Hitachi EX750-5, EX800H-5 Crawler Hydraulic Excavator Repair Service Technical Manual

–
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 Hitachi EX750-5, EX800H-5 Crawler Hydraulic Excavator.

APPLICABLE MODELS :

Hitachi Excavator EX750-5
Hitachi Excavator EX800H-5

TABLE OF CONTENTS :

(Operational Principle)

SECTION 1 GENERAL
GROUP 1 Specifications
GROUP 2 Component Specifications
GROUP 3 Component Layout

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 Swing Device
GROUP 3 Control Valve
GROUP 4 Pilot Valve
GROUP 5 Travel Device
GROUP 6 Others (Upperstructure)
GROUP 7 Others (Undercarriage)

(Troubleshooting)

SECTION 4 OPERATIONAL PERFORMANCE TEST
GROUP 1 Introduction
GROUP 2 Engine Test
GROUP 3 Excavator Test
GROUP 4 Component Test
GROUP 5 Standard

SECTION 5 TROUBLESHOOTING
GROUP 1 Diagnosing Procedure
GROUP 2 Component Layout
GROUP 3 Troubleshooting A
GROUP 4 Troubleshooting B
GROUP 5 Troubleshooting C
GROUP 6 Electrical System Inspection

CIRCUIT DIAGRAM

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Total Pages : 371

This service repair workshop technical 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.

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

–

(Operational Principle)

SECTION 1 GENERAL
GROUP 1 Specifications
SPECIFICATIONS
WORKING RANGES/ TRANSPORTING DIMENSIONS (BACKHOE)
WORKING RANGES/ TRANSPORTING DIMENSIONS (LOADING SHOVEL)
GROUP 2 Component Specifications
ENGINE
ENGINE ACCESSORIES
HYDRAULIC COMPONENTS
ELECTRICAL COMPONENTS
GROUP 3 Component Layout
MAIN COMPONENTS
ELECTRICAL SYSTEM (1)
ELECTRICAL SYSTEM (2)
ELECTRICAL SYSTEM (3)
CONTROL VALVE
OTHERS

SECTION 2 SYSTEM
GROUP 1 Control System
OUTLINE
ENGINE CONTROL
PUMP CONTROL
VALVE CONTROL
OTHER CONTROL
GROUP 2 Hydraulic System
OUTLINE
MAIN CIRCUIT
PILOT CIRCUIT
COUNTERWEIGHT REMOVE/INSTALL CIRCUIT (Optional)
GROUP 3 Electrical System
OUTLINE
POWER CIRCUIT
BULB CHECK CIRCUIT
ENGINE START CIRCUIT
CHARGING CIRCUIT
ACCESSORY CIRCUIT
SURGE VOLTAGE PREVENTION CIRCUIT
ENGINE STOP CIRCUIT

SECTION 3 COMPONENT OPERATION
GROUP 1 Pump Device
OUTLINE
MAIN PUMP
REGULATORS
PILOT PUMP
GROUP 2 Swing Device
OUTLINE
SWING MOTOR
VALVE UNIT
SWING PARKING BRAKE
SWING REDUCTION GEAR
GROUP 3 Control Valve
OUTLINE
CONTROL VALVE
HYDRAULIC CIRCUITS
FLOW COMBINER VALVE
CENTER BYPASS VALVE (Loading Shovel Only)
PUMP CONTROL VALVE
MAIN RELIEF VALVE
OVERLOAD RELIEF VALVE (With Make-Up Function)
HOLDING VALVE
ARM REGENERATIVE VALVE
GROUP 4 Pilot Valve
OUTLINE
OPERATION
GROUP 5 Travel Device
OUTLINE
TRAVEL REDUCTION GEAR
TRAVEL MOTOR
TRAVEL BRAKE VALVE
TRAVEL MOTOR DISPLACEMENT ANGLE SHIFT
PARKING BRAKE
GROUP 6 Others (Upperstructure)
PILOT SHUT-OFF VALVE
SHOCKLESS VALVE
SOLENOID VALVE
ACCUMULATOR
GROUP 7 Others (Undercarriage)
SWING BEARING
CENTER JOINT
TRACK ADJUSTER

REVISION REQUEST FORM

(Troubleshooting)

SECTION 4 OPERATIONAL PERFORMANCE TEST
GROUP 1 Introduction
OPERATIONAL PERFORMANCE TESTS
PREPARATION FOR PERFORMANCE TESTS
GROUP 2 Engine Test
ENGINE SPEED
INJECTOR AND VALVE CLEARANCE AD-JUSTMENT
GROUP 3 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
BOOM RAISE/SWING COMBINED OPERA-TION CHECK
GROUP 4 Component Test
PRIMARY PILOT PRESSURE
SECONDARY PILOT PRESSURE
SWING PREFERENCE CIRCUIT SHIFT CONTROL PRESSURE (MA Pressure)
MAIN RELIEF PRESSURE SHIFT CON-TROL PRESSURE (SA Pressure)
TRAVEL MODE SHIFT CONTROL PRES-SURE (SB Pressure)
MAIN RELIEF PRESSURE
OVERLOAD RELIEF VALVE SET PRES-SURE
MAIN PUMP FLOW TEST
SWING MOTOR DRAINAGE
TRAVEL MOTOR DRAINAGE
GROUP 5 Standard
OPERATIONAL PERFORMANCE STANDARD TABLE

SECTION 5 TROUBLESHOOTING
GROUP 1 Diagnosing Procedure
INTRODUCTION
DIAGNOSING PROCEDURE
Dr.EX
Dr.EX START-UP PROCEDURE
CLEARING THE SELF-DIAGNOSING FUNCTION
RETRIAL “A” (For problems with the con-troller (PVC and EC) )
RETRIAL “B” (For problems with the sen-sors)
FAULT CODE LIST
MONITORING FUNCTION
GROUP 2 Component Layout
OTHERS
MAIN COMPONENTS
ELECTRICAL SYSTEM (1)
ELECTRICAL SYSTEM (2)
ELECTRICAL SYSTEM (3)
CONTROL VALVE
GROUP 3 Troubleshooting A
SENSOR OPERATING RANGE LIST
TROUBLESHOOTING A PROCEDURE
FAULT CODE LIST
FAULT CODES 01, 02, 03, 04, 06(EC Failure)
FAULT CODE 05 (Communication Failure between PVC and EC)
FAULT CODES 09, 10 (EC Sensor Failure)
FAULTCODES 11, 12 (Engine Control Dial Failure)
FAULT CODE 13 (N Sensor Failure)
FAULT CODES 14, 15 (Overheat Switch L Failure, Hydraulic Oil Temperature Sensor Failure)
FAULT CODES 17, 18, 19, 21, 22 (PVC Failure)
FAULT CODE 20 (Communication Failure between PVC and EC)
FAULT CODES 23, 24 (Pump Control Failure)
FAULT CODES 25, 26, 33, 34 (DP Sensor Failure)
FAULT CODES 27, 28, 35, 36 (P Sensor Failure)
FAULT CODES 29, 30, 37, 38 (A Sensor Failure)
GROUP 4 Troubleshooting B
TROUBLESHOOTING B PROCEDURE
CORRELATION BETWEEN PART FAILURE AND ABNORMALITIES THAT MACHINE MAY SHOW
CORRELATION BETWEEN TROUBLES AND PART FAILURES
ENGINE SYSTEM TROUBLESHOOTING
TOTAL ACTUATOR SYSTEM TROUBLESHOOTING
FRONT ATTACHMENT SYSTEM TROUBLESHOOTING
SWING SYSTEM TROUBLESHOOTING
TRAVEL SYSTEM TROUBLESHOOTING
TROUBLESHOOTING FOR OTHER FUNCTIONS
ENGINE SPEED ADJUSTMENT
EC SENSOR INSTALLATION AND VOLT-AGE ADJUSTMENT
INSTALLATION AND ADJUSTMENT OF THE A SENSOR
GROUP 5 Troubleshooting C
TROUBLESHOOTING C (TROUBLESHOOTING FOR MONITOR) PROCEDURE
MALFUNCTION OF COOLANT TEMPERATURE GAUGE
MALFUNCTION OF FUEL GAUGE
MALFUNCTION OF INDICATOR BULB CHECK SYSTEM
MALFUNCTION OF ENGINE OIL LEVEL INDICATOR
MALFUNCTION OF COOLANT LEVEL IN-DICATOR
MALFUNCTION OF HYDRAULIC OIL LEVEL INDICATOR
MALFUNCTION OF ALTERNATOR INDICATOR
MALFUNCTION OF ENGINE OIL PRESSURE INDICATOR
MALFUNCTION OF OVERHEAT INDICA-TOR
MALFUNCTION OF FUEL LEVEL INDICATOR
MALFUNCTION OF AIR FILTER RESTRICTION INDICATOR
MALFUNCTION OF HOUR METER
MALFUNCTION OF BUZZER
MALFUNCTION OF WORK LIGHT INDICA-TOR
MALFUNCTION OF QUICK IDLE INDICATOR
GROUP 6 Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND MAINTENANCE
INSTRUCTIONS FOR DISCONNECTING CONNECTORS
FUSE CONTINUITY TEST
FUSIBLE LINK INSPECTION AND REPLACEMENT
HOW TO TROUBLESHOOT ALTERNATOR MALFUNCTIONS
CONTINUITY CHECK
VOLTAGE AND CURRENT CHECK
RELAY REPLACEMENT PROCEDURE
CIRCUIT CHECK

REVISION REQUEST FORM

CIRCUIT DIAGRAM
EX750-5 EX800H-5 HYDRAULIC CIRCUIT DIAGRAM (BACKHOE)
EX750-5 EX800H-5 HYDRAULIC CIRCUIT DIAGRAM (BACKHOE:C/W REMOVE/INSTALL DEVICE)
EX750-5 EX800H-5 HYDRAULIC CIRCUIT DIAGRAM (LOADING SHOVEL)
EX750-5 EX800H-5 ELECTRICAL CIRCUIT DIAGRAM1 (Serial No. A)
EX750-5 EX800H-5 ELECTRICAL CIRCUIT DIAGRAM2 (Serial No. A)
EX750-5 EX800H-5 ELECTRICAL CIRCUIT DIAGRAM 1 (Serial No. B)
EX750-5 EX800H-5 ELECTRICAL CIRCUIT DIAGRAM 2 (Serial No. B)
EX750-5 CAB HARNESS 1
EX750-5 CAB HARNESS 2
EX800H-5 CAB HARNESS 1
EX800H-5 CAB HARNESS 2
EX750-5 EX800H-5 CAB HARNESS 1
EX750-5 EX800H-5 CAB HARNESS 2
EX750-5 EX800H-5 ENGINE HARNESS
EX750-EX800H-ENGINE HARNESS
EX750-5 EX800H-5 ENGINE HARNESS
EX750-5 RELAY HARNESS
EX800H-5 RELAY HARNESS

–