Part of the Hitachi Repair Manuals.
A travel motor weeping oil or a pump losing pressure is where guesswork gets expensive, and this 587-page Hitachi workshop manual (OEM ID KM-1LSE) covers four Zaxis compact excavators. This Hitachi Zaxis 30, 35, 40 and 50 workshop manual PDF works through the pump device, control valve, swing device and pilot valve, with exploded views showing how each assembly comes apart. Undercarriage chapters take the swing bearing, travel device, track adjuster, idlers and rollers apart in order, while engine servicing fills nearly half the book, from cylinder head and crankshaft to injection pump and turbocharger. On a ZAXIS40 or 50, plunger to rotor bore clearance must stay at 0.40 mm or less; on your 30 or 35, torque lower roller bolts to 245 N·m (181 lbf·ft). Guess one clearance and you pay for that pump twice. Bookmarks split the scanned pages by section, and your copy rides on a laptop to wherever the machine is parked.
What's Inside This Hitachi Zaxis 30, 35, 40, 50 Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction | 2-3 | Additional References, Page Numbering, Safety Alert Symbols, Unit Conversion |
| Safety | 4-31 | Safety Alert Symbols, Signal Words, Emergency Procedures, Protective Clothing, Machine Operation, Maintenance Safety |
| General Information | 32-55 | Tightening, Bleeding Air, Painting |
| Upperstructure | 56-161 | Canopy, Counterweight, Pump Device, Control Valve, Swing Device, Pilot Valve, Solenoid Valve |
| Undercarriage | 162-235 | Swing Bearing, Travel Device, Center Joint, Track Adjuster, Front Idler, Upper and Lower Roller, Track |
| Front Attachment | 236-305 | Cylinder |
| Engine Mechanism | 306-349 | Engine Body, Lubricating System, Cooling System, Intake/Exhaust System, Fuel System, Turbo Charger System |
| Engine Servicing - General and Engine Body | 350-473 | General Precautions, Troubleshooting, Servicing Specifications, Maintenance Check List, Cylinder Head, Piston and Connecting Rod, Flywheel and Crankshaft |
| Engine Servicing - Lubricating and Cooling Systems | 474-547 | Draining Water and Oil, Oil Pump, Cooling System, Fan Belt, Radiator, Water Pump |
| Engine Servicing - Fuel System | 548-557 | Injection Pump, Injection Nozzle, Fuel Tightness |
| Engine Servicing - Electrical System | 558-577 | Starter, Alternator, Glow Plug, IC Regulator, Rectifier |
| Engine Servicing - Turbo Charger System | 578-585 | Checking, Disassembling and Assembling, Turbocharger |
| Electrical and Hydraulic Circuit Diagrams | 586-587 | Electrical Circuit Diagram, Hydraulic Circuit Diagram |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Zaxis 30, 35 | ||
| Upper roller mounting bolt torque | 88 N⋅m (9 kgf⋅m) (65 lbf⋅ft) | p. 42 |
| Lower roller mounting bolt torque | 245 N⋅m (25 kgf⋅m) (181 lbf⋅ft) | p. 42 |
| ZAXIS40, 50 | ||
| Clearance between the plunger diameter and the rotor bore diameter | 0.40 mm or less | p. 132 |
| Clearance between the plunger and the shoe | 0.4 mm or less | p. 132 |
| Counterweight mounting bolt torque | 295 N·m (30 kgf·m, 217 lbf·ft) | p. 43 |
| All Models | ||
| Guide (1) to housing (13) torque | 74 to 88 N·m (7.5 to 9.0 kgf·m, 54 to 65 lbf·ft) | p. 160 |
| Tube (9) to housing (13) torque | 47 to 74 N·m (4.8 to 7.6 kgf·m, 35 to 55 lbf·ft) | p. 160 |
| Oil filter bypass valve opening pressure | 98 kPa (1.0 kgf/cm², 14 psi) | p. 354 |
| Thermostat opening temperature | approx. 71 °C (160 °F) | p. 356 |
| Air cleaner nozzle air pressure | 690 kPa (7 kgf/cm², 100 psi) | p. 452 |
| ZAXIS30, 35 | ||
| Counterweight mounting bolt torque | 540 N·m (55 kgf·m, 400 lbf·ft) | p. 42 |
| Swing device mounting bolt torque | 137 N·m (14 kgf·m, 101 lbf·ft) | p. 42 |
Hitachi Zaxis 30, 35, 40, 50 Common Problems This Manual Covers
Hitachi Zaxis 30, 35, 40, 50 engine starter and glow plug check when the engine does not start
Test the starter and each glow plug following the Engine Servicing Electrical System procedures on page 558, after working down the engine does not start chart in Engine Troubleshooting. If both check good, move to the Fuel System section on page 548 and inspect the injection pump and injection nozzles before cranking again.
Manual Section: Engine Servicing - Electrical System p. 558Thermostat, fan belt or radiator check when the engine keeps overheating under working load
Check fan belt deflection first against 10 to 12 mm per page 450 and adjust if the belt is loose. Remove and test the thermostat; it should open at approx. 71 °C (160 °F) as listed on page 356. Then inspect the radiator and water pump using the Lubricating and Cooling Systems section on page 474.
Manual Section: Engine Servicing - Lubricating and Cooling Systems p. 474Oil filter element and oil pump check when engine oil pressure reads low
Check the oil level before anything else, then replace the oil filter element. Its bypass valve opens once inlet pressure runs 98 kPa (1.0 kgf/cm², 14 psi) above outlet, per page 354, so a clogged element lets unfiltered oil circulate. If pressure stays low, inspect the oil pump following the Lubricating and Cooling Systems section on page 474.
Manual Section: Engine Servicing - General and Engine Body p. 354Air cleaner element check when the engine shows low power and black or dark gray exhaust
Remove the air cleaner element and inspect it for dust loading. Clean it with compressed air, keeping nozzle pressure no higher than 690 kPa (7 kgf/cm², 100 psi) as page 452 specifies. If power and smoke do not improve, inspect the injection nozzles following the Fuel System section on page 548.
Manual Section: Engine Servicing - General and Engine Body p. 452Alternator, IC regulator and rectifier check when the machine battery keeps discharging
Test the alternator first, then check the IC regulator and rectifier following the Engine Servicing Electrical System procedures on page 558. Trace the charging circuit on the electrical circuit diagram at page 586 to find any open or grounded wire before you replace parts. Recheck the battery discharge chart in Engine Troubleshooting afterward.
Manual Section: Engine Servicing - Electrical System p. 558Frequently Asked Questions
What are the torque specifications for the lower roller mounting bolts on a ZAXIS30 or 35 excavator?
The lower roller mounting bolts for the ZAXIS30 and 35 models should be tightened to a torque of 245 N⋅m (25 kgf⋅m, 181 lbf⋅ft). p. 42
What is the pump suction hose replacement interval on the Hitachi Zaxis 30, 35, 40, 50 excavator?
The pump suction hose should be replaced every 2 years to ensure safe operation and prevent potential fire hazards. p. 51
What is the correct procedure for bleeding air from the hydraulic pump?
To bleed the hydraulic pump, remove the air bleeding plug from the top of the pump and fill the pump housing with hydraulic oil. Temporarily tighten the plug, start the engine at slow idle, slightly loosen the plug until oil oozes out, and then securely tighten the plug. p. 35
What is the torque specification for the counterweight mounting bolts on a ZAXIS40 or 50 excavator?
The counterweight mounting bolts for the ZAXIS40 and 50 models must be tightened to a torque of 295 N⋅m (30 kgf⋅m, 217 lbf⋅ft). p. 43
What is the standard valve clearance for the engine on the Hitachi Zaxis 30, 35, 40, 50 excavator?
The standard valve clearance for the engine when cold is 0.145 to 0.185 mm (0.0057 to 0.0072 in). p. 416
What exactly do I receive with this Hitachi Zaxis 30 Workshop Manual?
You download the Workshop Manual yourself: 587 pages, scanned PDF, available immediately. Keep a copy on every device you use.
Are there any print restrictions on this Hitachi Zaxis 30 manual?
Yes. No DRM, nothing blocks printing, so run off the pages you need on whatever printer you have.
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