Technical Manual Hitachi ZX40U-2, ZX50U-2 Excavator T1M9-E-01 (Preview)
T1M9-E-01
INTRODUCTION
CONTENTS
SAFETY
RECOGNIZE SAFETY INFORMATION
UNDERSTAND SIGNAL WORDS
FOLLOW SAFETY INSTRUCTIONS
PREPARE FOR EMERGENCIES
WEAR PROTECTIVE CLOTHING
PROTECT AGAINST NOISE
INSPECT MACHINE DAILY
TIDY UP INSIDE CAB
U
SE HANDHOLDS AND STEPS
ADJUST THE OPERATOR’S SEAT
FASTEN YOUR SEAT BELT
MOVE AND OPERATE MACHINE SAFELY
OPERATE ONLY FROM OPERATOR’S SEAT
JUMP STARTING
KEEP RIDERS OFF MACHINE
INVESTIGATE JOB SITE BEFOREHAND
PROVIDE SIGNALS FOR JOBS INVOLVING
MULTIPLE NUMBERS OF MACHINES
CONFIRM DIRECTION OF MACHINE TO BE
DRIVEN
DRIVE MACHINE SAFELY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
KEEP PERSONNEL CLEAR FROM WORKING
AREA
NEVER POSITION BUCKET OVER ANYONE
AVOID UNDERCUTTING
AVOID TIPPING
NEVER UNDERCUT A HIGH BANK
DIG WITH CAUTION
OPERATE WITH CAUTION
AVOID POWER LINES
DO NOT USE FOR CRANING OPERATIONS
P
ROTECT AGAINST FLYING DEBRIS
PARK MACHINE SAFELY
H
ANDLE FLUIDS SAFELY — AVOID FIRES
SAFETY TRANSPORTING
PRACTICE SAFE MAINTENANCE
WARN OTHERS OF SERVICE WORK
SUPPORT MACHINE PROPERLY
STAY CLEAR OF MOVING PARTS
PREVENT PARTS FROM FLYING
STORE ATTACHMENTS SAFELY
PREVENT BURNS
REPLACE RUBBER HOSES PERIODICALLY
AVOID HIGH-PRESSURE FLUIDS
PREVENT FIRES
EVACUATING IN CASE OF FIRE
BEWARE OF EXHAUST FUMES
PRECAUTIONS FOR WELDING AND GRINDING
AVOID HEATING NEAR PRESSURIZED FLUID
LINES
AVOID APPLYING HEAT TO LINES
CONTAINING FLAMMABLE FLUIDS
REMOVE PAINT BEFORE WELDING OR
HEATING
PREVENT BATTERY EXPLOSIONS
PRECAUTIONS FOR HANDLING REFRIGERANT
HANDLE CHEMICAL PRODUCTS SAFELY
DISPOSE OF WASTE PROPERLY
BEFORE RETURNING THE MACHINE TO THE
CUSTOMER
SECTION 1 GENERAL
Group 1 Specification
SPECIFICATIONS
WORKING RANGES
Group 2 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)
Group 3 Component Specifications
ENGINE
ENGINE ACCESSORIES
HYDRAULIC COMPONENT
FILTER
ELECTRICAL COMPONENT
SECTION 2 SYSTEM
Group 1 Control System
OUTLINE
ENGINE CONTROL
PUMP CONTROL
OTHER CONTROL
Group 2 Hydraulic System
OUTLINE
PILOT CIRCUIT
MAIN CIRCUIT
Group 3 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
Group 1 Pump Device
OUTLINE
MAIN PUMP P1
POWER CONTROL
FLOW RATE CONTROL
PS VALVE
Group 2 Revolution Sensing Valve
OUTLINE
OPERATION
Group 3 Swing Device
OUTLINE
SWING MOTOR
PARKING BRAKE
VALVE UNIT
SWING REDUCTION GEAR
Group 4 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
Group 5 Pilot Valve
OUTLINE
OPERATION
SHOCKLESS FUNCTION (ONLY FOR TRAVEL PILOT VALVE)
SHUTTLE VALVE (ONLY FOR TRAVEL PILOT VALVE)
Group 6 Travel Device
OUTLINE
TRAVEL REDUCTION GEAR
TRAVEL MOTOR
TRAVEL BRAKE VALVE
PARKING BRAKE
Group 7 Others (Upperstructure)
2-UNIT SOLENOID VALVE
PILOT RELIEF VALVE
BACK PRESSURE VALVE
AUXILIARY FLOW SELECTOR VALVE (OPTIONAL)
Group 8 Others (Undercarriage)
SWING BEARING
CENTER JOINT
TRACK ADJUSTER
SECTION 4 OPERATIONAL PERFORMANCE TEST
Group 1 Introduction
OPERATIONAL PERFORMANCE TEST
PREPARATION FOR PERFORMANCE TESTS
Group 2 Standard
OPERATIONAL PERFORMANCE STANDARD
MAIN PUMP P-Q DIAGRAM
Group 3 Engine Test
ENGINE SPEED
ENGINE COMPRESSION PRESSURE
VALVE CLEARANCE
NOZZLE CHECK
INJECTION TIMING
Group 4 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
Group 5 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 (PRESSURE PGR)
PUMP DELIVERY PRESSURE
PUMP DRIVING TORQUE
AUXILIARY FLOW SELECTOR VALVE (OPTION)
Group 6 Adjustment
GOVERNOR ADJUSTMENT
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
INTRODUCTION
DIAGNOSING PROCEDURE
Group 2 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)
Group 3 Troubleshooting B
TROUBLESHOOTING B PROCEDURE (DIAGNOSIS OF MACHINE BY SYMPTOM)
ENGINE SYSTEM TROUBLESHOOTING
ACTUATOR OPERATING SYSTEM TROUBLESHOOTING
FRONT ATTACHMENT SYSTEM TROUBLESHOOTING
SWING SYSTEM TROUBLESHOOTING
TRAVEL SYSTEM TROUBLESHOOTING
BLADE SYSTEM TROUBLESHOOTING
BOOM SWING SYSTEM TROUBLESHOOTING
AIR CONDITIONER SYSTEM TROUBLESHOOTING (Cab Version Only)
WORK AFTER REPLACING COMPONENTS
CHARGE AIR CONDITIONER WITH REFRIGERANT
PURGING PROCEDURE
WARM-UP OPERATION
INSPECTION
HOW TO LOWER BOOM WHEN ENGINE STOPS
HOW TO PREVENT HORN BLOWING AT KEY SWITCH POSITION OF OFF
Group 4 Troubleshooting C
TROUBLESHOOTING C PROCEDURE (DIAGNOSIS OF MONITOR)
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
Group 5 Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND MAINTENANCE
FUSE CONTINUITY TEST
BATTERY VOLTAGE CHECK
VOLTAGE CHECK
CONTINUITY CHECK
THE ATTACHED DIAGRAM LIST
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