Factory Technical Manual and Workshop Manual For Hitachi EX80U 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 EX80U
Contents
1.Technical Manual
INTRODUCTION
SAFETY
-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)
Others
-SYSTEM
–CONTROL SYSTEM
Outline
Engine Control
Pump Control
Travel Mode 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 Pumps (1 and 2)
Main Pump 3 and Pilot Pump
–SWING DEVICE
Outline
Swing Motor
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 V3lve
–PILOT VALVE
Outline
Operation
–TRAVEL DEVICE
Outline
Travel Motor
Travel Brake Valve
Travel Reduction Gear
–OTHERS (UPPERSTRUCTURE)
Pilot Shut-Off Valve
Shockless Valve
Solenoid Valve Unit
Pilot Relief Valve
EC Motor
–OTHERS (UNDERCARRIAGE)
Swing Bearing
Center Joint
Track Adjuster
-OPERATIONAL PERFORMANCE TEST
–INTRODUCTION
Operational Performance Tests
Preparation for Performance Test
–STANDARD
Operational Performance Standard Table
Main Pump P-Q Diagram
Sensor Activating Range
–ENGINE TEST
Engine Speed
Engine Compression Pressure
Valve Clearance
Nozzle Check
Injection Timing
–EXCAVATOR TEST
Travel Speed
Track Revolution Speed
Mistrack Check
Travel Motor 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
Boom Raise/Swing Combined Operation Check
–COMPONENT TEST
Primary Pilot Pressure
Secondary Pilot Pressure
Main Relief Valve Set Pressure
Overload Relief Valve Set Pressure
Main Pump Flow Rate Measurement
Swing Motor Drainage
Travel Motor Drainage
–ADJUSTMENT
Engine Speed Adjustment and Engine Learning
Boom Lowering Method When Engine Stalling
Check of Governor Lever and Fuel Cut Lever Position
-TROUBLESHOOTING
–GENERAL
Introduction
Diagnosing Procedure
Dr EX Operation
Main Controller Fault Code List
Main Controller Monitoring Item List
Dr EX Special Function (Service Mode)
Adjustment Data List
–COMPONENT LAYOUT
Main Components
Electrical System (Overview)
Electrical System (Monitor and Switches)
Pump Device
Travel Device
Swing Device
Component in Control Valve
–TROUBLESHOOTING A
Troubleshooting A Procedure
Fault Code List
Fault Code 01
Fault Code 07
–TROUBLESHOOTING B
Troubleshooting B Procedure
Relationship between Machine Trouble Symptoms and Related Parts
Correlation between Trouble Symptoms and Part Failures
Engine System Troubleshooting
All Actuator System Troubleshooting
Front Attachment System Troubleshooting
Swing System Troubleshooting
Travel System Troubleshooting
Blade System Troubleshooting
–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 Fuel Level Indicator
Malfunction of Air Filter Restriction Indicator
Malfunction of Electrolyte Level Indicator
Malfunction of Buzzer
Malfunction of Hour Meter
–ELECTRICAL SYSTEM INSPECTION
Precautions for Inspection and Maintenance
Instructions for Disconnecting Connectors
Fuse Continuity Test
Fusible Link Inspection
Battery Voltage Check
How to Troubleshoot Alternator Malfunctions
Continuity Check
Voltage and Current Check
Check by False Signal
Test Harness
2.Workshop Manual
INTRODUCTION
SAFETY
-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 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
–CONTROL VALVE
Remove and Install Control Valve 1
Disassemble Control Valve 1
Assemble Control Valve 1
Remove and Install Control Valve 2
Disassemble Control Valve 2
Assemble Control Valve 2
–SWING DEVICE
Remove and Install Swing Device
Disassemble Swing Reduction Gear
Assemble Swing Reduction Gear
Disassemble Swing Motor
Assemble Swing Motor
Maintenance Standard
–PILOT VALVE
Remove and Install Pilot Valves for Front Attachment and Swing
Disassemble Pilot Valve for Front Attachment and Swing
Assemble Pilot Valve for Front Attachment and Swing
Remove and Install Pilot Valve for Boom Swing
Disassemble Pilot Valve for Boom Swing
Assemble Pilot Valve for Boom Swing
–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 Shockless Valve
–SOLENOID VALVE
Remove and Install Solenoid Valve
Disassemble Proportional Solenoid Valve
Assemble Proportional Solenoid Valve Disassemble Pilot Relief Valve
Assemble Pilot Relief 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
Maintenance Standard
–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 AND LOWER ROLLER
Remove and Install Upper Roller
Disassemble and Assemble Upper Roller
Remove and Install Lower Roller
Disassemble Lower Roller
Assemble Lower Roller
Maintenance Standard
–TRACK
Remove and Install Rubber Track
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
Disassemble Boom Swing Cylinder
Assemble Boom Swing Cylinder
Disassemble Blade Cylinder
Assemble Blade Cylinder
Maintenance Standard
–GENERAL
Engine Specification
Identification
Lubrication
–INSPECTION AND MAINTENANCE
Engine Main Body
Lubricating System
Cooling System
Fuel System
Intake and Exaust System
Electrical System
–ENGINE SERVICING
Manihold
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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