Part of the Hitachi Repair Manuals.
This file covers the Hitachi Zaxis 40U-2 and 50U-2 reduced tail swing mini excavators, the ones running the Yanmar 4TNV88 at 29.8 kW. You get the Technical Manual (T1M9-E-01) with system theory, performance tests and troubleshooting, the Workshop Manual (W1M9-E-00) with teardown procedures for the swing device, travel device, pumps, valves and the whole front attachment, plus a complete Yanmar engine manual down to crankshaft and injection pump. Circuit diagrams and every harness sheet are in here too. One honest note: the publisher bound the technical volume into this file twice, so pages 933 to 1208 repeat the front sections. Nothing is missing and it is not a different revision, you simply get that volume twice as printed.
What's Inside This Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| Technical Manual: Introduction and Safety | 1-36 | Manual Composition, Volume Numbers, Safety Precautions, How to Use the Technical Volumes |
| Technical Manual: General | 37-58 | Specifications, Operating Weights, Working Range, Component Layout, Serial Number Locations |
| Technical Manual: System | 59-104 | Hydraulic System Routing, Pilot Circuit, Control System, Electrical System Architecture |
| Technical Manual: Component Operation | 105-196 | Main Pump, Control Valve, Pilot Valve, Swing Motor, Travel Motor, Solenoid Valve Unit |
| Operational Performance Test | 197-254 | Test Preparation, Engine Test, Excavator Test, Travel and Swing Speed, Cylinder Cycle Times, Drift Checks |
| Troubleshooting | 255-350 | Diagnosing Procedure, Fault Code List, Symptom-Based Flowcharts, Electrical System Inspection |
| Circuit Diagrams and Harness Sheets | 351-368 | Hydraulic Circuit Sheet, Electrical Circuit Sheet, Floor Harness, Main Harness, Engine Harness, Battery Harness, Air Conditioner and Optional Harnesses |
| Workshop Manual: Introduction and Safety | 369-404 | Workshop Volume Composition, Safety Labels, Precautions for Disassembling and Assembling |
| Workshop Manual: General Information | 405-436 | Tightening Torque Specification, Torque Chart, Piping Joint Standards, Maintenance Standard Terminology |
| Workshop Manual: Upperstructure | 437-566 | Cab, Swing Device, Swing Reduction Gear, Main Pump, Control Valve, Pilot Valve Removal and Overhaul |
| Workshop Manual: Undercarriage | 567-634 | Swing Bearing, Travel Device, Track Adjuster, Idler, Rollers, Sprocket, Rubber and Steel Track |
| Workshop Manual: Front Attachment | 635-710 | Boom, Arm, Bucket, Cylinders, Bushings and Pins, Blade and Boom Swing Components |
| Yanmar Engine: General, Inspection and Adjustment | 711-786 | Engine Specifications, Periodic Inspection, Valve Clearance, Injection Timing, Compression Measurement, Engine Troubleshooting |
| Yanmar Engine: Disassembly and Reassembly | 787-836 | Cylinder Head, Pistons and Connecting Rods, Crankshaft, Camshaft, Timing Gear, Flywheel |
| Yanmar Engine: Lubrication, Cooling, Fuel and Turbocharger | 837-868 | Oil Pump and Relief Valve, Cooling Circuit, Injection Pump and Governor, Turbocharger Overhaul |
| Yanmar Engine: Starting Motor and Alternator | 869-932 | Starter Motor Overhaul, Alternator Overhaul, Glow Plugs, Electrical Component Testing |
| Technical Manual, Second Printing: General, System and Component Operation | 933-1087 | Repeat of the Technical Volume As Bound by the Publisher, Same Content As the Opening Sections |
| Technical Manual, Second Printing: Performance Test and Troubleshooting | 1088-1208 | Repeat of the Performance and Diagnostic Volume As Bound by the Publisher |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Main relief valve - main pumps P1 | 25.3 +/- 1.0 MPa (258 +/- 10 kgf/cm2, 3678 +/- 145 psi) | p. 203 |
| Main relief valve - travel | 25.5 +/- 1.0 MPa (260 +/- 10 kgf/cm2, 3707 +/- 145 psi) | p. 203 |
| Main relief valve - swing | 21.6 +/- 1.0 MPa (220 +/- 10 kgf/cm2, 3140 +/- 145 psi) | p. 203 |
| Overload relief valve - boom, arm, bucket | 26.5 +/- 1 MPa (270 +/- 10 kgf/cm2, 3852 +/- 145 psi) | p. 203 |
| Primary pilot pressure | 6.6 +/- 0.5 MPa (67 +/- 5 kgf/cm2, 960 +/- 73 psi) | p. 203 |
| Secondary pilot pressure | 2.9 +/- 0.5 MPa (30 +/- 5 kgf/cm2, 422 +/- 73 psi) | p. 203 |
| Swing motor drainage at constant speed | 0.5 L/min or less | p. 203 |
| Travel motor leakage | 0 mm in 3 min | p. 201 |
| Swing motor leakage | 0 mm in 5 min | p. 201 |
| Mistrack in fast and slow travel modes | 200 mm or less per 20 m | p. 201 |
| Swing function drift | 163 mm or less per 90 degrees | p. 201 |
| Dig function drift - boom cylinder, bucket loaded | 5 mm or less in 5 min | p. 202 |
| Dig function drift - arm cylinder, bucket loaded | 8 mm or less in 5 min | p. 202 |
| Dig function drift - bucket bottom, bucket loaded | 100 mm or less in 5 min | p. 202 |
| Engine compression pressure | 3.43 +/- 0.1 MPa (35 +/- 1 kgf/cm2, 499 +/- 14.5 psi) | p. 201 |
| Nozzle injection pressure | 19.6 to 20.6 MPa (200 to 210 kgf/cm2, 2849 to 2995 psi) | p. 201 |
| Slow idle / fast idle speed | 1150 +/- 50 / 2650 +/- 50 min-1 | p. 201 |
| Travel speed, fast mode - rubber / steel crawler | 16.0 +/- 1.5 / 17.2 +/- 1.5 sec per 20 m | p. 201 |
| Boom raise cycle time, canopy version | 2.0 +/- 0.3 sec (40U-2), 2.2 +/- 0.3 sec (50U-2) | p. 202 |
| Operating weight range | 4260 to 4450 kg (40U-2), 4610 to 4800 kg (50U-2) | p. 39 |
