Hitachi Zaxis 40U-2 50U-2 Workshop Manual manuals in PDF

Factory Service Repair Manuals Set For Hitachi Zaxis 40U-2, 50U-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: 1208
Bookmarks: Yes
Searchable: Yes
Wiring Diagrams: Yes
Hydraulic Diagrams: Yes

Model

Hitachi 40u-2, 50u-2

Contents

1.Technical Manual
2.Circuits
3.Workshop manual
4.Training Text(Operational Principle)
5.Training Text(Performance Check & Troubleshooting)

1.Technical Manual
INTRODUCTION
SAFETY
-GENERAL
–SPECIFICATION
Specifications
Working Ranges
–COMPONENT LAYOUT
Main Components
Electrical Component Layout (Overview)
Electrical System (Controllers and Relays)
Electrical System (Monitor and Switches)
Engine
Swing Device
Travel Device
Control Valve
2-Unit Solenoid Valve
Revolution Sensing Valve / Pilot Filter
Auxiliary Flow Selector Valve (Optional)
–COMPONENT SPECIFICATIONS
Engine
Engine Accessories
Hydraulic Component
Filter
Electrical Component
-SYSTEM
–CONTROL SYSTEM
Outline
Engine Control
Pump Control
Other Control
–HYDRAULIC SYSTEM
Outline
Pilot Circuit
Main Circuit
–ELECTRICAL SYSTEM
Outline
Electric Power Circuit (key Switch : OFF)
Electric Power Circuit (Key Switch : ON)
Preheat 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
Power Control
Flow Rate Control
PS Valve
–REVOLUTION SENSING VALVE
Outline
Operation
–SWING DEVICE
Outline
Swing Motor
Parking Brake
Valve Unit
Swing Reduction Gear
–CONTROL VALVE
Outline
Hydraulic Circuit
Main Relief Valve
Overload Relief Valve
Make-Up Valve
Boom Anti-Drift Valve
Unload Valve
Differential Reducing Valve
Pressure Compensator
–PILOT VALVE
Outline
Operation
Shockless Function (Only for Travel Pilot Valve)
Shuttle Valve (Only for Travel Pilot Valve)
–TRAVEL DEVICE
Outline
Travel Reduction Gear
Travel Motor
Travel Brake Valve
Parking Brake
–OTHERS (UPPERSTRUCTURE)
2-Unit Solenoid Valve
Pilot Relief Valve
Back Pressure Valve
Auxiliary Flow Selector Valve (Optional)
–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
–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
Swing Motor Drainage
Travel Motor Drainage
Revolution Sensing Valve Output Pressure
Pump Delivery Pressure
Pump Driving Torque
Auxiliary Flow Selector Valve Pressure (Optional)
–ADJUSTMENT
Governor Adjustment

2.Circuits(T1M9-E-01 circuit)
ZAXIS40U-2/50U-2 HYDRAULIC CIRCUIT DIAGRAM
ZAXIS30U-2/35U-2/40U-2/50U-2 ELECTRICAL CIRCUIT DIAGRAM
ZAXIS30U-2/35U-2/40U-2/50U-2 FLOOR HAR-NESS
ZAXIS30U-2/35U-2/40U-2/50U-2 AIR CONDI-TIONER HARNESS (FLOOR) (Cab Version Only)
ZAXIS40U-2/50U-2 MAIN HARNESS
ZAXIS40U-2/50U-2 ENGINE HARNESS
ZAXIS40U-2/50U-2 BATTERY HARNESS (1), (2)
ZAXIS40U-2/50U-2 BOOM LIGHT HARNESSZAXIS30U-2/35U-2/40U-2/50U-2 CANOPY LIGHT HARNESS
ZAXIS30U-2/35U-2/40U-2/50U-2 AUTO-IDLE PRESSURE SENSOR HARNESS
ZAXIS30U-2/35U-2/40U-2/50U-2 IMMOBILIZER HARNESS (Optional)
ZAXIS30U-2/35U-2/40U-2/50U-2 TRAVEL ALARM HARNESS (FLOOR) (Optional)
ZAXIS40U-2/50U-2 TRAVEL ALARM HARNESS (ALARM) (Optional)
ZAXIS30U-2/35U-2/40U-2/50U-2 AIR CONDI-TIONER HARNESS (SOLENOID VALVE) (Cab Version Only)
ZAXIS30U-2/35U-2/40U-2/50U-2 AIR CONDI-TIONER HARNESS (COMPRESSOR) (Cab Ver-sion Only)
ZAXIS30U-2/35U-2/40U-2/50U-2 AUXILIARY FLOW SELECTOR VALVE (SWITCH) (Optional)
ZAXIS30U-2/35U-2/40U-2/50U-2 AUXILIARY FLOW SELECTOR VALVE (SOLENOID VALVE) (Optional)

2.Workshop Manual
INTRODUCTION
SAFETY
-GENERAL INFORMATION
–PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING
Precautions for Disassembling and Assembling
Maintenance Standard Terminology
–TIGHTENING
Tightening Torque Specifications
Torque Chart
Piping Joint
Periodic Replacement of Parts
–PAINTING
Painting
–BLEEDING AIR
Bleed Air from Hydraulic Oil Tank
–FLOOR-TILTING DEVICE
Floor-Tilting Device Operetion 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 Standard
–CONTROL VALVE
Remove and Install Control Valve
Disassemble And Assemble Control Valve
Remove and Install Relief Valve and Make-up Valve
Disassemble and Assemble Body
Disassemble Unload Section
Assemble Unload Section
Disassemble and Assemble Spool
Disassemble and Assemble Boom Anti-Drift Valve
Disassemble and Assemble Shuttle Valve and Pressure Compensation Valve
–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 Front Pilot Valve
Assemble Front Pilot Valve
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
–SOLENOID VALVE
Remove and Install 2-Unit Solenoid Valve
Disassemble 2-Unit Solenoid Valve
Assemble 2-Unit Solenoid Valve
Remove and Install 1-Unit Solenoid Valve
Structure of 1-Unit Solenoid Valve
–REVOLUTION SENSING VALVE
Remove and Install
Revolution Sensing Valve
Disassemble Revolution Sensing Valve
Assemble Revolution Sensing Valve
–AUXILIRY FLOW SELECTOR VALV< (OPTIONAL) Remove and Install Auxiliary Flow Selector Valve Disassemble Auxiliary Flow Selector Valve Assemble Auxiliary Flow Selector Valve -UNDERCARRIAGE --SWING BEARING Remove and Install Swing Bearing --TRAVEL DEVICE Remove and Install Travel Device Disassemble Travel Device Assemble Travel Device Disassemble and Assemble Brake Valve Maintenance Standard --CENTER JOINT Remove and Install Center Joint Disassemble Center Joint Assemble Center Joint --TRACK ADJUSTER Remove and Install Track Adjuster Disassemble Track Adjuster Disassemble Track Adjuster --FRONT IDLER Remove and Install Front Idler Disassemble and Assemble Front Idler Maintenance Standard --UPPER AND LOWER ROLLER Remove and Install Upper Roller Remove and Install Lower Roller Disassemble and Assemble Lower Roller Maintenance Standard --TRACK Remove and Install Rubber Track Maintenance Standard -FRONT ATTACHMENT --FRONT ATTACHMENT Remove and Install Front Attachment Maintenance Standards --CYLINDER Remove and Install Cylinders Disassemble Boom Cylinder Assemble Boom Cylinder Disassemble Arm Cylinder Assemble Arm Cylinder Disassemble Bucket Cylinder Assemble Bucket Cylinder Disassemble Boom Swing Cylinder Assemble Boom Swing Cylinder 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 For 4TNV94L/ 98 For 4TNV106 (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 4.Training Text(Operational Principle) -GENERAL --SPECIFICATION Specifications Working Ranges --COMPONENT Layout Main Components Electrical Component Layout (Overview) Electrical System (Controllers and Relays) Electrical System (Monitor and Switches) Engine Swing Device Travel Device Control Valve 2-Unit Solenoid Valve Revolution Sensing Valve / Pilot Filter Auxiliary Flow Selector Valve (Optional) --COMPONENT SPECIFICATIONS Engine Engine Accessories Hydraulic Component Filter Electrical Component -SYSTEM --CONTROL SYSTEM Outline Engine Control Pump Control Other Control --HYDRAULIC SYSTEM Outline Pilot Circuit Main Circuit --ELECTRICAL SYSTEM Outline Electric Power Circuit (key Switch : OFF) Electric Power Circuit (Key Switch : ON) Preheat 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 Power Control Flow Rate Control PS Valve --REVOLUTION SENSING VALVE Outline Operation --SWING DEVICE Outline Swing Motor Parking Brake Valve Unit Swing Reduction Gear --CONTROL VALVE Outline Hydraulic Circuit Main Relief Valve Overload Relief Valve Make-Up Valve Boom Anti-Drift Valve Unload Valve Differential Reducing Valve Pressure Compensator --PILOT VALVE Outline Operation Shockless Function (Only for Travel Pilot Valve) Shuttle Valve (Only for Travel Pilot Valve) --TRAVEL DEVICE Outline Travel Reduction Gear Travel Motor Travel Brake Valve Parking Brake --OTHERS (UPPERSTRUCTURE) 2-Unit Solenoid Valve Pilot Relief Valve Back Pressure Valve Auxiliary Flow Selector Valve (Optional) --OTHERS (UNDERCARRIAGE) Swing Bearing Center Joint Track Adjuster 5.Training Text(Performance Check & Troubleshooting) -OPERATIONAL PERFORMANCE TEST --INTRODUCTION Operational Performance Test Preparation for Performance Tests --STANDARD Operational Performance Standard Main Pump P-Q Diagram --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 Swing Motor Drainage Travel Motor Drainage Revolution Sensing Valve Output Pressure Pump Delivery Pressure Pump Driving Torque Auxiliary Flow Selector Valve Pressure (Optional) --ADJUSTMENT Governor Adjustment -TROUBLESHOOTING --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 What you get

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