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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 Hitachi Zaxis 40U-2, Zaxis 50U-2 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 |
Hitachi Zaxis 40U-2, Zaxis 50U-2 Common Problems This Manual Covers
Boom, arm or bucket drifts down under load and the owner cannot tell worn cylinder seals from a leaking control valve
Run the dig function drift checks in the Operational Performance Test section against the printed limits, 5 mm boom, 8 mm arm, 100 mm bucket bottom in 5 minutes. If a cylinder fails, the Workshop Manual Front Attachment section covers cylinder removal, seal replacement and pin and bushing standards for the rebuild.
Manual Section: Operational Performance Test p. 202Machine mistracks or one travel motor feels lazy, especially in fast mode
Measure mistrack against the 200 mm per 20 m limit, then run the travel motor leakage test, which allows 0 mm of movement in 3 minutes. A failed motor comes apart per the Undercarriage section, which also covers the track adjuster, idler and rollers you should inspect while the track is off.
Manual Section: Workshop Manual: Undercarriage p. 201Swing is sluggish, creeps on a slope, or groans under load
Check the swing relief at 21.6 MPa, swing motor drainage at 0.5 L/min or less at constant speed, and swing drift at 163 mm or less per 90 degrees. Fail those and the Upperstructure section takes you through swing motor and reduction gear removal and overhaul with maintenance standards.
Manual Section: Workshop Manual: Upperstructure p. 203Hard starting, smoke or low power from the Yanmar engine with no obvious cause
Work through the engine inspection sequence: valve clearance, compression against the 3.43 MPa spec, nozzle pressure at 19.6 to 20.6 MPa, and idle speeds of 1150 and 2650 rpm. The engine troubleshooting tables in the same section rank causes so you test the cheap items before pulling the head.
Manual Section: Yanmar Engine: General, Inspection and Adjustment p. 711Frequently Asked Questions
My boom or arm sinks when I park with a loaded bucket. How do I know if the cylinder is actually worn?
This is the strongest material in the book. The Operational Performance Test section gives hard drift limits with the bucket loaded: boom cylinder 5 mm or less in 5 minutes, arm cylinder 8 mm or less, bucket bottom 100 mm or less. Run the check exactly as written, warm oil, positions as specified. Inside the limit means leave it alone. Outside means seals or the control valve, and the troubleshooting flowcharts help you split those two before you pull anything apart. p. 202
The machine walks crooked, one track keeps falling behind. Is that a travel motor or something cheaper?
Start with the mistrack test: 200 mm or less deviation per 20 m in both fast and slow modes. Fail that and the manual has you check travel motor leakage next, the spec is 0 mm of drum movement in 3 minutes, a dead simple pass or fail. Also check the main relief for travel, 25.5 MPa. Half the time it is a stuck relief or pilot problem, not the motor, and the Troubleshooting section walks that order so you do not buy a motor you did not need. p. 201
Does this actually cover the Yanmar engine or just point me to a dealer?
Full engine manual, not a summary. Valve clearance, injection timing, compression measurement with a real number to test against, 3.43 MPa, plus nozzle injection pressure at 19.6 to 20.6 MPa. Then complete disassembly: cylinder head, pistons and rods, crankshaft, timing gear, injection pump and governor, turbocharger, starter and alternator overhaul. If the engine cranks slow, smokes or lacks power, you can chase it start to finish without leaving this file. p. 201
Digging feels weak and cycle times seem slow. Where do I start?
The Operational Performance Test section. It gives target cycle times per model, boom raise on a canopy 40U-2 is 2.0 seconds, 2.2 on the 50U-2, and the relief settings to verify: main relief 25.3 MPa on the P1 pumps, overload reliefs at 26.5 MPa for boom, arm and bucket, pilot pressures at 6.6 and 2.9 MPa. Test with a gauge before condemning the pump. The Component Operation section then explains how the main pump and control valve behave so the readings actually mean something. p. 203
Why do some pages in this file look like ones I already read? Am I missing a section?
No. The publisher bound the technical volume twice in the source document, so pages 933 to 1208 repeat the General, System, Component Operation, Performance Test and Troubleshooting sections from the front. We are telling you straight so you do not think pages were swapped or that the second copy is a newer revision. It is the same content, printed twice, exactly as bound. p. 933
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