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Part of the Hitachi Repair Manuals.
Wrenching on a Hitachi ZAXIS450 or ZAXIS460LCH? This 628-page workshop manual PDF (OEM #W16J-E-01) covers the whole family: 450, 450H, 450LC, 450LCH, and 460LCH hydraulic excavators, cab to track frame. Inside: step-by-step disassembly and reassembly for the pump device, control valve, swing device, and travel unit, plus full sections on boom, arm, and bucket cylinders and the complete engine, from fuel and cooling down to the turbocharger. You get factory torque values and component weights for every major job, so nothing gets guessed. Torque the 19 mm center joint hose to 29.5 N-m and the 41 mm to 205 N-m, then plan your rigging around the 35 kg pump front casing. Forum threads won't give you those numbers. Bookmarked chapters and a real text layer mean you type a spec, jump to the page, and get back to wrenching.
What's Inside This Hitachi ZAXIS 450 / 460LCH Manual
| System | Pages | Key Topics |
|---|---|---|
| Workshop Manual | 1 | - |
| Introduction | 2-3 | Additional References, Manual Composition, Page Number, Safety Alert Symbol, Units Used |
| Safety | 4-33 | Safety Information, Signal Words, Safety Instructions, Emergency Procedures, Protective Clothing, Machine Inspection, Cab Precautions, Handholds and Steps |
| General Information | 34-61 | Precautions for Disassembling and Assembling |
| Upperstructure | 62-237 | Cab, Pump Device, Control Valve, Swing Device |
| Undercarriage | 238-341 | Travel Device |
| Front Attachment | 342-381 | Hydraulic Circuit Pressure Release, Boom Cylinder, Arm Cylinder, Bucket Cylinder, Bushing, Side Cutter, Point, Arm and Bucket Connection |
| Engine and Accessory | 382-628 | Engine Mechanical, Engine Cooling, Engine Fuel, Starting and Charging, Engine Lubrication, Engine Induction |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Hexagon wrench size for hydraulic oil tank cap | 4 mm | p. 58 |
| Air filter installation torque | 4.9 N·m (0.5 kgf·m, 3.6 lbf·ft) | p. 68 |
| Center joint hose connection torque (19 mm) | 29.5 N·m | p. 90 |
| Front casing weight | 35 kg (77 lb) | p. 102 |
| Sensor A (86) installation bolt torque (5 mm) | 9.8 N·m (1.0 kgf·m, 7.2 lbf·ft) | p. 110 |
| Sensor A (86) installation bolt torque (6 mm) | 29.4 N·m (3.0 kgf·m, 21.5 lbf·ft) | p. 110 |
| Cylinder head bolt M18 torque | 177 N·m (130 lb ft) -> 245 N·m (181 lb ft) -> 60° to 90° | p. 404 |
| Fuel filter replacement turn | 2/3 of a turn | p. 423 |
| Fuel Filter torque | 52 N·m | p. 441 |
| M18 bolt torque 1st step | 177 N·m | p. 459 |
| Clearance between impeller and pump body | 1.7 - 2.7 mm (0.0669 - 0.1063 in.) | p. 546 |
| Tightening torque for front cover bolt | 28 N·m (2.8 kgm) | p. 186 |
Hitachi ZAXIS 450 / 460LCH Common Problems This Manual Covers
Hitachi ZAXIS450 overheat alarm sounds during heavy digging, coolant temperature gauge climbing into the red
Check coolant level and blow chaff out of the radiator core first. Then pull the thermostat and test it in heated water: it must begin opening at 79°C (174°F) and reach full open at 95°C (203°F), specs on page 548. Replace a lazy thermostat and torque the housing bolts to 39 N·m.
Manual Section: Engine Cooling Trouble p. 548Engine cranks slowly on cold mornings, starter drags, sometimes will not fire at all
Test the batteries before touching anything else; this machine runs a 24V system, battery layout on page 580. Load-test both batteries and clean the ground cable connections, then start the engine and verify charging output from the 24V, 50A alternator listed on page 393. A weak alternator kills batteries slowly over weeks.
Manual Section: Engine Hard Starting p. 580Boom and arm respond slow and jerky after hydraulic oil change or hose replacement
Relieve tank pressure before opening anything: loosen the hydraulic oil tank cap slowly with a 4 mm hexagon wrench, procedure on page 58. Bleed trapped air from the system, then verify hose connections at the pump device; torque 19 mm fittings to 29.5 N·m and 36 mm fittings to 180 N·m per page 94.
Manual Section: Upperstructure p. 94Engine down on power under load with black exhaust smoke, idles fine
Replace the fuel filter first: coat the gasket with clean fuel, spin the filter on until the gasket seats, then tighten an additional 2/3 of a turn with the filter wrench, procedure on page 423. Pull the air filter element and check for clogging; torque the element back down to 4.9 N·m on reinstall.
Manual Section: Engine Insufficient Power p. 423Engine stuck at idle, throttle dial does nothing, occasional stalling or hard hot restarts
Check the EC motor and EC sensor before condemning the fuel system; these control engine speed and cause idle-only behavior, stalling, and hard starting. Inspect connectors for corrosion and test the harness for continuity. When reinstalling the sensor, torque the 5 mm installation bolts to 9.8 N·m and the 6 mm bolts to 29.4 N·m, shown on page 110.
Manual Section: Upperstructure p. 110Frequently Asked Questions
What are the replacement specifications for the air filter element?
The air filter element is a maintenance item. According to the manual, you should remove the air filter (7) and install a new one into the duct (9) during the installation procedure for the cab. p. 68
What is the tightening torque for the fuel tank mounting bolts?
The tightening torque for the fuel tank mounting bolts (No. 5) is 210 N·m (21.5 kgf·m, 155 lbf·ft). p. 46
What is the standard valve clearance for the engine?
The standard valve clearance for both intake and exhaust valves is 0.40 mm (0.0016 in) when the engine is cold. p. 393
What is the procedure for bleeding air from the hydraulic pump?
To bleed air from the hydraulic pump, remove the air bleeding plug from the top of the pump and fill the pump housing with hydraulic oil. Temporarily tighten the plug, start the engine, and run at slow idle speed. Slightly loosen the plug until hydraulic oil oozes out, then securely tighten the plug. p. 39
What is the tightening torque for the cylinder head bolts?
The cylinder head bolts (M18) require a three-step tightening process: 1st step 177 N·m (18 kgm), 2nd step 245 N·m (25 kgm), and 3rd step 60-90 degrees. p. 460
What do I get after purchasing this Hitachi ZAXIS450 manual?
This is a 628-page searchable PDF ready for immediate download. Works on any device, so pull it up on your phone while you're under the hood. No shipping, no waiting.
Is this Hitachi ZAXIS450 Workshop Manual printable?
Absolutely. No DRM or copy protection. Print the whole manual or just the pages you need. Any home or office printer works.
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