Hitachi ZX55U-5A Mini Excavator Technical Repair Service Manual

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Information included in this Technical Manual: technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures for the Zaxis 55U-5A Hitachi Hydraulic Excavator.


TABLE OF CONTENTS :

SECTION 1 GENERAL
    Group 1 Specifications
    Group 2 Component Layout
    Group 3 Component Specifications
        
SECTION 2 SYSTEM
    Group 1 Control System
    Group 2 Hydraulic System
    Group 3 Electrical System
        
SECTION 3 COMPONENT OPERATION
    Group 1 Pump Device
    Group 2 Revolution Sensing Valve
    Group 3 Swing Device
    Group 4 Control Valve
    Group 5 Pilot Valve
    Group 6 Travel Device
    Group 7 Others (Upperstructure)
    Group 8 Others (Undercarriage)
        
SECTION 4 OPERATIONAL PERFORMANCE TEST
    Group 1 Introduction
    Group 2 Standard
    Group 3 Engine Test
    Group 4 Machine Performance Test
    Group 5 Component Test
        
SECTION 5 TROUBLESHOOTING
    Group 1 Diagnosing Procedure
    Group 2 Monitor
    Group 3 Troubleshooting A
    Group 4 Troubleshooting B
        
SERVICE MANUAL REVISION REQUEST FORM
The Attached Diagram List


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Vol No.: TAEB-EN-00
Total Pages : 404


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TAEB-EN-00
INTRODUCTION
SYMBOL AND ABBREVIATION
SAFETY
SECTION AND GROUP CONTENTS

SECTION 1 GENERAL
    Group 1 Specifications
        Std. Specification
        Working Ranges
    Group 2 Component Layout
        Main Component
        Electrical System (Overview)
        Electrical System (Relays)
        Electrical System (Relays) (Cab Spec. Machine)
        Electrical System (Monitor, Switches)
        Electrical System (Battery Room)
        Engine
        Swing Device
        Revolution Sensing Valve/Pilot Filter
        Travel Device
        Auxiliary Flow Rate Selector Valve (Optional)
        Control Valve
        2-Spool Solenoid Valve
    Group 3 Component Specifications
        Engine
        Engine Accessories
        Hydraulic Component
        Electrical Component
        
SECTION 2 SYSTEM
    Group 1 Control System
        Outline
        Engine Control
        Pump Control
        Valve Control
        Other Control
    Group 2 Hydraulic System
        Outline
        Pilot Circuit
        Main Circuit
    Group 3 Electrical System
        Outline
        Main Circuit
        Electric Power Circuit (Key Switch: OFF)
        CAN Circuit
        Electric Power Circuit (Key Switch: ON)
        Preheating Circuit (Key Switch: ON)
        Starting Circuit (Key Switch: START)
        Charging Circuit (Key Switch: ON)
        Pilot Shut-Off Circuit (Key Switch: ON)
        Auto Shut-Down Circuit (OP)
        Engine Stop Circuit (Key Switch: OFF)
        
SECTION 3 COMPONENT OPERATION
    Group 1 Pump Device
        Outline
        Main Pump P1
        Flow Rate Control
        Control by Signal Pressure
        Control by Own Pump Pressure
    Group 2 Revolution Sensing Valve
        Outline
        Operation
    Group 3 Swing Device
        Outline
        Swing Reduction Gear
        Swing Motor
        Parking Brake
        Valve Unit
    Group 4 Control Valve
        Outline
        Hydraulic Circuit
        Main Relief Valve
        Overload Relief Valve (with Make-Up Function)
        Make-Up Valve
        Boom Anti-Drift Valve
        Flow Rate Control Valve
        Unload Valve
        Differential Reducing Valve
        Pressure Compensator
    Group 5 Pilot Valve
        Outline
        Operation (Front Attachment / Swing and Travel Pilot Valves)
        Operation (Boom Swing / Blade / Auxiliary (Optional) Pilot Valve)
        Shockless Function (Only for Travel Pilot Valve)
        Shuttle Valve (Optional)
    Group 6 Travel Device
        Outline
        Travel Reduction Gear
        Travel Motor
        Parking Brake
        Travel Brake Valve
    Group 7 Others (Upperstructure)
        2-Spool Solenoid Valve
        Torque Control Solenoid Valve (Only Machine with the Air Conditioner (Optional) Attached)
        Auxiliary Flow Rate Selector Valve (Optional)
    Group 8 Others (Undercarriage)
        Swing Bearing
        Center Joint
        Track Adjuster
        
SECTION 4 OPERATIONAL PERFORMANCE TEST
    Group 1 Introduction
        Operational Performance Tests
        Preparation for Performance Tests
    Group 2 Standard
        Operational Performance Standard Table
        Main Pump P-Q Diagram
        Sensor Activating Range
    Group 3 Engine Test
        Engine Speed
        Lubricant Consumption
    Group 4 Machine Performance Test
        Travel Speed
        Track Revolution Speed
        Mistrack Check
        Travel Parking Leakage
        Swing Speed
        Swing Function Drift Check
        Swing Motor Leakage
        Maximum Swingable Slant Angle
        Swing Bearing Play
        Hydraulic Cylinder Cycle Time
        Dig Function Drift Check
        Control Lever Operating Force
        Control Lever Stroke
        Combined Operation of Boom Raise / Swing Function Check
        Clearance of Front Attachment Connecting Part
    Group 5 Component Test
        Primary Pilot Pressure
        Secondary Pilot Pressure
        Main Relief Set Pressure
        Overload Relief Valve Set Pressure
        Pump Driving Torque
        Swing Motor Drainage
        Travel Motor Drainage
        Revolution Sensing Valve Output Pressure (Pressure PGR)
        Pump Delivery Pressure
        Auxiliary Flow Rate Selector Valve Pressure (Optional)
        
SECTION 5 TROUBLESHOOTING
    Group 1 Diagnosing Procedure
        Introduction
        Diagnosis Procedure
        Electric System Inspection
        Precautions for Inspection and Maintenance
        Instructions for Disconnecting Connectors
        Fuse Inspection
        Slow Blow Fuse Inspection
        Battery Voltage Check
        Alternator Check
        Continuity Check
        Voltage Inspection Method
        Check by False Signal
    Group 2 Monitor
        Outline
        Operating Procedures of Service Menu
        Inspection of Fuel Gauge, Battery Voltage, Hour Meter, and Destination No
        Fuel Gauge and Coolant Temperature Gauge
        Factory Setting
    Group 3 Troubleshooting A
        Troubleshooting A (Base Machine Diagnosis by Using  Fault Codes) Procedure
        Fault Code List
        Fault Code W: 1304
        Fault Code W: 1310
        Fault Code W: 2304
        Fault Code W: 2306
        Fault Code W: 2307
    Group 4 Troubleshooting B
        Troubleshooting B (Machine Diagnosis by Using  Troubleshooting Symptom) Procedure
        Engine System Troubleshooting
        All Actuator System Troubleshooting
        Front Attachment System Troubleshooting
        Swing System Troubleshooting
        Travel System Troubleshooting
        Blade System Troubleshooting
        Boom Swing System Troubleshooting
        How to Lowering Boom in Case of Emergency and When Engine Stops
        
SERVICE MANUAL REVISION REQUEST FORM
The Attached Diagram List

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