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

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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


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(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
    
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