Hitachi FD2 1590 Service, Repairing the Air Valve, Tool Required, Disassembly, Reassembly

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Service

Service

Repairing the Air Valve

Tool Required

•Torque wrench

•Torx (T20) screwdriver or 7 mm (9/32 in.) socket wrench

•Needle-nose pliers

•O-ring pick

•Lithium base grease

Air Valve Repair Kit 255061 is available. Parts included in the kit are marked with a symbol, for example (4†). Use all the parts in the kit for the best results.

Disassembly

To reduce the risk of serious injury, whenever you are instructed to relieve pressure, always follow the Pres- sure Relief Procedure on page 11.

1.Relieve the pressure.

2.With a Torx (T20) screwdriver or 7 mm (9/32 in.) socket wrench, remove the six screws (3), air valve cover (2), and gasket (4). See FIG. 5.

3.Move the valve carriage (5) to the center position and pull it out of the cavity. Remove the valve block

(7)and o-ring (6) from the carriage. Using a nee- dle-nose pliers, pull the pilot block (18) straight up and out of the cavity. See FIG. 6.

4.Pull the two actuator pistons (11) out of the bearings

(12). Remove the u-cup packings (10) from the pis- tons. Pull the pilot pins (16) out of the bearings (15). Remove the o-rings (17) from the pilot pins. See FIG. 7.

5.Inspect the valve plate (8) in place. If damaged, use a Torx (T20) screwdriver or 7 mm (9/32 in.) socket wrench to remove the three screws (3). Remove the valve plate (8). See FIG. 8.

6.Inspect the bearings (12, 15) in place. See FIG. 7. The bearings are tapered and, if damaged, must be removed from the outside. This requires disassem- bly of the fluid section. See page 24.

7.Clean all parts and inspect for wear or damage. Replace as needed. Reassemble.

Reassembly

1.If you replaced the bearings (12, 15), reinstall as explained on page 24. Reassemble the fluid section.

2.Install the valve plate (8) in the cavity, seal down. Install the three screws (3), using a Torx (T20) screwdriver or 7 mm (9/32 in.) socket wrench. Tighten until the screws bottom out on the housing. See FIG. 8.

3.Install an o-ring (17†) on each pilot pin (16). Grease the pins and o-rings. Insert the pins into the bear- ings (15), narrow end first. See FIG. 7.

4.Install a u-cup packing (10†) on each actuator pis- ton (11), so the lips of the packings face the narrow end of the pistons. See FIG. 7.

5.Lubricate the u-cup packings (10†) and actuator pis- tons (11). Insert the actuator pistons in the bearings (12), wide end first. Leave the narrow end of the pis- tons exposed. See FIG. 7.

6.Grease the lower face of the pilot block (18†) and install so its tabs snap into the grooves on the ends of the pilot pins (16). See FIG. 6.

7.Grease the o-ring (6†) and install it in the valve block (7†). Push the block onto the valve carriage

(5). Grease the lower face of the valve block. See FIG. 6.

8.Install the valve carriage (5) so its tabs slip into the grooves on the narrow end of the actuator pistons (11). See FIG. 6.

9.Align the valve gasket (4†) and cover (2) with the six holes in the center housing (1). Secure with six screws (3†), using a Torx (T20) screwdriver or 7 mm (9/32 in.) socket wrench. Torque to 52-60 in-lb (5.6-6.8 N•m). See FIG. 5.

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Contents Important Safety Instructions Instructions Parts ListII 2 G Contents Certificate of Conformance Fire and Explosion Hazard Toxic Fluid or Fumes Hazard Installation General InformationTightening Clamps Before First Use GroundingAir Line MountingsFluid Suction Line Fluid Outlet Line KeyChanging the Orientation of the Fluid Inlet Outlet Ports Air Exhaust Ventilation Venting Exhaust AirPressure Relief Procedure Starting and Adjusting the PumpOperation Sanitize the Pump Before First UseOperation Maintenance Preventive Maintenance ScheduleLubrication FlushingTroubleshooting Problem Cause SolutionTroubleshooting Service Repairing the Air ValveDisassembly ReassemblyTorque to 52-60 in-lb Ball Check Valve Repair Tools RequiredStandard Diaphragm Repair Reassembly Cutaway view, with diaphragms in place Heavy-Duty Diaphragm Repair 24 104 403 106 101 Bearing and Air Gasket Removal Detail of air valve bearings FDA-Compliant Stainless Steel Sanitary Pumps Pump MatrixFD1111 FD1122 FD1211 FD1222 FD1113 FD1213 FD1132 FD1232 Repair Kit Matrix For 1040 Stainless Steel Sanitary PumpsFK1111 FK1111 FK1122 FK1211 FK1222 FK1113 FK1213 FK1132 FK1232Parts Detail of Heavy-Duty DiaphragmAir Motor Parts List Matrix Column Fluid Section Parts List Matrix Column Seat Parts List Matrix ColumnBall Parts List Matrix Column Diaphragm Parts List Matrix ColumnPump Mounting Dimensional Drawing1040 FDA Technical Data Wetted materials on all models SSTPerformance Chart Fluid Pressure CurvesTo find Fluid Outlet Pressure Air Consumption CurvesFD2111 FD2122 FD2211 FD2222 FD2113 FD2213 FD2132 FD2232 FD2 All 1590 Stainless Steel FDA-Compliant PumpsFK2111 For 1590 Stainless Steel Sanitary PumpsFK2111 FK2122 FK2211 FK2222 FK2113 FK2213 FK2132 FK2232 TI8927b Air Motor Parts List Matrix Column SST Pump Mounting Hole Pattern 1590 FDAMaximum fluid working pressure Psi 0.8 MPa, 8 bar To find Pump Air Pressure FD3111 FD3122 FD3211 FD3222 FD3113 FD3213 FD3132 FD3232 FD3 All 2150 SST FDA-Compliant PumpsFK3111 For 2150 Stainless Steel Sanitary PumpsFK3111 FK3122 FK3211 FK3222 FK3113 FK3213 FK3132 FK3232 110 103 Air Motor Parts List Matrix Column 113 510490 CLAMP, sanitary 2150 FDA Gpm 568 lpm Fluid Graco Standard Pump Warranty Extended Product WarrantyGraco Warranties Graco Information

FD2 1590 specifications

The Hitachi FD2 1590 is a noteworthy addition to the world of industrial and commercial machinery, designed to meet the evolving needs of businesses that require robust, dependable equipment for their heavy-duty operations. This machine is engineered for versatility, equipped to handle a variety of tasks efficiently.

One of the standout features of the Hitachi FD2 1590 is its powerful engine, which delivers impressive torque and horsepower. This allows the equipment to perform effectively in challenging conditions, providing the necessary force to tackle tough terrains and heavy loads. The fuel efficiency of the engine also contributes to reduced operational costs, making it a cost-effective solution for businesses.

The FD2 1590 embraces advanced technologies that enhance its operational capabilities. Among these technologies are sophisticated hydraulic systems that allow for smooth operation and precise control. This ensures that the machine can carry out tasks such as lifting, moving, and digging with greater accuracy and ease. The hydraulic system is designed for quick response times, enabling operators to navigate their workload efficiently.

Durability is a hallmark of the Hitachi FD2 1590, as it is constructed with high-quality materials that withstand the rigors of daily use. The robust frame and components are designed to resist wear and tear, minimizing maintenance needs and extending the lifespan of the equipment. This reliability is crucial for businesses that depend on their machinery for consistent performance.

Operator comfort and safety are also key considerations in the design of the FD2 1590. The operator's cabin is spacious and ergonomically designed, providing easy access to controls and excellent visibility of the work area. Safety features such as reinforced structures, emergency shut-off systems, and stability controls further enhance the protection of both the operator and the machine.

In terms of technological integration, the Hitachi FD2 1590 is compatible with various monitoring systems that streamline operations. These systems offer data analytics capabilities that allow operators to track performance metrics, fuel consumption, and maintenance schedules in real-time. This connectivity not only optimizes machine efficiency but also informs better decision-making for operational improvements.

In summary, the Hitachi FD2 1590 is a powerful, durable, and technologically advanced machine, ideal for heavy-duty applications. Its performance capabilities, alongside its operator-friendly design and safety features, make it a valuable asset for any business looking to enhance its operational efficiency.
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