Hitachi ZX27U 30U 35U Excavator Workshop + Technical Manual
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Hitachi ZX27U 30U 35U Excavator Workshop + Technical Manual
This Listing includes all of the manuals mentioned below:
- Hitachi ZX27U 30U 35U Excavator Workshop Manual
- Hitachi ZX27U 30U 35U Excavator Technical Manual
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DESCRIPTION:
Hitachi ZX27U 30U 35U Excavator Workshop + Technical Manual
- This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
- The machine specification and description according to destination may be explained on this manual.
- Be sure to thoroughly read this manual for correct product information and service procedures.
- This manual consists the Technical Manual, the Workshop Manual and the Engine Manual.
- Information included in the Technical Manual: Technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.
- Information included in the Workshop Manual: Technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and assemble / disassemble procedures.
- Information included in the Engine Manual: Technical information needed for redelivery and delivery and maintenance and repair of the machine, operation and activation of all devices and systems, troubleshooting and assemble / disassemble procedures
- Safety Alert Symbol and Headline Notations In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage. d This is the safety alert symbol.
- When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights.
- To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.
TABLE OF CONTENTS:
Hitachi ZX27U 30U 35U Excavator Workshop Manual
INDEX…………………………………………………… 0
INDEX(ZX27U/30U/35U)……………………………………… 0
INTRODUCTION…………………………………………….. 1
SAFETY………………………………………………….. 3
SECTION 1 GENERAL INFORMATION……………………………… 33
Group 1 Precautions for Disassembling and Assembling……… 35
PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING…………. 35
Group 2 Tightening……………………………………. 43
TIGHTENING TORQUE SPECIFICATIONS……………………. 43
TORQUE CHART……………………………………… 44
PIPING JOINT……………………………………… 47
Group 3 Painting……………………………………… 53
PAINTING…………………………………………. 53
Group 4 Bleeding Air………………………………….. 55
BLEED AIR FROM HYDRAULIC OIL TANK…………………… 55
SECTION 2 UPPERSTRUCTURE………………………………….. 59
Group 1 Canopy……………………………………….. 61
REMOVE AND INSTALL CANOPY………………………….. 61
Group 2 Counterweight…………………………………. 63
REMOVE AND INSTALL COUNTERWEIGHT……………………. 63
Group 3 Pump Device…………………………………… 65
REMOVE AND INSTALL PUMP DEVICE……………………… 65
DISASSEMBLE PUMP DEVICE (ZAXIS27u)………………….. 69
ASSEMBLE PUMP DEVICE (ZAXIS27u)…………………….. 73
DISASSEMBLE PUMP DEVICE (ZAXIS30u, ZAXIS35u)…………. 77
ASSEMBLE PUMP DEVICE (ZAXIS30u, ZAXIS35u)……………. 79
MAINTENANCE STANDARDS……………………………… 83
Group 4 Control Valve…………………………………. 85
REMOVE AND INSTALL CONTROL VALVE……………………. 85
DISASSEMBLE AND ASSEMBLE CONTROL VALVE………………. 90
Group 5 Swing Device…………………………………..105
REMOVE AND INSTALL SWING DEVICE……………………..105
DISASSEMBLE SWING REDUCTION GEAR…………………….110
ASSEMBLE SWING REDUCTION GEAR……………………….114
DISASSEMBLE SWING MOTOR…………………………….118
ASSEMBLE SWING MOTOR……………………………….120
MAINTENANCE STANDARDS………………………………124
Group 6 Pilot Valve……………………………………125
REMOVE AND INSTALL FRONT/ SWING PILOT VALVE…………..125
DISASSEMBLE TRAVEL PILOT VALVE………………………134
ASSEMBLE TRAVEL PILOT VALVE…………………………138
DISASSEMBLE FRONT ATTACHMENT PILOT VALVE……………..142
ASSEMBLE FRONT ATTACHMENT PILOT VALVE………………..146
DISASSEMBLE BOOM SWING AND BLADE PILOT VALVE………….150
A SSEMBLE BOOM SWING AND BLADE PILOT VALVE……………152
Group 7 Solenoid Valve…………………………………155
REMOVE AND INSTALL SOLENOID VALVE……………………155
DISASSEMBLE AND ASSEMBLE SOLENOID VALVE………………157
SECTION 3 UNDERCARRIAGE……………………………………163
Group 1 Swing Bearing………………………………….165
REMOVE AND INSTALL SWING BEARING…………………….165
Group 2 Travel Device………………………………….167
REMOVE AND INSTALL TRAVEL DEVICE…………………….167
DISASSEMBLE TRAVEL REDUCTION
GEAR (27u)……………..172
ASSEMBLE TRAVEL REDUCTION GEAR (27u)…………………174
DISASSEMBLE TRAVEL MOTOR……………………………178
ASSEMBLE TRAVEL MOTOR………………………………180
DISASEMBLE BRAKE VALVE……………………………..184
ASSEMBLE BRAKE VALVE……………………………….186
DISASSEMBLE TRAVEL REDUCTION GEAR (ZAXIS30u 35u)……..188
DISASSEMBLE TRAVEL REDUCTIONGEAR (ZAXIS30u 35u)………192
DISASSEMBLE AND ASSEMBLE BRAKE
VALVE (ZAXIS30u 35u)….198
MAINTENANCE STANDARDS………………………………200
Group 3 Center Joint…………………………………..203
REMOVE AND INSTALL CENTER JOINT……………………..203
DISASSEMBLE CENTER JOINT……………………………210
ASSEMBLE CENTER JOINT………………………………212
Group 4 Track Adjuster…………………………………215
REMOVE AND INSTALL TRACK ADJUSTER……………………215
DISASSEMBLE TRACK ADJUSTER………………………….216
ASSEMBLE TRACK ADJUSTER…………………………….222
Group 5 Front Idler……………………………………227
REMOVE AND INSTALL FRONT IDLER………………………227
DISASSEMBLE AND ASSEMBLE FRONT IDLER………………..228
MAINTENANCE STANDARD……………………………….230
Group 6 Upper and Lower Roller………………………….231
REMOVE AND INSTALL LOWER ROLLER……………………..231
DISASSEMBLE AND ASSEMBLE LOWER
ROLLER……………….234
MAINTENANCE STANDARD……………………………….236
Group 7 Track…………………………………………237
REMOVE AND INSTALL TRACKS…………………………..237
MAINTENANCE STANDARD……………………………….239
SECTION 4 FRONT ATTACHMENT…………………………………243
Group 1 Front Attachment……………………………….245
REMOVE AND INSTALL FRONT ATTACHMENT………………….245
MAINTENANCE STANDARDS………………………………250
STANDARD DIMENSIONS FOR ARM AND BUCKET CONNECTION……..255
Group 2 Cylinder………………………………………257
REMOVE AND INSTALL CYLINDER…………………………257
DISASSEMBLE CYLINDER……………………………….274
ASSEMBLE CYLINDER………………………………….278
DISASSEMBLE Arm Cylinder……………………………284
Assemble Arm Cylinder………………………………288
DISASSEMBLE BUCKET CYLINDER…………………………292
ASSEMBLE BUCKET CYLINDER……………………………296
BOOM SWING CYLINDER………………………………..300
BOOM SWING CYLINDER AND BLADE CYLINDER……………….306
MAINTENANCE STANDARD……………………………….312
SECTION 5 ENGINE………………………………………….315
SECTION 1 General Information…………………………..317
GENERAL REPAIR INSTRUCTION………………………….318
NOTES ON THE FORMAT OF THIS MANUAL…………………..318
APPEARANCE………………………………………..321
MAIN DATA AND SPECIFICATIONS………………………..322
TIGHTENING TORQUE SPECIFICATIONS…………………….323
ANGULAR NUT AND BOLT TIGHTENING METHOD……………….325
TIGHTENING TORQUE ON MAJOR COMPONENTS………………..327
GASKET LOCATION……………………………………332
MAINTENANCE……………………………………….335
RECOMENDED LUBRICATION OIL………………………….340
SECTION 2 Engine………………………………………341
GENERAL VIEW OF ENJINE……………………………..342
DISASSEMBLY……………………………………….343
INSPECTION AND REPAIR………………………………356
REASSEMBLY………………………………………..370
SECTION 3 Lubrication System……………………………391
LUBRICATION OIL CIRCULATION SYSTEM DIAGRAM……………392
OIL PUMP………………………………………….393
SECTION 4 Cooling System……………………………….395
COOLING WATER CIRCULATION SYSTEM DIAGRAM……………..396
WATER PUMP………………………………………..397
THERMOSTAT………………………………………..400
SECTION 5 Fuel System………………………………….401
FUEL CIRCULATION SYSTEM DIAGRAM……………………..402
GOVERNOR………………………………………….403
NOZZLE HOLDER ASSEMBLY……………………………..411
SECTION 6 Troubleshooting………………………………413
SECTION 7 Special Tool…………………………………419
SECTION 8 Service Standard……………………………..421
SECTION 9 Conversion Table……………………………..423
LENGTH……………………………………………424
AREA……………………………………………..425
VOLUME……………………………………………425
MASS……………………………………………..427
PRESSURE………………………………………….428
TORQUE……………………………………………429
TEMPERATURE……………………………………….430
Hitachi ZX27U 30U 35U Excavator Technical Manual
INDEX………………………………………………………….. 0
INDEX(ZX27U/30U/35U)…………………………………………….. 0
INTRODUCTION……………………………………………………. 1
SAFETY…………………………………………………………. 3
SECTION 1 GENERAL……………………………………………….. 33
Group 1 Specification………………………………………… 35
SPECIFICATIONS…………………………………………… 35
WORKING RANGES AND MACHINE DIMENSIONS FOR TRANSPORTATION……… 38
Group 2 Component Layout……………………………………… 41
MAIN COMPONENTS………………………………………….. 41
ELECTRICAL SYSTEM………………………………………… 42
RELAYS………………………………………………….. 43
MONITOR AND SWITCHES……………………………………… 44
SOLENOID VALVE UNIT………………………………………. 44
Group 3 Component Specifications………………………………. 45
ENGINE………………………………………………….. 45
ENGINE ACCESSORIES……………………………………….. 48
HYDRAULIC COMPONENT………………………………………. 49
FILTER………………………………………………….. 55
ELECTRICAL COMPONENT……………………………………… 55
SECTION 2 SYSTEM………………………………………………… 59
Group 1 Hydraulic System……………………………………… 61
OUTLINE…………………………………………………. 61
PILOT CIRCUIT……………………………………………. 62
MAIN CIRCUIT…………………………………………….. 64
Group 2 Electrical System…………………………………….. 71
OUTLINE…………………………………………………. 71
POWER CIRCUIT (KEY SWITCH OFF)…………………………….. 72
BULB CHECK CIRCUIT ACCESSORY CIRCUIT (KEY SWITCH : ON)……….. 74
PREHEATING CIRCUIT (KEY SWITCH:ON)…………………………. 76
STARTING CIRCUIT (KEY SWITCH : START POSITION)………………. 78
CHARGING CIRCUIT (KEY SWITCH : ON)…………………………. 80
ENGINE STOP CIRCUIT (KEY SWITCH OFF)……………………….. 81
SECTION 3 COMPONENT OPERATION…………………………………….. 85
Group 1 Pump Device………………………………………….. 87
OUTLINE…………………………………………………. 87
MAIN PUMP (P1, P2)……………………………………….. 89
MAIN PUMP (P3), PILOT PUMP (P4) (30U,35U)…………………… 90
PILOT PUMP (P4) (27U)…………………………………….. 91
HORSE POWER CONTROL OPERATION……………………………… 92
Group 2 Swing Device…………………………………………. 95
OUTLINE…………………………………………………. 95
SWING MOTOR……………………………………………… 96
PARKING BRAKE……………………………………………. 97
VALVE UNIT………………………………………………. 98
SWING REDUCTION GEAR………………………………………100
Group 3 Control Valve…………………………………………103
OUTLINE………………………………………………….103
HYDRAULIC CIRCUIT…………………………………………112
ARM REGENERATIVE VALVE…………………………………….116
BOOM ANTI-DRIFT VALVE……………………………………..118
FLOW COMBINER VALVE……………………………………….120
FLOW COMBINING SELECTOR VALVE………………………………122
MAIN RELIEF VALVE…………………………………………123
OVERLOAD RELIEF VALVE……………………………………..124
MAKE-UP VALVE…………………………………………….126
Group 4 Pilot Valve…………………………………………..127
OUTLINE………………………………………………….127
OPERATION………………………………………………..130
Group 5 Travel Device…………………………………………139
OUTLINE………………………………………………….139
TRAVEL MOTOR……………………………………………..140
TRAVEL BRAKE VALVE………………………………………..141
TRAVEL REDUCTION GEAR……………………………………..152
Group 6 Others (Upperstructure)………………………………..153
SOLENOID VALVE UNIT……………………………………….153
PILOT RELIEF VALVE………………………………………..154
Group 7 Others (Undercarriage)…………………………………155
SWING BEARING…………………………………………….155
CENTER JOINT……………………………………………..156
TRACK ADJUSTER……………………………………………158
SECTION 4 OPERATIONAL PERFORMANCE TEST……………………………..161
Group 1 Introduction………………………………………….163
OPERATIONAL PERFORMANCE TEST……………………………….163
PREPARATION FOR PERFORMANCE TESTS…………………………..164
Group 2 Standard……………………………………………..165
OPERATIONAL PERFORMANCE STANDARD……………………………165
Group 3 Engine Test…………………………………………..169
ENGINE SPEED……………………………………………..169
ENGINE COMPRESSION PRESSURE………………………………..170
VALVE CLEARANCE…………………………………………..171
NOZZLE CHECK……………………………………………..172
INJECTION TIMING………………………………………….174
Group 4 Excavator Test………………………………………..175
TRAVEL SPEED……………………………………………..175
TRACK REVOLUTION SPEED…………………………………….176
MISTRACK CHECK……………………………………………177
TRAVEL MOTOR LEAKAGE………………………………………178
SWING SPEED………………………………………………179
SWING FUNCTION DRIFT CHECK…………………………………180
SWING MOTOR LEAKAGE……………………………………….181
MAXIMUM SWINGABLE SLANT ANGLE………………………………182
SWING BEARING PLAY………………………………………..183
HYDRAULIC CYLINDER CYCLE TIME………………………………184
DIG FUNCTION DRIFT………………………………………..186
CONTROL LEVER OPERATING FORCE………………………………187
CONTROL LEVER STROKE………………………………………188
Group 5 Component Test………………………………………..191
PRIMARY PILOT PRESSURE…………………………………….191
SECONDARY PILOT PRESSURE…………………………………..192
MAIN RELIEF VALVE SET PRESSURE……………………………..194
OVERLOAD RELIEF VALVE SET PRESSURE………………………….198
PUMP DRIVING TORQUE……………………………………….200
SWING MOTOR DRAINAGE………………………………………202
TRAVEL MOTOR DRAINAGE……………………………………..204
SECTION 5 TROUBLESHOOTING…………………………………………209
Group 1 Diagnosing Procedure…………………………………..211
INTRODUCTION……………………………………………..211
DIAGNOSING PROCEDURE………………………………………212
Group 2 Troubleshooting A……………………………………..215
TROUBLESHOOTING A PROCEDURE (DIAGNOSIS OF MACHINE BY SYMPTOM)….215
ENGINE SYSTEM TROUBLESHOOTING………………………………216
ACTUATOR OPERATING SYSTEM TROUBLESHOOTING……………………220
FRONT ATTATCHMENT SYSTEM TROUBLESHOOTING…………………….224
SWING SYSTEM TROUBLESHOOTING……………………………….228
TRAVEL SYSTEM TROUBLESHOOTING………………………………230
BLADE SYSTEM TROUBLESHOOTING……………………………….233
BOOM SWING SYSTEM TROUBLESHOOTING…………………………..234
HOW TO LOWER BOOM WHEN ENGINE STOPS…………………………235
Group 3 Troubleshooting B……………………………………..237
TROUBLESHOOTING B PROCEDURE
(DIAGNOSIS OF MONITOR)…………..237
MALFUNCTION OF COOLANT TEMPERATURE GAUGE…………………….238
MULFUNCTION OF FUEL GAUGE………………………………….240
MALFUNCTION OF ALTERNATOR INDICATOR…………………………242
MALFUNCTION OF ENGINE OIL PRESSURE NDICATOR………………….243
MALFUNCTION OF OVERHEAT INDICATOR…………………………..244
MALFUNCTION OF FUEL LEVEL INDICATOR…………………………245
MALFUNCTION OF BUZZER……………………………………..246
MALFUNCTION OF HOUR METER………………………………….247
Group 4 Electrical System Inspection……………………………249
PRECAUTIONS FOR INSPECTION AND MAINTENANCE…………………..249
FUSE CONTINUITY TEST………………………………………251
BATTERY VOLTAGE CHECK……………………………………..252
VOLTAGE CHECK…………………………………………….253
CONTINUITY CHECK………………………………………….254
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
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