Technical Manual Hitachi ZX27U-2, ZX30U-2, ZX35U-2 Excavator | KM-1MJ-E (2008.06.12)

Technical Manual Hitachi ZX27U-2, ZX30U-2, ZX35U-2 Excavator KM-1MJ-E (2008.06.12) (Preview)

INDEX
INTRODUCTION
SAFETY
CONTENTS
SECTION 1 GENERAL
Specifications
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 (ZAXIS 27U-2)
CONTROL VALVE (ZAXIS 30U-2, 35U-2)
TRAVEL DEVICE
2-UNIT SOLENOID VALVE
TORQUE CONTROL SOLENOID VALVE (ONLY MACHINE WITH AIR CONDITIONER ATTACHED), FLOW RATE SELECTOR SOLENOID VALVE (OPTIONAL)
Component Specifications
ENGINE
ENGINE ACCESSORIES
HYDRAULIC COMPONENT
FILTER
ELECTRICAL COMPONENT
SECTION 2 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)
SECTION 3 COMPONENT OPERATION
Pump Device
OUTLINE
MAIN PUMPS (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) AND FLOW SELECTOR SOLENOID VALVE (OPTIONAL)
Others (Undercarriage)
SWING BEARING
CENTER JOINT
TRACK ADJUSTER
SECTION 4 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)
SECTION 5 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 0.5 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 HORN BLOWING AT KEY SWITCH POSITION OF OFF
Troubleshooting C
TROUBLESHOOTING C PROCEDURE
MALFUNCTION OF COOLANT TEPERATURE GAUGE
MULFUNCTION 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
SERVICE MANUAL REVISION REQUEST FORM
THE ATTACHED DIAGRAM LIST