Factory Technical Manual and Workshop Manual For Hitachi EX80-5 Excavators. Tons of illustrations, instructions, diagrams for step by step remove and install, assembly and disassembly, service, inspection, repair, troubleshooting, tune-ups.
Format: PDF
Language: English
Bookmarks: Yes
Searchable: Yes
Wiring Diagrams: Yes
Hydraulic Diagrams: Yes
Model
Hitachi EX80-5
Contents
1.Technical Manual
-GENERAL
–SPECIFICATION
Specifications
Working Ranges and Machine Transportation Dimensions Component Specification
–COMPONENT LAYOUT
Main Components
Electrical System (Overall System)
Electrical System (Monitor and Switch Panels)
Other Components
-SYSTEM
–CONTROL SYSTEM
Outline
Engine Control
Pump Control
–HYDRAULIC SYSTEM
Outline
Main Circuit
Pilot Circuit
–ELECTRICAL SYSTEM
Outline
Power Circuit
Bulb Check Circuit
Preheat Circuit
Engine Start Circuit
Charging Circuit
Surge Voltage Prevention Circuit
Accessory Circuit
Engine Stop Circuit
-COMPONENT OPERATION
–PUMP DEVICE
Outline
Main Pump
Pilot Pump
–SWING DEVICE
Outline
Swing Motor
Parking Brake Switch Valve
Valve Unit
Swing Reduction Gear
–CONTROL VALVE
Outline
Hydraulic Circuit
Flow Combiner Valve
Main Relief Set Pressure Change
Boom Anti-Drift Valve
Main Relief Valve
Overload Relief Valve
–PILOT VALVE
Outline
Operation
–TRAVEL DEVICE
Outline
Travel Motor
Travel Brake Valve
Travel Reduction Gear
–OTHERS (UPPERSTRUCTURE)
Pilot Shut-Off Valve
Shockless Valve
EC Motor
–OTHERS (UNDERCARRIAGE)
Swing Bearing
Center Joint
Track Adjuster
-OPERATIONAL PERFORMANCE TEST
–INTRODUCTION
Operational Performance Tests
Preparation for Performance Tests
–ENGINE TEST
Engine Speed
Engine Compression Pressure
Valve Clearance Adjustment
Nozzle Check
Injection Timing
–EXCAVATOR TEST
Travel Speed
Track Revolution Speed
Mistrack Check
Travel Parking Function Check
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 Boom Raise/Swing Function Check
–COMPONENT TEST
Primary Pilot Pressure
Secondary Pilot Pressure
Main Relief Valve Set Pressure
Overload Relief Valve Set Pressure
Main Pump Flow Test
Swing Motor Drainage
Travel Motor Drainage
–STANDARD
Operational Performance Standard Table
Main Pump P-Q Diagram
Injection Pump
-TROUBLESHOOTING
–DIAGNOSING PROCEDURE
Introduction
Diagnosing Procedure
Operating DrEX
MC System Fault Code List
DrEX Monitoring Function
DrEX Special Function (Service Mode)
Adjustable Data List
–COMPONENT LAYOUT
Main Components
Electrical System (Overall System)
Electrical System (Monitor and Switch)
Control Valve
Others
–TROUBLESHOOTING A
Troubleshooting A Procedure
Fault Code 01
Fault Code 07
Sensor Operating Range
–TROUBLESHOOTING B
Troubleshooting B Procedure
Relationship between Machine Symptoms and Problem Parts
Correlation between Trouble Symptoms and Part Failures
Engine Troubleshooting
Actuator Control System Troubleshooting
Front Attachment Control System Troubleshooting
Swing System Troubleshooting
Travel System Troubleshooting
Blade System Troubleshooting
Engine Speed Adjustment and Engine Learning
Boom Lowering Method When Engine Stalling
–TROUBLESHOOTING C
Troubleshooting C Procedure
Malfunction of Coolant Temperature Gauge
Malfunction of Fuel Gauge
Malfunction of Indicator Light Check System
Malfunction of Alternator Indicator
Malfunction of Engine Oil Pressure Indicator
Malfunction of Overheat Indicator
Malfunction of Air Filter
Restriction Indicator
Malfunction of Buzzer
Malfunction of Hour Meter
–ELECTRICAL SYSTEM INSPECTION
Precautions for Inspection and Maintenance
Instructions for Disconnecting Connectors
Fuse Continuity Test
Inspection and Replacement of Fusible Links
Battery Voltage Check
How to Troubleshoot Alternator Malfunctions
Continuity Check
Voltage and Current Check
Check Using False Signal
Circuit Check
2.Workshop Manual
-GENERAL INFORMATION
–PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING
Precautions for Disassembling and Assembling
–TIGHTENING TORQUE
Tightening Torque Specification
Torque Chart
Piping Joint
Periodic Replacement of Parts
-UPPERSTRUCTURE
–CAB
Remove and Install Cab
Dimensions of the Cab Glass
–COUNTERWEIGHT
Remove and Install Counterweight
–MAIN FRAME
Remove and Install Main Frame
–PUMP DEVICE
Remove and Install Pump Device
Disassemble Pump Device
Assemble Pump Device
Maintenance Standard
Disassemble and Assemble Pilot Pump
Disassemble and Assemble Blade Pump and Pilot Pump
–CONTROL VALVE
Remove and Install Control Valve
Disassemble Control Valve
Assemble Control Vave
Remove and Install Blade Control Valve
Disassemble Blade Control Valve
Assemble Blade Control Valve
–SWING DEVICE
Remove and Install Swing Device
Disassemble Swing Device
Assemble Swing Device
Disassemble Swing Motor
Assemble Swing Motor
Maintenance Standard
–PILOT VALVE
Remove and Install Right Pilot Valve
Remove and Install Left Pilot Valve
Disassemble Pilot Valve for Front Attachment
Assemble Pilot Valve for Front Attachment
–PILOT SHUT-OFF VALVE
Remove and Install Pilot Shut-off Valve
Disassemble Pilot Shut-off Valve
Assemble Pilot Shut-off Valve
–SHOCKLESS VALVE
Remove and Install Shockless Valve
Disassemble and Assemble Swing Shockless Valve
Disassemble and Assemble Front Attachment Shockless Valve
-UNDERCARRIAGE
–SWING BEARING
Remove And Install Swing Bearing
Disassemble Swing Bearing
Assemble Swing Bearing
–TRAVEL DEVICE
Remove And Install Travel Device
Disassemble Travel Device
Assemble Travel Device
Disassemble Travel Motor
Assemble Travel Motor
Disassemble And Assemble Brake Valve
Maintenance Standard
–CENTER JOINT
Remove And Install Center Joint
Disassemble Center Joint
Assemble Center Joint
–TRACK ADJUSTER
Remove And Install Track Adjuster
Disassemble Track Adjuster
Assemble Track Adjuster
–FRONT IDLER
Remove And Install Front Idler
Disassemble Front Idler
Assemble Front Idler
Maintenance Standard
–UPPER ROLLER
Remove And Install Upper Roller
Disassemble And Assemble Upper Roller
Remove And Install Lower Roller
Disassemble Lower Roller
Assemble Lower Roller
Maintenance Standard
–TRACKS
Remove And Install Tracks
Maintenance Standard
-FRONT ATTACHMENT
–FRONT ATTACHMENT
Remove and Install
Front Attachment
Maintenance Standard
Standard Dimensions for Arm and Bucket Connection
–CYLINDER
Remove and Install Cylinder
Disassemble Cylinder
Assemble Cylinder
Maintenance Standard
-ENGINE AND ACCESSORY
–GENERAL
Engine Specification
Identification
Lubrication
–INSPECTION AND MAINTENANCE
Engine Main Body
Lubricating System
Cooling System
Fuel System
Intake and Exhaust System
Electrical System
–ENGINE SERVICING
Manifold
Rocker Cover
Rocker Shaft
Cylinder Head
Gear Train
Injection Pump
Oil Pan
Oil Cooler
Oil Pump
Water Pump
Thermostat
–ENGINE MAIN BODY OVERHAULING
Precaution for Overhauling
Engine Main Body Overhauling
–SERVICE DATA
Engine Major Component
Tightening Torque
Engine Main Body Specifications
Standard Tightening Torque
–TROUBLESHOOTING
Trouble Shooting Chart
Hou to Use the Chart
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