Hitachi Zaxis 27U-2 30U-2 35U-2 Workshop Manual manuals in PDF

$29.00

Factory Service Repair Manual For Hitachi Zaxis 27U-2 30U-2 35U-2 Excavators. Tons of illustrations, instructions, diagrams for step by step remove and install, assembly and disassembly, service, inspection, repair, troubleshooting, tune-ups.

Photo 9 - Hitachi Zaxis 27U-2 30U-2 35U-2 Workshop Manual
Hitachi Zaxis 27U-2 30U-2 35U-2 Workshop Manual $29.00
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Factory Service Repair Manual For Hitachi Zaxis 27U-2 30U-2 35U-2 Excavators. Tons of illustrations, instructions, diagrams for step by step remove and install, assembly and disassembly, service, inspection, repair, troubleshooting, tune-ups.

Format: PDF
Language: English
Pages: 551
Bookmarks: Yes
Searchable: Yes
Number: KM-1MJ-E
Wiring Diagrams: Yes
Hydraulic Diagrams: Yes

Model

Hitachi 27U-2, 30U-2, 35U-2

Contents

1.Diagrams
2.Technical Manual
3.Workshop Manual

Workshop Manual

  • -GENERAL INFORMATION
    –PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING
    Precautions for Disassembling and Assembling
    –TIGHTENING
    Tightening Torque Specification
    Torque Chart
    Piping Joint
    Periodic Replacement of Parts
    –PAINTING
    Painting
    –BLEEDING AIR
    Bleed Air from Hydraulic Oil Tank
    –FLOOR-TILTING DEVICE
    Floor-Tilting Device Operation
    Procedure
    Procedure for Floor Tilting up
    Procedure for Floor Tilting down
  • -UPPERSTRUCTURE
    –CANOPY
    Remove And Install Canopy
    –COUNTERWEIGHT
    Remove And Install
    Counterweight
  • -PUMP DEVICE
    Remove And Install
    Pump Device
    Disassemble Pump Device
    Assemble Pump Device
    Maintenance Standards
    –CONTROL VALVE
    Remove And Install Control Valve
    Disassemble And Assemble
    Control Valve
    Disassemble And Assemble Body
    Disassemble Boom Anti-Drift Valve
    Assemble Boom Anti-Drift Valve
    Disassemble And Assemble Spool
    Disassemble And Assemble Arm
    Regenerative Valve, Check Valve And Orifice
    –SWING DEVICE
    Remove and Install
    Swing Device
    Disassemble Swing Device
    Assemble Swing Device
    Disassemble Swing Motor
    Assemble Swing Motor
    Maintenance Standards
    –PILOT VALVE
    Remove and Install Front Pilot Valve
    Remove and Install Travel Pilot Valve
    Remove and Install Blade Pilot Valve
    Remove and Install Boom Swing
    Pilot Valve
    Disassemble Right and Left
    Pilot Valves
    Assemble Right and Left Pilot Valves
    Disassemble Travel Pilot Valve
    Assemble Travel Pilot Valve
    Disassemble Pilot Valves for
    Boom Swing, Blade and Auxiliary
    Assemble Pilot Valves for
    Boom Swing, Blade and Auxiliary
    Group 7 Solenoid Valve
    Remove and Install Solenoid Valve
    Disassemble 2-Unit Solenoid Valve
    Assemble 2-Unit Solenoid Valve
    1-Unit Solenoid Valve
    Structure of 1-Unit Solenoid Valve
  • -UNDERCARRIAGE
    –SWING BEARING
    Remove and Install Swing Bearing
    –TRAVEL DEVICE
    Remove and Install Travel Device
    Disassemble Travel Device
    Assemble Travel Device
    Disassemble Travel Motor
    Assemble Travel Motor
    Disassemble and Assemble
    Brake Valve
    Maintenance Standards
    –CENTER JOINT
    Remove and Install Center Joint (ZAXIS27U-2)
    Disassemble Center Joint (ZAXIS27U-2)
    Assemble Center Joint(ZAXIS27U-2)
    Remove and Install Center Joint (ZAXIS30U-2, 35U-2)
    Disassemble Center Joint (ZAXIS30U-2, 35U-2)
    Assemble Center Joint (ZAXIS30U-2, 35U-2)
    –TRACK ADJUSTER
    Remove and Install Track Adjuster
    Disassemble Track Adjuster
    Assemble Track Adjuster
    –FRONT IDLER
    Remove and Install Front Idler
    Disassemble and Assemble Front Idler
    Maintenance Standards
    –UPPER AND LOWER ROLLER
    Remove and Install Upper Roller
    Remove and Install Lower Roller
    Disassemble and Assemble
    Lower Roller
    Maintenance Standards
    –TRACK
    Remove and Install Tracks
    Maintenance Standards
  • -FRONT ATTACHMENT
    –FRONT ATTACHMENT
    Remove and Install Front Attachment
    Maintenance Standards
    Standard Dimensions for Arm and Bucket Connection
    –CYLINDER
    Remove and Install Cylinders
    Disassemble Boom and Arm Cylinders
    Assemble Boom and Arm Cylinders
    Disassemble Bucket and Boom Swing Cylinders
    Assemble Bucket and Boom Swing Cylinders
    Disassemble Blade Cylinder
    Assemble Blade Cylinder
    Maintenance Standards
  • -ENGINE AND ACCESSORY
    –GENERAL
    Engine Nomenclature
    Specifications
    Fuel Oil, Lubricating Oil and Cooling Water
    Engine External Views
    Structural Description
    Exhaust Gas Emission Regulation
    –INSPECTION AND ADJUSTMENT
    Periodic Maintenance Schedule
    Periodic Inspection and Maintenance Procedure
    Adjusting the No-load Maximum or Minimum Speed
    Sensor Inspection
    Water Leak Check in
    Cooling Water System
    Radiator Cap Inspection
    Thermostat Inspection
    Adjusting Operation
    Long Storage
    –TROUBLESHOOTING
    Preparation before Troubleshooting
    Quick Reference Table for Troubleshooting
    Troubleshooting by Measuring
    Compression Pressure
    –DISASSEMBLY, INSPECTION AND REASSEMBLY OF ENGINES
    Complete Disassembly and Reassembly
    Cylinder Head: Disassembly Inspection and Reassembly
    Gear Train and Camshaft
    Cylinder Block
    –LUBRICATION SYSTEM
    Lubrication System Diagram
    Trochoid Pump Components
    Disassembly (Reverse the Procedure below for Assembly)
    Servicing Points
    Parts Inspection and Measurement
    –COOLING SYSTEM
    Cooling Water System
    Cooling Water Pump Components
    Disassembly (Reverse the Procedure below for Assembly)
    Servicing Points
    –FUEL INJECTION PUMP / GOVERNOR
    Introduction
    Fuel Injection Pump
    –TURBOCHARGER: DISASSEMBLY, INSPECTION AND REASSEMBLY
    Structure and Functions
    Service Standards and Tightening Torque
    Periodic Inspection Procedure
    Disassembly Procedure
    Washing and Inspection Procedure
    Reassembly Procedure
    Handling after Disassembly and Reassembly
    Troubleshooting
    –STARTING MOTOR
    For4TNV94L/98
    For4TNV106(T)
    –ALTERNATOR
    The 40A Alternator for 3TNV84 and Other Models
    –ELECTRIC WIRING
    Electric Wiring Diagram
    Precaution on Electric Wiring
    –SERVICE STANDARDS
    Engine Tuning
    Engine Body
    Lubricating Oil System (Trochoid Pump)
    –TIGHTENING TORQUE FOR BOLTS AND NUTS
    Tightening Torques for Main Bolts and Nuts
    Tightening Torques for Standard
    Bolts and Nuts

Technical Manual

  • INTRODUCTION
    SAFETY
  • -GENERAL
    –SPECIFICATION
    Specifications
    Working Ranges and Machine Dimensions for Transportation
    –COMPONENT LAYOUT
    Main Component Layout
    Electrical Component Layout (Overview)
    Electrical System (Controllers and Relays)
    Electrical System (Monitor and Switches)
    Engine
    Swing Device
    Control Valve (ZAXIS27U-2)
    Control Valve (ZAXIS30U-2, 35U-2)
    Travel Device
    2-Unit Solenoid Valve
    Torque Control Solenoid Valve (Only Machine with Air Conditioner Attached)/ Flow Selector Solenoid Valve (Optional)
    –COMPONENT SPECIFICATIONS
    Engine
    Engine Accessories
    Hydraulic Component
    Filter
    Electrical Component
  • -SYSTEM
    –CONTROL SYSTEM
    Outline
    Engine Control
    Pump Control
    Front Attachment Control
    Other Control
    –HYDRAULIC SYSTEM
    Outline
    Pilot Circuit
    Main Circuit
    –ELECTRICAL SYSTEM
    Outline
    Power Circuit (key Switch : OFF)
    Power Circuit (Key Switch : ON)
    Preheating Circuit (Key Switch : HEAT)
    Starting Circuit (Key Switch : START)
    Charging Circuit (Key Switch : ON)
    Engine Stop Circuit (Key Switch : OFF)
  • -COMPONENT OPERATION
    –PUMP DEVICE
    Outline
    Main Pump (P1, P2)
    Main Pump (P3), Pilot Pump (P4)
    Horse Power Control Operation
    –SWING DEVICE
    Outline
    Swing Motor
    Parking Brake
    Valve Unit
    Swing Reduction Gear
    –CONTROL VALVE
    Outline
    Hydraulic Circuit
    Arm Regenerative Valve
    Boom Anti-Drift Valve
    Flow Combiner Valve
    Flow Rate Combining Selector Valve
    Main Relief Valve
    Overload Relief Valve
    Make-Up Valve
    –PILOT VALVE
    Outline
    Operation
    Shockless Function (Only for Travel Pilot Valve)
    Shuttle Valve (Optional)
    –TRAVEL DEVICE
    Outline
    Travel Motor
    Parking Brake
    Travel Brake Valve
    Travel Reduction Gear
    –OTHERS (UPPERSTRUCTURE)
    2-Unit Solenoid Valve
    Pilot Relief Valve
    Torque Control Solenoid Valve (Only Machine with Attached Air Conditioner)/ Flow Selector Solenoid Valve (Optional)
    Group 7 Others (Undercarriage)
    Swing Bearing
    Center Joint
    Track Adjuster
  • -OPERATIONAL PERFORMANCE TEST
    –INTRODUCTION
    Operational Performance Test
    Preparation for Performance Tests
    –STANDARD
    Operational Performance Standard
    Main Pump P-Q Diagram (ZAXIS27U-2)
    Main Pump P-Q Diagram (ZAXIS30U-2, 35U-2)
    –ENGINE TEST
    Engine Speed
    Engine Compression Pressure
    Valve Clearance
    Nozzle Check
    Injection Timing
    –EXCAVATOR TEST
    Travel Speed
    Track Revolution Speed
    Mistrack Check
    Travel Motor Leakage
    Swing Speed
    Swing Function Drift Check
    Swing Motor Leakage
    Maximum Swingable Slant Angle
    Swing Bearing Play
    Hydraulic Cylinder Cycle Time
    Dig Function Drift
    Control Lever Operating Force
    Control Lever Stroke
    Combined Boom Raise/Swing
    Function Check
    –COMPONENT TEST
    Primary Pilot Pressure
    Secondary Pilot Pressure
    Main Relief Valve Set Pressure
    Overload Relief Valve Set Pressure
    Pump Driving Torque
    Swing Motor Drainage’
    Travel Motor Drainage’
    –ADJUSTMENT
    Fuel Lever Adjustment (ZAXIS27U-2 Only)
  • -TROBLESHOOTING
    –DIAGNOSING PROCEDURE
    Introduction
    Diagnosing Procedure
    –TROUBLESHOOTING A
    Troubleshooting A Procedure
    Error Indication List
    Wire Breakage and Short Circuit of Engine Control Dial (System Failure Indicator: Flickering Every 1 Sec)
    Motor Sensor Breakage and Short Circuit (System Failure Indicator: Flickering Every 05 Sec)
    Abnormal Motor (System Failure Indicator: Lit)
    –TROUBLESHOOTING B
    Troubleshooting B Procedure
    Engine System Troubleshooting
    Actuator Operating System Troubleshooting
    Front Attachment System Troubleshooting
    Swing System Troubleshooting
    Travel System Troubleshooting
    Blade System Troubleshooting
    Boom Swing System Troubleshooting
    How to Lower Boom when Engine Stops
    How to Prevent Hom Blowing at Key Switch Position of OFF
    –TROUBLESHOOTING C
    Troubleshooting C Procedure
    Malfunction of Coolant Temperature Gauge
    Malfunction of Fuel Gauge
    Malfunction of Preheat Indicator
    Malfunction of Alternator Indicator
    Malfunction of Engine Oil Pressure Indicator
    Malfunction of Overheat Indicator
    Malfunction of Fuel Level Indicator
    Malfunction of Monitor Buzzer
    Malfunction of Liquid Crystal Display (LCD)
    Malfunction of Hour Meter
    Malfunction of Auto-Idle Indicator
    –ELECTRICAL SYSTEM INSPECTION
    Precautions for Inspection and Maintenance
    Fuse Continuity Test
    Battery Voltage Check
    Voltage Check
    Continuity Check

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