PDF Technical Workshop Manual Hitachi ZX870-5G Excavator - 2 MB
This is a complete technical library for the Hitachi ZX870-5G series hydraulic excavator, including LCH and LCR models.
The bundle contains the Workshop Manual, Troubleshooting Manual, and Operational Principle Manual.
This collection provides service technicians with an unparalleled level of detail for diagnostics, repair, and understanding the machine's complex systems.
It's the ultimate resource for performing any service task, from simple adjustments to complete overhauls, with factory precision.
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--- Page 1 ---
PART NO. TOJBE-EN-00
ZX870-5G • 870LC-5G • 870H-5G • 870LCH-5G • 870LCR-5G HYDRAULIC EXCAVATOR TECHNICAL MANUAL OPERATIONAL PRINCIPLE
Technical Manual
Operational Principle
ZX
870-5G
870LC-5G
870H-5G
870LCH-5G
URL:http://www.hitachi-c-m.com 870LCR-5G
Hydraulic Excavator
TOJBE-EN-00
Service Manual consists of the following separate Part No.
Technical Manual (Operational Principle) : Vol. No.TOJBE-EN
Technical Manual (Troubleshooting) : Vol. No.TTJBE-EN
PRINTED IN JAPAN (K) 2011, 11 Workshop Manual : Vol. No.WJBE-EN
--- Page 3 ---
SECTION 1 GENERAL
Group 1 Specifications
Specifications
ZX870-5G, 870LC-5G
A C
G
L
B F
E
D
K J MJAC-12-007
I H
Model ZX870-5G ZX870LC-5G
Type of Front-End Attachment - 3.7 m Arm
Bucket Capacity (Heaped) m3 3.4 (3.0: CECE) 3.5 (3.1: CECE)
Operating Weight kg 80800 82600
Base Machine Weight kg 61100 62900
Engine - 360 kW/1800 min-1 (490 PS/1800 rpm)
A: Overall Width mm 4450
B: Cab Height mm 3690
C: Rear End Swing Radius mm 4600
D: Minimum Ground Clearance mm *890
E: Counterweight Clearance mm *1680
F: Engine Cover Height mm 3630
G: Overall Width of Upperstructure mm 4120
H: Undercarriage Length mm 5840 6360
I: Undercarriage Width (Extended/ Retracted) mm 4100/3480
J: Sprocket Center to Idle Center mm 4590 5110
K: Track Shoe Width mm 650 (Grouser shoe)
L: Overall Height mm 4290
Ground Pressure kPa (kgf/cm2) 121 (1.23) 112 (1.14)
Swing Speed min-1 (rpm) 7.4
Travel Speed (fast/slow) km/h 4.5/3.0
Gradeability % (Degree) 70 (35)
fNOTE: *The dimensions do not include the height of the shoe lug.
T1-1-1
--- Page 4 ---
SECTION 1 GENERAL
Group 2 Component Layout
Electrical System (Switch Panel)
1 2
3
16
4
15
5
6
13 14 7
8
9
23
22
21
12 11 10
20
19
17 18
TJAA-01-02-003 TDAA-05-02-059
1- Return to Previous Screen 7- Auto-Idle Switch 14- Wiper/Washer Switch 20- Auto-Lubrication Switch
Switch 8- Travel Mode Switch 15- AUTO/OFF Switch/Blower (Optional)
2- Return to Basic Screen/Level 9- Work Light Switch Switch 21- Swing Alarm Cancel Switch
Switch 10- Power Mode Switch 16- Temperature Control Switch/ (Optional)
3- Selector/Set Switch 11- Key Switch MODE Switch 22- Rear Work Light Switch
4- AM·FM Switch/Tuning Switch 12- TEN-key Switch 17- Travel Alarm Cancel Switch (Optional)
5- Power Switch/Volume Control 13- Overhead Window Wiper/ (Optional) 23- Beacon Light Switch (Optional)
Switch Overhead Window Washer 18- Seat Heat Switch (Optional)
6- Engine Control Dial Switch (Option) 19- Boom Mode Selector Switch
T1-2-5
--- Page 5 ---
SECTION 1 GENERAL
Group 2 Component Layout
A
A
a
TJAA-03-06-004
Section A-A
1
7 2
6 3
5 4
T178-03-06-002
a- Pilot Valve Side
1- Shockless Valve 3- Pump 1 Flow Rate Control 5- Swing Parking Brake Release 7- Auxiliary
2- Arm Flow Rate Control Valve Valve Spool
Control Spool 4- Flow Combiner Valve Control 6- Pump 2 Flow Rate Control
Spool Valve
T1-2-15
--- Page 6 ---
SECTION 1 GENERAL
Group 3 Component Specifications
Hydraulic Component
PUMP DEVICE Drive Gear Ratio Pump1 and 2: 57/53
Fan Pump: 1
Pilot Pump: 1
MAIN PUMP Type Variable Displacement Swash Plate Tandem Plunger Pump
Theoretical Displacement 270 cm3/rev (18.3 in3/rev)×2
Rated Pressure 31.9 MPa (325 kgf/cm2, 4627 psi)
REGULATOR Type Pump Control Solenoid Valve Operated Type
FAN PUMP Type Variable Displacement Swash Plate Plunger Pump
Maximum Flow 100.8 L/min (27 US gpm)
(Theoretical Value)
REGULATOR Type Pump Control Solenoid Valve Operated Type
PILOT PUMP Type SGP1A27F2H5-R693
Model Fixed Displacement Type Gear Pump
Theoretical Displacement 27.8 cm3/rev (1.7 in3/rev)×2
CONTROL VALVE Type Pilot Pressure Operated Type (4-Spools + 5-Spools)
Main Relief Set-Pressure Normal: 31.9 MPa (325 kgf/cm2, 4627 psi) at 365 L/min (96 US gpm)
Increases Pressure: 34.3 MPa (350 kgf/cm2, 4975 psi) at 500 L/min (132
US gpm)
Overload Relief Set- 35.3 MPa (360 kgf/cm2, 5120 psi) at 110 L/min (29 US gpm) (Boom,
Pressure Arm, Bucket)
33.3 MPa (340 kgf/cm2, 4830 psi) at 110 L/min (29 US gpm) (Auxiliary
Open , Auxiliary Close)
T1-3-7
--- Page 7 ---
SECTION 2 SYSTEM
Group 1 Controller
Outline
The following controllers are provided in this machine in
order to control functions. Each controller excluding the
communication controller communicates by using the
CAN circuit and sends or receives the required signal.
Controller Control Comment on
Control
MC Controls the engine, pumps, and valves. T2-2
ECF Controls the actual engine speed. T2-2
Monitor Controller Displays the operating information and alarms on the monitor. T5-2
Wiper / Light Controller Controls the wipers and work lights. T2-4
Air Conditioner Controller Controls the air conditioner. T2-4, T5-7
Radio Controller Controls the radio. T2-4
Communication Controller Sends the mails and operating information. T5-4
fNOTE: Refer to the corresponding group for details of
each controller control.
T2-1-1
--- Page 8 ---
SECTION 2 SYSTEM
Group 2 Control System
2
1 3 14
4
5
6
7
38
8
9
10
11
37 12 16
15
36
17
35
13
34 19 23 25 26
18 24
33 22
20
32
31 27
21 30
TJAC-02-02-002
29 28
1- Hydraulic Oil Temperature 10- Pressure Sensor (4-Spool Side) 21- Governor Lever 30- Pump 1 Control Pressure
Sensor 11- Pressure Sensor (5-Spool Side) 22- Engine Sensor
2- Pressure Sensor (Boom Raise) 12- Pressure Sensor (Attachment) 23- Coolant Temperature Sensor 31- Travel Mode Switch
3- Pressure Sensor (Boom Lower) (OP) 24- N Sensor 32- Slow Speed Position
4- Pressure Sensor (Arm Roll-In) 13- MC 25- Pump 1 Delivery Pressure 33- Fast Speed Position
5- Pressure Sensor (Arm Roll-Out) 14- MPDr. Sensor 34- Auto-Idle Switch
6- Pressure Sensor (Bucket 15- Monitor Controller 26- Pump 2 Delivery Pressure 35- Power Mode Switch
Roll-In) 16- Monitor Sensor 36- Engine Control Dial
7- Pressure Sensor (Bucket Roll- 17- CAN 27- Pump 2 Control Solenoid Valve 37- Key Switch
Out) 18- ECF 28- Pump 2 Control Pressure 38- Pilot Shut-Off Switch
8- Pressure Sensor (Swing) 19- EC Sensor Sensor
9- Pressure Sensor (Travel) 20- EC Motor 29- Pump 1 Control Solenoid Valve
T2-2-7
--- Page 9 ---
SECTION 2 SYSTEM
Group 2 Control System
2
1 3 14
4
5
6
7
38
8
9
10
11
37 12 16
15
36
17
35
13
34 19 23 25 26
18 24
33 22
20
32
31 27
21 30
TJAC-02-02-007
29 28
1- Hydraulic Oil Temperature 10- Pressure Sensor (4-Spool Side) 21- Governor Lever 30- Pump 1 Control Pressure
Sensor 11- Pressure Sensor (5-Spool Side) 22- Engine Sensor
2- Pressure Sensor (Boom Raise) 12- Pressure Sensor (Attachment) 23- Coolant Temperature Sensor 31- Travel Mode Switch
3- Pressure Sensor (Boom Lower) (OP) 24- N Sensor 32- Slow Speed Position
4- Pressure Sensor (Arm Roll-In) 13- MC 25- Pump 1 Delivery Pressure 33- Fast Speed Position
5- Pressure Sensor (Arm Roll-Out) 14- MPDr. Sensor 34- Auto-Idle Switch
6- Pressure Sensor (Bucket 15- Monitor Controller 26- Pump 2 Delivery Pressure 35- Power Mode Switch
Roll-In) 16- Monitor Sensor 36- Engine Control Dial
7- Pressure Sensor (Bucket Roll- 17- CAN 27- Pump 2 Control Solenoid Valve 37- Key Switch
Out) 18- ECF 28- Pump 2 Control Pressure 38- Pilot Shut-Off Switch
8- Pressure Sensor (Swing) 19- EC Sensor Sensor
9- Pressure Sensor (Travel) 20- EC Motor 29- Pump 1 Control Solenoid Valve
T2-2-17
--- Page 10 ---
SECTION 2 SYSTEM
Group 2 Control System
Pump Control System Layout
14
1
2
3
4
5
6 16
7
8
34 9
10
11 15
12
33
32
17
31
13 20 21 22 23
30
18
19
24
27
26 25
35
29
28
TJBE-02-02-001
1- Hydraulic Oil Temperature 9- Pressure Sensor (Travel) 19- Engine 27- Pump 1 Control Pressure
Sensor 10- Pressure Sensor (4-Spool Side) 20- Coolant Temperature Sensor Sensor
2- Pressure Sensor (Boom Raise) 11- Pressure Sensor (5-Spool Side) 21- N Sensor 28- To Main Relief Valve
3- Pressure Sensor (Boom Lower) 12- Pressure Sensor (Attachment) 22- Pump 1 Delivery Pressure 29- 4-Spool Solenoid Valve Unit
4- Pressure Sensor (Arm Roll-In) (OP) Sensor 30- Auto-Idle Switch
5- Pressure Sensor (Arm Roll-Out) 13- MC 23- Pump 2 Delivery Pressure 31- Power Mode Switch
6- Pressure Sensor (Bucket 14- MPDr. Sensor 32- Engine Control Dial
Roll-In) 15- Monitor Controller 24- Pump 2 Control Solenoid Valve 33- Key Switch
7- Pressure Sensor (Bucket Roll- 16- Monitor 25- Pump 2 Control Pressure 34- Pilot Shut-Off Switch
Out) 17- CAN Sensor 35- Fan Pump Control Solenoid
8- Pressure Sensor (Swing) 18- ECF 26- Pump 1 Control Solenoid Valve Valve
T2-2-27
--- Page 11 ---
SECTION 2 SYSTEM
Group 2 Control System
14
1
2
3
4
5
6 16
7
8
34 9
10
11 15
12
33
32
17
31
13 20 21 22 23
30
18
19
24
27
26 25
35
29
28
TJBE-02-02-006
1- Hydraulic Oil Temperature 9- Pressure Sensor (Travel) 19- Engine 27- Pump 1 Control Pressure
Sensor 10- Pressure Sensor (4-Spool Side) 20- Coolant Temperature Sensor Sensor
2- Pressure Sensor (Boom Raise) 11- Pressure Sensor (5-Spool Side) 21- N Sensor 28- To Main Relief Valve
3- Pressure Sensor (Boom Lower) 12- Pressure Sensor (Attachment) 22- Pump 1 Delivery Pressure 29- 4-Spool Solenoid Valve Unit
4- Pressure Sensor (Arm Roll-In) (OP) Sensor 30- Auto-Idle Switch
5- Pressure Sensor (Arm Roll-Out) 13- MC 23- Pump 2 Delivery Pressure 31- Power Mode Switch
6- Pressure Sensor (Bucket 14- MPDr. Sensor 32- Engine Control Dial
Roll-In) 15- Monitor Controller 24- Pump 2 Control Solenoid Valve 33- Key Switch
7- Pressure Sensor (Bucket Roll- 16- Monitor 25- Pump 2 Control Pressure 34- Pilot Shut-Off Switch
Out) 17- CAN Sensor 35- Fan Pump Control Solenoid
8- Pressure Sensor (Swing) 18- ECF 26- Pump 1 Control Solenoid Valve Valve
T2-2-37
--- Page 12 ---
SECTION 2 SYSTEM
Group 2 Control System
14
1
2
3
4
5
6 16
7
8
34 9
10
11 15
12
33
32
17
31
13 20 21 22 23
30
18
19
37
38 24
27
36
26 25
35
29
28
TJBE-02-02-011
1- Hydraulic Oil Temperature 10- Pressure Sensor (4-Spool Side) 21- N Sensor 29- 4-Spool Solenoid Valve Unit
Sensor 11- Pressure Sensor (5-Spool Side) 22- Pump 1 Delivery Pressure 30- Auto-Idle Switch
2- Pressure Sensor (Boom Raise) 12- Pressure Sensor (Attachment) Sensor 31- Power Mode Switch
3- Pressure Sensor (Boom Lower) (OP) 23- Pump 2 Delivery Pressure 32- Engine Control Dial
4- Pressure Sensor (Arm Roll-In) 13- MC Sensor 33- Key Switch
5- Pressure Sensor (Arm Roll-Out) 14- MPDr. 24- Pump 2 Control Solenoid Valve 34- Pilot Shut-Off Switch
6- Pressure Sensor (Bucket 15- Monitor Controller 25- Pump 2 Control Pressure 35- Fan Pump Control Solenoid
Roll-In) 16- Monitor Sensor Valve
7- Pressure Sensor (Bucket Roll- 17- CAN 26- Pump 1 Control Solenoid Valve 36- Air Conditioner Unit
Out) 18- ECF 27- Pump 1 Control Pressure 37- Ambient Temperature Sensor
8- Pressure Sensor (Swing) 19- Engine Sensor 38- CAN1
9- Pressure Sensor (Travel) 20- Coolant Temperature Sensor 28- To Main Relief Valve
T2-2-47
--- Page 13 ---
SECTION 2 SYSTEM
Group 2 Control System
15
14
1 17
2 16
3
4
5 20 21
6
7 18
43 8
9
10
11
12 19
42
41 25 23
22
40 13
39 24
38 27 28
26
37
36
35
29
34
32
31 30
33