to “Lock” position so that the machine will not move involuntarily.
iv) Any errors in the lifting method or rope sling method can cause the machine to move during lifting work and lead
to fatalities and injuries or machine damage.
v) Do not apply load suddenly to the lifting wire rope and sling.
vi) While lifting a load, never go under the machine or stand/walk nearby.
vii) A qualified worker undertakes sling work and lifting work.
Lift
1 Slinging the superstructure Wire rope
34 mmø × 3 000 mm
Use chain blocks, exclusive lifting slings and wire ropes Wire rope
Chain block for 34 mmø ×
to sling superstructure 00 as shown in Fig. 1. 5t-load 10 000 mm
Notes: Wire rope

34 mmø × 3 000 mm
i) Use exclusive lifting slings to install the Shackle
counterweight side by tightening bolt.
A detailed explanation on how to use the lifting sling
is found on the appendices (pages 259 to 262).
ii) Use protectors in two locations: to the right
forefront of the main frame/left forefront of the Bolt
main frame. See Fig. 1-a.
Protector
Weight of superstructure 00 :
ZX870-5 STD 19 580 kg (43 075 lb) Exclusive
lifting sling
ZX870-5 HD 19 800 kg (43 560 lb) Wire rope
Fig. 1
Wire rope used: 6 pcs. 00
34 mmø × 10 000 mm (L) : 2 pcs.
Protector
(1.3 inø) (390 in L)
34 mmø × 3 000 mm (L) : 4 pcs.
(1.3 inø) (117 in L)
Chain block for 5.0t load: 2 pcs.
Protector: 2 pcs.
Shackle for 5.0t load: 2 pcs. Fig. 1-a
Exclusive lifting jig: 1 set Hold
2 Cleaning the bottom (on which the swing bearing is

installed) of superstructure 00
CAUTION:
Before working under the superstructure, place
supports under the front, back, left and right of the
superstructure so that the load doesn’t drop.
Support for 5t load: 4 pcs.

1 Clean the bottom surface on which the swing

bearing is installed of superstructure 00 .
Support
2 Check the surface for any damage. 00
Note: Fig. 2

93
Step 3 Hold
Releasing the swing lock
Note:
To match the positions of the swing drive pinion and
internal gear of the swing bearing, release the swing
lock.
Fig. 1
Detail A
1 Releasing the swing brake
Note:
The illustration shows how to release the swing Fig. 2
brake by turning the swing pinion manually when the
swing pinion and swing bearing teeth cannot be Detail B
aligned during local assembly (at the time of
installation of the superstructure). a
IMPORTANT:
Remove the plug a from the center of the left and
right surfaces of the swing motor. Install the bolt b
and raise the brake piston (by about 3 mm).
This will enable you to turn the swing pinion manually.
Note:
Fig. 3
Once the undercarriage and superstructure have
been connected, return to the original state by
Detail C
performing the above procedure in the reverse
order. b
2 After cleaning off all the oil, carefully wash the parts.
Fig. 4
94
Hold
Step 4
Superstructure and track center frame direct connection
1 1 Lift up superstructure 00 .
00
2 Keep lifting superstructure 00 level as shown in
Fig. 1.
Notes:
i) Adjust the preinstalled chain blocks and keep
the superstructure level.
ii) To guide the superstructure safely, tie a rope
around it.
Rope
Rope used:
10 mmø × 10 000 mm (L): 2 pcs.
(0.4 inø) × (390 in L)
Rope
Fig. 1
CAUTION:
To connect it with the superstructure, place two sub- Hold
leaders, one in front of the superstructure and one at

the back of the superstructure. Follow the signals of
the leader to make sure that the parts do not damage.
CAUTIONS:
00
i) Make sure that no one goes directly under the
lifting superstructure.
ii) A qualified worker undertakes crane work.
2 Align the centers of the track center frame swing

bearing and the superstructure by moving lifting
superstructure 00 .
(*1) Grease guide ring Swing bearing

3 1 Check to make sure that the center of the track
center frame is aligned with the center of
superstructure 00 .
2 Slowly lower superstructure 00 by keeping it level.
Fig. 2
Notes:
i) Do not let the superstructure touch the grease
guide ring (*1) of the track center frame.
For (*1), refer to the photo shown in Fig. 5 on p. 92.
ii) Adjust the preinstalled chain blocks and keep Lower
the superstructure level relative to the swing
bearing. 00
4 Slowly lower the crane by keeping the front and back of

superstructure 00 level.
5 1 When the space between the undercarriage

(swing bearing) and superstructure (at a shown
by ) is about 200 mm (7.9 in), temporarily a
200 mm
stop the crane suspension work. (7.9 in)
2 Check that the space between the
undercarriage (swing bearing) and
superstructure is the equal between the front
Fig. 3
and back, and the left and right.
95
6 The following is the procedure to Detail A
engage the internal gear of the
swing bearing with the swing
drive pinion.
Lower
Note:
Aligning the bolt holes first can
damage the pinion or teeth of
swing bearing.
1 Lower the crane slightly and

bring the superstructure
down on the undercarriage.
Height of the eyes
Fig. 4
Detail B
Exclusive tools
(hook wrench and extension pipe)
2 Using special tools (hook

Pinion
wrench and extension pipe),
carefully align the swing
drive pinion teeth with the
Internal gear
internal gear.
Fig. 5
Note:
If the swing lock is released,
it will be easy to align.
Detail C
Hold
3 Align the pinion teeth with

the internal gear. Next,
slightly lower the crane to
engage the pinion and
internal gear with each other.
4 By aligning the pinion with

the internal gear, slowly
lower the crane.
Height of the eyes
Fig. 6
96
Note: Detail D
Hold
If you are unable to align the gear teeth, slightly
swing the crane to the left and right.
This will engage the gear teeth.
Sway
5 Slowly lower the crane by keeping the front and Sway
back of superstructure level.
6 When the space between the track center frame

and superstructure (at a shown by ) is
about 40 mm (1.6 in), stop lowering the crane. Fig. 7
Detail E
About 40 mm
(1.6 in)
7 Align the knock pin b of the track center frame a

bearing with the knock pin hole in the
superstructure.
b
Knock pin
Fig. 8
8 Slowly lower the crane by keeping the front and Detail F

back of the superstructure level. Hold
9 When the space between the track center frame

and superstructure (at c shown by ) is
about 2 mm to 3 mm (0.08 to 0.12 in), stop
lowering the crane.
Note:
Check to make sure that there are no foreign
substances between the swing bearing surface of
the track center frame and superstructure
installation surface.
2 to 3 mm
(0.08 to 0.12 in) c
Fig.9
97
7 1 Install 6-8 bolts and spacers at the front and back Detail G
of the swing bearing. Begin working from the
bottom of the track center frame.
Notes:
i) Be sure to apply lubricant to the bolt and then,
tighten. Use a lubricant that is a 1:1 mix of jell-
form zinc white and spindle oil.
ii) Before inserting the bolt, apply lubricant to the
in Fig. 11.
iii) Install the spacer to the bolt by facing the
2 Lower the crane until the surfaces of the track

Fig. 10
center frame and superstructure are in even
contact. Detail H
3 Using a ratchet wrench, temporarily tighten all the Spacer
＊
bolts and spacers.
＊
Note:
Keep the lifted superstructure in this state. ＊
Chamfered
surface
Bolt
8 1 Begin by tightening the bolt found on the swing

＊
bearing soft zone.
Fig. 11
2 Next, slowly swing the superstructure with a crane
and tighten the bolts with an impact wrench.
3 Use a hydraulic wrench (8S) to tighten the Detail I
superstructure connecting bolts.
M33 bolt tightening torque: 2 200 N·m

(220 kgf·m/1 623 lbf·ft)
CAUTION:
Work carefully so that you don’t get your hands stuck
between reaction force bar of the hydraulic wrench.
Notes:
i) After tightening the bolts completely, mark the
head of the bolt at the end. (Refer to Fig. 13.) Tightening of direct-connected bolt Fig. 12
ii) After all the bolts have been tightened (use hydraulic wrench to tighten.)
completely, retighten three-four of the bolts that Detail J

were tightened first and reconfirm the torque.
Note:
If there is no space to tighten the swing bearing,
install the bolts around the entire perimeter. Then,
completely tighten 5-6 bolts at the front and back.
Once you are able to start the machine, tighten the
rest completely while in swinging motion.
Mark
9 Remove the exclusive lifting slings, wire ropes and
chain blocks that were attached to the superstructure.
Fig. 13
98
Step 5 Detail A
Restoring the swing lock function (plug insertion)
IMPORTANT:
The assembly supervisor follows this procedure to
restore the functions of the swing lock. If the work is
not carried out properly, the device can be damaged.
Fig. 1
Detail B
1 Remove the bolt b that was screwed in on page 94

and insert the plug a instead (motors at the left and
right).
c
Fig. 2
Detail C
2 After cleaning off all the oil, carefully wash the parts.
a
Fig. 3
99
Step 6 Detail A
09
Center joint-vicinity work and travel hose connection work
a
c
1 Installing the stopper
Use bolts 13 and washers 12 to install center joint
stopper 09 and cover; rubber 08 .
M14 bolt tightening torque: 140 N·m

(14 kgf·m/103 lbf·ft) b
Width across flats: 22 mm d
Notes:
i) Before installing the bolts, apply lubricant to
them. C/J travel hose connection and C/J stopper installation Fig. 1
ii) After screwing in all of the bolts, tighten them by
Detail B
hand to the specified torque. Bolt 13
Washer 12
09 Washer 12
Stopper
Cover; rubber 08
2 Connecting the travel hoses
Fig. 2
1 Connect the left and right travel motor-use hoses
a , b and c , d to the center joint. Notes:
Hose tightening torque: 210 N·m i) Connect the hose so it does not touch other
(21 kgf·m/155 lbf·ft) parts.
Width across flats: 41 mm ii) Make sure that no dust has adhered to the seat
face of the hose.
2 After cleaning off all the oil, carefully iii) Do not damage the joining surfaces of the hose.
wash the parts. iv) Do not twist hose during connection. Their
v) Use O-rings e (P/No. 4187328 - 4) to connect
the hoses. Apply a thin layer of sealant #98D to
the O-ring before installation.
Detail C
b
c
a Fig. 3
e e
e
d
Center joint
Fig. 3
100
3 Connecting the pilot hose and drain hose Detail D
1 Connect the pilot hose f .
Tightening torque of hose f : 40 N·m

(4 kgf·m/30 lbf·ft)
f
O-ring g Pilot hose
2 Connect the drain hose h . Adapter 10
Fig. 4
Tightening torque of hose h : 95 N·m
Pilot hose connection
(9.5 kgf·m/70 lbf·ft)
Width across flats: 27 mm Detail E
Notes:
Drain hose
i) Connect the hose so it does not touch other h
parts.
ii) Make sure that no dust has adhered to the seat
face of the hose.
iii) Do not damage the joining surfaces of the hose.
iv) Do not twist hose during connection. Their
v) Use adapter 10 /O-ring g (P/No. 4509180 - 1), i
adapter 11 /O-ring i (P/No. 4506418 - 1) to O-ring
connect the hoses. Apply a thin layer of sealant Adapter 11
#98D to the O-ring before installation.
Fig. 5
3 After cleaning off all the oil, carefully Drain hose connection
wash the parts.
101
Step 7
ZX470-5B series Pre-cleaner
Installing the pre-cleaners 31
ZX470-5 class : 1 pc.
ZX670LC-5 class : 1 pc.
ZX870-5 class:
ZX870-5B series ~ 2 pcs.
ZX870-5G series ~ 1 pc.
1 Installing the pre-cleaner (ZX470-5 class)

Fig. 1-a
1 Remove the cap that is installed to the air intake
opening of the air cleaner so that rainwater
doesn’t enter.
2 Install the pre-cleaner using a band to fix it.
Tightening torque: 9 N·m

Note:
Before installing the bolts, apply lubricant around the
thread.
Fig. 1
ZX470-5G series Pre-cleaner

31
Fig. 2-a
Fig. 2
102
2 Installing the pre-cleaner (ZX670LC-5 class)
ZX670LC-5B series Pre-cleaner
1 Remove the cap that is installed to the air intake 31
doesn’t enter.
2 Install the pre-cleaner using a band to fix it.

Width across flats: 8 mm Fig. 3-a
Note:
thread.
Fig. 3
Pre-cleaner
ZX670LC-5G series
31
Fig. 4-a
Fig. 4
103
3 Installing the pre-cleaners (ZX870-5 class)
ZX870-5B series Pre-cleaner
1 Remove the cap that is installed to the air intake 31 × 2
doesn’t enter.
■ ZX870-5 class
･ ZX870-5B series ~ 2 pcs.
･ ZX870-5G series ~ 1 pc.
2 Install the pre-cleaner using a band to fix it. Fig. 5-a

Note:
thread.
Fig. 5
Pre-cleaner
ZX870-5G series
31
Fig. 6-a
Fig. 6
104
Step 8
ZX470-5B series 29 Muffler
Installing the muffler (ZAXiS-5B series)
1 Installing the ZX470-5 class muffler
1 Remove the muffler (P/No. 8086588) that was

used for transport, bolts (P/No. J921050) and nuts
(P/No. M520010).
Remove the cap.
Fig. 1-a
2 Install the proper muffler (P/No. 7060123).

Notes:
i) Before installing the bolts, apply lubricant around
the thread.
ii) The exhaust pipe for transportation is different
from that for operation. Assemble it by referring
to pages 120 and 121.
Fig. 1
2 Installing the ZX670LC-5 class muffler

ZX670LC-5B series 29 Muffler
(P/No. M520010).
Remove the cap.
M12 bolt tightening torque : 90 N·m

(9 kgf·m/66 lbf·ft) Fig. 2-a
Notes:
the thread.
Fig. 2
105
3 Installing the ZX870-5 class muffler
ZX870-5B series 29 Muffler
(P/No. M520010).
Remove the cap.

(9 kgf·m/66 lbf·ft) Fig. 3-a
Notes:
the thread.
Fig. 3
106
Transportation Exhaust Pipe
1/2
CAUTION:
Immediately after operation, the exhaust pipe is very 1
hot.
Ensure the exhaust pipe has cooled down sufficiently
before starting operation.
2
IMPORTANT:
i) Check and follow the local regulations on
transportation height on a public road.
ii) Install transportation exhaust pipe 2 only when
(1) Exhaust pipe (2) Exhaust pipe
transportation the machine. If the machine is for working for transport Fig. 4
operated with transportation exhaust pipe 2 , there
is a risk of damaging the machine.
The machine with standard exhaust pipe 1 may

exceed the required transportation height by the law.
Replace the exhaust pipe with transportation exhaust 1
pipe 2 before transporting the machine if necessary.
Consult your authorized Hitachi dealer before replacing
the exhaust pipe.
Fig. 5
Fig. 6
107
2/2
Transportation Exhaust Pipe Removal/Installation
1 Remove bolts 3 (4 used). Remove standard

1
exhaust pipe 1 .
Wrench size: 19mm
Tightening Torque: 90 N·m (9 kgf·m/66 lbf·ft)
2 Install transportation exhaust pipe 2 into exhaust

outlet 4 of the muffler (muffler filter). Secure
transportation exhaust pipe 2 with bolt 5 and
nut 6 .
Wrench Size: 17mm 3
Fig. 7
IMPORTANT:
Adjust the angle of the outlet of the transportation 4
exhaust pipe to prevent rain or foreign matter from
entering into the pipe while transporting the
machine. Cover the exhaust pipe while transporting
the machine.
If rain or foreign matter enters the muffler (muffler
filter), the muffler (muffler filter) may be damaged.
3 To replace exhaust pipe with the standard type,

reverse the above procedure. Fig. 8
Fig. 9
6
Fig. 10
108
6-3 Connection of travel hoses and installation of steps, handrails
Step 1
Connecting the travel motor hoses
1 Removing the travel motor covers
1 Remove the cover a from the travel motor.

2 In the same way, remove the opposite travel
motor cover.
2 Connecting the travel motor hoses
Note:
Stop the engine and move each operation lever
back and forward, left and right a few times to
release any residual pressure.
1 Remove the caps from the travel motor ports and
travel hoses. a Fig. 1
CAUTION:
In removing the caps from the hose ends, slowly
loosen the tightening bolt and remove the cap only
Tightening torque of M12 socket bolts ( b , c ):90 N·m
after confirming that all pressure has been released.
2 Connect travel hoses b , c , d and e to the Socket size: 10 mm
travel motor.
3 Connect the travel hoses for the opposite travel Tightening torque ( e ): 120 N·m
motor in the same manner. (12 kgf·m/89 lbf·ft)
Notes:
Tightening torque ( d ): 60 N·m
i) Connect the hose so it does not make contact
with other parts.
ii) Make sure that no dust has adhered to the seat
face of the hose.
iii) Do not damage the joining surfaces of the hose.
iv) Do not twist hose when connecting them.
Their service life will be shortened.
v) Use O-rings to connect the hoses.
Apply a thin layer of sealant #98D to the O-ring
before installation.
3 After connecting the travel motor hoseing, clean

away any residue oil from the outside of all parts.
Detail A
Example: ZX870-5 class
b c e
O-ring
A
A
Fig. 2
109
4 Installing the travel motor duct cover
1 Reinstall the travel motor cover a that was

removed in step 1 .
2 In the same way, install the travel motor cover and
travel motor duct cover to the opposite travel
motor.


Notes:
the thread.
ii) Screw in all of the bolts by hand before
tightening them to the specified torque.
ZX470-5 class
Front
Rear
Fig. 3
110
ZX670LC-5 class
Front
Rear
Fig. 4
ZX870-5 class
Rear
Front
Fig. 5
111
Step 2
Installing the steps (for the side frame)
※ 1 Use bolts, washers and spring washers to install Notes:

step 06 and step 07 to the side frame.
the thread.
M16 bolt tightening torque: 210 N·m ii) Screw in all of the bolts by hand before
(21 kgf·m/155 lbf·ft) tightening them to the specified torque.
2 Assemble the opposite side in the same way.
*900G shoe is pre-installed to the base machine for the shipment.

ZX470-5 class
06
550
Step (STD), upper
P/No. YA00003325
Weight: 11.7 kg × 4
240
Height: 125
07
Part Name P/No. Qty 550 Step (STD/H), lower 06
65
Bolt J901645 32 P/No. YA00002172

Washer, spring A590916 32 Weight: 8.49 kg × 4
Washer J222016 32 Height: 125
Fig. 1 07 Fig. 2
*900G shoe is pre-installed to the base machine for the shipment.

ZX670LC-5 class
580 06
P/No. 8127205
Track-side step
293
Height: 125
07 06
580 P/No. 8068378
90
Part Name P/No. Qty Weight: 13.2 kg × 4

Bolt J901650 32 Track-side step
07
Fig. 3 Fig. 4
*Only the track step 650G shoe and 750G shoe are available for
individual purchase. 900G shoe and above are pre-installed to the ZX870-5 class
base machine for the shipment.
588
06
P/No. 8127205
293
Track-side step
Height: 125
07
P/No. 8068378
06
580
Part Name P/No. Qty Weight: 13.2 kg × 4
90
Bolt J901650 32 Track-side step

Fig. 5 07
Fig. 6
112
Step 3
Installing the steps (for the superstructure)
※ Install the steps to the superstructure.

Notes:
the thread.
Bolt (P/No. J901235) × 14

ZX470-5 class
Washer; plain (P/No. Z449490) × 14
Washer; spring (P/No. A590912) × 14
515
515
1 700 2 340
Side step Side step

(P/No. 6028301) (P/No. 6028300)
(33.8 kg) (47.8 kg)
15
14 15 Fig. 1
Fig. 2
14
ZX670LC-5 class
Bolt; sems (P/No. J281230) × 12
500
500
1 710 2 740
Step (P/No. 6024183) Step (P/No. 6028198)

(30.3 kg) (54.5 kg)
15
14 15
Fig. 3 Fig. 4
14
ZX870-5 class
Bolt; sems (P/No. J281230) × 14
500
500
500
1 710 1 370 2 340
Step (P/No. 6024183) Step (P/No. 6024192) Step (P/No. 6024198)

(31.5 kg) (26.7 kg) (45.4 kg)
16
14 15 16
Fig. 5 15
Fig. 6
14
113
Step 4 -a (ZAXiS-5B series)
Installing the handrails
※ Install the handrails and ladder to the superstructure.

Notes:
M12 bolt tightening torque: 90 N·m i) Before installing the bolts, apply lubricant around
(9 kgf·m/66 lbf·ft) the thread.
Width across flats: 19 mm ii) Screw in all of the bolts by hand before
ZX470-5B series 37
37
1 029
642
1 772
35
284
1 000
37 754 35 37
Handrail (1) Ascending/descending ladder Handrail (2)
at the top of the fuel tank at the top of the fuel tank
P/No. YA40003168 P/No. YA40003436 P/No. YA40003435
Width: 55 mm Width: 425 mm Width: 115 mm
Weight: 12.4 kg Weight: 23.1 kg Weight: 2.85 kg
Fig. 1 Fig. 2
ZX670LC-5B series 36 37 37 37
90 112
2 117
1 019
662
662
36
919 880 242 243
404 754
35 37 37 37 34
P/No. YA40004521 P/No. YA40004523, 4151, 4152
Weight: 25.7 kg Weight: 17.5 kg 2.89 kg 2.89 kg
Hydraulic oil tank-side handrail Handrail at the top of the fuel tank 35
252
1 132
1 010
261 120 50 1 145 575

123
36 36 34
P/No. YA40004520 YA40004519 P/No. YA40004147
Weight: 4.54 kg 13.1 kg Weight: 3.23 kg
Handrail at the top of the battery box Lubricator box-side handrail
Fig. 3 Fig. 4
ZX870-5B series 37
1 100 315 252 123
36
1 432
570
34
Handrail at the top of the lubricator box Handrail at the right forefront
of the superstructure
P/No. YA40004145, 4146 P/No. YA40004147
Total weight: 17.7 kg Weight: 3.23 kg
36 34
1 149 659
1 019
Handrail at the top of the fuel tank

P/No. YA40004150, 4151, 4152
Weight: 25.5 kg
37
Fig. 5 Fig. 6
114
Step 4 -b (ZAXiS-5G series)
Installing the handrails
※ Install the handrails and ladder to the superstructure.

Notes:
the thread.
ZX470-5G series 37
37
35 37 37 38
1 772
1 017
1 029
642
754 1 000 284 1 430

35
Ascending/ Handrail (1) Handrail (2) Handrail at the top
descending ladder at the top of the at the top of the of the pump room
O/T fuel tank fuel tank
P/No. YA40003436 P/No. YA40003168 P/No. YA40003435 P/No. 8124297
Width: 425 mm Width: 55 mm Width: 115 mm Width: 165 mm
Weight: 23.1 kg Weight: 12.4 kg Weight: 2.85 kg Weight: 20.5 kg
38
Fig. 1 Fig. 2
35 37 37 37 ZX670LC-5G series 36 37 37 34
112
112
2 117
1 019
662
662
36
54 1 210 243 243
404 754 P/No. YA40006925 YA40006924 YA40004152

Weight: 17.6 kg 2.89 kg 2.89 kg 37
P/No. YA40004521 Handrail at the top of the fuel tank
Weight: 25.7 kg
Hydraulic oil tank-side handrail
35
36 36 34
252
1 132
1 010
261 120 50 1 145 575

123
P/No. YA40004520 YA40004519 P/No. YA40004147

Weight: 4.54 kg 13.1 kg Weight: 3.23 kg
Handrail at the top of the Lubricator box-
lubricator box side handrail
Fig. 3 Fig. 4
ZX870-5G series 37
123 252
1 149 461 34
36
1 019
37
575
Handrail at the top of the fuel tank Handrail at the right forefront of the superstructure
P/No. YA40005315, 4151, 4152 P/No. YA40004147
Total weight: 25.0 kg Weight: 3.23 kg
34
1 100 315
36
1 432
Handrail at the top of the lubricator box

P/No. YA40004145, 4146
Total weight: 17.7 kg
Fig. 5 Fig. 6
115
Step 5 28 Headlight × 2
ZX470-5 class
Installing the attachments 27
Mirror
1 Installing the side mirror assemblys 26

1 Mirror
Use bolts, stays and clamps to install the side
mirror assemblys.
2 Adjustment of back mirrors

Adjust the back mirrors. 25
Check to make sure that the rear visible range from Wiper
the driver’s seat is good.


(9 kgf·m/66 lbf·ft) Fig. 1
ZX670LC-5 class
2 Installing the wiper 28 Headlight × 2
27
26
1 Install the wiper arms and blade. Mirror Mirror
･ ZX470-5 class : 1 pc.

･ ZX670LC-5 class : 1 pc.
･ ZX870-5 class : 2 pcs.
2 Install the wiring coupler of the wiper. 25

Wiper
Note:
Before wiring, clean off the anti-rust agent and rust
on the coupler.
3 Installing the headlights
1 Install the headlights to the top of the cab. Fig. 2

ZX870-5 class 28 Headlight × 2
27
Mirror
2 Install the wiring couplers of the headlights.
Mirror
26
Note:
on the couplers.
Wiper × 2
25
Fig. 3
116
Step 6
Touch-up paint for the superstructure and assembly check
1 Touch-up paint for the superstructure

After installing the steps and handrails, touch up
the paint.
Fig. 1
Detail A
2 Superstructure post-assembly check
Check to make sure that all the bolts of the
superstructure are properly tightened.
Fig. 2
117
118
6-4 Greasing of swing bearing
Greasing (1) Detail A
1 The machine is provided with a pneumatically operated a

grease lubricator connected to the hose reel and a
grease gun.
Operation procedure (Refer to the next page for the

specific greasing method.)
(1) Connect air supply hose to lubricator pump a .
(2) Pull out the grease hose from hose reel c while
holding grease gun b .
(3) Stop pulling out when the reel clicks and desired
hose length is obtained; the hose will be locked
automatically. b
(4) Connect grease gun b to the desired grease
fitting and pull the gun lever; grease will be
supplied automatically by air pressure.
IMPORTANT:
Run the engine at medium speed or more when
supplying grease using the lubricator. c
Fig. 1
2 Start the engine. Example: ZX670LC-5 class
3 Supply grease to 3 points as shown in Fig. 3.
Notes:
i) When using a lubricator, increase the engine
speed above medium speed.
ii) If an optional automatic greasing system is not
equipped, the ZX470-5 class, ZX670LC-5 class,
and ZX870-5 class come equipped with a
standard air grease gun. Grease up at the swing Fig. 2
bearing with the air grease gun manually.
iii) Insufficient greasing will cause wear to the pins. Detail B
Swing bearing Swing bearing
Swing bearing Fig. 3
119
4 Lubrication method
(1) Turn power switch d ON to activate the pump.

Grease is sucked up and supplied to high-pressure d
grease gun b .
e
IMPORTANT:
When the pump begins to suck grease, any air inside
pump a will be mixed in, making grease turn whitish.
Open check valve cock e to bleed this air-mixed
grease. Securely close check valve cock e when all a
air-mixed grease is bled out.
(2) Grab high-pressure grease gun b and pay out the Fig. 4
hose from hose reel c to the length required.
(3) Press hydro-chuck g protruding from high-

pressure grease gun b into a grease nipple and
pull the lever to discharge grease.
(4) Release the lever when greasing is complete;

grease discharge will stop.
IMPORTANT:
When detaching hydro-chuck g from grease nipple h ,
grease nipple h tip may break unless a special care,
g
is taken, as follows:
f
· Tip nozzle f a little so as to release the connecting
b
pressure applied to hydro-chuck g .
· Slowly detach hydro-chuck g from nipple h .
(5) When all greasing work is complete, turn power

switch d OFF, then pull grease gun b lever to
release remaining pressure from grease gun b ,
pump a and hose. Doing so provides longer life of c
the components. A little grease will be discharged Fig. 5
at this time.
Note: g
The hose has a limited service life. Periodically
inspect the hose for cracks, grease leakage, or any
other damage. If any damage is found, replace the
hose.
h
Fig. 6
120
6-5 Final check of the superstructure
Step 1
Radiator b
Checking the liquid level
IMPORTANT:
The assembly supervisor confirms the check items
as stated in the following procedure.
If the work is not carried out properly, the device can
be damaged.
Reservoir tank
Radiator
Fig. 2
ZX470-5 class
Detail A
FULL
Fig. 1 LOW
Fig. 3-a
ZX670LC-5 class
Detail A'
1 Check the coolant level (FULL/LOW) inside the

reservoir tank a . FULL
If the level is low, replenish the coolant from the
radiator opening b . LOW
For details, refer to the operator’s manual.
IMPORTANT: Fig. 3-b

While the coolant is hot, do not remove the radiator
cap.
High temperature coolant can gush forth from the
ZX870-5 class
radiator, and this can result in injuries. Detail A''
Once the coolant temperature drops, gradually loosen a
the cap.
Confirm that the coolant level is between FULL and
LOW marks on the level gauge. FULL
Remove the radiator cap and if the level is low,
replenish the coolant. LOW
Fig. 3-c
121
IMPORTANT: Example: ZX470-5 class
The assembly supervisor confirms the check items
as stated in the following procedure.
Swing Reduction
be damaged.
Engine
Travel Reduction Fig. 4
2 Check the oil level a in all the swing decelerator-use Detail B

reducing gears.
a
CAUTION:
The machine is very hot right after operation. Before
checking the oil level, sufficiently cool the machine.
Fig. 5
3 Check the oil level b in the engine oil pan. Detail C

CAUTION:
The machine is very hot right after operation. Before b
Fig. 6
4 Check the oil level c in the final drive (both sides). Detail D
IMPORTANT:
Never stand in front of the final drives when doing this
work. c
Loosen the plug by 2 to 3 turns to allow any residual
pressure in the travel device to escape, before fully
removing the plug.
If the plug is removed without letting residual pressure Fig. 7
escape, the plug and gear oil may gush from the
machine, causing injury. Do not stand or place your
face directly in front of the plug.
122
IMPORTANT:
Confirm the check items stated in the following
procedure.
be damaged. Detail E
5 Check the fuel level inside the fuel tank.

CAUTION:
Handle the fuel carefully.
Turn off the engine before fueling.
Smoking is prohibited while fueling the tank or working
with fuel systems.
Check the fuel indicator a or fuel level gage b on the Fig. 9

monitor panel.
If necessary, replenish the fuel from the fill cap c .
Detail F
Example: ZX670LC-5 class a
Monitor Fuel Tank
Fig. 10
ZX470-5 class
Detail G
Fig. 8
Fig. 11-a
ZX870-5 class ZX670LC-5 class

Detail G'' Detail G'
c c
Fig. 11-c Fig. 11-b
123
IMPORTANT:
procedure.
be damaged.
Example: ZX670LC-5 class
Pump Transmission
Fig. 12
6 Check the oil level inside the pump transmission. Detail H

1 Remove the dipstick a .

The oil level must be between the marks.
2 Place the dipstick to the original position and then,
replenish the oil if necessary.
a
CAUTION:
The machine is very hot right after operation. Before
Fig. 13
124
IMPORTANT: Example: ZX670LC-5 class
procedure.
be damaged.
7 Check the hydraulic oil tank level

1 Check that the oil level inside the hydraulic oil tank
is between the marks on the level gauge a .
Note:
While supplementing the hydraulic oil, release the Hydraulic Oil Tank
air from the main pump. (To release the air, refer to
the instructions on page 127.) Fig. 14
Detail I
ZX470-5 class Fig. 15-a ZX670 LC-5 class Fig. 15-b ZX870-5 class Fig. 15-c
Fig. 15
Detail J
2 If the oil is not enough, replenish from the tank

opening.
Level check a
Fig. 16
125
Step 2
Checking the battery
1 Connect the battery cable to the battery.

Before connecting the battery cable, clean the
connection-part to clean off the anti-rust agent and
rust.
2 Confirm the battery fluid level and check the
specific gravity of the battery.
ZX470-5 class ZX870-5 class
Fig. 1 Fig. 3
Detail A
ZX670LC-5 class
Connection of the battery cable

Fig. 4
Fig. 2
126
6-6 Releasing the air from the main pumps Example: ZX670LC-5 class
IMPORTANT:
If there is no oil inside the hydraulic pump or the oil is
mixed with air, the main pump can damage when the
engine is started.
Be sure to release the air from the main pump.
The machine is equipped with two main pumps. Bleed
air from these pumps after changing hydraulic oil.
1 Release the air by performing the following procedure.
1 Remove plug a from the top of each pump side

to release trapped air.
2 Fill the pumps with oil and temporarily tighten the
plug a . Fig. 1
3 Start the engine and run at slow idle. Put a "Do
Not Operate" tag on the pilot control shut-off lever. Detail A
Make sue the pilot control shut-off lever is in the a
LOCK position.
4 Slowly loosen the plug a to release trapped air.
Retighten the plug a when air stops and oil flows
from the hose ends.
5 Purge air from the hydraulic system by running the
engine at slow idle and operating all control levers
slowly and smoothly for 15 minutes.
6 Position the machine with the arm cylinder fully
retracted and the bucket cylinder fully extended.
7 Lower the bucket to the ground. Fig. 2
Note:
Follow steps 6 and 7 above only when the front
attachment is installed. Example: ZX670LC-5 class Hydraulic Oil Tank
8 Turn the auto-idle switch off.
9 Stop the engine. Remove the key from the key
switch.
10 Pull the pilot control shut-off lever to the LOCK
position.
11 Check the gauge b on the hydraulic oil tank as
shown in Figs. 3 and 4.
Add hydraulic oil if necessary.
2 Retighten dust sensor plug securely.
Tightening torque: 157 ∼ 176 N·m

16 ∼ 18 kgf·m Fig. 3
115 ∼ 130 lbf·ft
CAUTION! Detail B
This operation must be done slowly. Avoid abrupt
operation.
3 Confirm hydraulic oil level in the hydraulic tank. Add b

hydraulic oil if required.
4 After the air has been released, carefully clean the

Fig. 4
parts from which the oil has flowed out.
127
128
6-7 Trial operation of superstructure
Trial operation
1 1 Start the engine.
Refer to the OPERATION MANUAL for details.
2 Check the operation of the gauges. Swing
3 Check the travel and swing functions.
CAUTION:
This operation must be done slowly. Avoid abrupt
operation.
4 Check for oil leakage. Confirm that there is no oil

leaking from the assembled areas.
5 Check the amount of oil in the hydraulic tank.
If the oil level is low, add oil through the oil filler
port on the hydraulic tank.
Fig. 1
CAUTION:
Make sure nobody other than the operator is in or on
the hydraulic excavator before starting the operation.
Traveling Fig. 2
2 Confirm that machine noise is maintained at specified

levels. Example: ZX670LC-5 class
Detail A
Fig. 4 Fig. 3
129
130
ZX470-5 class/ZX670LC-5 class/ZX870-5 class of Assembly Manual
MOUNTING PROCEDURE FOR

FRONT-END ATTACHMENTS
ATTACHMENTS
BACKHOE FRONT
132
7. Assembly Procedure for Backhoe Front
7-1 Preparation
Backhoe front assembly chart
Step 1 Fig. 1
Preparing the necessary parts

BACKHOE FRONT (1/2)
Item Model
00 4698938 4643511 4698977 Boom cylinder (R) 1
01 4698939 4643512 4698978 Boom cylinder (L) 1
02 ── ── 4089703 Split flange 8

 ZX870-5 class
03 ── ── M341445 Socket bolt 16 
04 4636821 ── ── Hose 4 Base machine - boom cylinders (ZX470-5 class)

04 ── 4676598 4641092 Hose 2 Boom cylinder rod  ZX670LC-5 class/
05 ── 4644297 4641093 Hose 2 Boom cylinder bottom  ZX870-5 class
06 ── 4508805 4508805 O-ring 6 Boom cylinder bottom, rod 
07 4187328 4187328 4187328 O-ring ＊1) ＊1) ZX470-5 class∼8/ZX670LC-5 class∼2
ZX870-5 class∼2
08 (✽✽✽✽✽✽✽) (✽✽✽✽✽✽✽) (✽✽✽✽✽✽✽) Boom 1
09 (✽✽✽✽✽✽✽) (✽✽✽✽✽✽✽) (✽✽✽✽✽✽✽) Arm 1
10 (✽✽✽✽✽✽✽) (✽✽✽✽✽✽✽) (✽✽✽✽✽✽✽) Bucket 1
11 ── ── 4653141 Hose 2 STD arm, H arm, reinforced H (R) arm, long arm
11 ── ── 4366652 Hose 2 Semi-long arm
11 ── ── 4660158 Hose 2 BE arm, reinforced BE (BER) arm
11 ── 4373644 ── Hose 2 STD arm, H arm
11 ── 4660117 ── Hose 2 Semi-long arm
11 ── 4364317 ── Hose 2 BE arm
11 4640114 ── ── Hose 2 H arm
11 4659204 ── ── Hose 2 Arm BE2.5m, arm BE2.9
11 4659744 ── ── Hose 2 Semi-long arm
Legend
(✽✽✽✽✽✽✽): No part number is given.
133
(2/2)
Item Model
12 ――― ――― 4508805 O-ring 2 (BK cylinder), boom side
12 ――― ――― 4508805 O-ring 2 (BK cylinder), arm side
12 ――― ――― 4510169 O-ring 2

 (Base machine - boom)
12 ――― ――― 4508805 O-ring 3 
12 ――― 9808805 ――― O-ring 2 (BK cylinder), boom side

12 ――― 4508805 ――― O-ring 2 (BK cylinder), arm side
12 ――― 4508805 ――― O-ring 5 (Base machine - boom)
12 4508805 ――― ――― O-ring 2 (BK cylinder), boom side
12 Z966993 ――― ――― O-ring 2 (BK cylinder), arm side
12 4508805 ――― ――― O-ring 4 (Base machine - boom)
13 ――― ――― 4487692 O-ring 2 (Between link - bucket)
13 ――― 4487585 ――― O-ring 2 (Between link - bucket)
13 4487682 ――― ――― O-ring 2 (Between link - bucket)
14 ――― ――― 4643720 Thrust plate 2
14 ――― 4379157 ――― Thrust plate 2
14 4264610 ――― ――― Thrust plate 1
15 ――― ――― 4487586 O-ring 2 (Between arm - bucket)
15 ――― 4487585 ――― O-ring 2 (Between arm - bucket)
15 4487682 ――― ――― O-ring 2 (Between arm - bucket)
16 ――― ――― 4643721 Thrust plate 2
16 ――― 4379158 ――― Thrust plate 2
16 4264609 ――― ――― Thrust plate 2
17 4336570 4336570 4336570 Light assembly ＊1) ＊1) ZX470-5 class∼1pc.
ZX670LC-5 class ∼1pc.
ZX670LC-5 USA specification∼2pcs.
ZX870-5 class∼2pcs.
COUNTERWEIGHT (1/1)
Item ZX470-5 class ZX670LC-5 class ZX870-5 class
No. ZX470-5B ZX470-5G ZX670LC-5B ZX670LC-5G ZX870-5B ZX870-5G
46 5011325 5013038 5012286 Counterweight (STD) 1
46 5013279 YA40001178 YA40001179 Counterweight (removal/installation) 1
46
4635562 4714214 4631671 Bolt (STD) 2
47
4658786 YA00002468 4341856 Bolt (removal/installation) 2
4103743 Washer ＊2) ＊2) ZX470-5 ∼4 pcs.
48 4114413 Washer 2 ZX670LC-5 ∼4 pcs.
M660045 4455400 Nut, U (STD) 2 ZX870-5 ∼2 pcs.
49
4246150 4246150 4246150 Nut, castle (removal/installation) 2
4345741 Shim (STD) ＊3) ＊3) ZX470-5 ∼4 pcs.
50
4345741 4345741 4345741 Shim (removal/installation) 4 ZX670LC-5 ∼4 pcs.
51 J912455 J912470 Bolt 4 ZX870-5 ∼2 pcs.
53 4346036 Spacer 2
54 4221465 Stopper 2
55 4070951 4380636 Shim (t1.0) 4
4071071 4071071 4380637 Shim (t0.5), STD ＊4) ＊4) ZX470-5 ∼2 pcs.
56 4071071 4071071 4380637
Shim (t0.5), removal/installation 2 ZX670LC-5 ∼2 pcs.
57 4070952 Washer, lock 2 ZX870-5 ∼4 pcs.
58 4070953 Plate 2
J222024 Washer (STD) 4
59 A590924 Washer, spring (removal/installation) 4
60 9701925 9701925 9701925 Pin, ring (removal/installation) 2
61
62 9318950 9318951 Camera 1
134
7-2 Preparing to assemble the backhoe front
Step 1
Preparing to assemble the base machine Hold
＊ Getting the base machine ready
1 Before you begin to work, extract the boom foot

pin that is mounted to the body.
Pin weight: ZX470-5 class 103 kg (227 lb)
ZX670LC-5 class 178 kg (392 lb)
ZX870-5 class 248 kg (546 lb)
Nylon sling: 1pc.
Notes:
i) Firmly tie a nylon sling around the pin, making
sure that the sling doesn’t slide.
Next, lift the pin with a crane and then, pull it out.
ii) The foot pin has a shim.
Use this shim to assemble the boom.
Fig. 1
Temporarily store the shim.
2 Clean off the anti-rust that is applied to the boom Lift
foot pins and pin holes.
3 Apply grease to the above boom foot pins and pin
holes.
Step 2 Wire rope
12 mm ø × 5 000 mm
Installing the boom cylinders
1 Wiring the boom cylinder
1 Slightly lift boom cylinder (left) 01 with wire ropes

as shown in Fig. 1.
Boom cylinder weight: ZX470-5 class 420 kg (925 lb)
ZX670LC-5 class 550 kg (1 210 lb)
ZX870-5 class 850 kg (1 870 lb)
01
Wire rope used: a
12 mmø × 5 000 mm (L) : 2 pcs.
(0.5 inø) (195 in L)
2 Clean off the anti-rust that is applied to the bosses

a , b at the boom cylinder bottom and rod.
3 Apply grease to the holes in the bosses a and b .
Fig. 1
CAUTION: b
one under the lifting boom cylinder.
Note: 00 Boom cylinder (right)

Hydraulic
A qualified worker undertakes sling work and crane duct-side
work.
2 1 Lift boom cylinder 01 .

2 To lift, keep the boom cylinder level.
Note:
Assemble the boom cylinder carefully. The left and
right sides are not the same as shown in Fig. 2. 01 Boom cylinder (left) Fig. 2
Install the cylinder to the machine, the hydraulic
duct-side face down.
135
Hold
3 Getting the boom cylinder bottom pins ready
1 Before you begin to work, extract the boom

cylinder bottom pins that is mounted to the body.
ZX870-5 class 41 kg (90 lb)
Nylon sling: 1 pc.
Notes:
sure that the sling doesn’t slide. Next, lift the pin
with a crane and then, pull it out.
ii) The bottom pin has a shim(s).
Pin
Use shim(s) to assemble the cylinder.
Fig. 3
2 Clean off the anti-rust that is applied to the boom
foot pins and pin holes.
Hold
3 Apply grease to the above bottom pins and pin
holes.
4 Installing the boom cylinder (left) 01 Move
1 Lift boom cylinder (left) 01 and move it to the

machine so that the bottom of the boom cylinder Bolt
(left) 01 is aligned with the boss hole on the frame. Spring washer
Plate
Note: b
Assemble the boom cylinder with the hydraulic duct
side downward.
2 To insert the pin, align the pin holes of boom
cylinder (left) 01 . 01
3 Check clearance c .
Assemble with the
If c measures 4 mm or more, use the shims that hydraulic duct downward
was attached to the pin and mount this to the pin
head. Adjust the shim to minimize the space Fig. 4
within a range of 0< c <4.
4 Insert the pin b . ZX470-5 class
Detail A
Lift the pin b with a crane to insert it. Work Shim
carefully to avoid scratching the cylinder seal.
Firmly tie a nylon sling around the pin, making
Pin b
with a crane and then, insert it in place.
Plate
WARNING:
・ Never put your finger inside the hole to align the pin Cab side
holes. Bolt Clearance c
・ Work carefully. When using a hammer metal Spring
washer Fig. 5-a
fragments can fly up, and this can cause injuries.
Wear protective gear such as goggles and helmet. ZX670LC-5 class/ZX870-5 class
・ Do not go under the boom cylinder to insert the pin. Detail A'
Shim
5 Use a bolts and spring washers to tighten the plate.
Pin b
Notes:
the thread. Plate
tightening them to the specified torque. Clearance
c
M20 bolt tightening torque: 400 N·m Bolt Cab side
(40 kgf·m/295 lbf·ft) Spring washer
Fig. 5-b
136
5 Place boom cylinder (left) 01 horizontally on the support.
Note:
Use a V block to cover the hose at the bottom of the
boom cylinder to prevent it from being damaged.
Support: 1 pc.
01
V block: 2 pcs. V block
6 Installing boom cylinder (right) 00

Boom cylinder support
1 Lift boom cylinder (right) 00 and move it to the
machine so that the bottom of the boom cylinder
(right) 00 is aligned with the boss hole on the
frame. Fig. 6
Hold
Note:
Assemble the boom cylinder with the hydraulic duct
side downward. Move
2 To insert the pin, align the pin holes of boom

cylinder (right) 00 .
3 Check clearance c .
If c measures 4 mm or more, use the shims that
00
was attached to the pin and mount this to the pin
head. Adjust the shim to minimize the space
within a range of 0< c <4.
4 Insert the pin a .
Work carefully to avoid scratching the cylinder seal.
Assemble with the
Firmly tie a nylon sling around the pin, making hydraulic duct downward
Boom cylinder support
WARNING:
・ Never put your finger inside the hole to align the pin
Fig. 7
holes.
・ Work carefully. When using a hammer metal ZX470-5 class
Detail B
Shim
Wear protective gear such as goggles and helmet. Plate
・ Do not go under the boom cylinder to insert the pin. Pin a
5 Use a bolts and spring washers to tighten the
plate.
Notes:
Outside Bolt
i) Before installing the bolts, apply lubricant around Spring
washer
the thread.
Clearance c
Fig. 8-a
ZX670LC-5 class/ZX870-5 class
M20 bolt tightening torque: 400 N·m Detail B'
(40 kgf·m/295 lbf·ft) Shim
7 Place the boom cylinder (right) horizontally on the Pin a

support in the same way as the boom cylinder (left). Plate
Note: Clearance
c Bolt
Use a V block to cover the hose at the bottom of the Outside Spring washer
boom cylinder to prevent it from being damaged. Fig. 8-b
137
ZX470-5 class
Step 3 O-ring
04 ∼ 1 07 ∼ 1 (4187328) 07 ∼ 1
Connecting the boom cylinder hoses ＊ 4) ＊ 4)
Hose
04 ∼ 1 (4636821) 07 ∼ 1
1 Connecting the boom cylinder hoses ＊ 4)
O-ring 07 ∼ 1
Note: ＊ 4)
07 ∼ 1 (4187328)
Stop the engine and operate the control lever ＊ 4)
several times to release the residual pressure inside
07 ∼ 1
the line. ＊ 4)
1 Remove the covers at the hose ends.
Hose
CAUTION: 04 ∼ 1
(4636821)
There might be residual pressure inside the hose when
Hose
you remove the covers at the hose ends. Gradually 04 ∼ 1
loosen the bolts and remove the covers only after 07 ∼ 1
＊ 4)
confirming that the pressure has been released.
07 ∼ 1
2 Connect two boom cylinder hoses 04 and two ＊ 4) Fig. 1-a
boom cylinder hoses 05 from the base machine to
the boom cylinders. ZX670LC-5 class
(ZX670LC-5 class/ZX870-5 class)
Hose (outer) O-ring O-ring
To install, use split flanges 02 and socket bolts 03 04 ∼ 1 (4676598) 06 ∼ 1 (4508805) 07 ∼ 1 (4187328)
(ZX870-5 class only). ＊ 3) ＊ 3)
Hose (inner)
For ZX470-5 class, use four hoses 04 . 05 ∼ 1 (4644297) 07 ∼ 1
＊ 3)
ZX470-5 class O-ring 06 ∼ 1
06 ∼ 1 (4508805) ＊ 3)
Hose tightening torque: 300 N·m
＊ 3)
(＊ 4) (30 kgf·m/221 lbf·ft)
Width across flats: 41 mm 06 ∼ 1
＊ 3)
ZX670LC-5 class
Hose tightening torque (M14 bolt): 140 N·m Hose
(＊ 3) (14 kgf·m/103 lbf·ft) 04 ∼ 1
(outer)
Socket size: 12 mm
Hose
ZX870-5 class 05 ∼ 1
06 ∼ 1 (inner)
Hose tightening torque (M14 bolt): 140 N·m ＊ 3)
(＊ 1) (14 kgf·m/103 lbf·ft) O-ring
06 ∼ 1
Socket size: 12 mm ＊ 3) Fig. 1-b
Hose tightening torque: 210 N·m
(＊ 2) (21 kgf·m/155 lbf·ft) ZX870-5 class
Width across flats: 41 mm Hose (outer) O-ring O-ring
04 ∼ 1 (4641092) 06 ∼ 1 (4508805) 07 ∼ 1 (4187328)
＊ 1) ＊ 2)
Notes: Hose (inner)
05 ∼ 1 (4641093) 07 ∼ 1
i) Do not twist hose during connection. Their ＊ 2)
service life will be shortened. O-ring 06 ∼ 1
ii) Connect the hose so it does not touch other 06 ∼ 1 (4508805) ＊ 1)
parts. ＊ 1)
iii) Make sure that no dust has adhered to the 06 ∼ 1

seat face of the hose. ＊ 1)
iv) Do not damage the joining surfaces of the hose.
v) Use six O-rings 06 and two O-rings 07 to Hose
connect the hoses. Apply a thin layer of 04 ∼ 1
(outer)
sealant #98D to the O-ring before installation.
(ZX670LC-5 class/ZX870-5 class) Hose
05 ∼ 1
For ZX470-5 class, use eight O-rings 07 . 06 ∼ 1 (inner)
＊ 1)
2 After connecting the hoses, thoroughly wipe
06 ∼ 1
off the greasy areas. ＊ 1)
Fig. 1-c
138
Step 4
Bleeding the boom cylinders
1 Bleeding the boom cylinders

Start the engine and set it to run at low idle. Slowly Boom cylinder
extend the boom cylinders to bleed any air trapped
inside, repeating the process until the cylinder rods
extend at constant speed.
Notes:
i) Avoid operating the cylinders jerkily, rapidly or in
any other way which could damage the cylinder
Fig. 1
seals.
ii) For the first 4 repetitions, stop the cylinders
100mm before the rod stroke end.
iii) Move the cylinders to full stroke on the 5th
repetition.
iv) Hold the cylinders at stroke end for 1 minute to
allow all air to escape under relief pressure.
2 1 After releasing the air from the boom cylinders,

thoroughly wipe off the greasy areas.
2 Afterwards, set the machine to the state for the
next process.
139
Step 5 08
Preparing to install the boom Wooden block
Arm cylinder
1 Installing the boom
Place wooden blocks under boom 08 as shown in Fig. 1.
Weight of boom 08 :
HD boom 4 370 kg (9 615 lb)
ZX470-5 class
BE boom 4 450 kg (9 790 lb)
STD boom 6 560 kg (14 430 lb)
ZX670LC-5 class H boom 6 580 kg (14 475 lb)
BE boom 6 130 kg (13 485 lb)
STD boom 8 210 kg (18 060 lb)
H boom 8 210 kg (18 060 lb)
ZX870-5 class BE boom 7 680 kg (16 895 lb)
Reinforced R boom 8 280 kg (18 215 lb)
Reinforced BE boom 7 690 kg (16 920 lb) Fig. 1
Wooden block: 2 pcs.

Size: 500 mm (L) × 500 mm (W) × 500 mm (H)
(20 in) (20 in) (20 in)
Detail A
Note: Nylon sling
Each wooden block must be strong enough to Lever block
withstand weight of at least 5 000 kg (11 000 lb).
Nylon sling
2 Fixing the arm cylinder rod

Use a nylon sling and lever block to fix the arm cylinder
rod as shown in Figs. 1 and 2.
Nylon sling: 2 pcs.
Lever block: 1 pc. Fig. 2

For 1 metric ton (1.1 US ton) load
CAUTION:
Install the nylon sling and lever block to the designated
positions to keep the cylinder rod from extending.
Fix them. Otherwise, the cylinder can suddenly extend
and cause a major accident.
Note:
Fix the arm cylinder with the lever block so that the
cylinder rod does not extend during work.
140
Step 6
Preparing to install the arm
1 Installing the arm

Place wooden blocks under boom 09 as shown in Fig. 1.
09
Weight of arm 09 :
Semi-long arm 2 640 kg (5 810 lb)
HD arm 2 540 kg (5 590 lb)
ZX470-5 class
BE (2.5m) arm 2 650 kg (5 830 lb)
BE (2.9m) arm 2 540 kg (5 590 lb) Wooden
STD arm 3 620 kg (7 965 lb) block
H arm 3 720 kg (8 185 lb)
ZX670LC-5 class
Fig. 1
BE arm 3 820 kg (8 405 lb)
STD arm 4 310 kg (9 480 lb)
H arm 4 490 kg (9 880 lb)
Reinforced H arm 4 610 kg (10 140 lb)
ZX870-5 class BE arm 4 630 kg (10 185 lb)
Reinforced BE arm 4 760 kg (10 470 lb)
Long arm 4 950 kg (10 890 lb)
Wooden block: 2 pcs.

Size: 500 mm (L) × 500 mm (W) × 500 mm (H)
(20 in) (20 in) (20 in)
Bucket cylinder
Note:
Each wooden block must be strong enough to c
b
withstand weight of at least 2 500 kg (5 500 lb).
a
2 Cleaning the arm pin holes

1 Clean off the anti-rust from the pins a , b that are d
inserted to the top of the arm.
2 Before you begin to work, extract the pins a , b
from the top of the arm. Fig. 2
Notes:
ii) The pin has a thrust plate.
Use this thrust plate to assemble the bucket.
Temporarily store the thrust plate.
Weight of pin a : ZX470-5 class 53 kg (117 lb)
3 Clean the pin holes a and b . ZX670LC-5 class 76 kg (167 lb)
4 Clean off the anti-rust from the pin c that is ZX870-5 class 94 kg (207 lb)
inserted into the arm.
5 Extract the pin c from the arm beforehand. Weight of pin b : ZX470-5 class 52 kg (114 lb)
Note: ZX870-5 class 81 kg (178 lb)
Firmly tie a nylon sling around the pin, making sure Weight of pin c : ZX470-5 class 24 kg (53 lb)
that the sling doesn’t slide. Next, lift the pin with a ZX670LC-5 class 35 kg (77 lb)
crane and then, pull it out. ZX870-5 class 44 kg (97 lb)
6 Clean the pin holes c and d . Nylon sling: 1 pc.
141
3 Fix the link A with the nylon sling and lever block so
that the bucket cylinder rod does not extend. Bucket cylinder
Nylon sling: 1 pc.
Lever block: 1 pc.

For 1 metric ton (1.1 US ton) load
Note:
Fix the link A with the lever block and nylon sling so
that the cylinder rod does not extend during work.
Fig. 3
Detail B
Nylon sling
Link A
Bucket cylinder
Lever block
Fig. 4
142
Step 7 B
Preparing to install the bucket B

b ×2
1 Preparing the bucket
1 Preparing to install the bucket 10 .
10
a ×2
Weight of bucket 10 :
1.9 m3 BK 1 590 kg (3 500 lb)
2.1 m3 BK 1 650 kg (3 630 lb)
ZX470-5 class
2.3 m3 BK 1 810 kg (3 980 lb)
B series 1.9 m3 ROCK 2 070 kg (4 555 lb)
G series 1.6 m3 BK 1 480 kg (3 255 lb)
2.65 m3 BK 1 930 kg (4 245 lb) Fig. 1
ZX470-5 class 2.1 m3 ROCK 2 170 kg (4 475 lb) Detail A
(G series only) 2.3 m3 ROCK 2 260 kg (4 970 lb) Fig. 2
Apply grease
2.5 m3 ROCK 2 360 kg (5 190 lb)
2.9 m3 GP 2 200 kg (4 840 lb)
ZX670LC-5 class
2.9 m3 ROCK 2 850 kg (6 270 lb)
3.5 m3 BK 2 980 kg (6 555 lb)
3.5 m3 ROCK 3 790 kg (8 340 lb) Apply grease
3.5 m3 ROCK, reinforced 4 830 kg (10 625 lb)
3.7 m3 ROCK 3 900 kg (8 580 lb)
ZX870-5 class 3.7 m3 ROCK, reinforced 4 970 kg (10 935 lb)
4.3 m3 ROCK BE 4 270 kg (9 395 lb)
4.3 m3 ROCK, reinforced 5 690 kg (12 520 lb) Dust seal
4.5 m3 BE 3 980 kg (8 755 lb)
4.5 m3 ROCK BE 4 400 kg (9 680 lb)
2 Clean the two pin holes a and two pin holes b Fig. 3-a
ZX470-5 only
shown in Fig. 1. Section B
Dust seal
2 Install dust seals in four locations of ZX470-5B series
1.9m3 lock bucket shown in Section B in Fig. 1 as Dust
seal
shown in Figs. 3 and 3-a.
3 Apply grease to the bucket pin holes, joint at the arm- Bucket
end and joint at the link as shown in Fig. 2 (4 locations
in total). ZX470-5B series1.9m3 lock bucket
Fig. 3
The bucket mounting pins a and b have been

installed to the arm in advance.
b
Remove them from the arm.
Weight of bucket mounting pin (reference) a

Model Weight a Weight b
3.4 m, 3.9 m
H3.4 m, BE2.5 m
53 kg 52 kg
BE2.9 m, 2.9 m
ZX470-5 class (117 lb) (114 lb)
R3.4 m, BER2.5 m Fig. 4
BER2.9 m
39 kg 38 kg ZX470-5 class/ZX670LC-5 class
4.9 m (86 lb) (84 lb)
3.6 m, 4.2 m 76 kg 65 kg b
ZX670LC-5 class H3.6 m, BE2.9 m (167 lb) (143 lb)
53 kg 52 kg
5.3 m (117 lb) (114 lb)
3.7 m, 4.4 m 94 kg 81 kg
H3.7 m (207 lb) (178 lb) a
76 kg 65 kg
ZX870-5 class 5.4 m (167 lb) (143 lb)
98 kg 81 kg
BE2.9 m (216 lb) (178 lb)
Fig. 5
143
144
Lift
7-3 Installing the boom
Step 1 Wire rope
18 mmø × 3 000 mm
Installing the boom
Wire rope
18 mmø × 10 000 mm
1 Cleaning the boom
Chain block for 5t load
1 Clean the boss holes a in boom 08 .
2 After cleaning, apply grease to the boss holes a .
Wire rope
18 mmø ×
2 Wiring the boom 12 000 mm
1 Using a chain block, wire ropes, shackles and Wire rope
protector, sling the boom as shown in Fig. 1. 18 mmø × 3 000 mm
Protector
2 To lift, adjust the boom to keep boom holes a Shackle
level.
Note:
Adjust the preinstalled chain block and keep the Boom 08
boom level.
a
CAUTION:
one under the lifting boom.
Fig. 1
a
Note:
A qualified worker undertakes sling work and crane
work.
Weight of boom 08 : Wire rope used: 4 pcs.

HD boom 4 370 kg (9 615 lb) 18 mmø × 3 000 mm (L) : 2 pcs.
ZX470-5 class (0.7 inø) (117 in L)
BE boom 4 450 kg (9 790 lb)
STD boom 6 560 kg (14 430 lb) 18 mmø × 10 000 mm (L) : 1 pc.
ZX670LC-5 class H boom 6 580 kg (14 475 lb) (0.7 inø) (390 in L)
BE boom 6 130 kg (13 490 lb) 18 mmø × 12 000 mm (L) : 1 pc.
STD boom 8 210 kg (18 060 lb) (0.7 inø) (468 in L)
H boom 8 210 kg (18 060 lb)
ZX870-5 class BE boom 7 680 kg (16 895 lb) Protector: 1 pc.
Reinforced R boom 8 280 kg (18 215 lb)
Chain block (for 5t load): 1 set
Reinforced BE boom 7 690 kg (16 920 lb)
Shackle (for 5t load): 2 pcs.
3 Moving the boom Lift

Align the heights of the pin holes a of the
Move
boom foot with the foot pin holes b of the
main frame and slowly bring them towards the
machine.
a Cab
Notes: b
i) Move the boom carefully so that it
doesn’t touch the cab.
ii) A hanging boom is very dangerous
because it can all of a sudden move in
the most unexpected way. Guide it by Rope
tying a wire rope around the end of the

boom.
Fig. 2
Rope used:
8 mmø × 5 000 mm (L)： 1 pc.
(0.3 inø) (195 in L)
145
Hold
4 Installing the boom
1 Align the pin holes of the boom foot a with that of

a
the main frame b .
b
Note:
It is easier to align the boom pins if the outer
perimeter of the boom that’s located inside the
machine is marked.
Fig. 3
Detail A
2 Insert boom foot pins into a and b .
Mark
Try not to use a hammer. By adjusting, the pin
can be pushed inside with your hands.

ZX870-5 class 248 kg (546 lb)
Fig. 4
Nylon sling: 1 pc.
Hold
Notes:
i) Confirm that grease has been applied to the pins
ii) Firmly tie a nylon sling around the pin, making
WARNING:
Fig. 5
holes. Hold
・ Work carefully. When using a hammer metal
Wear protective gear such as goggles and helmet.
・ Do not go under the boom cylinder to insert the pin.
b
a
3 Insert a shim between the boss on the cab-side

frame and boom foot boss. Fig. 6
Adjust the shims so that clearance c is c <1.
The clearance on the opposite side should be
Detail B Pin Shim
minimal.
Clearance
Cab side
c
Frame-side boss Boom foot boss Fig. 7
146
4 After inserting the pin, tighten the plate with the Spring washer
bolts and spring washers. Plate Bolt
Notes:
the thread.

Fig. 8
Detail C
Bolt
Spring
washer
Plate
Fig. 9
5 Place a block at the end of the boom and lower Lower

the boom onto the block.
Wooden block: 1 pc.

100 mm (L) × 800 mm (W) × 50 mm (H)
(4 in) (30 in) (2 in)
Wooden block
Fig. 10
6 Remove the wire ropes, chain block and shackles Remove the
wire rope.
that are used to lift the boom.
Fig. 11
147
Step 2 ZX470-5 class
Connecting the hoses between the base machine and boom Detail A
1 Connecting the hoses

※ ※ ※ ※
Note:
Stop the engine and operate the control lever
several times to release the residual pressure inside
the line.
1 Remove the covers at the hose ends. ＊ 1)

b Hose
a Hose
CAUTION: Fig. 1-a
There might be residual pressure inside the hose when
you remove the covers at the hose ends. Gradually Note:
loosen the bolts and remove the covers only after For ZX670LC-5 class and ZX870-5 class, the number tags,
confirming that the pressure has been released. 1 and 2 , are attached to the boom side hose and base
machine side hose. When you connect the hoses, make
2 Connect the hoses a , b ＊ 1) or ＊ 2) from the
sure to match the hose numbers.
base machine to the boom.
＊ 1) ZX470-5 class ∼ 4 pcs. Tag.2 12
＊ 2) ZX670LC-5 class/ZX870-5 class ∼ 5 pcs.
3 Check to make sure that the hoses is not Tag.2
touching the frame, etc. Sometimes, the swing
Tag.1
device and hoses are touching when the boom
cylinder is extended to the maximum. Assemble
ZX670LC-5 class Tag.1
carefully.
Tightening torque: 1-1/2 hose: 205 N·m Detail A'

1-1/4 hose: 140 N·m ※
Notes:
i) Do not twist hose during connection. Their ※
ii) Connect the hose so it does not touch other
＊ 2)
parts as shown in Fig. 2. b Hose
a Hose ※
iii) Make sure that no dust has adhered to the seat Fig. 1-b
face of the hose.
Tag.2 12
v) Use O-rings 12 to connect the hoses.
Apply a thin layer of sealant #98D to the O-ring Tag.2
Tag.1
2 After connecting the hoses, thoroughly wipe off the ZX870-5 class
Tag.1
greasy areas.
Detail A''
Detail B
※
※
＊ 2)
※ b Hose
a Hose
Fig. 2 Fig. 1-c
148
ZX470-5 class
Step 3 Detail A
Connecting the boom cylinder rods Pin
Push
1 Getting the boom cylinder pins ready for installation
1 ZX470-5 class boom uses an integrated pin that’s

installed into the boom cylinder rod. Push the pin
all the way into the boss on the opposite side.
Before you begin to work, extract the pins that are
used to install the ZX670LC-5 class and ZX870-5 Insert the pin all the way into the boss. Fig. 1-a
class boom arm cylinder rods.

Pin weight: ZX670LC-5 class 33 kg (73 lb)
Detail A'
Nylon sling: 1 pc.
Notes:
i) Firmly tie a nylon sling around the pin, making Pin
Extract the pin beforehand. Fig. 1-b
ii) The pins has a shim(s).
Use shim(s) to assemble the cylinder.
2 Clean off the anti-rust that is applied to the boom Hold

cylinder rod pins.
3 Apply grease to the above pins and pin holes.
Lift the pin with a

crane and pull it out.
Fig. 2
149
Hold
2 Connecting the boom cylinder rods
ZX670LC-5 class
1 Firmly tie a nylon sling around the boom cylinder, Pin
Nylon sling ZX870-5 class
making sure that the sling doesn’t slide. Next, lift Do not pull out the
the boom cylinder with a crane and then, insert it ZX470-5 class pin as it is
an integrated type. Push
in place. it from the opposite side.
Plate
Nylon sling: 1 pc.
Spring
High-lift work vehicle: 2 pcs. washer
Bolt
Notes:
i)For aligning the pin holes and installing the
pins, always work on a high-lift work vehicles.
ii) Use a high-lift work vehicles to work at a
height.
2 Start the engine. Lift the boom to extend the boom
cylinder rod to align it with the boom boss. Insert Fig. 3
the pin. High-lift work vehicle
To extract, firmly tie a nylon sling around the pin, Hold
making sure that the sling doesn’t slide. Next, lift
the pin with a crane and then, pull it out. Nylon sling
Note:
To eliminate the space between the cylinder rod
boss and the boom center boss, adjust the space at
the bottom using a shim.
WARNING:
holes.
Fig. 4
Hold
3 Tighten the washer and stopper with the bolts and
washers (ZX470-5)
Tighten the plate with the bolts and spring
washers. (ZX670LC-5/ZX870-5)
Notes:
the thread.

Width across flats: 30 mm Fig. 5
ZX470-5 class ZX670LC-5 class/ZX870-5 class
Detail B Detail B'
Bolt Plate
Pin Spring washer
Pin
Bolt
Stopper
Washer
Do not pull out the ZX470-5 class pin as it is an Plate (ZX670LC-5 class only)
(ZX870-5 class has no plate)
integrated type. Push it from the opposite side.
Fig. 6-a Fig. 6-b
3 Install the opposite boom cylinder in the same way.
150
Step 4
Connecting the boom cylinder grease hoses and electrical wiring
1 Connecting the boom cylinder grease hoses
1 Attach the boom cylinder grease hose to the rod

as indicated in Fig. 1.

Width across flates: 19 mm Grease hose
Notes:
i) Make sure not to twist the hose during Fig. 1
installation as doing so can shorten their service
life. Detail A
ii) Install the hose such that they do not contact Electric wire
other parts.
iii) Check that the hose mating faces are free of
dust and contaminants.
iv) Make sure not to damage the hose mating faces
Connect
during installation.
2 Attach the grease hose for the opposite side in the

same manner.
Fig. 2
3 After connecting the grease hoses, clean away
any residue grease from the outside of all parts.
Arm cylinder
2 Connecting the electrical wiring at the boom bottom

Connect the electrical wiring for the head lights as
indicated in Fig. 2.
Note:
Before connecting the electric wires, remove the
anti-corrosive and any rust from the couplers.
3 Remove the lever blocks and nylon slings used to fix

the arm cylinder in "Step 5- 2 " on page 140. (See Figs.
3 and 4) Fig. 3
Detail B
Nyion sling
Lever block
Nyion sling
Fig. 4
151
Step 5 Detail A
Greasing (2)
a
1 The machine is provided with a pneumatically operated
grease lubricator connected to the hose reel and a
grease gun.
Operation procedure (Refer to the next page for the

detailed greasing method.)
hose length is obtained; the hose will be locked b
automatically.
fitting and pull the gun lever; grease will be
IMPORTANT: c Fig. 1
supplying grease using the lubricator.
Legend: ZX470-5 class
2 Start the engine.
3 1 Supply grease to 2 points as shown in Figs. 2 and 3.

2 Supply grease to 4 points as shown in Figs. 4 and 5.
Notes:
speed above medium speed. Fig. 2
Detail B
equipped, the ZX470-5 class, ZX670LC-5 class
standard air grease gun. Grease up at the front
pins with the air grease gun manually.
iii) Insufficient greasing will wear the pins.
BOOM CYL. BOTTOM BOOM CYL. BOTTOM
Fig. 3
Detail C
Fig. 4 BOOM CYL. ROD

BOOM FOOT
Fig. 5
152

grease gun b .
e
IMPORTANT:
a
grease. Securely close check valve cock e when all
Fig. 6
(2) Grab high-pressure grease gun b and pay out the


IMPORTANT:
g
f
b

release remaining pressure from grease gun b , c
pump a and hose. Doing so provides longer life of Fig. 7
the components. A little grease will be discharged
at this time.
g
Note:
hose.
h
Fig. 8
153
Step 6
Per-parathion bleeding the arm cylinder
＊ Bleeding the arm cylinder
Lift the arm cylinder with a crane as indicated in Fig. 1,

place block a under the lifted cylinder, and lower the
Lower
arm cylinder back onto the block.
Block a
Fig. 1
154
Step 7
Air bleeding of arm cylinder
CAUTION:
Make sure that nobody other than the operator is in or
on the hydraulic excavator.
2 Idle the engine sufficiently to release the air in the

hydraulic system.
3 Check for unusual vibration or noise.
4 Operate each cylinder a few times to bleed the air
in the hydraulic system, according to the following
procedure.
Note:
The engine speed should be kept as low as
possible. Retract
Extend
Fig. 1
2 Procedure
Action
1 Start the engine.
Note:
Run the engine at low speed.
2 Move each cylinder back and forth five times.
Notes:
i) Avoid moving the cylinder suddenly or quickly,
or the seals may be burnt.
ii) Stop the cylinder 100 mm before the cylinder rod
hits the stroke end during the first four cycles.
iii) Move the cylinder at full stroke on the fifth cycle.
3 Hold the cylinder at the stroke end for a minute to

apply relief pressure and bleed the air from the
cylinder. Repeat the procedure twice.
4 Stop the engine.
Bleeding Locations & Cylinder Positions for Bleeding Air
155
3 Recheck the oil level in the hydraulic tank. If the oil
level is low, refill the tank.
Fig. 2
Detail A
Fig. 3
Detail B
Level check
Fig. 4
156
7-4 Installing the arm
Step 1
Installing the arm
1 Lift the boom end about 3 500 mm (135 in) off the
ground. 3 500 mm
(135 in)
2 Preparing to install the arm
Fig. 1
1 Before you begin to work, extract the pin a from
the boom end.
Weight of pin a : ZX470-5 class 61 kg (134 lb)

ZX870-5 class 109 kg (240 lb) Hold
Nylon sling: 1pc.
Notes:
Pin a
ii) The pin has a thrust plates and shims. Store
them as they will be reused to assemble the
arm.
2 Clean off the anti-rust that is applied to the pin a .
3 Apply grease to the pin a and pin holes.
3 Slinging the arm
1 Apply grease to the pin holes b in the arm.

2 Sling wire ropes, chain blocks and shackles over
the arm as shown in Fig. 3. Fig. 2
Weight of arm 09 :
Semi-long arm 2 640 kg (5 810 lb) Hold
HD arm 2 540 kg (5 590 lb)
ZX470-5 class
BE (2.5m) arm 2 650 kg (5 830 lb)
BE (2.9m) arm 2 540 kg (5 590 lb Wire rope
Wire rope
STD arm 3 620 kg (7 965 lb) 14 mmø × 10 000 mm
14 mmø × 3 000 mm
H arm 3 720 kg (8 185 lb)
ZX670LC-5 class
BE arm 3 820 kg (8 405 lb) Shackle
Chain block for
STD arm 4 310 kg (9 480 lb) 2.5t load
H arm 4 490 kg (9 880 lb)
Reinforced H arm 4 610 kg (10 140 lb)
ZX870-5 class BE arm 4 630 kg (10 185 lb)
Reinforced BE arm 4 760 kg (10 470 lb)
Semi-long arm 4 640 kg (10 210 lb) Wire rope
Long arm 4 950 kg (10 890 lb) 14 mmø × 3 000 mm
b
Wire rope used: 6 pcs.
14 mmø × 10 000 mm (L) : 2 pcs. Shackle
(0.55 inø) (390 in L)
14 mmø × 3 000 mm (L) : 4 pcs.
(0.55 inø) (117 in L)
Arm 09
Shackle (for 2.5t load): 4 pcs.
Chain block (for 2.5t load): 2 pcs.

Fig. 3
Note:
work.
157
Lift
4 Lifting the arm
Lift the arm to keep the pin holes a in the arm level.
Note:
Adjust the preinstalled chain blocks and keep the
arm level.
CAUTION:
The work is dangerous, so make sure that there is no a
one under the lifting arm.
Fig. 4
Lift
5 Moving the arm
Move
1 Prepare the high-lift work vehicles c as shown in
Fig. 5.
High-lift work vehicle: 2 pcs. b
Arm
Note:
A lifting boom is very dangerous because it can all
of a sudden move in the most unexpected way.
Guide it by tying a rope around the end of the boom.
c High-lift
Rope work vehicle
Fig. 5
Rope used:
8 mmø × 5 000 mm (L): 1pc.
(0.3 inø) (195 in L)
Hold
2 Slowly bring the arm towards the pin holes b at

the boom end. b
3 To insert the pins, work on a high-lift work vehicle
to align the pin holes b . Continue the rest of the
work on the high-lift work vehicle.
Fig. 6
4 Align arm pin holes a with the boom pin holes b .
Hold
a b
Fig. 7
158
6 Installing the boom and arm connection pin
1 Insert the pin to fix the boom and arm.

Hold
To insert the pin, slide in the thrust plates c to
the left and right between the boom and arm.
Insert the shims d to the left and right as much
as possible so that the arm is brought to the
center.
Clearance a :
0< a ≦ 1 (right side) Bolt
0< a ≦ 1 (left side), cab side ZX470-5 class Spring
washer
Minimum (right side) ZX670LC-5 class
Stopper
a <1 (left side), cab side ZX870-5 class
Pin
Notes:
Fig. 8
i) The pin is very heavy. Handle with the utmost
care.
ii) Firmly tie a nylon sling around the pin, making Detail A
Thrust Thrust
d Shim plate c Pin d Shim plate c
with a crane and then, insert it in place. Boom
Cab side
ZX870-5 class 109 kg (240 lb)
Bolt
Nylon sling: 1pc. Spring
washer
WARNING: Arm a
・ Never put your finger inside the hole to align the pin Clearance a Clearance
Stopper Fig. 9
holes.
CAUTION:
Work very carefully when you are working at a height
so that you don’t accidentally fall.
2 Install the stopper.

To prevent the pin from coming loose, use 3 bolts,
3 spring washers and 1 stopper to install.
Notes:
the thread.

159
3 Position a wooden block under the arm end and
slowly lower the arm to the ground.
Remove the wire ropes and
chain blocks and shackles
attached to the arm.
Lower
Wooden block: 1 pc.
100 mm (L) × 800 mm (W) × 50 mm (H)
(4 in) (30 in) (2 in)
4 Remove the wire ropes and chain blocks and

shackles attached to the arm.
Wooden block
Fig. 10
160
Step 2
Installing the arm cylinder

Lift
1 Slinging the arm cylinder

Nylon sling Arm cylinder
1 Tie the nylon sling around the arm cylinder.
2 Use a crane to lift up the arm cylinder.
Nylon sling: 1pc.
3 To align the pin hole center of the arm cylinder

rod with the pin hole center of the arm bracket,
slowly pull up the arm cylinder using a crane to
align the two pin holes.
Fig. 1
4 When the pin holes are aligned, start the

Hold
engine. Slowly extend the arm cylinder in the
direction as shown by an arrow. Align the pin
Pin hole of arm Arm cylinder
hole center of the arm cylinder rod with the pin
bracket
hole center of the arm bracket. (Fig. 2)
2 Inserting the pin

Fig. 2
1 Before insertion, apply grease to the pin.
2 Using a crane, lift the pin that’s used to connect the

Hold
arm cylinder and insert.
Arm cylinder
Note:
Firmly tie a nylon sling around the pin, making sure
that the sling doesn’t slide. Next, lift the pin with a
crane and then, insert it in place.

Pin
Nylon sling: 1pc.
WARNING: Fig. 3
holes.
161
3 Installing the stopper
For ZX470-5 class, tighten the bolt and double nuts.
For the ZX670LC-5 class and ZX870-5 class, tighten the
pin using two bolts and the respective spring washers
and one plate to prevent the pin from coming loose. Pin
Plate
Notes:
Spring washer
the thread.
Bolt
Fig. 4
(40 kgf·m/295 lbf·ft) ZX470-5 class
Detail A
Width across flats: 30 mm Double nut
CAUTION:
Work very carefully when you are working at a height
so that you don’t accidentally fall.
Pin Bolt
Fig. 5-a

Detail A'
Pin
Plate
Bolt
Spring
washer Fig. 5-b
162
Step 3
Connecting the arm cylinder-use grease hose
1 Install the grease hose to the arm cylinder rod (refer to

Figs. 2 and 3).
To install the grease hose on the arm cylinder rod,
keep the angle of the adapter at an angle of 10-30
degrees (A).
This prevents the hose and cylinder installation bracket
from interfering with each other.
Tightening torque: 30 N·m Fig. 1

Width across flats: 19 mm Detail A
Notes: Adapter
i) Do not twist hose during connection. Their (A)

parts.
iii) Make sure that no dust has adhered to the seat Fig. 2
face of the hose.
Detail B
Grease hose
2 After connecting the hose, thoroughly wipe off the Don’t touch here.
greasy areas.
Fig. 3
163
Step 4
Connecting the bucket cylinder hoses and grease hose
Note:
Bucket cylinder
Stop the engine and move each operation lever
back and forward, left and right a few times to
release any residual pressure.
1 Connecting the bucket cylinder hoses Bucket cylinder hose

11
1 Remove the covers from the pipe ends.
CAUTION:
In removing the caps from the hose ends, slowly
loosen the tightening bolt and remove the cap only
after confirming that all pressure has been released.
2 Connect hose 11 between the boom and bucket Fig. 1

cylinder.

(ZX470-5 class) 110 N·m
Socket size: 10 mm
(ZX670LC-5 class/ZX870-5 class) 140 N·m
Socket size : 12 mm
Notes:
i) When connecting hoses, do not twist them, or
their service life will be shortened.
ii) Connect the hoses so as not to contact parts.
iii) Make sure that there is no dust sticking to the
seat faces of the hoses.
iv) Pay attention not to damage the joining surfaces
of the hoses.
v) Use O-rings 12 to install the hoses.
Apply a thin layer of sealant #98D to the O-rings
before installation. Nylon sling
3 Install the bucket cylinder hose 11 for the opposite

side in the same manner.
Link A
Lever block
2 After connecting the hoses, clean away any residue oil
from the outside of all parts.
3 Removing the nylon sling and lever block used to

fasten the link A in "Step 6- 3 on page 142.
Fig. 2
164
4 Connect grease hose at part a Fig. 3 by . Detail A

Notes:
i) When connecting hose, do not twist them, or
their service life will be shortened.
ii) Connect the hose so as not to contact parts.
iii) Make sure that there is no dust sticking to the
seat faces of the hose.
iv) Pay attention not to damage the joining surfaces Fig. 3
of the hose.
5 After connecting the grease hose, clean away any

residue grease from the outside of all parts.
Fig. 4
165
Step 5 Detail A
Greasing (3)
a
1 Operation procedure (Refer to the next page for the
automatically.
fitting and pull the gun lever; grease will be b
IMPORTANT:
c Fig. 1
2 Start the engine.
3 1 Supply grease to 1 point as shown in Figs. 2 and 3.

2 Supply grease to 4 points as shown in Fig. 4.
Fig. 2
Notes: Detail B
ARM CYL. BOTTOM
Fig. 3
Detail C
BOOM AND ARM JOINT

ARM CYL. ROD
BUCKET CYL. BOTTOM
Fig. 4
166

grease gun b .
e
IMPORTANT:
a
grease. Securely close check valve cock e when all
Fig. 5


IMPORTANT:
g
grease nipple h tip may break unless a special care, f
is taken, as follows: b

release remaining pressure from grease gun b , c
pump a and hose. Doing so provides longer life of Fig. 6
at this time.
g
Note:
hose.
h
Fig. 7
167
Step 6
Air bleeding of arm cylinder and bucket cylinder
Roll out
Retract
Roll in
Extend
CAUTION:
Make sure that nobody other than the operator is in or
on the hydraulic excavator.
Fig. 1
hydraulic system.
procedure.
Note:
The engine speed should be kept as low as possible.
2 Procedure
Action
1 Start the engine.
Note:
Notes:

4 Stop the engine.
168
3 Recheck the oil level in the hydraulic tank. If the oil
level is low, refill the tank.
Fig. 2
Detail A
Fig. 3
Detail B
Level check
Fig. 4
169
170
7-5 Installing the bucket
(Case 1: in the event of installing a bucket without using a crane)
Step 1
Installing the bucket
1 Preparing to install the bucket
1 Place bucket 10 as shown in Fig. 1.

2 Confirm that grease has been applied to the pin
holes a and b of the bucket.
b
a
1.9 m3 BK 1 590 kg (3 500 lb)
2.1 m3 BK 1 650 kg (3 630 lb)
ZX470-5 class 10
2.3 m3 BK 1 810 kg (3 980 lb)
G series 1.6 m3 BK 1 480 kg (3 255 lb)
2.65 m3 BK 1 930 kg (4 245 lb)
ZX470-5 class 2.1 m3 ROCK 2 170 kg (4 475 lb) Fig. 1
(G series only) 2.3 m3 ROCK 2 260 kg (4 970 lb)
2.5 m3 ROCK 2 360 kg (5 190 lb)
2.9 m3 GP 2 200 kg (4 840 lb)
ZX670LC-5 class
2.9 m3 ROCK 2 850 kg (6 270 lb)
3.5 m3 BK 2 980 kg (6 555 lb)
3.5 m3 ROCK 3 790 kg (8 340 lb)
3.7 m3 ROCK 3 900 kg (8 580 lb)
ZX870-5 class 3.7 m3 ROCK, reinforced 4 970 kg (10 935 lb)
4.3 m3 ROCK BE 4 270 kg (9 395 lb)
4.5 m3 BE 3 980 kg (8 755 lb)
4.5 m3 ROCK BE 4 400 kg (9 680 lb)
2 Deciding the position of the arm end
1 Lift the arm end about 2 500 mm (98 in) off the
ground.
2 Apply grease to the pin holes c and d at the
arm end.
c
d
2 500 mm
(98in)
Fig. 2
171
3 Moving the arm link
Start the engine. Move the boom and arm to bring the
pin holes a at the arm-end link closer to the pin holes
b of the bucket.
a
b
Fig. 3
4 Aligning the link and bucket pin holes
Align the pin holes a of the arm link with the pin holes
b of the bucket.
a b
Fig. 4
172
5 Connecting the link and bucket
1 Carefully align the link and bucket pin hole centers

and insert the pin.
ZX870-5 class 81 kg (178 lb)
Nylon sling: 1pc.
Notes:
i) Apply grease to the pin before insertion.
Next, lift the pin with a crane and then, insert it
Bolt
in place.
Spring Example: ZX670LC-5 class
washer ZX870-5 class
WARNING:
・ Never put your finger inside the hole to align the pin Stopper
holes.
Fig. 5
・ Work carefully. When using a hammer metal Pin
・ Do not go under the boom cylinder to insert the pin. ZX470-5 class
Detail A
Bolt
2 For ZX670LC-5 class and ZX870-5 class, tighten

the stopper with bolts and spring washers to
prevent the pin from coming loose.
For ZX470-5 class, ZX470-5B 1.9m3 lock bucket
and ZX870-5 (BER) class, tighten the bolt and
double nuts.
Pin Double nut
Notes: Fig. 6-a
the thread. ZX470-5B 1.9m3 lock bucket]
ii) Screw in all of the bolts by hand before Detail A'
tightening them to the specified torque. Dust seal Bolt
Pin
ZX470-5/ZX870-5
Dust
M20 bolt tightening torque: 400 N·m seal
(40 kgf·m/295 lbf·ft) Double
nut
ZX670LC-5
M16 bolt tightening torque: 210 N·m A dust seals is installed to the bucket. Work
(21 kgf·m/155 lbf·ft) carefully so that you don’t damage the seal.
Width across flats: 24 mm Fig. 6-b
ZX870-5 class (BER) ZX670LC-5 class/ZX870-5 class

Detail A''' Detail A''
Stopper Bolt
Pin Spring washer
Bolt
Stopper
Double nut
Pin
Fig. 6-d Fig. 6-c
173
6 Installing the O-rings (between the link and bucket)
1 Set O-rings 13 between the bucket and link.
Note:
Work carefully so that you don’t damage the O-rings
at the link boss.
2 Tighten the nut of O-rings 13 while referring to

Fig. 10-a.
Note:
Tighten the double nuts using two spanners.
Fig. 7
Detail D Detail B
This pin is for ZX670LC-5 class and ZX870-5 class.
The pin for ZX470-5 class is also installed in the
same location.
Bolt
Pin
Spring washer
O-ring 13
Fig. 10 Fig. 8
Note: Detail C
To facilitate the assembly, the bolt has
been made long. After the assembly, Link
Detail E cut the bolt to ☆ 10-20mm and then, use. O-ring 13
(Bolt size: M5)
☆ 10 ~ 20 ☆ 10 ~ 20
Slit
Bucket
Double nut Double nut
While assembling, make sure

13
Fig. 9
that gaps are not formed.
Fig. 10-a
174
7 Aligning the bucket and arm pin holes
1 Start the engine and slightly lift the bucket off the
ground.
2 By lifting the bucket off the ground slightly and
moving the arm to and fro, align the pin hole a at
the arm-end with the bucket pin holes b .
Or else, the pin holes can be aligned by
extending/retracting the bucket cylinder and
adjusting the arm angle.
a
b
Fig. 11
a b
Fig. 12
175
8 Connecting the bucket and arm Example: ZX670LC-5
class
1 Align the pin hole center at the arm end with the pin
hole center of the bucket. Then, adjust the clearance.
Notes:
ZX470-5 class
Measure the clearance (a) between the left bucket
(cab side) and arm and confirm that it is 0.5<(a)≦ 1.5.
(cab side) and arm and confirm that it is (a)<1.
Bolt
2 Insert the pin to connect the arm and bucket.
Push the bucket towards the left (towards the cab) Spring washer Fig. 13
Stopper Pin
and insert the necessary number of thrust plates 14
and 16 to the left side between the bucket and arm. ZX470-5 class
Minimize the clearance to the right. Detail F
Adjust the thrust plate so Double nut
Pin weight: ZX470-5 class 53 kg (117 lb) Bucket that the clearance is within
ZX670LC-5 class 76 kg (167 lb) the 0.5<(a)≦ 1.5mm range. Cab side
ZX870-5 class 98 kg (216 lb) ( 14 , 16 ) (a)
Nylon sling: 1pc.
Notes:
ii) Firmly tie a nylon sling around the pin, making Bolt
sure that the sling doesn’t slide. Next, lift the pin Arm Pin Fig. 14-a
ZX470-5 class 1.9m3 lock bucket
WARNING: Detail F'
・ Never put your finger inside the hole to align the pin Dust Dust seal Bolt
Pin
holes. seal
Double
Wear protective gear such as goggles and helmet. nut
3 For ZX670LC-5 class and ZX870-5 class, tighten A dust seals is installed to the bucket.
the stopper with bolts and spring washers to Work carefully so that you don’t damage the seal. Fig. 14-b
For ZX470-5 class, ZX470-5B 1.9m3 lock bucket and Detail F''
ZX870-5 (BER) class, tighten the bolt and double Adjust the thrust plate so that the
nuts.
Bucket clearance is within the (a)<1mm range. Pin
Cab side (a) ( 14 , 16 )
Notes:
the thread.
tightening them to the specified torque. Bolt
Spring
M20 bolt tightening torque: 400 N·m washer
(40 kgf·m/295 lbf·ft) Arm
Stopper Fig. 14-c
ZX870-5 class (BER)
Detail F'''
Notes:
Double nut
Be sure to adjust so that the clearance is within the
0.5<(a)≦ 1.5 range for
ZX470-5 class
and the (a)<1 range for
class. Bolt
Stopper
Pin Fig. 14-d
176
9 Installing the O-rings (between the arm and bucket)
1 Set O-rings 15 between the bucket and arm.
Note:
Install the O-rings. Pay attention to the arm boss
while assembling.
2 Tighten the nut of O-rings 15 while referring to Fig.

18-a.

Note:
Fig. 15
Detail I Detail G
This pin is for ZX670LC-5 class and ZX870-5
class. The pin for ZX470-5 class is also
Bucket installed in the same location. Pin
O-ring 15
Arm
Fig. 18 Fig. 16
Note: Detail H
been made long. After the assembly, O-ring 15
Detail J cut the bolt to ☆ 10-20mm and then, use. Arm
(Bolt size: M5)
☆ 10 ~ 20 ☆ 10 ~ 20
Bucket
Slit
Double nut Double nut Thrust plate

14 and/or 16
While assembling, make sure 15 (a) Fig. 17
Fig. 18-a
177
178
7-5' Installing the bucket
(Case 2: in the event of installing a bucket using a crane)
Step 1
Installing the bucket
1 Preparing to install the bucket.
1 Apply grease to pin holes a and b on the arm

a
side.
2 Check that grease has been applied to pins c
and d on the bucket side. c
d
Fig. 1
2 Wiring the bucket Lift
1 Sling the wire ropes and chain block over bucket 10

as show in Fig.2. Wire rope
14 mmø × 3 000 mm
Notes:
i) Use protectors on e and f (see Fig. 2) to
Wire rope
prevent damage to the bucket. Chain block for 2t 14 mmø × 10 000 mm
ii) Adjust the preinstalled chain block and keep the load
Wire rope
bucket level. 14 mmø × 3 000 mm
Protector e
CAUTION:
The work is dangerous, so make sure that there is no f
c
one under the lifting bucket.
Note: c
work.
2 Lift the bucket to keep the pin holes c in the

bucket level.
Bucket 10
1.9 m3 BK 1 590 kg (3 500 lb) Fig. 2
2.1 m3 BK 1 650 kg (3 630 lb)
ZX470-5 class
2.3 m3 BK 1 810 kg (3 980 lb)
G series 1.6 m3 BK 1 480 kg (3 255 lb)
2.65 m3 BK 1 930 kg (4 245 lb)
ZX470-5 class 2.1 m3 ROCK 2 170 kg (4 475 lb)
(G series only) 2.3 m3 ROCK 2 260 kg (4 970 lb)
2.5 m3 ROCK 2 360 kg (5 190 lb)
2.9 m3 GP 2 200 kg (4 840 lb)
ZX670LC-5 class
2.9 m3 ROCK 2 850 kg (6 270 lb)
3.5 m3 BK 2 980 kg (6 555 lb) Wire rope used: 3
3.5 m3 ROCK 3 790 kg (8 340 lb) 14 mmø × 10 000 mm (L) : 1pc.
3.5 m3 ROCK, reinforced 4 830 kg (10 625 lb) (0.55 inø) (390 in L)
3.7 m3 ROCK 3 900 kg (8 580 lb) 14 mmø × 3 000 mm (L) : 2 pcs.
ZX870-5 class 3.7 m3 ROCK, reinforced 4 970 kg (10 935 lb) (0.55 inø) (117 in L)
4.3 m3 ROCK BE 4 270 kg (9 395 lb)
4.3 m3 ROCK, reinforced 5 690 kg (12 520 lb) Protector: 2 pcs.
4.5 m3 BE 3 980 kg (8 755 lb)
4.5 m3 ROCK BE 4 400 kg (9 680 lb) Chain block (for 2t load): 1pc.
179
3 Start the engine and lift the arm end about 2 500 mm
(98 in) off the ground.
2 500 mm
(98in)
Fig. 3
Lift
4 Moving the bucket to the arm
Move
1 Lift the bucket to a height such that pin hole a in
the arm end are level with pin holes b in the
bucket.
2 Move the bucket to pin hole a .
b
Fig. 4
180
Hold
5 Installing the bucket pin
1 To insert the pin, align the pin holes centers and

then, adjust the clearance.
Notes:
ZX470-5 class
(cab side) and arm and confirm that it is
0.5<(a)≦ 1.5.

(cab side) and arm and confirm that it is (a)<1.
2 Insert the pin to connect the arm and bucket.

Push the bucket towards the left (towards the cab)
and insert the necessary number of thrust plates
14 and 16 to the left side between the bucket and Fig. 5
arm.
Minimize the clearance to the right. ZX470-5 class
Pin weight: ZX470-5 class 53 kg (117 lb) Detail A
Adjust the thrust plate so that
ZX670LC-5 class 76 kg (167 lb) the clearance is within the
Bucket
ZX870-5 class 98 kg (216 lb) 0.5<(a)≦ 1.5 range. Cab side
( 14 , 16 ) (a)
Nylon sling: 1 pc.
Notes:
Next, lift the pin with a crane and then, insert it in Arm Pin Fig. 6-a
place.
WARNING:
Detail A'
holes. Adjust the thrust plate so that the
clearance is within the (a)<1 range. Pin
・ Work carefully. When using a hammer metal Bucket
fragments can fly up, and this can cause injuries. (a) ( 14 , 16 )
Cab side
Notes:
Be sure to adjust so that the clearance (a) is within
the 0.5<(a)≦ 1.5 range for
Arm Fig. 6-b
ZX470-5 class
and the (a)<1 range for
181
3 For ZX670LC-5 class and ZX870-5 class, tighten Hold

double nuts.
Notes:
the thread.

Notes:
Fig. 7
Be sure to adjust so that the clearance is within the
0.5<(a)≦ 1.5 range for ZX470-5 class
ZX470-5 class Detail B
Double nut
and the (a)<1 range for Bucket
Cab side
Bolt
Arm Pin
Fig. 8-a
ZX470-5 class 1.9m3 lock bucket

Detail B'
Dust Dust seal Bolt

Pin
seal
Double
nut
Dust seals are installed to the bucket.

Work carefully so that you don’t damage the seal. Fig. 8-b

Detail B''' Detail B''
Bucket Pin
Double nut
Cab side
Bolt
Bolt Spring
Stopper washer
Pin
Arm
Fig. 8-d Stopper Fig. 8-c
182
Hold
6 Installing the O-rings (between the arm and bucket)
1 Set O-rings 15 between the bucket and arm.
Note:
Install the O-rings. Pay attention to the arm boss
while assembling.
2 Tighten the nut of O-rings 15 while referring to Fig.

12-a.

Note:
Fig. 9
Detail E Detail C
This pin is for ZX670LC-5 class and
Bucket ZX870-5 class. The pin for ZX470-5 class Pin
is also installed in the same location.
O-ring 15
Arm
Fig. 12 Fig. 10
Note: Detail D
been made long. After the assembly, O-ring 15
Detail F cut the bolt to ☆ 10-20mm and then, use. Arm
(Bolt size: M5)
☆ 10 ~ 20 ☆ 10 ~ 20
Slit Bucket
Double nut Double nut Thrust plate

14 and/or 16 (a) Clearance
While assembling, make sure 15
Fig. 11
Fig. 12-a
183
Extend the bucket cylinder
7 Adjusting the arm angle
1 Set the arm angle to

between 120° to 140°.
2 Extend the bucket
cylinder such that pin
holes a of the bucket
link aligns with pin holes
0˚
b of the bucket. 14
to
0˚
12
a
b a b
Fig. 13 Fig. 14
184
8 Connecting the link and bucket
1 Carefully align the link and bucket pin hole centers

and insert the pin.
2 Insert the pin to connect the bucket and link.

ZX870-5 class 81 kg (178 lb)
Nylon sling: 1 pc.
Notes: Bolt
i) Apply grease to the pin before insertion. Spring washer
ii) Firmly tie a nylon sling around the pin, making Stopper
WARNING:
・ Never put your finger inside the hole to align the pin Fig. 15
Pin
holes. Example: ZX670LC-5 class
ZX870-5 class
fragments can fly up, and this can cause injuries. ZX470-5 class
Wear protective gear such as goggles and helmet. Detail G
・ Do not go under the boom cylinder to insert the pin. Bolt
3 For ZX670LC-5 class and ZX870-5 class, tighten

double nuts.
Pin Double nut
Notes: Fig. 16-a
the thread.
ZX470-5B 1.9m3 lock bucket
ii) Screw in all of the bolts by hand before Detail G'
tightening them to the specified torque. Dust seal Bolt
Pin
ZX470-5/ZX870-5
M20 bolt tightening torque: 400 N·m Dust
seal
(40 kgf·m/295 lbf·ft) Double
Width across flats 30 mm nut
ZX670LC-5
(21 kgf·m/155 lbf·ft) Dust seals are installed to the bucket.
Work carefully so that you don’t damage the seal.
Fig. 16-b

Detail G''' Detail G''
Stopper Bolt
Pin Spring washer
Bolt
Stopper
Double nut
Pin
Fig. 16-d Fig. 16-c
185
9 Installing the O-rings (between the link and bucket)
1 Set O-rings 13 between the bucket and link.
Note:
Work carefully so that you don’t damage the O-rings
at the link boss.
2 Tighten the nut of O-rings 13 while referring to

Fig. 20-a.

Note:
Fig. 17
Detail J Detail H
This pin is for ZX670LC-5 class and ZX870-5 class.
The pin for ZX470-5 class is also installed in the
same location.
Bolt
O-ring 13 Pin Spring washer
Fig. 20 Fig. 18
Note: Detail I
been made long. After the assembly, Link
Detail K cut the bolt to ☆ 10-20mm and then, use. O-ring 13
(Bolt size: M5)
☆ 10 ~ 20 ☆ 10 ~ 20
Slit
Bucket
Double nut Double nut
While assembling, make sure 13 Fig. 19

Fig. 20-a
186
Step 2
Installing the lights Detail A

Light 17
※ Installing the lights
1 Install the bracket a and lights 17 to the

boom.
Bracket
Light 17
■ Installation locations: a
ZX470-5 class Left side of the boom
ZX670LC-5 class (1 location).
a
ZX670LC-5 class (For U.S.A.) Left and right sides of Bracket
ZX870-5 class the boom (2 locations).
c d
Notes:
i) Before installing the bolts, apply lubricant around Fig. 1
the thread.

Bracket ( a ) (14 kgf·m/103 lbf·ft)

Light ( 17 ) (1.0 kgf·m/7 lbf·ft)
2 Connect the wiring couplers c and d .
Note:
from the coupler.
187
Step 3
Connecting the auto lubricator-use grease hoses
1 Connection the boom cylinder-use auto lubrication

hoses
1 Connect the grease hoses to the bottom of the
boom cylinder as shown in Fig. 2.

Fig. 1
Notes:
i) Do not twist hose during connection. Their
service life will be shortened. Detail A
ii) Connect the hose so it does not touch other Boom cylinder
parts. bottom
iii) Make sure that no dust has adhered to the seat

face of the hose.
2 In the same way, assemble the grease hose on Boom cylinder

the opposite side. bottom
3 After connecting the grease hoses, thoroughly
wipe off the greasy areas. Fig. 2
2 Connecting the auto-lubrication hoses at the boom

back
1 Connect the grease hoses to the back of the
boom as shown in Fig. 4.
(4 kgf·m/30 lbf·ft) Fig. 3
Notes:
i) Do not twist hose during connection. Their Detail B
parts.
face of the hose.
2 In the same way, assemble the grease hose on

the opposite side.
3 After connecting the grease hoses, thoroughly
wipe off the greasy areas.
Fig. 4
188
3 Connecting the auto-lubrication hoses between the
boom and arm
1 Connect the grease hoses a and b from the

boom to the arm as shown in Fig. 6.
Tightening torque a : 40 N·m

Width across flats: 22 mm Fig. 5
Tightening torque b : 30 N·m
Detail C
Notes:
i) Do not twist hose during connection. Their
parts.
face of the hose.
a
iv) Do not damage the joining surfaces of the hose. b
2 In the same way, assemble the grease hoses on

the opposite side.
3 After connecting the grease hoses, thoroughly Fig. 6
wipe off the greasy areas.
189
Step 4 Detail A
Greasing (4)
a
1 Operation procedure (Refer to the next page for the
automatically.
fitting and pull the gun lever; grease will be b
IMPORTANT:
Note: c Fig. 1
Protective cap is attached to each grease fitting of
the bucket pin and link pin. Cap Head
Remove cap as shown below before greasing.
Removing/installing procedure:
Insert a screw driver into the cap cavity along the
arrow e direction, and scoop out the cap by
g
applying force in the arrow f direction.
When installing, push the cap by hand in the arrow
g direction until it bottoms or tap using screw driver
Grease
Fitting Cavity
grip. f
Cap e Screw
Pin
Driver
Fig. 2
2 Start the engine.
3 Supply grease to 9 points as shown in Fig. 3. Detail B
Notes:
Fig. 3
190
d
(1) Turn power switch d ON to activate the pump. e
Grease is sucked up and supplied to high-pressure
grease gun b .
IMPORTANT:
When the pump begins to suck grease, any air inside a
grease. Securely close check valve cock e when all Fig. 4



IMPORTANT: g
f
b
(5) When all greasing work is complete, turn power c Fig. 5

release remaining pressure from grease gun b ,
pump a and hose. Doing so provides longer life of g
at this time.
Note:
hose.
h Fig. 6
5 After the oil has run out, clean the parts carefully.
191
192
7-6 Installing the counterweight
CAUTION
IMPORTANT: Detail A
When you assemble the counterweight
removal/installation device, be sure to carefully read
the separate operation manual (ENMJAA-NACW1-1).
Note:
The part number and quantity for counterweight
mechanism are different for each model.
Assemble the counterweight while referring to the
data by model.
Step 1 Fig. 1
Installing the counterweight
CAUTION:
i) When you are installing the counterweight, you
will note that the muffler is situated very close to
the parts that you are working with. The muffler
can be very hot.
Be careful not to touch it. You might burn yourself.
ii) The end of the muffler is very sharp.
The pointed-end can pierce clothes or skin.
Work carefully to avoid injuries.
The end protrudes from the housing cover.
Climb on the machine carefully so that you don’t
stumble.
1 To install counterweight 46 , remove the covers a and

Cover b
b from the bottom of the superstructure.
2 Slinging the counterweight Cover a Fig. 2
1 Sling wire ropes, chain block and shackles over

Lift
counterweight 46 as shown in Fig. 3.
Weight of counterweight 46 :
ZX470-5 class: STD. 9 080 kg (19 975 lb) Wire rope
Removal 8 400 kg (18 480 lb) 24 mmø× Wire rope
ZX520LCH-5: 9 780 kg (21 516 lb) 5 000 mm 24 mmø×
ZX670LC-5 class: STD. 10 400 kg (22 880 lb) 10 000 mm
Removal 9800 kg (21 560 lb) Chain block
ZX870-5 class: STD. 13300 kg (29 260 lb)
Removal 12400 kg (27 280 lb) Shackle
Wire rope used: 3 pcs.

24 mmø × 10 000 mm (L): 1 pc.
(0.95 inø) (390 in L) Wire rope
24 mmø × 5 000 mm (L): 2 pcs. 24 mmø×
(0.95 inø) (195 in L) 5 000 mm
Shackle (for 7t load): 2 pcs.
Chain block (for 7t load): 1pc.
2 Lift counterweight 46 with a crane.
3 Adjust the chain block to keep counterweight 46 Fig. 3

level.
46
CAUTION: Counterweight
The work is dangerous, so make sure that there is no Note:

one under the lifting counterweight. A qualified worker undertakes sling work and crane work.
193
Lift
3 Installing the counterweight
Move
1 Slowly bring counterweight 46 closer to the main
frame. Insert the counterweight protrusion into the
frame installation holes. 50
46
Note: Counterweight
Adjust the chain block that is used to lift the
counterweight to insert the protrusion of the
counterweight into the frame installation holes.
49
CAUTION: 48 Apply
The work is dangerous, so make sure that there is no lubricant
to the
one under the lifting counterweight. back of
bolt head.
2 Insert the washers a into the counterweight 46 ＊
mounting bolts as shown in Figs. 4, 6-a and 6-b.
Bolt
＊
Note: Washer a
Apply lubricant
to the thread.
Before inserting the bolt, apply lubricant to the bolt Fig. 4
Hole for protrusion of counterweight
threads and back of bolt heads (at ＊ in Fig. 4).
Use lubricant that is a 1:1 mix of jell-form zinc Hold
3 STD
Screw the shim, washers b and U nuts into the
bolts with your hand, working from the main frame
side.
Removal Device
Screw the shim, washers b and castle nuts into
the bolts with your hand, working from the main
frame side.
At this point, don’t assemble the ring pin yet.
Notes:
i) Until the surfaces are completely joined,
Bolt
temporarily tighten all bolts with your hand.
ii) Confirm that there is no space between the
contact surfaces.
iii) The shim has to be installed in a certain direction.
Install as shown in Figs. 6-a and 6-b.
To make sure that the nuts don’t loosen, place
Fig. 5
the shims between the castle nuts and plate that
is welded to the frame.
STD Removal Device

Detail B Detail B'
Washer a Bolt Washer a Bolt
Shim Shim
46 46
Washer b
Nut; U Washer b Protrusion Protrusion
Fig. 6-a pin: ring Nut: castle Fig. 6-b
pin: ring
Note: Note:
The shapes of washers a and washers b are At this point, don’t
different for the ZX870-5 class. The one with the Washer assemble the ring pins
larger diameter is outer washer a . Nut: castle Fig. 6-c yet.
194
Model Part Name Drawing of Parts
STD 47
48
STD 49
50
Parts Part No. Qty
Counterweight mounting bolt
47 Bolt 4635562 2
48 Washer 4103743 4
49 Nut, U M660045 2
688
50 Shim 4345741 4
ZX470-5
Removal Device
class Removal Device 47
Parts Part No. Qty 48
47 Bolt 4658786 2
49
48 Washer 4103743 4
50
60
49 Nut;Castle 4246150 2
Counterweight mounting bolt
50 Shim 4345741 4
60 Pin;ring 9701925 2
688
Fig. 7-a
STD
STD 47 48 49 50
628 40 50
0
ø7
Parts Part No. Qty
75
81
47
70
Bolt 4714214 2
48 Washer 4103743 4
(Distance across corners)
t=10
(Distance across corners) Width = 30
49 Nut, U 4455400 2
50 Shim 4345741 4
ZX670LC-5 Removal Device
Removal Device 47 48 49
class 648 65
0
ø7
Parts Part No. Qty
80.8
47 Bolt YA00002468 2
75
48 Washer 4103743 4
(Distance across corners) t=10
49 Nut;Castle 4246150 2 (Distance across corners)
50 Shim 4345741 4 60 50
60 Pin:ring 9701925 2 ø93 50
102
70
Width = 30 Fig. 7-b

75 (Distance across corners)
STD
STD 748
50 50 48 10 49 40 47
720
Parts Part No. Qty
ø70
50
70
81
Shim 4345741 2
48 Washer 4114413 2 (M45x3.0)
48 Washer 4103743 2 48 10
49 Nut, U 4455400 2
80
47
ZX870-5 Bolt 4631671 2
class Removal Device Removal Device

Parts Part No. Qty 50 60 48 49
50 ø85 10 65
80.8
50 Shim 4345741 4
48 Washer 4103743 2
ø70
70

48 Washer 4114413 2
49 Nut;Castle 4246150 2 47 (Distance across corners) 48
753 10
47 Bolt 4341856 2
60
80
Pin;ring 9701925 2
75
Fig. 7-c
195
4 Temporary tightening of the counterweight Detail C
Bolt (upper)
1 Lower the crane that is suspending the
Temporarily
counterweight until the bottom of the counterweight tighten the
protrusion hits the bottom of the frame holes. bolt with a
ratchet.
Note:
The counterweight protrusion should touch the hole.
They should never be in a floating state.
2 Using a ratchet, slightly tighten the counterweight
mounting bolts (upper) and then, tighten until the Protrusion Fig. 8
counterweight is attached to the frame.
3 For ZX470-5, ZX670LC-5, insert a shims and Hold
plates into the protrusion at the counterweight
bottom. Work from the inside of the frame. Then,
temporarily tighten with lock washers and bolts.
For the ZX870-5 class, insert a shims, spacers
and stoppers into the protrusion at the
counterweight bottom. Work from the inside of the
Shim
frame. Then, temporarily tighten the STD device
with washers and bolts, and the removal device Plate
or
with spring washers and bolts. stopper
If there is a gap at the plate or spacer, use shims
(t=1.0, 0.5) to adjust. Bolt (upper)
Confirm that there is no gap between the
counterweight and frame.
Bolt
4 After deciding the number of the shims, temporarily
tighten the bolts at the protrusion of the counterweight Spring washer
using a ratchet. or Fig. 9
washer
Note:
thread.
5 After temporarily tightening the bolts using a
ratchet, reconfirm that there is no gap between the
counterweight and frame.
STD Removal Device

Detail D Detail D'
ZX670LC-5 class ZX670LC-5 class
ZX470-5 class ZX470-5 class
Plate Plate
Washer; Lock Washer; Lock
Bolt Bolt
Shim Fig. 10-a Shim Fig. 10-c
ZX870LC-5 class ZX870LC-5 class

(STD: Washer) (Removal: Washer Spring)
Spacer Spacer
Stopper Stopper
Washer Washer
Spring
Bolt Bolt
Shim Fig. 10-b Shim Fig. 10-d
196
Model Part name Drawing of Parts

41.6
80
ø1
46
58 51 57
STD / Removal Device
70
ZX470-5 58
51
Plate
Bolt
4070953
J912455
2
4
t=22
t=1.2
80 80
class 57 Washer, lock 4070952 2
55
ø1
56
ø1
55 Shim 4070951 4
56 Shim 4071071 2
t=1.0 t=0.5
Fig. 11-a

41.6
80
ø1
46
51 57 58
STD / Removal Device

ZX670LC-5 51 Bolt J912455 4
70
t=1.2
t=22
class 57
58
Washer, lock
Plate
4070952
4070953
2
2 ø1
80
ø1
80
55 Shim 4070951 4 55 56
56 Shim 4071071 2
t=1.0 t=0.5
Fig. 11-b

STD
53 54 51
STD 00 180 85
ø2
Parts Part No. Qty
75
53 Spacer 4346036 2 t=8 t=32

54 Stopper 4221465 2
51 Bolt J912470 4 59 6 55 56
00 00
59 ø2 ø2
ø48
Washer J222024 4
55 Shim 4380636 4
ZX870-5 56 Shim 4380637 4

t=1.0 t=0.5
class Removal Device

Removal Device
53 54 51
00 180 85
Parts Part No. Qty ø2
53 Spacer 4346036 2
75
54 Stopper 4221465 2 t=8 t=32

51 Bolt J912470 4
55 Shim 4380636 4 59 55 56
00 00
ø41.3
56 Shim 4380637 2 ø2 ø2
7.2
59 Washer; Spring A590924 4
t=1.0 t=0.5
Fig. 11-c
197
STD Removal Device
Detail E Detail E'
Bolt (upper) Bolt (upper)
Completely Completely
tighten the bolt tighten the bolt
with a power with a power
wrench. wrench.
Fig. 12-a Fig. 12-b

Hold
Fit the ring pin.
5 Complete tightening of the counterweight
1 Completely tighten the counterweight mounting

bolts (upper) with a power wrench.
Fig. 12-c
IMPORTANT:
Tighten the bolts (upper) to the specified torque. Shim
Plate
or
Counterweight tightening torque (M45 bolt): Stopper Bolt (upper)
(ZX470-5 class) 2 400 N·m
(240 kgf·m/1 770 lbf·ft)
Bolt
Counterweight tightening torque (M45 bolt): Spring washer
(ZX670LC-5 class/ZX870-5 class) 2 800 N·m or
Fig. 13
(280 kgf·m/2 065 lbf·ft) Washer
Width across flats (bolt side): 65 mm
Width across flats (U; nut/castle nut): 65 mm Detail F
CAUTION:
2 Fix the removal device with ring pins to stop the

castle nuts from coming loose. (Fig, 12-c)
3 Completely tighten the bolts at the protrusion of
the counterweight.
ZX470-5 class Fig. 14
Stopper plate tightening torque (M24 bolt): ZX670LC-5 class Hold

ZX470-5 class
450 N·m
ZX670LC-5 class/ZX870-5 class Fig. 14-a
Stopper plate tightening torque (M24 bolt) ZX870-5 class

700 N·m
4 For the ZX470-5 class and ZX670LC-5 class, bend Fig. 14-b
the plate and lock the bolts as shown in Fig. 14-a.
For the ZX870-5 class, use a washers for the STD
and spring washers for the removal device as
shown in Fig. 14-b. Tighten.
198 Fig. 15
6 Procedure after installing the counterweight
1 Remove the wire ropes, chain blocks and Remove the

wire ropes.
shackles that were used to lift counterweight 46 .
46
Fig. 16
2 Install the cover a and cover b that were

removed in 1 .

Notes:
the thread.
Fig. 17
a
IMPORTANT:
When you assemble the counterweight
removal/installation device, be sure to carefully read
the separate operation manual (ENMJAA-NACW1-1).
199
Step 2
Installing the rear monitor camera
※ Installing the rear monitor camera
1 Install the rear monitor camera on the

counterweight as shown in Figs. 2 and 4.

Notes:
Fig. 3
the thread.
ii) Screw in all of the bolts by hand before Example: ZX650LC-5 class
Detail A
2 Fix the wire harness with a clamps.
3 Bundle the unnecessary wire harnesses with a
clip bands.
62 Bolt, sems
Example: ZX470-5 class Monitor camera Clip
Clip band
Clip
Wire harness
Fig. 1
Detail B
ZX470-5 class 62
Monitor camera
Clip band
Fig. 4
Wire harness Bolt Camera
Clamp
Camera harness
Relay harness Fig. 4-a
CAUTION:
Connect the camera harness to the relay harness at the point
shown above.
Fig. 2 Do not pull out the harness that is found inside the camera body.
(This applies to ZX450-5 - ZX850-5.)
Install the camera harness so that it does not touch the camera
installation bracket. Otherwise, the harness can damage.
200
7-7 Bleeding the all cylinders and checking for hoses interference
Step 1
Boom raise
Bleeding the hydraulic cylinders operation
Arm roll-out
Arm
roll-in Boom lower
CAUTION: Bucket
Bucket
Make sure that nobody other than roll-out
roll-in
the operator is in or on the
hydraulic excavator.
Fig. 1
hydraulic system.
procedure.
Note:
The engine speed should be kept as low as
possible.
2 Procedure
Action
1 Start the engine.
Note:
Notes:

4 Stop the engine.
201
3 Recheck the oil level in the hydraulic tank. If there is Detail A
insufficient oil, refill the tank through the oil filler port.
Position the front-end attachment as illustrated in
Fig. 3 when checking the oil level.
Level check
Fig. 2
Fig. 3
202
Step 2
Checking for hoses interference Boom raise
1 For ZX670LC-5 class and ZX870-5 class, confirm that

tag nos. 1 and 2 on the pipe side match those on the
hose side as shown in Fig. 3.
Problem area
Hose
2 Checking for hoses interference

Check that, when the boom is fully raised and lowered,
the hoses between the base machine and boom do not
contact the central covers on the base machine or Fig. 1
other peripheral devices, or hit against location ZX470-5 class
indicated below. Detail A
If there is hose interference, adjust the connection of
※ ※
affected hoses to the control valve.
CAUTION:
When operating the boom, ensure that no-one other
than the operator is in, on, or in the close vicinity of the
machine.
※ ※
Fig. 2-a
ZX670LC-5 class
Detail A'
※ ※
Tag.2
ZX670LC-5 class
※ ※
Tag.2 Fig. 2-b
Tag.1 ZX870-5 class

Detail A''
※ ※
ZX870-5 class
Fig. 3
※ ※ Fig. 2-c
203
204
7-8 Adjusting the track link tension Note:
Remove any rocks and other debris caught in the
1 Adjusting the track link tension
sprockets.
1 Rotate the superstructure 90°, and tilt the machine
over to one side by lowering the bucket.
Make sure to keep the angle between the arm and
boom in the range 90° to 110°, and place the
rounded front of the bucket flat against the ground
during this procedure. 90° ~ 110°
2 Jack up the machine as shown in Fig. 1.

3 Place wooden blocks under the main frame to
support the machine, as indicated in Fig. 1.
Fig. 1
Wooden blocks: 2 pcs.
Wooden block
1 200 mm (L) × 800 mm (W) × 1 000 mm (H)
(47 in) (30 in) (40 in)
4 Rotate the uplifted track link forwards through 2 Detail A

turns, and then backwards through 2 turns.
2 Measuring the distance between the top of the lower

shoes, and the bottom of the track frame. Measure the
distance between the base of the track frame and the
back of the track shoes, at the center of the track
frame.
The standard distance is as detailed below.
Model ZX470-5 ZX670LC-5 ZX870-5
L
ZX450-5 ZX450LC-5 ZX650LC-5 ZX850-5 ZX850LC-5
Standard ZX470H-5 ZX470LCH-5 ZX520LCH-5 ZX670LCH-5 ZX870H-5 ZX870LCH-5
tension ZX470R-5 ZX470LCR-5 ZX670LCR-5 ZX870R-5 ZX870LCR-5
Fig. 2
(Length L) 380∼430 390∼440 430∼480 450∼500 400∼500 470∼530
3 To loosen the track link tension, slowly loosen valve a Detail B

(24mm hex) to release excess grease.
1 to 1.5 turns of the valve should be sufficient.
If grease does not escape at a constant rate, slightly
rotate the uplifted track link. Tighten valve a on
completion of adjusting the track link tension.
Tightening torque: 150 N·m (15 kgf·m/111 lbf·ft)
CAUTION:
Over-loosening valve a or loosening the valve over-
abruptly can cause the valve to fly off the machine or
pressurized grease to shoot from the valve, due to the
Fig. 3
adjuster cylinder being highly pressurized. Make sure
to keep your face and body parts well away from valve
a , and to loosen the valve slowly. Under no Detail C
circumstances should grease fitting b be loosened.
a
4 Adjusting the track link tension
b
1 If the track link tension is outside the range of the
standard tension, tighten or loosen the track link
appropriately (see the next page).
2 After adjusting both the left and right track links,
equalize the left and right track link tensions by
driving the machine forward and backward.
Grease outlet
3 Recheck the track link tension. If the tension is
outside the range of the standard value, readjust
Fig. 4
the track links.
205
Detail D
Loosen the Track
b a
CAUTION:
Do not loosen valve a quickly or loosen it too much
as high-pressure grease in the adjusting cylinder
may gush out. Loosen carefully, keeping body parts
and face away from valve a .
Never loosen grease fitting b .
IMPORTANT: Fig. 5
When gravel or mud is packed between sprockets
and track links, remove it before loosening.
1 To loosen the track, slowly turn valve a b a

counterclockwise using long socket 24; grease
will escape from the grease outlet.
2 Between 1 to 1.5 turns of valve a is sufficient

to loosen the track.
3 If grease does not drain smoothly, slowly rotate

the raised track. Grease Outlet
4 When the proper track sag is obtained, turn

Fig. 6
valve a clockwise and tighten to 150 N·m
(15 kgf·m/111 lbf·ft).
Detail E
Tighten the Track
CAUTION:
b a
It is abnormal if the track remains tight after turning
valve a counterclockwise or it the track is still loose
after charging grease to fitting b . In such cases,
NEVER ATTEMPT TO DISASSEMBLE the track or
track adjuster, because of dangerous high pressure
grease inside the track adjuster. See your
authorized dealer immediately.
To tighten the track, connect a grease gun to grease

fitting b and add grease until the sag is within
Fig. 7
specifications.
206
7-9 Final trial operation check
Step 1
After check
Detail A
1 After connecting all the hoses, check that no hose hits

against other hose or parts.
2 1 Adjust the track link tension appropriately. (See

pages 205 and 206 "Adjustment of track link
tension".)
2 Check all functions of the machine. (See "Checks

after completing the assembly")
3 Recheck the oil level in the hydraulic tank. If there

is insufficient oil, refill the tank through the oil filler
port.
CAUTION:
Before starting, make sure there is no person other
Fig. 1
than the operator in the hydraulic excavator.
Note:
After the above procedures 1 and 2 are
completed, carry out work at 60% to 70% of full
power for the first 50 operating hours, before
commencing full-power operation.
Fig. 2
Step 2
Final checks for the backhoe front-end
1 Thoroughly clean any oil from the machine

with rags. Detail A
2 On full completion of the backhoe assembly, recheck

that all bolts are tightened to the specified torque.
Fig. 1
207
208
7-10 Applying grease to the backhoe front b
ZX470-5 class
1 Greasing
Greasing locations and grease types
1 After assembling the backhoe front,

apply grease to the locations that are b
shown in Figs. 1 to 3. a
b
Greasing locations Greasing points
a Front joint pin

9
(around the bucket)
Fig. 1
b Front joint pin
11
(parts other than the above) b
ZX670LC-5 class
b
b
a
2 Select the grease while referring to the following

chart.
Brand Names of Recommended Grease
Where to be Bucket, Arm and Boom, Swing Gear,

applied Swing Bearing, etc.
Fig. 2
Manufacturer −20 to 45 °C (−4 to 113 °F)
b
Nippon Koyu SEP 2 *1
ZX870-5 class
British Petroleum BP Energrease LS-EP2
b
Caltex Oil Multifax EP2
Esso Beacon EP2
Idemitsu Kosan Daphne Coronex Grease EP2

b
Mobil Oil Mobilux EP2
a
Nippon Oil Epinoc Grease AP2
Shell Oil Shell Alvania EP2 *2
NOTE: The machine shipped from the factory is filled with

lubricants marked with .
*1 Front Joint Pin and Swing Bearing
*2 Swing Gear
Fig. 3
209
Lubrication with the lubricator
The machine is fitted with a lubricator and hose reel,
which can be used for easy-operation pneumatic
lubrication.
a
CAUTION:
Lubrication of the top of the boom and arm is d
performed at height. Take appropriate measures to
avoid falling from the machine.
e
Note:
Set the engine to run at medium idle or higher when
using the lubricator.
3 Lubricator Operation
1 Turn power switch d ON to activate the pump.

Grease is sucked up and supplied to high-
Fig. 4
pressure grease gun b .
CAUTION:
When the pump starts up, any air trapped inside pump
a will be mixed in, with the discharged air making the
grease turn whitish. Open check valve cock e to
bleed this aerated grease. Securely close check valve
cock e when all aerated grease has bled out.
2 Hold high-pressure grease gun b and pay out the

3 Press hydro-chuck g protruding from high-
pressure grease gun b into the grease nipple,
and pull the lever to discharge grease.
4 Release the lever when greasing is complete;
g
f
CAUTION:
When detaching hydro-chuck g from grease nipple h , b
grease nipple h tip may break unless special care is
taken, as follows:
• Tilt nozzle f a little so as to release the connecting
• Slowly detach hydro-chuck g from nipple h .
Fig. 5
c
5 When all greasing work is complete, turn power
switch d OFF, then pull grease gun lever to
release any remaining pressure from grease gun
b , pump a , and the hose so as to ensure long
component life. A little grease will be discharged g
at this time.
Note:
inspect the hose for cracks, grease leakage, or any h
other damage. If any damage is found, replace the Fig. 6
hose.
210
7-11 Disassembly procedure for shipment
1 ZX470-5B Series YA00011084 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .213
2 ZX470-5G Series YA00011092 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215
3 ZX670LC-5B Series YA00011163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217
4 ZX670LC-5G Series YA00016556 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
5 ZX870-5B Series YA00011358 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221
6 ZX870-5G Series YA00011094 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223
211
212
ZX470-5B series

Stamp the base machine S/No.
The following parts such as counterweight Standard Removal/installation-use
installation bolts are separately packed.
The following parts are separately packed
(For STD C/W)
· Bolt (P/No. 4635562) x2
(common to removal/installation device)
· Washer (P/No. 4103743) x4 Seal the hose ends with plastic
· Nut; U (P/No. M660045) x2 Part Name P/No. Qty cap or paper tape Apply anti-rust oil
· Shim (P/No. 4345741) x4 (for both sides). to the plated part.
Plate
(Anti-rust P-1320)
(For C/W removal/installation device-use)
For STD C/W: 688 (When counterweight removal/installation device is attached)
Bolt
For removal/installation · Bolt (P/No. 4658786) x 2 Washer; lock
C/W: 708 · Washer (P/No. 4103743) x 4
Base machine-boom cylinder hoses P/No. 4636821 (9kg) x 4
· Nut; castle (P/No. 4246150) x 2 Shim
· Pin; ring (P/No. 9701925) x 2
· Shim (P/No. 4345741) x 4 Shim
Apply
Install the following parts. anti-rust oil. Apply
(For C/W removal/installation device-use) anti-rust oil.
Cover (P/No. YA40004292) x 1
Bolt; sems (P/No. J271230) x6 The high-pressure hose should be contained Cylinder; boom (R) P/No. 4698938 (420kg) x 1
in a frame and should not be protruding. Cylinder; boom (L) P/No. 4698939 (420kg) x 1
(When counterweight removal/installation device is attached)
Cover (P/No. YA60001776) x 1 · O-ring (P/No. 4508805) x4
Bolt; sems (P/No. J271230) x6 · Flange; split (P/No. 4089703) x8 Install the following parts.
· Bolt; socket (P/No. M341445) x 16 · Pin (P/No. 8100446) x 1
Weight of · Cover (P/No. 4199393) x4 · Plate (P/No. 4335757) x 1
(Distance across corners) counterweight (kgw) · Plug (P/No. 94-2023) x4 · Bolt (P/No. J912045) x 2
Parts that were installed to the base machine. · Washer (P/No. J222020) x 2
ZX470-5 standard *Apply anti-rust oil to the pin. Remove the wiper arm and blade
For removal/installation device (to be packed separately).
Remove the normal muffler (P/No. 7060123) and Install the following parts. Do not remove the motor.
bolts (P/No. J271230 x 4).
· Nut (P/No. 4188138) x 4 (Nuts should be attached to the motor.)
Use a bolt (P/No. J921050 x 1) to install the (With the cab handrail attached)
shipment-use muffler (P/No. 8086588). · Cap (P/No. 4189095) x 4
· O-ring (P/No. 4187328) x 4 Remove both the mirror and stay
(to be packed separately).
(With the cab handrail removed) Install the following parts to mirror
P/No. 4675257.
Track frame tightening bolts, etc. are separately packed. · Stay (P/No. YA40001274) x1
Lifting bracket Remove both the mirror and stay (to be
Bolt (P/No. J833310) x 24 · Clamp (P/No. 4201441) x2
Spacer (P/No. 4320218) x 24 packed separately). Install the following
· Bolt; sems (P/No. J260845) x4
3870 (when the normal muffler is installed)

3100 (when the normal muffler is installed)
parts to mirror P/No. 4675257.
· Stay (P/No. YA40001224) x 1
· Clamp (P/No. 4376895) x1
(for STD cab)

(for HD cab)
Remove the cab handrail (to be packed separately).
C (Includes lug height)

Screw the installation bolts into the cab side.
(for STD cab)

Side frame (with shoe)
(for HD cab)
In case of no reassembly at port,
install the side frame retraction
bolts to the side frame.
Pre-cleaner
(with band)
P/No. 4465368 (4.0kg) x 1
Normal muffler In case of no reassembly at
*When you use a pre-cleaner, install (Includes lug height)
P/No. 7060123 (10.7kg) x 1 port, install the following
the rain cap that was ordered with
the machine parts (support) to the
(to be packed separately) machined surface on the
track center frame.
· Bracket (P/No. 9757191) x4
· Washer (P/No. 4459340) x8
Do not remove the cover Plug the travel pilot hose with the · Bolt (P/No. J921290) x8
(with C/W removal/installation bracket) (DH, JD machines) following parts. (with the side frame retracted)
(P/No. 8124946 x 1). · Nut (P/No. J950012) x8
(When counterweight removal/installation device is attached only) (with C/W removal/installation kit) (DH, JD machines) Plug; union (P/No. 4222076) x 2
(pilot)
Remove the side frame (*Without installation bolts, travel pipes and steps) Plug; union (P/No. 4225492) x 2
steps, installation bolts, etc. Display "P1" on a
Step (upper) metal plate, etc. (left).
(drain)
Shoe width Total width Weight (with C/W removal/installation bracket) (DH, JD machines)
P/No. YA00003325 (Refer to SECTION A.)
Weight: 11.7kg x 4 (with C/W removal/installation kit) (DH, JD machines)
Height: 125
Cover the travel hoses with the Display "P1" on a metal plate,
following parts. etc. (right).
· Cover (P/No. 4126786) x4 (Refer to SECTION A.)
Step (lower)
· Flange; split (P/No. 4085560) x8
P/No. YA00002172 · O-ring (P/No. Z966993) x4
Weight: 8.49kg x 4 · Bolt; socket (P/No. M341240) x 16 Weight of base machine without side frame (Reference) Weight and measurements of base machine with side frame
Height: 125 Center joint
Weight Attachment-less Shoe width Weight
Superstructure body main body
(kg)
Weight of base machine without side frame

*Install the 900G shoe to the base machine.
*Place 8 step installation bolts in a single vinyl bag and attach to C/W removal/installation specification Weight (kg)
the step.
Removal/installation bracket only
The following parts such as a rear monitor High-pressure hose
Part Name P/No Qty With removal/installation kit on P1 displayed-side
camera are separately packed.
(left)
· Camera assembly (P/No. 9318950) x1 Bolt High-pressure hose
· Bolt; sems (P/No. J271025) x3 on P1 displayed-side
Washer; spring
· Harness; wire (P/No. 3118217) x1 (right)
· Bolt; sems (P/No. J271020) x9 Apply anti-rust oil. Washer
· Clip (P/No. 4190272) x9
Apply anti-rust oil
to the plated part.
(Anti-rust P-1320)
Fix the cylinder with the following Install the following parts.
Install the following parts. parts so that it doesn't extend. · Pin (P/No. 3093215) x 1
· Cover (P/No. 4167789) x 4 · Pipe (P/No. 4335865) x 1 (With wire protector) · Bolt (P/No. 4276312) x 1
Stamp the base machine
· O-ring (P/No. 4508805) x 4 · Wire (P/No. 4701492) x 1 · Nut (P/No. J951020) x 2
S/No. at the bottom of
Measurement F
· Bolt (P/No. J901430) x 16 · Rope clip (P/No. 94-2901) x 2 *Apply anti-rust oil to the pin.
front nameplate.
Seal the hose ends with a
Install the following parts. plastic cap or paper tape Apply anti-rust oil to Install the following parts.
(for both sides). Install the following parts. the plated part. · Pin (P/No. 3104742) x 1
· Cover (P/No. 4336672) x 2 HD arm (Anti-rust P-1320) · Bolt (P/No. 4276312) x 1
· O-ring (P/No. 4508805) x 2 P/No. 4640114 (L=1600) (8.99kg) X2 · Pin (P/No. 3104744) x 1
· Bolt (P/No. J932013) x 1 · Nut (P/No. J951020) x 2
Fix the cylinder and boom with wires. Semi-long arm · Nut (P/No. J951020) x 2 *Apply anti-rust oil to the pin.
(Shown here is the HD boom.)
Measurement H
Apply anti-rust oil. P/No. 4659744 (L=2300) (12.1kg) X2 *Apply anti-rust oil to the pin.
Stamp the base machine Measurement E
S/No. at the bottom of front (With wire protector)
nameplate. Install the following parts. Notes:
Boom Measurement E Measurement F Weight of base machine (kgw) 1. After disassembly, touch up the paint on each part.
· Pin (P/No. 8100447) x 1 (Shown here is the HD arm.)
Fix the grease hose to the pipe. Install · Washer (P/No. 4040931) x 1 Apply anti-rust oil. 2. Check the fuel level and add if necessary.
the grease elbow to the hose · Stopper (P/No. 4206989) x 1 Seal the hose ends with a 3. The shim for each joint should be installed to the pin. (However, no need
Measurement G
(temporarily tighten). Protect the elbow · Bolt (P/No. J912050) x 3 plastic cap or paper tape to install if it is not already installed.)
with a vinyl cap or paper tape. · Washer (P/No. J222020) x 3 2.5m, 2.9m BE arm (for both sides). Install the following parts. 4. The machine S/N should be stamped at the bottom right at the back of
*Apply anti-rust oil to the pin. P/No. 4659204 (L=2000) (11.1kg) x 2 Arm Measurement G Measurement H Weight of base machine (kgw)
· Cover (P/No. 4336674) x 2 the counterweight. (Example: "10001")
Install the following parts. Remove the boom lamp 5. If shoe is 900G or below, the step should be separately packed.
Boom-arm hoses (for bucket cylinder) · O-ring (P/No. Z966993) x 2 Semi-long
· Pin (P/No. 3104745) x1 · Headlamp (P/No.4336570) x1 To be packed together with the arm 6. Refer to the list of unit shipment parts for parts other than those shown in
· Washer (P/No. 4040931) x1 · Screw (P/No. M430610) x1 Using wires, etc., fix the space-adjuster boss the illustration (key, data, oil, optional device, etc.).
· Stopper (P/No. 4117700) x2 · Washer; plain (P/No. A590106) x1 so that it doesn't drop 7. Rust-proof the bolts, frame joints, screw holes, machined surfaces, etc.
· Bolt (P/No. J912050) x8 · Harness; wire (P/No. 4271787) x1 (space adjuster mechanism-mounted bucket only). 8. When the high-pressure travel hose is disconnected, attach a label (metal
· Harness; wire (P/No. 4271788) x1 To be shipped in
· Washer (P/No. J222020) x8 plate) to the superstructure side and to the travel device side using wire,
the state in which
*Apply anti-rust oil to the pin. Apply anti-rust oil. it left the factory etc. (P1 only).
(packaged) 9. At the time of shipment, the tank fuel-level is 1803or less (870mm from
the top of fuel flange. See Fig. 1.). However, for special shipment cases
Install the following parts.
Measurement J
Stamp the base machine

with oil level designation, instructions will be provided by the production
· Clamp; pipe (P/No. 4190127) x 1 control dept.
S/No. at the bottom of front · Bolt; sems (P/No. J271270) x 1 Cast-in letters, P1
Place 14 side steps installation bolts nameplate.
(for front and back) in a single bag Display "P1" on
Plug the travel device with the following
and attach to the side step. a metal plate, etc.
· Plug; union (P/No. 4223518) x 2 Fig. 1. Fuel level at the time of shipment
· Bolt (P/No. J901235) x 14 (pilot)
· Washer; plain (P/No. Z449490) x 14 · Plug; union (P/No. 4223519) x 2
· Washer; spring (P/No. A590912) x 14 (drain)
Bucket
Measurement I
Ascending/descending ladder Handrail (1) Handrail (2) Cast-in letters, P1

Bucket Measurement I Measurement J Bucket width Weight
O/T above the fuel tank above the fuel tank Plug the travel device with the following parts.
Display "P1" on
Width: 425mm Width: 55mm Width: 115mm · Cover (P/No. 4336674) x4 (Left) Travel devices (Right) a metal plate, etc.
23.1kg 12.4 kg 2.85jg · Flange; split (P/No. 4085560) x8
Side step (back) Side step (front) P/No. P/No. P/No. · O-ring (P/No. Z966993) x4
· Bolt; socket (P/No. M341240) x 16
P/No. 6028301 P/No. 6028300 Hitachi machine: YA40003436 Hitachi machine: YA40003168 Hitachi machine: YA40003435
lock JD machine: 7051444 JD machine: 8124571 JD machine: 8124573
213
ZX470-5G series
Apply anti-rust
Install the following parts. oil.
Stamp the base machine · Pin (P/No. 3093215) x 1 Install the following parts.
S/No. at the bottom of front · Bolt (P/No. 4276312) x 1 · Pin (P/No. 3104742) x 1 The high-pressure hose should be
nameplate. · Nut (P/No. J951020) x 2 · Bolt (P/No. 4276312) x 1 contained in a frame and should not Parts that were installed
*Apply anti-rust oil to the pin. · Nut (P/No. J951020) x 2 be protruding. Cover the hose ends. to the base machine
Apply anti-rust oil *Apply anti-rust oil to the pin. · O-ring (P/No. 4508805) x4
Install the following parts. to the plated part.
Apply anti-rust oil to · Flange; split (P/No. 4089703) x8
· Pin (P/No. 3104744) x 1 (Anti-rust P-1320) · Bolt; socket (P/No. M341445) x 16
· Bolt (P/No. J932013) x 1 Apply anti-rust the plated part. Seal the hose ends with a
oil. · Cover (P/No. 4199393) x4 plastic cap or paper tape
· Nut (P/No. J951020) x 2 (Anti-rust P-1320)
Measurement
· Plug (P/No. 94-2023) x4
*Apply anti-rust oil to the pin. (for both ends).
Cylinder; boom (R) P/No. 4698938 (420kg) x 1 Install the following parts.
H
Cylinder; boom (L) P/No. 4698939 (420kg) x 1 · Pin (P/No. 8100446) x 1
· Plate (P/No. 4335757) x 1
· Bolt (P/No. J912045) x 2 Base machine-boom cylinder hoses P/No. 4636821 (9kg) x 4
· Washer (P/No. J222020) x 2 Remove both the mirror and stay
Apply anti-rust oil. *Apply anti-rust oil to the pin. (to be packed separately).
Measurement G (Shown here is the HD arm.) Install the following parts. Install the following parts to mirror
P/No. 4675257.
Install the following parts. · Nut (P/No. 4188138) x 4
P/No. 5011325 Arm Measurement G Measurement H Base machine weight (kgw) · Cap (P/No. 4189095) x 4 · Stay
· Cover (P/No. 4336674) x 2 Lifting bracket · O-ring (P/No. 4187328) x 4 (P/No. YA40001274) x 1
· O-ring (P/No. Z966993) x 2 Semi-long · Clamp
(P/No. 4201441) x 2
Remove both the mirror and
· Bolt; sems
stay (to be packed separately).
Stamp the base machine S/No. (P/No. J260845) x 4
Install the following parts to
mirror P/No. 4675257. Remove the wiper arm and
The following parts are separately packaged. · Stay blade (to be packed separately).
across corners)
*C (includes lug height)

(P/No. YA40001224) x 1 Do not remove the motor. (The
Part Name Part No. Qty · Clamp nut should be attached to the
A (For STD cab)

B (For HD cab)
(P/No. 4376895) x 1 motor.)
(Distance
Plate · Bolt; sems
(P/No. J260850) x 4
Bolt
Washer; lock
Shim
(Includes lug height)
Shim
The following parts such as The following parts such

counterweight installation bolts are as a rear monitor camera
separately packed. are separately packed.
· Bolt (P/No. 4635562) x2 · Camera assembly (P/No. 9318950) x1
3340 (for 600G shoe)
· Washer (P/No. 4103743) x4 · Bolt; sems (P/No. J271025) x3
· Nut; U (P/No. M660045) x2 · Harness; wire (P/No. 3118217) x1 3490 (for 750G shoe)
· Shim (P/No. 4345741) x4 · Bolt; sems (P/No. J271020) x9 Seal the hose ends with a
· Clip (P/No. 4190272) x9 plastic cap or paper tape Attachment-less Shoe width Weight
(for both ends). base machine (mm) (kg)
Apply anti-rust oil (With wire protector)
For C/W: 688 to the plated part.
Apply anti-rust oil.
Fix the cylinder with the
(Anti-rust P-1320) following parts so that it doesn't
extend.
· Pipe (P/No. 4335865) x 1 HD arm
· Wire (P/No. 4701492) x 1 P/No. 4640114 (L=1600) (8.99kg) x 2
Measurement
· Rope clip (P/No. 94-2901) x 2 Semi-long arm

Install the following parts. P/No. 4659744 (L=2300) (12.1kg) x 2
F
· Cover (P/No. 4167789) x 4 Install the following parts. Fig. 1 Amount of fuel at the time of shipment
· O-ring (P/No.4508805) x 4 · Cover (P/No. 4336672) x 2 (With wire protector)
· Bolt (P/No. J901430) x 16 · O-ring (P/No. 4508805) x 2
(Shown here is the HD boom.)

Stamp the base machine Measurement E · Pin (P/No. 8100447) x1 2.5m, 2.9m BE arms
S/No. at the bottom of front
nameplate. · Washer (P/No. 4040931) x1 P/No. 4659204 (L=2000) (11.1kg) x 2
Boom Measurement E Measurement F Base machine weight (kgw) · Stopper (P/No. 4206989) x1 Boom-arm hose (for bucket cylinder) *+60mm when a pre-cleaner is attached
Fix the grease hose to the pipe. Install the · Bolt (P/No. J912050) x3 Packed together with the arm Seal the hose ends with a
grease elbow to the hose (to be tightened · Washer (P/No. J222020) x3 plastic cap or paper tape.
temporarily). Protect the elbow with a vinyl *Apply anti-rust oil to the pin.
cap or paper tape. Using wires, etc., fix the space- To be shipped in
Remove the boom lamp assembly. Fix the cylinder and adjuster boss so that it doesn't drop. the state in which it Notes:
Install the following parts. boom with wires. (Space adjuster mechanism- left the factory Install the following parts. 1. After disassembly, touch up the paint on each part.
· Headlamp (P/No. 4336570) x1 mounted bucket only) (packaged)
· Pin (P/No. 3104745) x 1 · Clamp; pipe 2. Check the fuel level and add if necessary.
Measurement J
· Screw (P/No. M430610) x1

· Washer (P/No. 4040931) x 1 (P/No. 4190127) x 1 3. The shim for each joint should be installed to the
· Washer; plain (P/No. A590106) x1 Apply anti-rust oil.
· Stopper (P/No. 4117700) x 2 · Bolt; sems
· Harness; wire (P/No. 4271788) x1 pin. (However, no need to install if it is not already
· Bolt (P/No. J912050) x 8 (P/No. J271270) x 1
· Washer (P/Mo. J222020) x 8 installed.)
Stamp the base machine S/No.
*Apply anti-rust oil to the pin. at the bottom of front nameplate.
4. The machine S/N should be stamped at the bottom
right at the back of the counterweight (example:
Step (upper) "10001").
P/No. YA00003325 5. Refer to the list of unit shipment parts for parts
Place 14 side step installation bolts Weight: 11.7kg x 4 Measurement I Bucket other than those shown in the illustration (key, data,
(for front and back) in a single bag Height: 125 oil, optional device, etc.).
and attach to the side step. Measurement Measurement Bucket
Bucket I J width Weight 6. Apply anti-rust oil to the bolts, frame joints, screw
· Bolt (P/No. J901235) x 14
· Washer; plain (P/No. Z449490) x 14 Step (lower) holes, machined surfaces, etc.
· Washer; spring (P/No. A590912) x 14 P/No. YA00002172 Ascending/ Handrail (1) above Handrail (2) above Handrail above the 7. At the time of shipment, the tank fuel-level is 1753
Weight: 8.49kg x 4 descending ladder the fuel tank the fuel tank pump room or less (870mm from the top of fuel flange. See Fig.
Height: 125 O/T Width: 55mm Width: 115mm Width: 165mm 1.). However, for special shipment cases with oil
Width: 425mm 12.4kg 2.85kg 20.5kg level designation, instructions will be provided by
23.1kg P/No. YA40003168 P/No. YA40003435 P/No. 8124297 the production control dept.
*Place 8 side step installation bolts in a P/No. YA40003436
single vinyl bag and attach to the step.
Part Name P/No. Qty

lock BK
Side step (rear) Side step (front) Bolt lock BK
P/No. 6028301 P/No. 6028300 Washer; spring lock BK
Washer lock BK
215
ZX670LC-5B series
Removal/installation counterweight With removal/installation kit Without removal/installation kit

Counterweight installation parts are separately packed.
P/No Qty Part Name P/No. Qty
Part Name
Stamp the base machine Pin
Bolt (Distance
S/No. (right bottom). (Distance across corners) Plate
Washer across corners)
Bolt
Nut; castle Remove both the lamp assembly and bracket (to be packed separately).
Washer Install the following parts to lamp P/No. 4336570. Install the installation bolt, etc. to the boom.
Pin; ring
Plate Note: The Europe specification boom comes with a left lamp.
Bolt Part Name P/No. Qty
Height: 200 Height: 40 Apply anti-rust oil to the pin. The USA specification boom also comes with a right lamp.
Washer; lock Bolt
(Distance across corners) P/No. YA6001776 P/No. YA40007008 (The boom comes with a light harness.)
Plate Washer Fix the cylinder with the following parts
Weight: 15.6 kg Weight: 9.10 kg Fix the rubber grease hose to the pipe. Part Name so that it doesn't extend.
Shim P/No. Qty
Installation bolt J271230 x 6 Installation bolt: J271230 x 6 Install the grease elbow to the hose.
Shim Attach a vinyl cap or paper tape to the elbow. Bracket
Cover above the counterweight Cover above the counterweight For USA specification, Part Name P/No. Qty
Shim Screw
(To be installed to C/W) (To be installed to C/W) two each. Pipe
Width = 30 Washer; plain
Wire
Apply anti-rust oil to the plated part.
STD counterweight Plug with the following parts. Rope clip
(Anti-rust P-1320)
Counterweight installation parts are separately packed. Part Name P/No. Qty Apply anti-rust oil.
Part Name P/No. Qty Cover Fix the cylinder and boom with wires.
Bolt O-ring (At shipment work site)
Washer Bolt
Width = 30 Plug with the following parts.
Height: C Nut; U (Distance across corners) (Distance across corners) Apply anti-rust oil.
Shim Boom Width: C Install the following parts. Part Name
Stamp the base machine S/No. P/No. Qty
Bolt Install the following parts. at the bottom of front nameplate. Boom Weight (kg) Part Name P/No. Qty Cover
Counterweight Washer; lock Pin O-ring
Part Name P/No. Qty Remove both the mirror and stay H boom
P/No. Weight (kg) Plate Pin (to be packed separately). STD boom Stopper Flange; split
Shim Install the following parts to mirror P/No. 4675257. The following parts should be attached
Shim BE boom Bolt Bolt; socket
For removal/ together with the arm assembly.
installation Shim Shim · Stay (P/No. YA40001273) x 1 Washer
· Clamp (P/No. 4376895) x 1 · Boom arm hose x 2
Remove four bolts P/No. J271245 that are used to install normal Plate In the event the cab light is placed to the original position, Plate · O-ring P/No. 4487585 (for bucket) x 4
· Bolt; sems (P/No. J260850) x 4
Install the high-pressure hose to the base machine. muffler P/No. 7060238. Bolt install the plug (P/No. 4669483) to the connector from Plate; thrust Seal with the cover that was Install the following parts.
Use the following parts to plug the hose ends. Use one bolt P/No. J921050 and nut P/No. M520010 to install Washer which the harness was removed. Plate; thrust shipped together with the cylinder.
shipment-use muffler P/No. 8086588. Part Name P/No. Qty
Seal with a plastic cap Parts used Apply anti-rust oil to the pin. Apply anti-rust oil to the pin.
or paper tape. Part Name P/No. Qty (with the C/W removal/installation kit) Apply anti-rust oil to Pin
(with the C/W removal/installation bracket) Remove both the mirror and stay Stamp the base machine S/No. the plated part. Stopper
O-ring (to be packed separately). at the bottom of front nameplate. (Anti-rust P-1320) Bolt
Flange; split
(when the normal muffler is installed)
(when the normal muffler is installed)
Install the following parts to mirror P/No. 4675257.

Bolt; socket · Stay (P/No. YA40001274) x 1 Washer
(height of air cleaner)
Cover Install the following parts. · Clamp (P/No. 4201441) x 2 Apply anti-rust oil to the pin.
(height of air cleaner)
· Bolt; sems (P/No. J260845) x 4

Plug
2640 (standard cab)

Part Name P/No. Qty
Pin Remove the wiper arm and blade Install the following parts.
Hose P/No. Length Weight (kg) Qty
3550 (standard cab)

2750 (HD cab)
STD/H arm-use Bolt (to be packed separately). Part Name P/No. Qty
3660 (HD cab)

Washer Do not remove the motor. (Install the nut to the motor.)
Semi-long arm-use Pin
Install the following parts. Width: C
BE arm-use Shim Stopper
Boom arm hose Shim Part Name Bolt
P/No. Qty Apply anti-rust oil.
(packed together with the arm assembly) Apply anti-rust oil to the pin. Base machine Pin Arm Weight (kg) Washer
650G shoe Plate Arm H arm Plate; thrust
Seal with a plastic cap 750G shoe Bolt STD arm Plate; thrust
or paper tape to the seal.
Includes lug height. 900G shoe Washer Semi-long arm Apply anti-rust oil to the pin.
P/No. Weight: (with the side frame retracted)
Apply anti-rust oil to the pin. BE arm
Pre-cleaner
(to be packed separately) Plug with the following parts.
Includes lug height (with C/W removal/installation bracket) Weight of base machine (with side frame) (kg)
Part Name Apply anti-rust oil.
*When you use a pre-cleaner, P/No. Qty
(with C/W removal/installation kit) Shoe
install the rain cap that was O-ring (with C/W removal/ (with C/W removal/ Bucket Weight (kg) Stamp the base
installation bracket) installation kit)
ordered with the machine. Display "P1" on Display "P1" on Cap machine S/No. at the
650G shoe
a metal plate, etc. a metal plate, etc. Nut bottom of front nameplate.
750G shoe
(Refer to SECTION A.) (Refer to SECTION A.)
Cover 900G shoe
Domestic, general export USA, JD Plug

P/No. 4676598 x 2 P/No. YA00002495 x 2 Weight of base machine (without side frame) (kg) Plug the travel device
Weight: 9.99kg x 2 L=1150 Weight: 6.96kg x 2 L=1150 (with C/W removal/ (with C/W removal/ with the following parts.
installation bracket) installation kit) Cast-in letters, P1
P/No. 4644297 x 2 P/No. YA00002494 x 2 Weight (kg) Plug; union (P/No. 4223518) x 2
Side frame STD body (pilot)
STD track guard Full track guard Display "P1"
Weight: 6.61kg x 2 L=1150 Weight: 3.78kg x 2 L=1150 HD body Plug; union (P/No. 4223519) x 2 on a metal plate, etc. Width: C
Boom cylinder hose Boom cylinder hose Center of gravity 650G shoe (drain) Bucket
750G shoe
Note: Excludes tightening bolts. Center joint Notes:
(Distance across corners) 900G shoe
1. After disassembly, touch up the paint on each part.
Side frame (with shoe)
Plug the travel device 2. After disassembly, replenish the base machine with hydraulic oil.
with the following parts. Hydraulic oil level
· Bolt; sems (P/No. J271270) 1/3 High-pressure hose on Cover (P/No. 4336674) x 4 1) For machine with the front attachment assembled
· Clamp; pipe (P/No. 4190127) 1/3 P1 displayed-side (left) Cast-in letters, PI
High-pressure hose on Flange; split (P/No. 4085560) x 8 340mm from the upper plate of the hydraulic oil tank
P1 displayed side (right) O-ring (P/No. Z966993) x 4 [Left] [Right] 2) For front attachment-less machine
Bolt; socket (P/No. M341240) x 16
Travel devices 130mm from the upper plate of the hydraulic oil tank
Track frame tightening bolts, etc. 3. Check the fuel level and add if necessary.
are separately packed. (83.4 kg) 4. The shim for each joint should be installed to the pin.
*For 900G shoe, install the parts to the base machine.
Bolt (P/No. 4218943) x 28 (However, no need to install if it is not already installed.)
Spacer (P/No. 4218944) x 28 Place 8 step installation bolts 5. Stamp the base machine S/No. on the counterweight.
P/No. P/No. P/No. in a single vinyl bag and 6. If shoe is above 900G, the step should be attached to the side
Hitachi machine : Hitachi machine : Hitachi machine : attach to the step. P/No. 8127205 frame.
P/No. JD machine : JD machine : Weight : 27.6kg x 4 7. Refer to the list of unit shipment parts for parts other than those
JD machine : Part Name P/No. Qty
Hitachi machine : YA40004521 Track-side step Fig. 1 Fuel level at shown in the illustration (key, data, oil, etc.).
Weight : Weight : Weight : Bolt
JD machine : YA40002223 Height : 125 the time of shipment 8. When the high-pressure travel hose is disconnected, attach a label
Apply anti-rust oil Handrail above the battery box Lubricator box-side handrail
Weight: 25.7kg Handrail above the fuel tank Washer
to the plated part. (metal plate) to the side from which the hose was removed
Hydraulic oil tank-side handrail (Anti-rust P-1320) (superstructure) and to the opposite side (travel device) using wire,
Place the step installation bolts P/No. 8068378 etc. (P1 only).
Seal with the plug that Apply anti-rust oil. in a vinyl bag and such and attach to the step. Weight: 13.2kg x 4 9. At the time of shipment, the tank fuel-level is 2253or less
was shipped together Bolt; sems (P/No. J281230) x 12 Track-side step (1120mm from the top of fuel flange. See Fig. 1.).
with the cylinder. Height: 125 However, for special shipment cases with oil level designation,
P/No. 9318951 instructions will be provided by the production control dept.
Weight: 2.48kg Seal with a vinyl
Rear monitor camera cap or paper tape.
(to be packed separately with air cap)
Cylinder; boom (R) (P/No. 4643511)

Cylinder; boom (L) (P/No. 4643512) Step (P/No. 6024183) Step (P//No. 6028198)
217
ZX670LC-5G series
Install the installation bolts, etc. to the boom.

Part Name P/No. Qty
Bolt
Part Name P/No. Qty Washer
Stamp the base machine Pin Remove both the lamp assembly
S/No. (right bottom). Plate and bracket (to be packed separately).
STD counterweight Install the following parts to
Bolt
Counterweight installation parts are separately packed. lamp P/No. 4336570.
Washer
Part Name P/No. Qty (The boom comes with light harness.) Part Name P/No. Qty
Plate
Bolt Part Name P/No. Qty Pipe
Apply anti-rust oil to the pin. Wire
Washer (Distance across flats) (Distance across flats) Width = 30 Bracket
Nut; U Screw Rope clip
Fix the rubber grease hose to the pipe.
Shim Install the grease elbow to the hose. Washer; plain Fix the cylinder with the above parts so that
Bolt Attach a vinyl cap or paper tape to the elbow. it doesn't extend.
Apply anti-rust oil
Washer; lock to the plated part. Apply anti-rust oil.
Plate Plug with the following parts. (Anti-rust P-1320).
Shim (Distance across flats) Part Name P/No. Qty Plug with the following parts.
Shim Cover
Part Name P/No. Qty
O-ring
Counterweight Fix the cylinder and Cover
Bolt boom with wires
P/No. Weight (kg) O-ring
Apply anti-rust oil to the pin. (At shipment work site) Install the following parts. Flange; split
Height: C P/No. Qty Bolt; socket
Stamp the base machine S/No. Weight (kg) Part Name
Boom Width: C
at the bottom of front nameplate. Pin
H boom
Install the high-pressure hose to the base machine. Stopper
Install the following parts. STD boom
Use the following parts to plug the hose ends. Boom Bolt
Part Name P/No. Qty BE boom
Part Name P/No. Qty Washer The following parts should be
Pin Remove both the mirror and stay Plate installed together with the arm assembly.
O-ring (to be packed separately).
Shim Plate; thrust · Boom arm hose x 2
Flange; split Install the following parts to mirror P/No. 4675257.
Shim In the event the cab light is placed Plate; thrust · O-ring P/No. 4487585 (for bucket) x 4
Bolt; socket · Stay (P/No. YA40001273) x 1
Plate to the original position, install the
Apply anti-rust oil to the pin. Seal with the cover that was
Cover · Clamp (P/No. 4376895) x 1 plug (P/No. 4669483) to the connector Install the following parts.
Bolt · Bolt; sems (P/No. J260850) x 4 shipped together with the cylinder.
Plug from which the harness was removed. Part Name P/No. Qty
Washer
P/No. 4465368 Weight: 4 kg Apply anti-rust oil Pin
Apply anti-rust oil to the pin. Remove both the mirror and stay Stamp the base machine S/No.
Pre-cleaner to the plated part. Stopper
(to be packed separately). at the bottom of front nameplate.
(packed separately) (Anti-rust P-1320) Bolt
Install the following parts to mirror P/No. 4675257.
(Height of air cleaner)
Install the following parts. Washer

*When you use a pre-cleaner, · Stay (P/No. YA40001274) x 1
install the rain cap that was P/No. Qty · Clamp (P/No. 4201441) x 2
(Height of air cleaner)
Part Name Apply anti-rust oil to the pin.

ordered with the machine. · Bolt; sems (P/No. J260845) x 4
2640 (STD cab)
Pin
2750 (HD cab)

Bolt
3550 (STD cab)

3660 (HD cab)
Remove the wiper arm and blade Install the following parts.
Washer (to be packed separately).
Shim Do not remove the motor. Part Name P/No. Qty
Seal with a plastic Shim (Install the nut to the motor.) Pin
Includes lug height Width: C
cap or paper tape. Apply anti-rust oil the pin. Stopper
Install the following parts. Apply anti-rust oil.
Bolt
Includes lug height Base machine Part Name P/No. Qty Arm Weight (kg) Washer
650G shoe Pin Arm H arm Plate; thrust
Plug with the
following parts. 750G shoe Plate STD arm Plate; thrust
900G shoe Bolt Semi-long arm Apply anti-rust oil to the pin.
Part Name P/No. Qty (with the side frame retracted)
Hose P/No. Length Weight (kg) Qty O-ring Washer BE arm
Display "P1" on a metal Display "P1" on a metal Apply anti-rust oil to the pin.
STD/H arm-use plate, etc. plate, etc. Cap Weight of base machine (with side frame) (kg) Weight of base machine (without side frame) (kg)
Semi-long arm-use (Refer to SECTION A.) (Refer to SECTION A.) Nut Apply anti-rust oil.
BE arm-use Cover Shoe Bucket Weight (kg) Stamp the base machine
STD base machine
Plug S/No. at the bottom
650G shoe HD base machine
of front nameplate.
750G shoe
Boom arm hose 900G shoe
(packed together with the arm assembly)

Plug the travel device
Seal with a plastic cap or with the following parts.
paper tape to the seal. Weight (kg) Cast-in letters, P1
Side frame Plug; union (P/No. 4223518) x 2
STD track cover Full track cover (pilot) Display "P1"
650G shoe Plug; union (P/No. 4223519) x 2 on a metal plate, etc. Width: C
Center of gravity 750G shoe (drain)
Bucket
Note: Excludes the tightening bolt 900G shoe Center joint
Notes:
Side frame (with shoe) Plug the travel device 2. After disassembly, replenish the base machine with hydraulic oil.
P/No. Install the following parts.
Weight: with the following parts. Hydraulic oil level
· Bolt; sems (P/No. J271270) x 1/3 High-pressure hose on Cover (P/No. 4336674) x 4
P/No. P1 displayed side (left) 1) For machine with the front attachment assembled
· Clamp; pipe (P/No. 4190127) x 1/3 Flange; split (P/No. 4085560) x 8 Cast-in letters, P1
Weight: High-pressure hose on 340mm from the upper plate of the hydraulic oil tank
P1 displayed side (right) O-ring (P/No. Z966993) x 4 [Left] [Right] 2) For front attachment-less machine
Boom cylinder hoses Bolt; socket (P/No. M341240) x 16
Travel devices 130mm from the upper plate of the hydraulic oil tank
3. Check the fuel level and add if necessary.
*For 900G shoe, install the parts to the base machine. 4. The shim for each joint should be installed to the pin.
(However, no need to install if it is not already installed.)
5. Stamp the base machine S/No. on the counterweight.
Place 8 step installation bolts
P/No. P/No. P/No. in a single vinyl bag and attach 6. If shoe is above 900G, the step should be attached to the side
Weight: Weight: Weight: to the step. P/No. 8127205 frame.
P/No. YA40004521 Weight : 27.6kg x 4 7. Refer to the list of unit shipment parts for parts other than those
Weight: 25.7 kg Handrail above the fuel tank Handrail above the lubricator box Lubricator box-side handrail Part Name P/No. Qty Track-side step Fig. 1 Fuel level at the time of shipment shown in the illustration (key, data, oil, etc.).
Hydraulic oil tank-side handrail Bolt Height : 125 8. When the high-pressure travel hose is disconnected, attach a
Track frame tightening bolts, etc. are Washer
separately packaged. (83.4 kg) Apply anti-rust oil to label (metal plate) to the side from which the hose was removed
Bolt (P/No. 4218943) x 28 the plated part. (superstructure) and to the opposite side (travel device) using
Apply anti-rust oil. (Anti-rust P-1320) P/No. 8068378 wire, etc. (P1 only).
Spacer (P/No. 4218944) x 28 Place the step installation bolts in a vinyl bag
and such and attach to the step. Weight: 13.2kg x 4 9. At the time of shipment, the tank fuel-level is 2303or less
Seal with the plug that Apply anti-rust oil. Bolt; sems (P/No. J281230) x 12 Track-side step (940mm from the top of fuel flange. See Fig. 1.).
was shipped together Height: 125 However, for special shipment cases with oil level designation,
with the cylinder. instructions will be provided by the production control dept.
Attach a vinyl cap

P/No. 9318951 or paper tape.
Weight: 2.48 kg
Rear monitor camera Cylinder; boom (R) (P/No. 4643511)
(to be separately packed with air cap) Cylinder+ boom (L) (P/No. 4643512) Step (P/No. 6024183) Step (P//No. 6028198)
219
ZX870-5B series
Removal/installation counterweight Without removal/installation kit

With removal/installation kit Seal with a plastic cap or paper tape.
Counterweight installation parts are separately packaged.
Part Name P/No Qty (Distance

across corners)
across corners)
Shim
Pin; ring (Distance
(Distance
across corners) Apply anti-rust oil to the pin. Install the following parts.
Washer
Nut; castle Part Name P/No. Qty Apply anti-rust oil to the
Fix the rubber grease hose so that it doesn't dangle. Pin plated part.
Bolt (Anti-rust P-1320)
Install the grease elbow to the hose (temporarily tighten). Plate
Spacer Cover above the counterweight Cover above the counterweight Attach a vinyl cap or paper tape to the elbow.
*Install to the counterweight. *Install to the counterweight. Bolt Apply anti-rust oil.
Stopper
Stamp the base Bolt Washer
machine S/No. Boom cylinder hoses Boom cylinder hoses Plug with the following parts. Fix the cylinder and boom
P/No. YA60002024 P/No. YA40004678
(right bottom) Washer; spring Height: 720 Height: 40 (other than USA, with protector) (for USA, without protector) with wires
Washer Weight: 19.6 kg Weight: 14.1 kg
Part Name P/No. Qty (at shipment work site).
P/No. P/No.
Shim Installation bolt: J271230 x 6 Installation bolt: J271230 x 6 Weight: Weight:
Cover
Shim P/No. P/No. O-ring Part Name P/No. Qty
Weight: Weight: Bolt Cover
across corners)
Others (to be packed separately) Others (to be packed separately) Cover O-ring
O-ring
(Distance
STD counterweight O-ring P/No. 4508805 x 6 O-ring P/No. 4508805 x 6
Flange, split
across corners)
O-ring P/No. 4187328 x 2 O-ring P/No. 4187328 x 2
Counterweight installation parts are separately packaged. Bolt Bolt; socket
(Distance
Part Name P/No Qty Plug with the above parts.
Shim Apply anti-rust oil.
Plug with the following parts. Fix the cylinder with the Width: C Apply anti-rust oil to the pin.
Washer Stamp the base machine
across corners)
Install the high-pressure hose to the main body. S/No. at the bottom of front following parts so that it doesn't
Nut; U Part Name P/No. Qty nameplate. extend.
Use the following parts to plug the hose ends. Install the following parts.
(Distance
Bolt O-ring Remove both the lamp assembly and bracket STD, H, BE specifications R, BER specifications
Height: C Washer Part Name P/No. Qty (to be packed separately). Part Name P/No. Qty
Cap Part Name P/No. Qty Part Name P/No. Qty
Install the following parts to lamp P/No. 4336570. Pipe
Spacer Cover Cap Pin Pin
Counterweight Stopper Cover Lamps are installed to both sides. Wire
Nut (The boom comes with light harness.) Plate Plate
Bolt Plug Rope clip
P/No. Weight (kg) Plug Part Name P/No. Qty Bolt Stopper
Washer Flange; split
Bracket Washer Bolt
For removal/ Shim Flange; split
installation
Plug with the following parts. Screw Boom Weight (kg) Plate; thrust Nut
Shim O-ring
Washer STD boom Plate; thrust Plate; thrust
O-ring Part Name P/No. Qty
H boom Stopper Plate; thrust
Bolt; socket O-ring Install the installation bolts, etc.
to the boom. BE boom Plate
Bolt; socket Cover
Part Name P/No. Qty Shim
Flange; split R boom
With removal/installation kit 7525 (when the side frame LC is installed) Bolt Shim
Only for Russia Bolt; socket BER boom
With removal/installation kit specification, pack the entire In the event the cab light is placed to the original Washer Bolt
position, install the plug (P/No. 4669483) to the
Plug
cab in a wooden crate Washe
P/No. Removal/installation bracket only 7310(when side frame LC is installed) (to prevent theft). connector from which the harness was removed.
Follow the packing list for instructions on how to pack the light.
Weight: Removal/installation bracket only Install the fixing brackets, U bolts, etc. to the cab. Apply anti-rust oil to the pin.
Normal muffler Fix the cab-side harness so that it doesn't dangle. Install the following parts.
Apply anti-rust oil to the pin. Remove the handrail
No removal/installation 7080 (when side frame LC is installed) Apply anti-rust oil to the
Remove the normal muffler (P/No. 7060238 x 1) and bolts (to be packed separately). Seal with the cover that was plated part. P/No.
No removal/installation Install the following parts. Qty R, BER specifications
(P/No. J271235 x 4). Use a bolt (P/No. J921050 x 1) and nut Remove both the mirror and stay (to be shipped together with the cylinder. (Anti-rust P-1320) STD, H, BE,
Specification semi-long Long P/No. Qty
(P/No. M520010 x 1) to install the shipment-use muffler Part Name P/No. Qty packed separately). Install the following parts
(P/No. 8086588). Protect the antenna with to mirror P/No. 4675257. Apply anti-rust oil to the pin. Pin Pin
vinyl, etc. (rust prevention). Pin
Shim Remove both the mirror and stay (to be · Stay (P/No. YA40001274) x 1 Install the following parts. Stopper Stopper
(When the normal muffler is installed)
Includes packed separately). Install the following parts · Clamp (P/No. 4201441) x2 Bolt Bolt
Shim · Bolt; sems (P/No. J260845) x4 Part Name P/No. Qty
lug height to mirror P/No. 4675257.
Washer Washer
Shipment-use muffler
(When the side frame is installed)
Plate Stay (P/No. YA40001273) x1 Pin

frame is removed)
Clamp (P/No. 4376895) x1

(When the center
Bolt Remove the wiper arm and blade (to be packed Plate
muffler is removed)
(For H cab: 2385)
Bolt; sems (P/No. J260850) x4

Washer; spring separately). Do not remove the motor. Bolt
(When the side
3690 (When the side frame is installed)

(For H cab: 3805)
(Install the nut to the motor.) Install the following parts.

Washer
Install the following parts. Remove the handrail P/No.
Pre-cleaner (to be packed separately). Weight of base machine without undercarriage (kg) Stamp the base machine S/No. Width: C STD, H, Qty
Part Name P/No. Qty at the bottom of front nameplate. Apply anti-rust oil. Specification semi-long Long
(with band) Base machine
Pin Weight (kg) Apply anti-rust oil to the pin.
P/No. C/W specification Pin
removal/installation
When a pre-cleaner is used Shim specification STD body HD body The following parts are separately packed. Stopper
Protect the swing device
(to be packed separately) pinion with vinyl bag. None Part Name P/No. Qty Arm Weight (kg)
Includes Shim Bolt
*When you use a pre-cleaner, lug height Removal/installation bracket only O-ring (for link A) STD arm
Plate Washer
install the rain cap that was
ordered with the machine. Bolt With removal/installation kit O-ring (for arm end) H arm
P/No.
Place the swing device pinion on the Washer; spring Base machine Plate, thrust (t=2.0) R arm Qty
block, etc. so that it doesn't directly Weight of base machine without side frame (kg) Specification
touch the ground Fix with wire, etc. so that the Apply anti-rust oil to the pin. 650G shoe BE arm
Plate, thrust (t=1.0)
bolts don't drop. Base machine Weight (kg) Pin
Cover the grease bath with vinyl sheet so that it is 750G shoe C/W specification *For long arm specification BER arm
not exposed to wind and rain. Place a plywood (maximum width with the side frame retracted)
removal/installation
STD body HD body Stopper
Install the following parts. 900G shoe specification Part Name P/No. Qty Semi-long arm
board inside so that water doesn't collect on the Bolt
Pin (P/No. 4293389) x 2 1020G shoe None O-ring
vinyl sheet. Long arm
Removal/installation bracket only
Washer
Only for 1020G shoe, Plate, thrust (t=2.0)
side frame cannot be With removal/installation kit
In case of no reassembly at port, install the retracted. Plate, thrust (t=1.0)
following parts (support) to the machined Seal with a plastic cap or paper tape.
P/No.
surface of track center frame. Stamp the base machine
Wright: S/No. at the bottom of
Bracket (P/No. 9757191) x 4
Rear monitor camera Washer (P/No. 4459340) x 8 To connect directly, attach metal front nameplate.
(to be separately packaged with air cap) Bolt (P/No. J921290) x 8 Install the following parts to the C/J plates to both the C/J side and
Nut (P/No. J950012) x 8 Display "P1" on a metal and hose. hose side to ensure that there is
plate, etc. (right). no assembly of the wrong hose. C/J installation parts are separately packed.
Apply anti-rust oil to the Nut (P/No. 4188138) x 4: C/J side
Display "P1" on a metal (Refer to SECTION A.) machined surface. Cap (P/No. 4189095) x 4: C/J side Part Name P/No. Qty
Install the following parts to
plate, etc. (left). O-ring (P/No. 4187328) x 8: C/J side Cover
Track center frame the C/J side and hose side.
(Refer to SECTION A.) and hose side
Plug (P/No. 4210056) x 4: hose side Plug (P/No. A885003) x 1: C/J side Stopper Width: C
Plug (P/No. A885004) x 1: C/J side Adapter
Plug the high-pressure travel pilot Plug the travel pilot hose with Plug (P/No. 4225492) x 1: hose side Bucket Weight (kg)
hose with the following parts. Plug (P/No. 4222076) x 1: hose side Adapter
the following parts. Hose P/No. Length Weight (kg) Qty

Cover (P/No. 4126786) x 4 Plug; union (P/No. 4222076) x 2
Washer
High-pressure hose on High-pressure hose on STD, H arm,
Flange; split (P/No. 4085560) x 8 (pilot) Bolt
P1 displayed-side (right) P1 displayed-side (left) reinforced H arm, long arm
(Distance across corners) O-ring (P/No. Z966993) x 4 Plug; union (P/No. 4225492) x 2 , reinforced
Bolt; socket (P/No. M341240) x 16 (drain) Semi-long arm
Center joint
BE arm, reinforced BE arm
, reinforced
Install connection bolts, other Boom arm hose
than those shown at left, to the After disassembly, apply anti-rust (packed together with the arm assembly)
side frame. oil to the machined surfaces of the
, reinforced
With bolts and travel
*For 1020G shoe, install all of the track frame and side frame. hose cover Install the handrail installation bolt to Install the handrail installation bolt to
Install the handrail installation bolts the base machine. the base machine.
Track frame tightening bolts are separately packed. bolts to the side frame.
to the base machine. Bolt; sems (P/No. J271240) x 8 Bolt; sems (P/No. J271235) x 4
Bolt (P/No. 4639684) x 24 Bolt (P/No. 4639684) x 44 Bolt; sems (P/No. J271235) x 10 Only for reinforced bucket specification, package the following parts separately.
Spacer (P/No. 4218944) x 24
Spacer (P/No. 4218944) x 44 · Dust seal P/No. 4152605 x2
· Dust seal P/No. 4123879 x2
*Bolts are not separately packed for 1020G shoe.
Notes:
*Only 650G shoe and 750G shoe for the track step are available for unit dispatch. 1. After disassembly, touch up the paint on each part.
900G shoe and above are all attached to the side frame for shipment. 2. After disassembly, replenish the base machine with hydraulic oil.
Hydraulic oil level
Handrail above the fuel tank
(Max. width) For front attachment-less machine
Center of Side frame (with shoe) P/No. (Hitachi color) Handrail above the lubricator box
gravity 100mm from the upper plate of the hydraulic oil tank
P/No. (JD color) P/No. (Hitachi color) Handrail at right front of the superstructure
(The center of gravity represents the state with 3. Check the fuel level and add if necessary.
Use the following bolts, etc. to assemble P/No. (JD color) P/No. (Hitachi color)
Place 8 step installation bolts in a single track steps, without hose covers and bolts.) 4. The shim for each joint should be installed to the pin.
vinyl bag and attach to the step. · Clamp; pipe P/No. 4190127 x 2 Use the following bolts, etc. to assemble. P/No. (JD color)
Center of gravity Weight (kg) · Bolt; sems P/No. J271270 x 2
(However, no need to install if it is not already installed.)
Side frame Side frame STD Side frame LC · Clamp; pipe P/No. 4190127 x 1 Weight: 3.23 kg
Part Name P/No. Qty Side Track Total weight: 25.5 kg 5. Stamp the base machine S/No. on the counterweight.
frame guard STD track guard Full track guard STD track guard Full track guard · Bolt; sems P/No. J271270 x 1
6. If shoe is below 900G, the step should be separately packed.
Bolt 650G shoe Total weight: 17.7 kg Cast-in letters, P1
Fig. 1 Fuel level at the time 7. Refer to the list of unit shipment parts for parts other than those shown in the
Washer 750G shoe Display "P1" on a
P/No. of shipment illustration (key, data, oil, etc.).
metal plate, etc.
Weight: 900G shoe Plug the travel device with the following parts. 8. When the high-pressure travel hose is disconnected, attach a label (metal
Track-side step 1020G shoe Plug; union (P/No. 4223518) x 2 plate) to the side from which the hose was removed (superstructure) and to
Height: 125 (pilot) the opposite side (travel device) using wire, etc. (P1 only)
Apply anti-rust oil to the Place the step installation bolts in a vinyl bag
plated part. Plug; union (P/NO. 4223519) x 2 9. At the time of shipment, the tank fuel-level is 2503or less
and such and attach to the step.
Apply anti-rust oil. (Anti-rust P-1320). Bolt; sems (P/No. J281230) x 14 (drain) (1120mm from the top of fuel flange).
Apply anti-rust oil. Cast-in letters, P1 However, for special shipment cases with oil level designation, instructions
Plug the travel device with the following parts.
will be provided by the production control dept.
Cover (P/No. 4336674) x 4 [Left] [Right] Display "P1" on a
Seal with the plug
that was shipped Flange; split (P/No. 4085560) x 8 metal plate, etc.
together with the
Travel devices
O-ring (P/No. Z966993) x 4
P/No. cylinder. Attach a vinyl cap or
paper tape. Bolt; socket (P/No. M341240) x 16
Weight:
Track-side step Cylinder; boom (R) (P/No. 4698977)
Height: 125 Cylinder; boom (L) (P/No. 4698978) Step (P/No. 6024183) Step (P/No. 6024192) Step (P/No. 6024198)
221
ZX870-5G series
Seal with a plastic cap or paper tape.
Apply anti-rust oil to the pin. Install the following parts.
Part Name P/No. Qty Apply anti-rust oil to the

Stamp the Fix the rubber grease hose so that it doesn't dangle. Pin plated part.
base machine S/No. Install the grease elbow to the hose (temporarily tighten). (Anti-rust P-1320).

(right bottom) Attach a vinyl cap or paper tape to the elbow.
Plate
Bolt Apply anti-rust oil.
Counterweight
Washer

Counterweight installation parts are separately packed. Fix the cylinder and boom
Boom cylinder hose Plug with the following parts.
with wires
Part Name P/No. Qty (with protector) P/No. Qty
Part Name (at shipment work side).
Shim P/No. 4641092 x 2
Weight: 13.4kg x 2 L=1540
Cover
Washer

P/No. 4641093 x 2 O-ring Part Name P/No. Qty
Nut; U Weight: 8.86kg x 2 L=1540 Bolt Cover
Bolt Others (to be packed separately) Cover O-ring
Washer
O-ring P/No. 4508805 x6 O-ring Flange; split
Spacer O-ring P/No. 4187328 x2
Bolt Bolt; socket
Stopper
Plug with the above parts.
Bolt
Washer Apply ant-rust oil. Apply anti-rust oil to the pin.
Height: C Plug with the following parts. Width: C
Shim Stamp the base machine S/No. Fix the cylinder with the following
Install the high-pressure hose to the main body.
Counterweight Shim Use the following parts to plug the hose ends. Part Name P/No. Qty at the bottom of front nameplate. parts so that it doesn't extend. Install the following parts.
O-ring specifications specifications
P/No. Weight (kg) Part Name P/No. Qty Remove both the lamp assembly and bracket (to be packed Part Name P/No. Qty
Cap separately). Install the following parts to lamp P/No. 4336570. Part Name P/No. Qty Part Name P/No. Qty
Cover Pipe
Cap Note: Lamps are installed to both sides. Pin Pin
Cover Wire
Nut (The boom comes with a light harness.) Plate Plate
Plug Rope clip
Plug Part Name P/No. Qty Bolt Stopper
Flange; split
Bracket Washer Bolt
Flange; split
Plug with the following parts. Screw Boom Weight (kg) Plate; thrust Nut
O-ring
Washer STD boom Plate; thrust Plate; thrust
O-ring Part Name P/No. Qty
Install the installation bolts, etc, H boom Stopper Plate; thrust
Bolt; socket O-ring
to the boom. BE boom Plate
Bolt; socket Cover
Part Name P/No. Qty R boom Shim
Only for Russia Flange; split
specification, pack the In the event the cab light is placed to the Bolt BER boom Shim
Bolt; socket
entire cab in a wooden original position, install the plug (P/No. Washer Bolt
crate (to prevent theft). 4669483) to the connector from which the Plug
Washer
harness was removed.
Follow the packing list for instructions on how to pack the light.
Install the fixing brackets, U bolts, etc. to the cab. Apply anti-rust oil to the pin.
Apply anti-rust oil to the pin. Fix the cab-side harness so that it doesn't dangle. Install the following parts.
(When the side frame LC is installed) Apply anti-rust oil to the
Remove the handrail (to be packed separately). Seal with the cover that was plated parts. P/No.
Install the following parts. Qty specifications
shipped together with the cylinder. (Anti-rust P-1320). Specification Long
Part Name P/No. Qty Remove both the mirror and stay semi-long P/No. Qty
Protect the antenna with (to be packed separately). Apply anti-rust oil to the pin.
Pin Pin Pin
vinyl bag, etc (rust prevention) Install the following parts to mirror P/No. 4675257.
Remove both the mirror and stay (to be Install the following parts. Stopper Stopper
Shim · Stay (P/No. YA40001274) x1
Includes lug packed separately). Install the following parts Bolt Bolt
height Shim to mirror P/No. 4675257. · Clamp (P/No. 4201441) x2 Part Name P/No. Qty
(When the side frame is removed)
(When the center frame is removed)
Plate · Bolt; sems (P/No. J260845) x4 Pin Washer Nut

· Stay (P/No. YA40001273) x1
Bolt · Clamp (P/No. 4376895) x1 Plate

(For H cab: 2385)
Remove the wiper arm and blade

Washer; spring (to be packed separately). Bolt
(For H cab: 3805)
Do not remove the motor. (Install the nut to the motor.) Install the following parts.
Remove the handrail Washer
Install the following parts. (to be packed P/No.
Pre-cleaner separately). Weight of base machine without undercarriage (kg) Stamp the base machine S/No. Width: C Qty
Part Name P/No. Qty at the bottom of front nameplate. Apply anti-rust oil. Specification Long
(with band) semi-long
Pin Weight (kg) Apply anti-rust oil to the pin.
P/No. 4465366 x 1 Pin
STD HD
When using a pre-cleaner Shim Protect the swing device pinion base machine base machine The following parts are separately packed. Stopper
(to be packaged separately) Shim with a vinyl bag. Part Name P/No. Qty Arm Weight (kg) Bolt
*When you use a pre- Includes lug height Plate Weight of base machine without side frame (kg) O-ring (for link A) STD arm Washer
cleaner, install the rain cap Bolt O-ring (for arm end) H arm
that was ordered with the Base machine Weight (kg) P/No.
Washer; spring Plate; thrust (t=2.0) R arm Qty
machine. Place the swing device pinion on the block, etc. shoe STD HD Specification
Fix with wire, etc. so that Apply anti-rust oil to the pin. base machine base machine
so that it doesn't directly touch the ground.
shoe Plate; thrust (t=1.0) BE arm
the bolts don't drop. Pin
Cover the grease bath with vinyl sheet so that it is *For long arm specification BER arm
not exposed to wind and rain. shoe Stopper
Install the following parts. A (maximum width with the side frame retracted) Part Name P/No. Qty
Place a plywood board inside so that water
Semi-long arm
Pin (P/No. 4293389) x 2 Bolt
doesn't collect on the vinyl sheet. O-ring Long arm
Nut
Plate; thrust (t=2.0)
In case of no reassembly at port, install the Plate; thrust (t=1.0) Apply anti-rust oil.
following parts (support) to the machined Stamp the base Seal with a plastic cap or paper tape.
P/No. 9318951
surface of track center frame. machine S/No. at the
Weight: 2.48 kg bottom of front
Bracket (P/No. 9757191) x4
Rear monitor camera To connect directly, attach metal plates nameplate.
Washer (P/No. 4459340) x8
(to be separately packed with air cap) Install the following parts to the C/J to both the C/J side and hose side to
Bolt (P/No. J921290) x8 ensure that there is no assembly of
Display "P1" on a and hose.
Nut (P/No. J950012) x8 metal plate, etc. (right). the wrong hose. C/J installation parts are separately packed.
Apply anti-rust oil to the Nut (P/No. 4188138) x 4: C/J side
Display "P1" on a (Refer to SECTION A.) machined surface. Cap (P/No. 4189095) x 4: C/J side Part Name P/No. Qty
Install the following parts to the
metal plate, etc. (left). O-ring (P/No. 4187328) x 8: C/J side Cover
Track center frame and hose side
C/J side and hose side.
(Refer to SECTION A.) Stopper Width: C
Plug (P/No. 4210056) x 4: hose side Plug (P/No. A885003) x 1: C/J side
Plug (P/No. A885004) x 1: C/J side Adapter
Plug the high-pressure travel Plug the travel pilot hose with Plug (P/No. 4225492) x 1: hose side Bucket Weight (kg)
hose with the following parts. Plug (P/No. 4222076) x 1: hose side Adapter
the following parts. Hose P/No. Length Weight (kg) Qty

Cover (P/No. 4126786) x4 Plug; union (P/No. 4222076) x2 Washer
High-pressure hose on High-pressure hose on P1 STD, H arm,
Flange; split (P/No. 4085560) x8 (pilot) P1 displayed-side (right) displayed-side (left) Bolt
(Distance across corners) reinforced H arm, long arm
O-ring (P/No. Z966993) x4 Plug; union (P/No. 4225492) x2 , reinforced
Center joint Semi-long arm
Bolt; socket (P/No. M341240) x 16 (drain)
, reinforced BE arm, reinforced BE arm
Boom arm hose
Install direct-connection bolts, After disassembly, apply anti-rust (packed together with the arm assembly)
other than those shown at left, to oil to the machined surfaces of the , reinforced
With tightening bolts
the side frame. track frame and side frame. and travel hose cover Install the handrail installation bolt to
Track frame tightening bolts are separately packed. Install the handrail installation bolts Install the handrail installation bolt to
the base machine.
to the main body. the base machine.

Bolt (P/No. 4639684) x 24 Bolt; sems (P/No. J2771240) x 8 Bolt; sems (P/No. J2771235) x 4
Bolt; sems (P/No. J271235) x 10 Only for reinforced bucket specification, package the following parts separately.
Spacer (P/No. 4218944) x 24
· Dust seal P/No. 4152605 x 2
· Dust seal P/No. 4123879 x 2
*Bolts are not separately packed for 1020G shoe. Notes:
*Only 650G shoe and 750G shoe for the track step are available for unit dispatch. 2. After disassembly, replenish the base machine with hydraulic oil.
900G shoe and above are all attached to the side frame for shipment. Hydraulic oil level
For front attachment-less machine
(Max. width)
Handrail above the fuel tank 100mm from the upper plate of the hydraulic oil tank
Center of Side frame (with shoe) P/No. Handrail above the lubricator box 3. Check the fuel level and add if necessary.
gravity
Use the following bolts, etc. to assemble P/No. Handrail at right front of the superstructure 4. The shim for each joint should be installed to the pin.
(The center of gravity represents the state with track steps,
Clamp; pipe P/No. 4190127 x 2 Use the following bolts to assemble P/No. YA40004147 (However, no need to install if it is not already installed.)
Place 8 step installation bolts in a single without hose covers and bolts.)
vinyl bag and attach to the step. Bolt; sems P/No. J271270 x 2 Clamp; pipe P/No. 4190127 x 1 Weight: 3.23kg 5. Stamp the base machine S/No. on the counterweight.
Center of gravity Weight (kg) Total weight: 25.0 kg Bolt; sems P/No. J271270 x 1
P/No. Qty Side Track Side frame Side frame STD Side frame LC 6. If shoe is below 900G, the step should be separately packed.
Part Name frame guard STD track guard Full track guard STD track guard Full track guard Total weight: 17.7 kg
7. Refer to the list of unit shipment parts for parts other than those shown in the
Bolt shoe Cast-in letters, P1
illustration
Washer shoe Fig. 1 Fuel level at the time of shipment
P/No. 8127205 Display "P1" on a (key, data, oil, etc.).
metal plate, etc.
Weight: 27.6kg x 4 shoe Plug the travel device with the following parts. 8. When the high-pressure travel hose is disconnected, attach a label (metal plate)
Track-side step Plug; union (P/No. 4223518) x 2 to the side from which the hose was removed (superstructure) and to the
Height: 125 (pilot) opposite side (travel device) using wire, etc. (P1 only)
Apply anti-rust oil to the Place the step installation bolts in a vinyl bag Plug; union (P/NO. 4223519) x 2
plated part. and such and attach to the step.
9. At the time of shipment, the tank fuel-level is 2503or less
Apply anti-rust oil. (drain) (1120mm from the top of fuel flange).
(Anti-rust P-1320). Bolt; sems (P/No. J281230) x 14
Apply anti-rust oil. Cast-in letters, P1 However, for special shipment cases with oil level designation, instructions will
Cover the travel device with the following parts. be provided by the production control dept.
Cover (P/No. 4336674) x 4 Display "P1" on a
[Left] [Right]
Seal with the plug that Flange; split (P/No. 4085560) x 8 metal plate, etc.
was shipped together O-ring (P/No. Z966993) x 4
P/No. 8068378 Travel devices
with the cylinder. Attach a vinyl cap or
Bolt; socket (P/No. M341240) x 16
Weight: 13.2kg x 4 paper tape.
Track-side step Cylinder; boom (R) (P/No. 4698977)
Height: 125 Cylinder; boom (L) (P/No. 4698978) Step (P/No. 6024183) Step (P/No. 6024192) Step (P/No. 6024198)
223
8. Side Frame Extension and Retraction Method
1 Precautions when extending or retracting the side frames

Accumulation of dust or debris on the mounting faces of the track frames and side frames can lead to the loosening of
bolts. Thoroughly clean all affected portions of the frames before performing any work.
Note:
The side frames should be retracted only during transportation (when loading onto or off a truck and when operating
the machine during loading /unloading). Under no circumstances should the side frames be retracted during digging
work on when driving the machine. Operation of the machine with the side frames retracted (or one side frame
retracted) will lead to machine instability and potentially cause damage to the track and side frame bolts.
Note:
The ZX470-5G series is an integrated side frame and truck frame model. The “Side frame extension and retraction
method” page does not apply to this series.
225
2 Side frame extension procedure
[Tools used]
(1) Sling rope (20mm diameter × 8mm, 6 × 37
ordinary Z strand class A, maximum load: 3 tons),
6 ropes used
· Before slinging, confirm that none are snapped or
kinked.
(2) Lever block (JIS B8819, L32T or equivalent),
2 blocks used
· Check the lever block for damage.
(3) Power wrench (includes attachments), torque
wrench - width across flats: 55 mm
(4) Air compressor (for cleaning sliding surfaces)
(5) Soft protector
CAUTIONS:
i) This is group work.
Before you begin working, have a thorough
briefing to discuss the work procedure, etc.
To operate the front attachment for this work,
keep adequate distance from the machine as it
is dangerous.
Fig. 1
ii) Damaged lever block or wire rope can cause a
major accident.
Before you begin to work, check the conditions
of the lever block and wire rope.
iii) To extend the side frame by using a front
attachment, keep everyone away from the
machine.
Note:
work.
CAUTION:
90˚∼110˚
Do not loosen guide bolt 9 of the side frame.
IMPORTANT:
When side frame 3 is in retracted state, all holes are
not installed with side frame tightening bolts 1 .
Lubricant is applied to the screw holes on side frame
Fig. 2
3 where bolts 1 have not been installed, and dust
and soiling can collect there. Thoroughly clean the
surfaces of the screws before installing the tightening
bolts. If the bolts are still difficult to tighten, re-tap the
1. Remove side frame mounting bolts 1 from the side
screw holes.
frame on the extending side.
Tap: M33, Pitch: 3 mm ZX470-5 class ZX470-5 class: 3 bolts x 2 locations, total: 6 bolts
Tap: M36, Pitch: 3 mm ZX670LC-5 class/ZX870-5 class ZX670LC-5 class: 4 bolts x 2 locations, total: 8 bolts
ZX870-5 class: 5 bolts x 2 locations, total: 10 bolts
IMPORTANT:
2. Rotate the superstructure towards the extending side
Before you begin to work, use compressed air to
frame so that the front attachment is at a straight
completely clean the sliding surface of the side frame.
angle relative to the side frame.
Any dirt, sand or gravel stuck to the track frame 2 and
3. Set the arm and boom angles to form an angle of
side frame 3 contact surfaces can interrupt the work
between 90 to 110 degrees. Then, lower the bucket
and result in loosening bolt 1 .
onto the ground.
226
ZX470-5 class
1
3
Fig. 3-a
ZX670LC-5 class 1
3
1
9
Fig. 3-b
ZX870-5 class 3
1
9 Fig. 3-c
227
4. Tie two wire ropes 4 around the front and back of
the side frame (one strand on each side).
Connect lever blocks 5 to both ends of the wire 4
rope.
Install soft protectors 6 between the corner of side 3
frame 3 and wire rope 4 to prevent side frame 6
3 and wire rope 4 from damaging.
5. Hook two wire ropes 8 around the bracket of
bucket 7 . Connect the rope ends to lever block 5 .
Then, extend the front attachment slowly until the
wire ropes are no longer loose.
Place soft protector 6 between the bucket bracket
corner and wire rope to prevent the wire rope from
5 Fig. 4
damaging.
6. Retracting the side frame (track gauge)
To jack up the side frame, turn OFF the boom
mode switch and raise the machine just enough so
to lift the front attachment off the ground.
7. While lowering the boom, lift the side frame of the
extending side about 50mm off the ground. 6
If the side frame is lifted too high, the extension will 7
become large. 8
8. To equally extend the back (travel device side) and
front (front idler side) of side frame 3 , operate
lever block 5 until guide 10 of the side frame
touches the stopper of the track frame.
CAUTION:
If lever block 5 is disabled, it means that the
Fig. 5
resistance relative to the extension force is too large.
If this happens, don’t force it to move.
Lever block 5 and wire rope can damage or fly about,
causing fatal accidents or serious injuries.
Suspend the work and check that the front and back of
the side frame are extended to the same length and
that the frame has been raised to the appropriate
height.
Take the necessary modifications.
CAUTION:
5
After the side frame has been jacked up off the ground,
5
never operate the arm to extend side frame 3 .
Operating the arm will pull the wire rope due to excess
tension. 7
This can cause damage to the lever block or wire rope,
8
leading to fatal accidents or serious injuries.
Fig. 6
9. When guide 10 of the side frame touches the track

frame stopper, install side frame tightening bolts 1
＊ 1) and temporarily tighten with your hands. If ＊ 1) ZX470-5 class: 10 bolts x 2 locations, total: 18 bolts
there are difficulties to tighten with your hand, it ZX670LC-5 class: 11 bolts x 2 locations, total: 22 bolts
means that the bolt center and screw hole center ZX870-5 class: 11 bolts x 2 locations, total: 22 bolts
are not aligned.
Using a lever block, re-align the centers of the bolt
and screw hole.
228
ZX470-5 class
1
3
10
Fig. 7-a
ZX670LC-5 class 3
1
10
Fig. 7-b
ZX870-5 class 1
3
10
Fig. 7-c
229
CAUTION:
Be sure to operate the boom slowly. If you operate the
boom suddenly, the lever block and wire rope can
damage or fly about, causing fatal accidents or serious
injuries. Keep adequate distance from the machine
during boom operation.
10. Slightly loosen lever block 5 , lift the boom and

slightly lower track frame 2 .
If lever block 5 is excessively loosened at this
point, side frame 3 will retract and you will not be
able to re-tighten the temporarily tightened bolts
with your hand.
Keep the bolts slightly loose. In the same way, 5
Fig. 8
lower track frame 2 minimally.
11. After lowering track frame 2 slightly, re-tighten
with your hands (ratchet wrench) bolts 1 that were
temporarily tightened.
12. To lower track frame 2 , repeat steps 10 and 11 Ratchet wrench
three to four times until the track frame touches the
ground and retighten bolts 1 with your hands.
13. Loosen the lever block 5 . Remove the lever block
and wire ropes.
14. Using a power wrench and torque wrench, tighten
bolts 1 to the specified torque.
1
Fig. 9
IMPORTANT:
Be sure to apply a thin layer of lubricant to the bolt
threads.
15. Use the same procedure to extend the side frame

on the opposite side.
Power wrench
1
Fig. 10
Tightening torque
Model Bolt diameter Width across flats
(mm) N·m kgf·m lb·fb
ZX470-5 class M33-Pitch 3 50 1750 175 1291
ZX670LC-5 class M36-Pitch 3 55 2800 280 2065
ZX870-5 class M36-Pitch 3 55 2800 280 2065
230
ZX470-5 class
1
3
Fig. 11-a
ZX670LC-5 class 1
3
Fig. 11-b
ZX870-5 class 3
1
Fig. 11-c
231
3 Side frame retracting procedure
CAUTION:
Never loosen bolt 9 of the side frame guide.
IMPORTANT:
Using compressed air, clean the surfaces where track
frame 2 and side frame 3 are in contact and remove
the muck, sand and gravel.
Required tools:
Power boost wrench (includes attachments)
Torque wrench (width across flats: 55 mm)
Air compressor (for cleaning sliding surfaces)
1. Remove bolts 1 ＊ 1) from the retracting side ＊ 1) ZX470-5 class : 18 bolts

frame 3 . ZX670LC-5 class : 22 bolts
2. Retracting the side frame (track gauge) ZX870-5 class : 22 bolts
To jack up the side frame, turn OFF the boom
mode switch and raise the machine just enough so
to lift the front attachment off the ground.
3. Swing towards side frame 3 that will be retracted.
Position the superstructure so that it is at a straight
angle relative to the track link. Jack up side frame 3 .
4. Side frame 3 will slide due to the deadweight,
guide 10 will touch the stopper of track frame 2 ,
and the side frame will stop.
If the side frame doesn’t slide in this state, slowly
move to and fro the track link that is not touching
the ground.
IMPORTANT:
The angle between the boom and arm should be
between about 90 to 110 degrees. 90° ~ 110°
11
It should not be any tighter.
If side frame 3 still does not retract, lower the
superstructure and swing it 180 degrees. Use the front
About 15°
attachment to jack up the side track on the opposite
side about 15 degrees off the ground, slowly roll out Fig. 12
the arm and retract side frame 3 .
IMPORTANT:
Don’t jack up track 11 extensively or suddenly move
the arm operation lever. Doing so can damage the
track frame.
5. After sliding side frame 3 , slowly lower the

machine on the ground.
6. Tighten bolts 1 ＊ 2) of side frame 3 to the ＊ 2) ZX470-5 class : 3 bolts × 2 locations, total: 6 bolts
specified torque. ZX670LC-5 class : 4 bolts × 2 locations, total: 8 bolts
ZX870-5 class : 5 bolts × 2 locations, total: 10 bolts
For tightening torque, refer to pages 21, 72, 76, 83,
88 and 230.
7. Repeat the above steps 1 to 6 to retract the

opposite side.
232
ZX470-5 class
1 1
3 3
1
1
2 2
9 10
Fig. 13-a
ZX670LC-5 class
1 1
3 3
1
2 2
9 10 Fig. 13-b
ZX870-5 class 1
1
3
3
1
1
2
10
9 Fig. 13-c
233
Machine disassembly
It is necessary to disassemble the machine for transportation.
The disassembly procedure is the reverse of the assembly procedure.
Refer to the assembly instructions.
Long-distance travel
The machine has a maximum travel speed of 4.6km/h. Drive the machine over level surfaces as much as possible.
Avoid riverbeds or any other areas covered with rounded stones, as travelling over such surfaces can bend the track shoes.
For long-distance heavy transportation, pre-inspect the machine, and determine the quantity of traffic along the intended
route, the quality of the road surface and the width of the road.
If you are to cross any bridges, check for restrictions on heavy vehicles, and reinforce the bridge if it is not strong enough to
hold the machine.
Take due care when crossing railway lines, and lay planks or equivalent over the rails to avoid riding up directly onto the rails.
Notes:
i) Pre-inspect the undercarriage to avoid damage during long-distance travel.
ii) Use protective fittings on plates to avoid damaging the road surface. Be particularly careful when steering over
sealed road surfaces in the summer. Take care to avoid hitting overhead wires.
iii) If necessary, position a person in front of the machine to direct it.
iv) Cross rivers carefully, checking the river bottom regularly with the bucket.
Make sure not to exceed the maximum water depth.
234
ZX470-5 class/ZX670LC-5 class/ZX870-5 class of Assembly Manual
CHECKS
&
PERFORMANCE STANDARDS
CHECKING
236
9. Post-assembly Inspection
1 After assembly, clean and wipe each part
thoroughly with a rag.
2 Inspect the excavator

before starting the engine. CYLINDERS AND
HYDRAULIC LINES
Check for oil leaks.
Example:
ZX670LC-5 class
RESERVOIR
Check coolant level.
PINS AND BOLTS
Check for looseness
or absence.
RADIATOR
Clean fins.
OIL COOLER
Clean fins.
OPERATOR'S CAB
Clean.
HYDRAULIC OIL TANK

Check oil level.
ENGINE Fig. 1
Check oil level.
FINAL DRIVE
Check oil level.
Post-assembly inspection
1 Electrical system
Check for worn or frayed wire harnesses and
loose connections.
2 Boom, bucket, arm, frame, and tracks
Check for deformed, broken, or missing parts.
3 Hardware
Check for loose or missing parts.
4 Hydraulic system
Check for leaks, kinked hoses and lines, or hoses
that rub against each other or other parts.
5 Lubrication
Check the lubrication points listed in the Operation
Manual.
6 Protective devices
Check guards and fenders.
7 Check that the parts are correctly reassembled.
8 Apply touch-up paint if necessary, after
Fig. 2
completing assembly.
237
3 -a Inspecting the instruments (ZX-5B series)
Check the instruments immediately after starting the
engine.
1 2 3 4 5 6 7
IMPORTANT:
If a gauge does not operate correctly as shown below,
STOP THE ENGINE IMMEDIATELY and take all 17 8
necessary measures.
9
16
Basic Screen
15
1 - Work Mode Display
14
2 - Muffler Filter
10
3 - Power Mode Display
4 - Hour Meter, Clock
5 - Auto-Lubrication Display (Optional) 13
6 - Fan Reverse Display (Optional)
7 - Preheat Display
8 - Seat Belt Display
9 - Fuel Gauge
10 - Sub Meter
11 - Radio Display
12 - Air Conditioner Display
13 - Coolant Temperature Gauge 11
12
14 - Overload Alarm Display (Optional)
15 - Travel Mode Indicator
16 - Auto Shut-Down Display
17 - Auto-Idle Display Fig. 3-a
Fig. 4-a
238
3 -b Inspecting the instruments (ZX-5G series)
Check the instruments immediately after starting the
engine.
1 2 3 4 5 6
IMPORTANT:
If a gauge does not operate correctly as shown below,
STOP THE ENGINE IMMEDIATELY and take all 7
necessary measures.
8
Basic Screen
13
1 - Work Mode Display
2 - Auto-Idle Display
9
3 - Power Mode Display
4 - Auto-Lubrication Display (Optional)
5 - Hour Meter, Clock 12
6 - Preheat Display
7 - Seat Belt Display
8 - Fuel Gauge
9 - Sub Meter
10 - Radio Display
11 - Air Conditioner Display
12 - Coolant Temperature Gauge
13 - Travel Mode Indicator 10
11
Fig. 3-b
Fig. 4-b
239
4 Engine revolution measurement
Pass standard (ZX-5B series)
Standard
Item (new machine)
ZX470-5B series ZX670LC-5B series ZX870-5B series
Low idle 900 ± 50 900 ± 50 900 ± 50
Engine Auto idle 1 380 ± 50 1 180 ± 50 1 180 ± 50
revolution speed 1 680 ± 50 1 630 ± 50 1 630 ± 50
P mode
(min-1) High idle 1 800 ± 50 1 750 ± 50 1 750 ± 50
HP mode 2 100 ± 50 1 850 ± 50 1 850 ± 50
Pass standard (ZX-5G series)
Standard
Item (new machine)
Low idle 900 ± 100 900 ± 100 900 ± 100
Engine Auto idle 1 230 ± 100 1 250 ± 100 1 250 ± 100
revolution speed E mode 1 780 ± 100 1 820 ± 100 1 820 ± 100
(min-1) High idle P mode 1 785 ± 100 1 850 ± 100 1 850 ± 100
HP mode 1 785 ± 100 1 850 ± 100 1 850 ± 100
240
10. Checking Machine Performance
The figures and tolerances listed on the next page onward are
Note:
for new machines.
Measure each actuator speed after sufficiently
The measurements should be performed under the following
operating the machine.
conditions:
· Engine speed: Maximum
· Hydraulic oil temperature: 50° ± 5°C
· Site: Firm level ground
241
TRACK LINE OFF AMOUNT WHEN TRAVELING
Note:
Perform inspection over a broad, flat workspace.
If such a space is not available, the "TRACK LINK
SPEED FOR 3 FULL TURNS" check should be
used as an indication of track line off.
1 Preparation
Fig. 1
2 Measurement
1 Move both travel levers to the stroke end.

2 Measure the largest deviation distance "a"
between the machine trace and a line drawn
between the start and stop points of the machine,
as shown the Fig. 2.
a
m
20 . 6 ft)
(65
Bring machine to rest over

7~9m
(25 ~ 30 ft)
Fig. 2
3 Pass standard
Front
Unit: mm (in)
Item Standard FORWARD
Deviation distance
≦ 200 （7.8）
(High speed/low speed)
REVERSE
242
TRACK LINK SPEED FOR 3 FULL TURNS
1 Preparation
90° ~ 110°
Fig. 3
1 Mark any one of the track shoes on the side

where this test is to be performed.
2 Jack up the track to be tested. (Fig. 3)
2 Measurement
Front
1 Accelerate the engine to maximum speed.
2 Measure the time required to make three full FORWARD
turns.
3 Repeat this test for both tracks in the forward and
reverse directions.
REVERSE
3 Pass standard
Unit: sec.
Standard
ZX470-5 class ZX520LCH-5 ZX670LC-5 ZX870-5 class

Item class class
ZX470LC-5 ZX870LC-5
ZX470-5 ZX470LCH-5 ZX870-5 ZX870LCH-5
Fast
Track link speed/3 rev. 20.5±2.0 22.0±2.0 27.2±2.0 25.4±2.0 28.5±2.0 30.9±2.0
spead
Slow
Track link speed/3 rev. 28.5±2.0 30.5±2.0 35.4±2.0 36.7±2.0 42.0±2.0 45.5±2.0
spead
243
SWING SPEED FOR 3 FULL TURNS
1 Preparation
Fig. 4
2 Measurement
1 Set the swing control lever to full stroke.

2 Measure the time required for three full turns at a
constant speed.
Front
SWING RIGHT
Three full turns
SWING LEFT
Fig. 5
3 Pass standard
Unit: sec.
Standard
Item
Swing speed/3 rev. R 18.0±1.5 20.1±1.5 23.0±1.5
Swing speed/3 rev. L 18.0±1.5 20.1±1.5 23.0±1.5
244
AMOUNT OF COASTING DURING SWING
1 Preparation
Fig. 6
1 The arm cylinder should be fully extended.

2 The bucket cylinder should be fully retracted.
MEASURE THE DIFFERENCE
3 Place an aligning mark between the swing frame
and the track frame.
4 Swing the superstructure so that the swing frame
is at 90° to the track frame.
MARK ON THE FRAME

MARK ON THE SWING BEARING
Fig. 7
2 Measurement
1 Set the swing control lever to full stroke.

2 After swinging 180°, return the lever to the neutral
position.
3 Measure the amount of coasting.
Amount of
coasting
Swing stop
180° swing
Fig. 8
3 Pass standard
Unit: mm (in)
Standard
Item
Less than Less than Less than

R
1 377 (54.2) 1 035 (40.4) 1 512 (58.9)
Amount of coasting
L
1 377 (54.2) 1 035 (40.4) 1 512 (58.9)
245
CYLINDER SPEED (Backhoe front)
1 Action
Fig. 9
Fig. 10
2 Measurement
Repeat the time measurement at least 3 times for each

item and record the average time.
Fig. 11
3 Pass standard
Unit: sec.
Item ZX470-5 class ZX670LC-5 class ZX870-5 class
Raise 3.4±0.3 4.1±0.3 4.6±0.4

Boom cylinder Fig. 9
Lower 2.5±0.3 2.9±0.3 2.9±0.4
Roll-in 3.9±0.3 4.0±0.4 4.2±0.4

Arm cylinder Fig. 10
Roll-out 3.0±0.3 3.1±0.4 3.2±0.4
Roll-in 2.9±0.3 2.9±0.3 3.4±0.4

Bucket cylinder Fig. 11
Roll-out 2.2±0.3 2.5±0.4 2.8±0.4
246
AMOUNT OF HYDRAULIC CYLINDER CREEP
1 Preparation
With a full load in the bucket, set the front-end

attachment as shown below.
1 200 mm
(47 in)
Fig. 12
2 Measurement
Mark Mark
1 Stop the engine.
2 Measure the amount of creep over 5 minutes.
A−B = Natural lowering Fig. 13
3 Pass standard
Unit: mm
Backhoe Front
Item
Boom cylinder, mm/5min ≦15 ≦5 ≦–5
Arm cylinder, mm/5min ≦10 ≦10 ≦10
Bucket cylinder, mm/5min ≦15 ≦15 ≦–15
Natural lowering of front

attachment, mm/5 min. ≦100 ≦100 ≦100
4 Touch-up paint
After completing the field assembly, touch up the pain

as necessary.
247
248
11. Appendix (drawings of lifting parts)
11-1 ZX470-5 class superstructure lifting parts . . . . . . 251 ∼ 254
1 Assembly drawing (right-side bracket) 8123248 ∼ 1
2 Assembly drawing (left-side bracket) 8123249 ∼ 1
3 Spacer 4241784 ∼ 4
4 Bolt J833004 ∼ 2
5 Nut J953030 ∼ 2
11-2 ZX670LC-5 class superstructure lifting parts . . . . 255 ∼ 258
3 Spacer 4241784 ∼ 4
4 Bolt J833004 ∼ 2
5 Nut J953030 ∼ 2
11-3 ZX870-5 class superstructure lifting parts . . . . . . 259 ∼ 262
3 Spacer 4241784 ∼ 4
4 Bolt J833006 ∼ 2
5 Nut J953030 ∼ 2
11-4 Instructions for lifting the base machine assembly . . . 263 ∼ 265
249
Hold
Lifting the superstructure
WARNING:
1) Use a lifting wire ropes and other lifting sling that
are not damaged or worn and that are sufficiently
strong.
2) Contact the nearest Hitachi branch or sales office
to learn the correct way to lift, the size and types
of lifting wire ropes and lifting sling.
3) To lift, bring the lock lever to “Lock” position so
that the machine will not move involuntarily.
4) Any errors in the lifting method or wire rope sling
method can cause the machine to move during
lifting work and lead to fatalities and injuries or Superstructure lifting device
machine damage. Fig. 1
5) Do not apply sudden load to the lifting wire ropes
and lifting sling.
6) While lifting a load, never go under the machine
Hold
or stand/walk nearby.
Note:
A qualified worker undertakes sling work and lifting
work.
The superstructure stated here is a machine with no

counterweight, front attachment and side frames to be
disassembled.
To lift the base machine, use the lifting device found where the
counterweight is installed and also, the part to which the boom
cylinder is installed.
Boom cylinder installation part
Fig. 2
250
11-1 ZX470-5 class superstructure lifting parts
3 Spacer 4241784 ∼ 4
4 Bolt J833004 ∼ 2
5 Nut J953030 ∼ 2
251
Dimensional drawing
1. ZX470-5 class assembly drawing (right-side bracket)
Detail A
700
32
DWG. No.
Fig. 1 8123248
252
2. ZX470-5 class assembly drawing (left-side bracket)
Detail B
32
700
DWG. No.
Fig. 2 8123249
253
3. Spacer
Detail C
φ 70 t ＝ 16
φ 33
DWG. No.
Fig. 3 4241784
4. Bolt
Detail D
46 19 120
M30x3
DWG. No.
Fig. 4 J833004
5. Nut
Detail E
46 24
DWG. No.
M30x3
Fig. 5 J953030
254
11-2 ZX670LC-5 class superstructure lifting parts
3 Spacer 4241784 ∼ 4
4 Bolt J833004 ∼ 2
5 Nut J953030 ∼ 2
255
Dimensional drawing
1. ZX670LC-5 class assembly drawing (right-side bracket)
Detail A
800
DWG. No.
Fig. 1 8102865
256
2. ZX670LC-5 class assembly drawing (left-side bracket)
Detail B
32
800
1485
300
DWG. No.
Fig. 2 8102864
257
3. Spacer
Detail C
φ 70 t ＝ 16
φ 33
DWG. No.
Fig. 3 4241784
4. Bolt
Detail D
46 19 120
M30x3
DWG. No.
Fig. 4 J833004
5. Nut
Detail E
46 24
M30x3
DWG. No.
Fig. 5 J953030
258
11-3 ZX870-5 class superstructure lifting parts
3 Spacer 4241784 ∼ 4
4 Bolt J833006 ∼ 2
5 Nut J953030 ∼ 2
259
Dimensional drawing
1. ZX870-5 class assembly drawing (right-side bracket)
Detail A
900
200
1640
DWG. No.
Fig. 1 8102726
260
2. ZX870-5 class assembly drawing (left-side bracket)
Detail B
200
900
1640
DWG. No.
Fig. 2 8102725
261
3. Spacer
Detail C
φ 70 t ＝ 16
φ 33
DWG. No.
Fig. 3 4241784
4. Bolt
Detail D
46 19 130
M30x3
DWG. No.
Fig. 4 J833006
5. Nut
Detail E
46 24
M30x3 DWG. No.
Fig. 5 J953030
262
11-4 Instructions for lifting the base machine assembly
1 ZX470-5 class
Fig. 1
Fig. 2
263
2 ZX670LC-5 class
Fig. 3
264
3 ZX870-5 class
Fig. 4
265
NOTES
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266
267
FORWORD
These completed assembly check sheets are intended for use in

checking whether the machine has been assembled correctly and
completely.
All components requiring field assembly are illustrated in
perspective view, so that even an inexperienced serviceman will
be able to verify the assembly procedure easily.
We recommend that you use these check sheets to check all field
assembled sections.
Building up product quality Maintaining machine quality through

at the field assembly stage correct preventive maintenance
268
Report No. 01
COMPLETED ASSEMBLY CHECK

REPORT FOR THE ZX470-5 class/ZX670LC-5 class/ZX870-5 class
D / M / Y
Inspection date
Country: Machine Serial No.:

Customer name: Engine Serial No.:
Dealer name:
Inspected by :
Specifications
Front att. Date of Date of
Front att. Capacity Hour meter Inspection
S/No. Delivery
Boom m D/M/Y D/M/Y
Arm m
□ Backhoe front Bucket m3 Hours
(Hitachi use) (Hitachi use)
Type of work □ Mining ( □ Coal □ Coal Overburden □ Gold □ Other )

□ Stone Crushing □ Quarry
□ Civil Engineering Work □ Road Building □ Land Development
□ Pipelaying □ Other
□ Dredging
□ Other
ANY COMMENTS
269
Report No. 02
ZX470-5 class/ZX670LC-5 class/ZX870-5 class ASSEMBLY CHECK SHEET (1/4)

SATISFACTORY
UNSATISFACTORY
CORRECTED
Inspected by:
Undercarriage/Superstructure (1/2)
6-2 Connection of undercarriage and superstructure
Case A: In the case of ZX470- 5 class/ZX670LC- 5 class

6-2-1 Connecting the superstructure (with track center frame) and side frame
No. Step Page Checking item Mark
1 1 67 Preparing the side frame (right)
2 2 68 〜 69 Slinging the superstructure
3 3 70 〜 72 Connecting the superstructure and side frame (right)
4 4 73 〜 76 Connecting the superstructure and side frame (left)
5 5 77 〜 78 Removing the lifting sling
Case B: In the case of ZX870- 5 class

6-2-2 Connecting the track center frame and side frames
6 1 79 Preparing the side frame (right)
7 2 80 Preparing the track center frame
8 3 80 Slinging the track center frame
9 4 81 〜 83 Connecting the track center frame and side frame (right)
10 5 84 〜 88 Connecting the side frame (left) and track center frame
11 6 89 〜 90 Removing the wire rope
6-2-3 Connecting of undercarriage and superstructure

12 1 91 〜 92 Preparing the track center frame, cleaning and finish
13 2 93 Slinging the superstructure
14 3 94 Releasing the swing lock
15 4 95 〜 98 Superstructure and track center frame direct connection
16 5 99 Restoring the swing lock function (plug insertion)
17 6-1 100 Installing the stopper
18 6-2 100 Connecting the travel hoses
19 6-3 101 Connecting the pilot hose and drain hose
20 7 102 〜 104 Installing the pre-cleaners
21 8 105 〜 108 Installing the mufﬂer
ANY COMMENTS
270
Report No. 03

SATISFACTORY
UNSATISFACTORY
CORRECTED
Inspected by:
Undercarriage/Superstructure (2/2)
6-3 Connection of travel hoses and installation of steps, handrails

22 1 109 〜 111 Connecting the travel motor hoses
23 2 112 Installing the steps (for the side frame)
24 3 113 Installing the steps (for the superstructure)
25 4 114 〜 115 Installing the handrails
26 5-1 116 Installing the side mirror assemblys
27 5-2 116 Installing the wiper
28 5-3 116 Installing the headlights
29 6-1 117 Touch-up paint for the superstructure
30 6-2 117 Superstructure post-assembly check
6-4 Greasing of swing bearing

31 − 119 〜 120 Greasing (1)
6-5 Final check of the superstructure

32 1-1 121 Check the coolant level (FULL/LOW) inside the reservoir tank
33 1-2 122 Check the oil level in all the swing decelerator-use reducing gears
34 1-3 122 Check the oil level in the engine oil pan
35 1-4 122 Check the oil level in the final drive (both sides)
36 1-5 123 Check the fuel level inside the fuel tank
37 1-6 124 Check the oil level inside the pump transmission
38 1-7 125 Check the hydraulic oil tank level
39 2 126 Checking the battery
6-6 Releasing the air from the main pumps

40 − 127 Releasing the air from the main pumps
6-7 Trial operation of superstructure

41 − 129 Trial operation of superstructure
ANY COMMENTS
271
Report No. 04

SATISFACTORY
UNSATISFACTORY
CORRECTED
Inspected by:
Backhoe front (1/2)
7-2 Preparing to assemble the backhoe front

1 1 135 Preparing to assemble the base machine
2 2 135 〜 137 Installing the boom cylinders
3 3 138 Connecting the boom cylinder hoses
4 4 139 Bleeding the boom cylinders
5 5 140 Preparing to install the boom
6 6 141 〜 142 Preparing to install the arm
7 7 143 Preparing to install the bucket
7-3 Installing the boom

8 1 145 〜 147 Installing the boom
9 2 148 Connecting the hoses between the base machine and boom
10 3 149 〜 150 Connecting the boom cylinder rods
11 4 151 Connecting the boom cylinder grease hoses and electrical wiring
12 5 152 〜 153 Greasing (2)
13 6 154 Per-parathion bleeding the arm cylinder
14 7 155 〜 156 Air bleeding of arm cylinder
7-4 Installing the arm

15 1 157 〜 160 Installing the arm
16 2 161 〜 162 Installing the arm cylinder
17 3 163 Connecting the arm cylinder-use grease hose
18 4 164 〜 165 Connecting the bucket cylinder hoses and grease hose
19 5 166 〜 167 Greasing (3)
20 6 168 〜 169 Air bleeding of arm cylinder and bucket cylinder
ANY COMMENTS
272
Report No. 05

SATISFACTORY
UNSATISFACTORY
CORRECTED
Inspected by:
Backhoe front (2/2)
7-5 Installing the bucket

21 1 171 〜 177 Installing the bucket (Case 1)
21' 1' 179 〜 186 Installing the bucket (Case 2)
22 2 187 Installing the lights
23 3-1 188 Connection the boom cylinder-use auto lubrication hoses
24 3-2 188 Connecting the auto-lubrication hoses at the boom back
25 3-3 189 Connecting the auto-lubrication hoses between the boom and arm
26 4 190 〜 191 Greasing (4)
7-6 Installing the counterweight

27 1 193 〜 199 Installing the counterweight
28 2 200 Installing the rear monitor camera
7-7 Bleeding the all cylinders and checking for hoses interterence
29 1 201 〜 202 Bleeding the hydraulic cylinders
30 2 203 Checking for hoses interference
7-8 Adjusting the track link tension

31 – 205 〜 206 Adjusting the track link tension
7-9 Final trial operation check

32 1 207 After check
33 2 207 Final checks for the backhoe front-end
7-10 Applying grease to the backhoe front

34 – 209 〜 210 Applying grease to the backhoe front
ANY COMMENTS
273
Report No. 06
SATISFACTORY
IMPLEMENT SPEEDS
UNSATISFACTORY
CORRECTED
Inspected by:
The figures and tolerances listed below are for new machines.
For machines already in operation, a certain allowance is
permitted according to working conditions and the hourmeter
reading on the machine.
The measurements should be performed under the following
conditions:
1. TEST CONDITIONS
Pass standard (ZX-5B series)
Standard
Test Result
Item (new machine)
ZX470-5B series ZX670LC-5B series ZX870-5B series 　　　 °
C (°
F)
Low idle 900 ± 50 900 ± 50 900 ± 50
Auto idle 1 380 ± 50 1 180 ± 50 1 180 ± 50
Engine
(min-1)
High idle P mode 1 800 ± 50 1 750 ± 50 1 750 ± 50
HP mode 2 100 ± 50 1 850 ± 50 1 850 ± 50
Pass standard (ZX-5G series)

Standard
Test Result
Item (new machine)
ZX470-5G series ZX670LC-5G series ZX870-5G series 　　　 °
C (°
F)
Low idle 900 ± 100 900 ± 100 900 ± 100
Auto idle 1 230 ± 100 1 250 ± 100 1 250 ± 100
Engine
(min-1))
High idle P mode 1 785 ± 100 1 850 ± 100 1 850 ± 100
HP mode 1 785 ± 100 1 850 ± 100 1 850 ± 100
274
Report No. 07
SATISFACTORY
UNSATISFACTORY
CORRECTED
Inspected by:
2. TRACK LINE OFF AMOUNT WHEN TRAVELING
Unit: mm (in)
Working Time
Item Standard Test Pattern Evaluation
1 2 3 Avg.
Forward
High speed
Backward
Deviation distance ≦ 200（7.8）
Forward
Low speed
Backward
a
m
20 . 6 ft)
( 5
6
Bring machine to rest over

7~9m
(25 ~ 30 ft)
ANY COMMENTS
275
Report No. 08
SATISFACTORY
UNSATISFACTORY
CORRECTED
Inspected by:
3. TRACK LINK SPEED FOR 3 FULL TURNS
Unit: sec
Standard Working Time
ZX470-5 class ZX520LCH-5 ZX670LC-5 ZX870-5 class

Item class class Test Pattern Evaluation
ZX470LC-5 ZX870LC-5 1 2 3 Avg.
ZX470-5 ZX870-5
ZX470LCH-5 ZX870LCH-5
Forward
Backward
Fast Track link
20.5 ± 2.0 22.0 ± 2.0 27.2 ± 2.0 25.4 ± 2.0 28.5 ± 2.0 30.9 ± 2.0
Speed speed/3 rev.
Forward
Backward
Forward
Backward
Slow Track link
28.5 ± 2.0 30.5 ± 2.0 35.4 ± 2.0 36.7 ± 2.0 42.0 ± 2.0 45.5 ± 2.0
Speed speed/3 rev.
Forward
Backward
ANY COMMENTS
276
Report No. 09
SATISFACTORY
UNSATISFACTORY
CORRECTED
4. SWING SPEED FOR 3 FULL TURNS
Inspected by:
Three full turns
Unit: sec
Item Evaluation
ZX470-5 class ZX670LC-5 class ZX870-5 class 1 2 3 Avg.
Swing speed/3 rev. R 18.0 ± 1.5 20.1 ± 1.5 23.0 ± 1.5
Swing speed/3 rev. L 18.0 ± 1.5 20.1 ± 1.5 23.0 ± 1.5
5. AMOUNT OF COASTING DURING SWING
Amount
of coast
Swing stop Swing start
180° swing
Unit: mm (in)
Standard Coasting Amount
Item Evaluation
R
1 377 (54.2) 1 035 (40.4) 1 512 (58.9)
Amount of coasting
L
1 377 (54.2) 1 035 (40.4) 1 512 (58.9)
277
Report No. 10
SATISFACTORY
UNSATISFACTORY
CORRECTED
Inspected by:
6. CYLINDER SPEED (Backhoe front)
Unit: sec
Item Evaluation
Raise
Raise 3.4 ± 0.3 4.1 ± 0.3 4.6 ± 0.4
Lower Lower 2.5 ± 0.3 2.9 ± 0.3 2.9 ± 0.4
Roll-
3.9 ± 0.3 4.0 ± 0.4 4.2 ± 0.4
in
Roll-
3.0 ± 0.3 3.1 ± 0.4 3.2 ± 0.4
Arm Roll-in out
Arm Roll-out
Roll-
2.9 ± 0.3 2.9 ± 0.3 3.4 ± 0.4
Bucket
in
Roll-out
Roll-
2.2 ± 0.3 2.5 ± 0.4 2.8 ± 0.4
Bucket out
Roll-in
ANY COMMENTS
278
Report No. 11
SATISFACTORY
UNSATISFACTORY
CORRECTED
Inspected by:
7. AMOUNT OF HYDRAULIC CYLINDER CREEP
1 200 mm
(47 in)
Unit: mm
Criterion Measured Data
Item Backhoe Front Evaluation
1 2 3 Avg.
Boom cylinder, mm/5min ≦ 15 ≦5 ≦ –5
Arm cylinder, mm/5min ≦ 10 ≦ 10 ≦ 10
Bucket cylinder, mm/5min ≦ 15 ≦ 15 ≦ –15
Natural lowering of front

≦ 100 ≦ 100 ≦ 100
attachment, mm/5 min.
ANY COMMENTS
279
NOTES
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280
Head Office: 5-1, Koraku 2-chome, Bunkyo-ku.
Tokyo 112-0004 Japan
Telephone: Tokyo (03) 3830-8050
Facsimile: Tokyo (03) 3830-8202
Printed in Japan KG

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KO-493-01

ZX470 -5 class ZX670-5 class ZX870-5 class

ZX-5B series ZX870-5B series

Model Code: ZX470-5B / ZX470LC-5B / ZX470H-5B / ZX470LCH-5B / ZX470R-5B / ZX470LCR-5B

ZX670LC-5B series assembly procedure chart

Model Code: ZX670LCH-5B / ZX670LCR-5B

ZX870-5B series assembly procedure chart

Model Code: ZX870-5B / ZX870LC-5B / ZX870H-5B / ZX870LCH-5B / ZX870R-5B / ZX870LCR-5B

Model Code: ZX470-5G / ZX470LC-5G / ZX470H-5G / ZX470LCH-5G

ZX670LC-5G series assembly procedure chart

Model Code: ZX670LCR-5G / ZX670LCH-5G

ZX870-5G series assembly procedure chart

Model Code: ZX870-5G / ZX870LC-5G / ZX870H-5G / ZX870LCH-5G

1 RECOGNIZE SAFETY INFORMATION

Follow recommended precautions and safe operating

2 UNDERSTAND SIGNAL WORDS

DANGER indicates an imminently hazardous situation

WARNING indicates a potentially hazardous situation

CAUTION and NOTE provide cautionary remarks and

DANGER and WARNING safety signs are located near

To avoid confusing machine protection with personal

Safety signs should be installed, maintained, and

Learn how to operate the machine and its controls

Keep your machine in proper working condition.

4 DESIGNATE ONE LEADER AND TWO

5 CLEAN THE MACHINE REGULARLY

Do not spray water or steam inside the cab.

1 Deciding the signal method and supervisor

The signal method is decided by the driver and signal

To hang a wire rope over an angular material, put a

3 Cautionary remarks for load suspension

• Use a hook that comes with a stopper.

• Use a sling rope, suspension chain or nylon sling of

• Never pass a hanging load over someone’s head.

• Make sure that no one goes directly under the

4 Manual adjustment of the wire rope

Wear close fitting clothing and safety equipment

You may need:

8 PREPARE FOR EMERGENCIES

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance

9 PREPARE SUITABLE LIFTING TOOLS

11 SUPPORT RAISED EQUIPMENT

12 SAFETY AT HEIGHT Fig. 1-13

Falling is one of the major causes of personal injury.

Never jump on or off the machine. Never mount or

Be careful of slippery conditions on platforms, steps,

14 PREVENT BATTERY EXPLOSIONS

Never check the battery charge by placing a metal

Do not charge a frozen battery - it may explode. Warm

Disconnect the negative ground cable before working

• Avoid this hazard by relieving pressure before

• Search for leaks with a piece of cardboard, taking

• If an accident occurs, see a doctor familiar with this Fig. 1-18

Fig. 1-19 Fig. 1-20 Fig. 1-21

16 CHECK EQUIPMENT SAFETY

Wear a suitable hearing protective device such as

18 FASTEN YOUR SEAT BELT

Be sure to remain seated with seat belt securely

19 BEWARE OF EXHAUST FUMES

If you must operate in a building, be sure there is

Never lubricate or service the machine while it is