Service Manual Hitachi ZAXIS ZX10U-2 / ZX8-2 Excavator

Service Manual (Manual No. KM-1MR-E) for Hitachi Zaxis 10U-2 and 8-2 Hydraulic Excavator consisting of the following separate Volumes: Technical Manual : Vol. No. T1MR-E (T1MR-E-00) Workshop Manual : Vol. No. W1MR-E (W1MR-E-00) Hitachi Excavator, Mini Excavator, Hitachi ZX10U-2, ZAXIS 10U-2, ZX8-2, ZAXIS 8-2, Yanmar Engine T1MR-E-00_Technical Manual COVER INTRODUCTION SAFETY SECTION AND GROUP CONTENTS SECTION 1 GENERAL Group 1 Specification SPECIFICATIONS WORKING RANGES Group 2 Component Layout Main Component Layout Electrical Component Layout (Overview) Electrical System (Relays) Electrical System (Lamp Unit, Hour Meter) ENGINE CONTROL VALVE (ZAXIS 8-2) CONTROL VALVE (ZAXIS 10U-2) SWING DEVICE TRAVEL DEVICE 2-SPOOL SOLENOID VALVE AIR BLEED SOLENOID VALVE Group 3 Component Specifications ENGINE ENGINE ACCESSORIES HYDRAULIC COMPONENT FILTER ELECTRICAL COMPONENT SECTION 2 SYSTEM Group 1 Hydraulic System OUTLINE PILOT CIRCUIT MAIN CIRCUIT Group 2 Electrical System OUTLINE MAIN CIRCUIT ELECTRICAL POWER CIRCUIT (KEY SWITCH: OFF) ELECTRICAL 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) LAMP UNIT CIRCUIT SECTION 3 COMPONENT OPERATION Group 1 Pump Device OUTLINE MAIN PUMPS (PUMPS 1, 2) PILOT PUMP Group 2 Swing Device OUTLINE SWING MOTOR VALVE UNIT Group 3 Control Valve OUTLINE HYDRAULIC CIRCUIT MAIN RELIEF VALVE OVERLOAD RELIEF VALVE MAKE-UP VALVE Group 4 Pilot Valve OUTLINE (ZAXIS 10U-2 ONLY) OPERATION (ZAXIS 10U-2 ONLY) Group 5 Travel Device OUTLINE TRAVEL MOTOR TRAVEL BRAKE VALVE TRAVEL REDUCTION GEAR Group 6 Others (Upperstructure) 2-SPOOL SOLENOID VALVE PILOT RELIEF VALVE AIR BLEED SOLENOID VALVE Group 7 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 (ZAXIS 10U-2 ONLY) MAIN RELIEF VALVE SET PRESSURE OVERLOAD RELIEF VALVE SET PRESSURE SWING MOTOR DRAINAGE TRAVEL MOTOR DRAINAGE Group 6 Adjustment FUEL LEVER ADJUSTMENT SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure INTRODUCTION DIAGNOSING PROCEDURE Group 2 Troubleshooting B TROUBLESHOOTING B PROCEDURE (DIAGNOSIS OF MACHINE BY SYMPTOM) ENGINE SYSTEM TROUBLESHOOTING ACTUATOR SYSTEM TROUBLESHOOTING (ZAXIS8-2) ACTUATOR SYSTEM TROUBLESHOOTING (ZAXIS10U-2) FRONT ATTACHMENT SYSTEM TROUBLESHOOTING SWING SYSTEM TROUBLESHOOTING TRAVEL SYSTEM TROUBLESHOOTING BOOM SWING SYSTEM TROUBLESHOOTING BLADE SYSTEM TROUBLESHOOTING SIDE FRAME EXTEND/RETRACT SYSTEM TROUBLESHOOTING HOW TO LOWER BOOM IN CASE OF EMERGENCY AND WHEN ENGINE STOPS ZAXIS10U-2 ONLY) Horn Blowing Prevention Procedure when Key Switch is OFF Group 3 Troubleshooting C TROUBLESHOOTING C PROCEDURE DIAGNOSIS OF LAMP UNIT) MALFUNCTION OF ALTERNATOR INDICATOR MALFUNCTION OF ENGINE OIL PRESSURE INDICATOR MALFUNCTION OF OVERHEAT INDICATOR MALFUNCTION OF HOUR METER Group 4 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 ZX8-2 HYDRAULIC CIRCUIT DIAGRAM ZX10U-2 HYDRAULIC CIRCUIT DIAGRAM ZX8-2/10U-2 ELECTRICAL CIRCUIT DIAGRAM ZX8-2/10U-2 MAIN HARNESS ZX8-2/10U-2 STAND HARNESS ZX8-2/10U-2 LIGHT HARNESS ZX8-2/10U-2 AIR BLEED SOLENOID VALVE HARNESS ZX8-2/10U-2 BATTERY CABLE+/- W1MR-E-00_Workshop Manual INTRODUCTION CONTENTS SAFETY RECOGNIZE SAFETY INFORMATION UNDERSTAND SIGNAL WORDS FOLLOW SAFETY INSTRUCTIONS PREPARE FOR EMERGENCIES WEAR PROTECTIVE CLOTHING PROTECT AGAINST NOISE INSPECT MACHINE USE HANDHOLDS AND STEPS FASTEN YOUR SEAT BELT (ROLL BAR EQUIPPED MACHINES) MOVE AND OPERATE MACHINE SAFELY OPERATE ONLY FROM OPERATOR'S SEAT JUMP STARTING 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 HANDLE 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 H ANDLE CHEMICAL PRODUCTS SAFELY DISPOSE OF WASTE PROPERLY SECTION 1 GENERAL Group 1 Precautions for Disassembling and Assembling PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING Group 2 Tightening TIGHTENING TORQUE SPECIFICATIONS TORQUE CHART PIPING JOINT PERIODIC REPLACEMENT OF PARTS Group 3 Painting PAINTING Group 4 Bleeding Air BLEED AIR FROM HYDRAULIC OIL TANK SECTION 2 UPPERSTRUCTURE Group 1 Main Frame REMOVE AND INSTALL MAIN FRAME Group 2 Pump Device REMOVE AND INSTALL PUMP DEVICE DISASSEMBLE PUMP DEVICE ASSEMBLE PUMP DEVICE STRUCTURE OF PILOT PUMP Group 3 Control Valve REMOVE AND INSTALL CONTROL VALVE DISASSEMBLE AND ASSEMBLE CONTROL VALVE DISASSEMBLE BODY ASSEMBLE BODY DISASSEMBLE SPOOL ASSEMBLE SPOOL DISASSEMBLE AND ASSEMBLE CHECK VALVE Group 5 Swing Device REMOVE AND INSTALL SWING DEVICE DISASSEMBLE SWING DEVICE ASSEMBLE SWING DEVICE Group 5 Pilot Valve REMOVE AND INSTALL PILOT VALVE (ZAXIS10U-2 ONLY) DISASSEMBLE PILOT VALVE (ZAXIS10U-2 ONLY) ASSEMBLE PILOT VALVE (ZAXIS10U-2 ONLY) Group 6 Solenoid Valve REMOVE AND INSTALL 2-SPOOL SOLENOID VALVE DISASSEMBLE 2-SPOOL SOLENOID VALVE ASSEMBLE 2-SPOOL SOLENOID VALVE REMOVE AND INSTALL AIR BLEED SOLENOID VALVE STRUCTURE OF AIR BLEED SOLENOID VALVE SECTION 3 UNDERCARRIAGE Group 1 Swing Bearing REMOVE AND INSTALL SWING BEARING Group 2 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 STANDARD Group 3 Center Joint REMOVE AND INSTALL CENTER JOINT DISASSEMBLE CENTER JOINT ASSEMBLE CENTER JOINT Group 4 Track Adjuster REMOVE AND INSTALL TRACK ADJUSTER DISASSEMBLE AND ASSEMBLE TRACK ADJUSTER Group 5 Front Idler REMOVE AND INSTALL FRONT IDLER DISASSEMBLE AND ASSEMBLE FRONT IDLER MAINTENANCE STANDARD Group 6 Upper and Lower Roller REMOVE AND INSTALL LOWER ROLLER STRUCTURE OF LOWER ROLLER MAINTENANCE STANDARD Group 7 Track REMOVE AND INSTALL TRACK MAINTENANCE STANDARD SECTION 4 FRONT ATTACHMENT Group 1 Front Attachment REMOVE AND INSTALL FRONT ATTACHMENT MAINTENANCE STANDARD STANDARD DIMENSIONS FOR ARM AND BUCKET CONNECTION Group 2 Cylinder REMOVE AND INSTALL CYLINDER DISASSEMBLE BOOM CYLINDER ASSEMBLE BOOM CYLINDER DISASSEMBLE ARM CYLINDER ASSEMBLE ARM CYLINDER DISASSEMBLE BUCKET AND BOOM SWING CYLINDERS ASSEMBLE BUCKET AND BOOM SWING CYLINDERS DISASSEMBLE SIDE FRAME EXTEND/RETRACT CYLINDER ASSEMBLE SIDE FRAME EXTEND/RETRACT CYLINDER DISASSEMBLE BLADE CYLINDER ASSEMBLE BLADE CYLINDER MAINTENANCE STANDARD SECTION 5 ENGINE Section 1 Introduction Troubleshooting Quick Reference Table For Troubleshooting Troubleshooting Charts Electric Wiring SERVICE MANUAL REVISION REQUEST FORM