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This complete service repair workshop manual PDF download for the EX400 Hitachi Hydraulic Excavator has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.
TABLE OF CONTENTS :
SECTION 01 HOW TO USE
SECTION 02 SPECIFICATIONS
SECTION 03 GENERAL
SECTION 04 SUPERSTRUCTURE
SECTION 05 UNDERCARRIAGE
SECTION 06 FRONT-END ATTACHMENT
SECTION 07 HYDRAULIC SYSTEM
SECTION 08 PNEUMATIC SYSTEM
SECTION 09 ELECTRICAL SYSTEM
SECTION 10 TROUBLSHOOTING
SECTION 11 ENGINE
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Total Pages : 1004
This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.
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EX400 HYDRAULIC EXCAVATOR SERVICE MANUAL
SECTION 01 HOW TO USE
Group 01 Section & Group Contents
Group 02 Introduction
Introduction
Care of the Handling
Symbols
Group 03 Features of This Manual
Construction
Tab
Page
Contents
Group 04 Safty Information
SECTION 02 SPECIFICATIONS
Group 01 General Specifications
Dimensions
Weights and Ground Pressures
Backhoe Attachments
Loading Shovel Attachments
Working Ranges
Lifting Capacities
Group 02 Components Specifications
Engine
Main Pump
Pilot Pump
Control Valve
Swing Motor
Travel Motor
Center Joint
Pilot Valve (for Travel)
Pilot Valve (for Swing,Boom,Arm,Bucket)
Control Neutralizer Valve
Shockless Valve
Accumulator
Hydraulic Tank
Suction Filter
Full-Flow Filter
Air Breezer
Bypass Check Valve
Pilot Filter
Oil Cooler
Solenoid Valve(E-P Control)
Solenoid Valve(Pump Control)
Solenoid Valve(EHC Valve)
Mode Selection Cylinder
Boom Cylinder
Arm Cylinder
Bucket Cylinder
Group 03 Torque Reference
Group 04 Others
Maintenance Intervals
Group 05 Conversion Table
SECTION 03 GENERAL
Group 01 Introduction
Group 02 Construction
Group 03 Hydraulic System
Hydraulic System
Main Hydraulic Circuit
Pilot Hydraulic Circuit
Group 04 Electric System
Main Circuit
Control System
Monitor System
Group 05 Maintenance
Removeal and Instrallation (Cab, Front Attachment, Superstructure)
Maintenance
Name Plate
SECTION 04 SUPERSTRUCTURE
Group 01 Superstructure
Main Frame and Counter-Weight
Engine
Hydraulic Oil Tank
Fuel Tank
Swing Device
Electric Parts
Cab Heater
Engine Control Lever
Main Piping
Oil Cooler Piping
Cover
Pump Device
Control Box
Cab Group
Pilot Piping
Control Lever
Group 02 Hydraulic Pump Device
O/P, Hydraulic Pump
Outline
Function
Operation
D/A, Main Pump
Disassembly
Assembly
D/A, Pump Transmission
Disassembly
Assembly
Parts List
D/A, HY-ZFS Gear Pump
Disassembly
Inspection
Assembly
Group 03 Control Valve
O/P, Control Valve
General
Construction and Function
D/A, Control Valve
Disassembly
Inspection
Assembly
Group 04 Swing Device
O/P, Swing Motor
Outline
Function
D/A, Cab Motor
Disassembly
Inspection
Assembly
D/A, Swing Reduction Device
Disassembly
Assembly
Special Tools
Group 05 Pilot Valve
O/P, Pilot Valve
Outline
Function
D/A, HV Type Pilot Valve (Front-End Attachment)
Disassembly
Assembly
Special Tools
D/A, HV Type Pilot Valve (Travel)
Disassembly
Assembly
Special Tools
Group 06 Control Neutralizer Valve
O/P, Control Neutralizer Valve
Outline
Function
D/A, Control Neutralizer Valve
Disassembly
Assembly
Group 07 Shockless Valve
O/P, Shockless Valve
Outline
Function
D/A, Shockless Valve
Disassembly
Inspection
Assembly
Group 08 Accumulator
O/P, Accumulator
Outline
Function
Group 09 Solenoid Valve
O/P, Solenoid Valve (Three Spools)
Outline
Function
D/A, Solenoid Valve (Three Spools)
Disassembly
Inspection
Assembly
O/P, Solenoid Valve (One Spool)
Outline
Function
D/A, Solenoid Valve (One Spool)
Disassembly
Inspection
Assembly
O/P, EHC Valve
Outline
Function
Group 10 Mode Selection Cylinder
D/A, Mode Slection Cylinder
Disassembly
Assembly
SECTION 05 UNDERCARRIAGE
Group 01 Undercarrige
Track Frame
Swing Bearing
Travel Device and Piping
Front Idler
Adjuster
Upper Roller and Lower Roller
Track Link
Center Joint
Group 02 Travel Device
O/P, Travel Motor
Outline
Operation
Parking Brake
Brake Valve
D/A, Travel Motor
Disassembly
Inspection
Assembly
D/A, Travel Device
Disassembly
Assembly
Travel Device
Group 02 Center Joint
O/P, Center Joint
Outline
D/A, Center Joint
Disassembly
Assembly
Special Tools
SECTION 06 FRONT-END ATTACHMENTS
Group 01 Front-End Attachment
Boom Assembly
Arm Assembly
Bucket Assembly
Front Pipings
Group 02 Hydraulic Cylinder
Operational Principle
Construction and Function
Disassembly and Assembly
Disassembly
Inspection
Assembly
Special Tools
Group 03 Pin and Bushing
Specifications
Group 04 Point and Side Cutter
Maintenance
SECTION 07 HYDRAULIC SYSTEM
Group 01 Outline
Group 02 Main Hydraulic Circuit
Suction Circuit and Delivery Circuit
Return Circuit
Drain Circuit
Group 03 Pilot Circuit
Suction,Delivery and Return Circuit
Accumulator
Control Neutralizer Valve
Pump Displacement Control Circuit
Travel Control Circuit
Heat-Run Circuit
Swing Parking Brake
Group 04 Single Operation
Boom Raise Circuit Operation
Boom Lower Circuit Operation
Arm Roll-In Circuit Operation
ArmRoll-Out Circuit Operation
Bucket Circuit Operation
Swing Circuit Operation
Travel Circuit Operation
Group 05 Combined Operation
Outline
Combined Swing and Boom Operation
Combined Swing and Arm Roll-In Operation
Combined Swing and Arm Roll-Out Operation
Combined Swing and Bucket Operation
Combined Boom and Arm Operation
Combined Swing and Travel Operation
Combined Boom and Travel Operation
Combined Arm and Travel Operation
Combined Bucket and Travel Operation
Group 06 Heavy Lift Operation (option)
Group 07 Hydraulic Circuit Diagram
SECTION 08 PNEUMATIC SYSTEM
Group 01 General
Group 02 Air-Compressor
Grpoup 03 Governor
Group 04 Auto-Drain Valve
Group 05 Circuit Diagram
SECTION 09 ELECTRICAL SYSTEM
Group 01 Safety Precautions
Safety Precautions
Group 02 Specifications
Battery, Starter, Safety Relay, Alternator, Headlight, Wiper Motor, Speaker,
Room light, Radio, Relay (Horn), Relay (Service Meter etc.), Relay(Battery), Fuse
Group 03 Construction and Function
Construction of Electrical System
Monitor
Control (E-P Control:SDX) System
Travel Speed Change
Function of Seneors and Relays
Group 04 Circuit Operations
Characteristics of Electrical Circuit
Electrical Circuit
Battery Circuit
Preheat Circuit
Starting Circuit
Charging Circuit
Engine Stop Circuit
Accessory Circuit
Gauge Panel Circuit
Control Circuit
Group 05 Maintenance
Gauge Panel
Assembly and Adjustment of Engine Control (Mode Selection) Device
SECTION 10 TROUBLSHOOTING
Group 01 Introduction
General Information
Notes on Performance Measurement
Group 02 Diagnose Malfunctions
Malfunctions Phenomena
Hydraulic System
Electric System
Group 03 Excavator Performance Test
Introduction
Engine Performance Measurement
Travel Performance Measurment
Swing Performance Measurement
Front Attachment
Control Levers Performance Measurement
Group 04 Components Performance Standard
Introduction
Pilot Relief Valve
Main Relief Valve
Overlord Relief Valve
Swing Crossover Relief Valve
Travel Crossover Relief Valve
Main Hydraulic Pump
Travel Motor
Swing Motor
Group 05 Electrical System Test
Commom Circuit Test
Articles Necesary for Electric Circuit Test
Measurrement Procedure
Measurement Standard
SECTION 11 ENGINE
Group 01 General Information
General Repair Instructions
Notes on the Format of Engine Section
Maine Date and Specifications
Design Features and General Outline
Tightening Toque Specifications
Anglular Nut and Bolt Tightening Method
Major Parts Fixing Nuts and Bolts
Identifications
Group 02 Maintenance
Lubricating System
Fuel System
Cooling System
Valve Clearance Adjustment
Injection Timing
Compression Pressure Measurement
Turbocharger Inspection
Engine Repair Kit
Recommended Lubricants
Engine Oil Viscosity Chart
Group 03 Engine Assembly-1 (Disassembly)
Engine Assembly General Description
Disassembly 1st Step
Disassembly 2nd Step
Disassembly 3rd Step
Cylinder Head Disassembly Step
Piston and Connecting Rod Disassembly Step
Rocker Arm and Shaft Disassmbly Step
Camshaft and Gear Disassmbly Step
Crankshaft Disassmbly Step
Group 04 Engine Assembly-II (Inspection and Repair)
Cylinder Head
Valve Guide
Valve and Valve Seat Insert
Valve Spring
Tappet
Push Rod
Rocker Arm Shaft and Rocker Arm
Idler Gear and Idler Gear Shaft
Camshaft
Cylinder Body and Liner
Piston and Piston Ring
Piston Pin
Connecting Rod
Crankshaft and Bearing
Flywheel and Flywheel Housing
Timing Gear Case Cover
Group 05 Engine Assembly-III (Reassembly)
Piston and Connecting Rod Reassembly Step
Cylinder Head Reassembly Step
Rocker Arm and Rocker Arm Shaft Reassembly Step
Reassembly 1st Step
Reassembly 2nd Step
Reassembly 3rd Step
Reassembly 4th Step
Engine Tuning Operation
Group 06 Lubricating System
Genral Description
Oil Pump
Main Oil Filter
Oil Cooler
Group 07 Cooling System
General Description
Water Pump
Thermastat
Group 08 Fuel System
General Description
Fuel Filtter
Injection Nozzle
Group 09 Turbo Charger
General Description
Identification
Roter Shaft Play Inspection
Group 10 Air Compressor
General Description
Disassembly Steps
Inspection and Repairs
Reassembly Step
Group 11 Engine Electricals
Starter Motor
Alternator
Intake Heater
Group 12 Troubleshooting
Hard Starting
Unstable Low Idling
Insufficient Power
Excessive Fuel Consumption
Excessive Oil Consumption
Overheating
White Exhaust Smoke
Darkish Exhaust Smoke
Oil Pressure does not Rise
Abnormal Engine Noise
Group 13 Special Tools
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