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Part of the Hitachi Repair Manuals.
Need real factory data for your Hitachi ZAXIS27U-2, 30U-2, 35U-2, 40U-2, or 50U-2? This 890-page Hitachi technical manual (OEM #T1MJ-E-00) covers the whole U-2 mini excavator family along with their Yanmar 3TNV82A through 4TNV106(T) engines. You get full electrical circuit diagrams with connector terminal locations for every harness: floor, main, engine, battery, even the immobilizer. Hydraulic circuit diagrams show relief valve pressure settings, and a huge troubleshooting-by-symptom section walks you from complaint to cause, backed by operational performance standards for travel speed, swing drift, and cylinder cycle times. Verify the overheat switch trips at 110°C (230°F), and run fuel filters rated at 5 microns, not whatever fits. A mistracking excavator will not diagnose itself. Bookmarked front to back; type a spec in the search bar, jump to the page, and get the machine digging again.
What's Inside This Hitachi Zaxis 27U-2 - 50U-2 Manual
| System | Pages | Key Topics |
|---|---|---|
| Circuit Diagrams and Harnesses | 1-22 | Hydraulic Circuit Diagrams, Electrical Circuit Diagrams, Floor, Main, Engine and A/C Harnesses, Immobilizer and Auto-Idle Sensor Harnesses, Auxiliary Flow Selector Valve |
| Technical Manual: Introduction and Safety | 23-56 | Safety Alert Symbols, Safety Instructions, Protective Equipment |
| Technical Manual: General | 57-86 | Specifications, Component Layout |
| Technical Manual: System | 87-134 | Control System, Hydraulic System |
| Technical Manual: Component Operation | 135-212 | Pump Device, Main and Pilot Pumps, Horse Power Control |
| Operational Performance Tests | 213-272 | Performance Test Preparation, Operational Performance Standards |
| Troubleshooting | 273-344 | Diagnosing Procedure, Error Indication List (ZX30U-2/35U-2), Diagnosis by Symptom, Engine System Troubleshooting |
| Workshop Manual: Safety and General | 345-399 | Safety Instructions, Floor-Tilting Device Operation |
| Workshop Manual: Upperstructure | 400-525 | Control Valve Removal and Installation, Pilot Valve Service, Swing Device |
| Workshop Manual: Undercarriage | 526-615 | Travel Device, Sprocket Wear Standards, Track Service |
| Workshop Manual: Front Attachment | 616-675 | Boom, Arm and Bucket Cylinders, Blade Cylinder, Boom Swing Service |
| Yanmar Tnv Engine Manual | 676-890 | Engine Disassembly, Inspection and Reassembly, Inspection and Adjustment Schedules, Starting Motor and Electrics |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Wire size | 0.5 mm | p. 218 |
| Inspection interval for electrical cables and wires | 8 to 10 hours | p. 51 |
| Engine Oil Filter Filtration | 25 μm | p. 83 |
| Fuel Filter Filtration | 5 μm | p. 83 |
| Overheat Switch Operating Temperature | 110°C (230°F) | p. 84 |
| Alternator rotating speed for starter relay 2 to stop magnetizing | 1350 ± 210 min-1 | p. 126 |
| ZAXIS27U-2 | ||
| ZAXIS27U-2 Operating Weight | 2720 kg | p. 61 |
| ZAXIS27U-2 Swing Speed | 9.1 min-1 | p. 61 |
| ZAXIS30U-2 | ||
| ZAXIS30U-2 Operating Weight | 2990 kg | p. 62 |
| ZAXIS30U-2 Swing Speed | 9.3 min-1 | p. 62 |
| ZAXIS35U-2 | ||
| ZAXIS35U-2 Operating Weight | 3400 kg | p. 63 |
| ZAXIS35U-2 Swing Speed | 9.3 min-1 | p. 63 |
Hitachi Zaxis 27U-2 - 50U-2 Common Problems This Manual Covers
Hitachi ZAXIS35U-2 all hydraulic functions slow and weak, boom and bucket barely respond at full throttle
Check main relief pressure at both pumps against the 24.5 MPa setting on page 80. If pressure is good, pull the suction strainer and look for sludge on the 105 micron screen, then replace the 10 micron pilot filter (page 83). Bleed air from the pilot circuit and retest every function.
Manual Section: Actuator Operating System Troubleshooting p. 80Starter cranks slowly or not at all in cold weather, engine fires briefly then dies
Load-test the battery and clean both terminals down to bright metal, checking cable routing against the battery harness layout on page 13. If the starter drops out early, remember starter relay 2 stops magnetizing once alternator speed reaches 1350 min-1 (page 126). Replace the 5 micron fuel filter if the engine starves after firing.
Manual Section: Engine System TroubleshootingBlown fuses and intermittent electrical faults, frayed wiring and missing terminal caps under the floor plate
Inspect every harness for loose, kinked, hardened, or frayed wires each shift; the manual sets an 8 to 10 hour inspection interval on page 51. Trace shorted circuits with the floor harness diagram on page 5 and the main harness on page 7. Replace damaged runs with matching 0.5 mm wire and fit new terminal caps.
Manual Section: Floor Harness p. 5Coolant temperature gauge climbs into the red during heavy digging, overheat alarm sounds
Top off low coolant and blow debris out of the radiator core from the fan side. Verify the overheat switch closes at 110°C (230°F), the operating spec on page 84. If actual temperature is normal but the gauge still climbs, test the coolant gauge sender circuit through the monitor troubleshooting steps.
Manual Section: Monitor Troubleshooting p. 84One track travels slower than the other, machine pulls to the side and mistracks on grades
Swap the travel motor supply hoses side to side and watch whether the slow track follows the swap; that separates motor wear from a control valve fault. Test drive circuit pressure against the 24.5 MPa main relief setting on page 80, then work the travel chart in Troubleshooting B starting on page 285.
Manual Section: Travel System TroubleshootingFrequently Asked Questions
What are the recommended service intervals for the engine oil and filter?
The standard engine oil service interval is 250 hours or every 12 months. In the early period of use, the engine oil gets dirty rapidly due to initial wear, so it is recommended to replace the engine oil earlier. p. 103
What is the valve clearance specification for the 3TNV82A engine?
For the 3TNV82A engine, the standard valve clearance for both intake and exhaust valves is 0.15 to 0.25 mm, with a limit of 0.35 mm. p. 131
What is the tightening torque for the cylinder head bolts on a 3TNV82A engine?
The tightening torque for the cylinder head bolts on a 3TNV82A engine is 61.7 to 65.7 N·m (6.3 to 6.7 kgf·m). p. 138
How do I troubleshoot if the engine starter does not rotate?
First, check the fuse and connections. If the battery voltage and electrolyte density are normal, check if the terminal voltage on the starter is normal. If there is no voltage or less than 12 V at terminal B, check the battery and connections. p. 137
What is the standard compression pressure for the 3TNV82A engine?
The standard compression pressure for the 3TNV82A engine at 250 min-1 is 3.16 ± 0.1 MPa (31 ± 1 kgf/cm²), with a limit of 2.45 ± 0.1 MPa (25 ± 1 kgf/cm²). p. 147
What format is this Hitachi ZAXIS27U-2 & variants manual in?
This is a 890-page searchable PDF ready for immediate download. Works on any device, so pull it up on your phone while you're under the hood. No shipping, no waiting.
Is this Hitachi ZAXIS27U-2 & variants Technical Manual printable?
Absolutely. No DRM or copy protection. Print the whole manual or just the pages you need. Any home or office printer works.
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