Construction Machine · Hitachi

Hitachi ZX490 Excavator Tuning and Power Upgrade

Name: Hitachi ZX490 Excavator Tuning and Power Upgrade
Brand: Hitachi

The Hitachi ZX490 is Hitachi's crawler excavator. The engine control unit (ECU) software is recalibrated on the machine's own original file; the original software is backed up.

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Hitachi ZX490 power remap

A power remap on the Hitachi ZX490 recalibrates the fuel quantity, injection timing, boost pressure and torque limiter maps. On an excavator the engine drives the hydraulic pumps directly; with more torque in reserve, rpm drops less when digging, slewing and travelling at the same time. The calibration respects the limits of the engine and the hydraulic system.

Hitachi ZX490 DPF, EGR and AdBlue fault solution

Excavators spend long periods idling and under light load; in these conditions the particulate filter (DPF) cannot clean itself, asks for frequent regeneration and blocks. The EGR valve and cooler collect soot; with a NOx sensor, pump or injector fault in the AdBlue (SCR) system the machine enters limp mode and work on site stops. The cause is diagnosed first; the software solution is applied according to the ECU type.

Hitachi ZX490 DPF Fault Solution Hitachi ZX490 EGR Fault Solution Hitachi ZX490 AdBlue Fault Solution

Construction Machine DPF Fault Solution Construction Machine EGR Fault Solution Construction Machine AdBlue Fault Solution

ECU and compatibility for the Hitachi ZX490

Services with a verified solution for Hitachi in our library: Stage 1 Remap, DPF Delete, EGR Delete and AdBlue / SCR Delete. The same model can carry a different ECU depending on build year and engine option, so we confirm compatibility for the Hitachi ZX490 from a photo of the ECU label or from the file read out.

Where is the difference noticed on the Hitachi ZX490?

Digging in hard ground and working with a breaker
Digging, slewing and moving the boom at the same time
Truck loading, where cycle time matters
At high altitude and in hot weather

Services available for Hitachi (excavator)

Stage 1 Remap

Software that optimises the engine's power and torque maps within safe limits.

DPF Delete

Software deactivation of the diesel particulate filter (DPF/FAP) functions and fault codes.

EGR Delete

Software deactivation of the exhaust gas recirculation (EGR) valve control and fault codes.

AdBlue / SCR Delete

Software deactivation of the AdBlue/SCR dosing system and its fault/warning functions.

Frequently asked questions

Which software services are available for the Hitachi ZX490?

Services with a verified solution for Hitachi in our library: Stage 1 Remap, DPF Delete, EGR Delete and AdBlue / SCR Delete. We confirm on the file which of them apply to the ECU fitted to your Hitachi ZX490.

How much power does the Hitachi ZX490 gain with a remap?

The gain depends on the engine option, the ECU type and the machine's power level within its range. Rather than quote a fixed figure, we read the original file first and tell you what increase is possible.

How do I find out which ECU my Hitachi ZX490 has?

The exact type is read from the label on the ECU or with a diagnostic tool. A photo of the label and the model year of the machine are enough.

How long does the job take, and can it be done on site?

Most ECUs are read and written through the diagnostic socket and the job is completed the same day; some units are removed and worked on the bench. Contact us for on-site service.

Can the original software be restored?

Yes. The original software is archived and the Hitachi ZX490 can be returned to its factory setting on request.

Why does the machine cut power when there is an AdBlue fault?

When the emission system detects a fault, the ECU first gives a warning; if the fault is not fixed it limits torque and engine speed in stages, and at the final stage the machine runs at idle only. This is how the system is designed to behave. Power returns once the cause is fixed or a software solution matching the ECU type is applied.

Why does DPF regeneration not complete in the field or on site?

Regeneration needs the exhaust temperature to stay high for a while; low load, idling and short work cycles do not provide that. Faults in the differential pressure sensor, the EGR or the injectors also stop regeneration. The soot load and sensor values are read first; depending on the cause we recommend a forced regeneration, cleaning or a software solution.

Does the EGR job give the machine more power?

The EGR job is not a power remap; no power gain should be expected from it alone. Because the loss of pull and the power reduction caused by a faulty EGR disappear, the machine returns to its factory output. If more power is wanted, a power remap is applied separately.

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