Hitachi Ex75UR-5 75US-5 Excavator Operational Principle Technical Manual – PDF DOWNLOAD

Description

Hitachi Ex75UR-5 75US-5 Excavator Operational Principle Technical Manual

FILE DETAILS:

Hitachi Ex75UR-5 75US-5 Excavator Operational Principle Technical Manual 

Language : English
Pages : 987
Downloadable : YES
Format : PDF
Size : 21.9 MB

DESCRIPTION:

Hitachi Ex75UR-5 75US-5 Excavator Operational Principle Technical Manual 

INTRODUCTION:

TO THE READER:
• This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
• Be sure to thoroughly read this manual for correct product information and service procedures.
• If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual.

ADDITIONAL REFERENCES:

• Please refer to the materials listed below in addition to this manual.
• The Operator’s Manual
• The Parts Catalog
• The Engine Manual
• Parts Catalog of the Engine
• Hitachi Training Material

MANUAL COMPOSITION:
• This manual consists of three portions: the Technical Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual.
• Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems.
• Information included in the Technical Manual (Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures.
• Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assemble/ disassemble procedures.

TABLE OF CONTENTS:

Hitachi Ex75UR-5 75US-5 Excavator Operational Principle Technical Manual 

index_to 1
INDEX 1
INDEX(TO) 1
INTRODUCTION 1
SECTION 1 GENERAL 1
SECTION 2 SYSTEM 1
SECTION 3 COMPONENT OPERATION 1
Intro 2
INDEX 2
INDEX(TO) 2
INTRODUCTION 2
SECTION 1 GENERAL 2
SECTION 2 SYSTEM 2
SECTION 3 COMPONENT OPERATION 2
T01 4
INDEX 4
INDEX(TO) 4
INTRODUCTION 4
SECTION 1 GENERAL 4
Specifications 6
SPECIFICATIONS 6
WORKING RANGES AND MACHINE TRANSPORTATION DIMENSIONS 8
COMPONENT SPECIFICATION 10
Component Layout 16
MAIN COMPONENTS 16
ELECTRICAL SYSTEM (Overall System) 17
ELECTRICAL SYSTEM 19
OTHERS 21
SECTION 2 SYSTEM 4
SECTION 3 COMPONENT OPERATION 4
T02 22
INDEX 22
INDEX(TO) 22
INTRODUCTION 22
SECTION 1 GENERAL 22
SECTION 2 SYSTEM 22
Control System 24
OUTLINE 24
ENGINE CONTROL 25
PUMP CONTROL 31
OTHER CONTROLS 35
Front Control System 36
OUTLINE 36
FRONT FUNCTION CONTROL 37
Hydraulic System 58
OUTLINE 58
MAIN CIRCUIT 59
PILOT CIRCUIT 67
Electrical System 70
OUTLINE 70
POWER SOURCE CIRCUIT (Key Switch: OFF) 71
BULB CHECK CIRCUIT (Key Switch: ON) 72
PREHEAT CIRCUIT (Key Switch: HEAT) 73
ENGINE START CIRCUIT (Key Switch: START) 75
CHARGING CIRCUIT (KEY SWITCH: ON) 77
SURGE VOLTAGE PREVENTION CIRCUIT 80
ACCESSORY CIRCUIT 81
ENGINE STOP CIRCUIT 82
SECTION 3 COMPONENT OPERATION 22
T03 84
INDEX 84
INDEX(TO) 84
INTRODUCTION 84
SECTION 1 GENERAL 84
SECTION 2 SYSTEM 84
SECTION 3 COMPONENT OPERATION 84
Pump Device 86
OUTLINE 86
MAIN PUMPS (1 and 2) 88
MAIN PUMP 3 AND PILOT PUMP 91
Swing Device 92
OUTLINE 92
SWING MOTOR 93
VALVE UNIT 95
SWING REDUCTION GEAR 97
Control Valve 98
OUTLINE 98
HYDRAULIC CIRCUIT105
FLOW COMBINER VALVE109
MAIN RELIEF SET PRESSURE CHANGE110
BOOM ANTI-DRIFT VALVE111
MAIN RELIEF VALVE113
OVERLOAD RELIEF VALVE114
Pilot Valve116
OUTLINE116
OPERATION118
Travel Device126
OUTLINE126
TRAVEL MOTOR127
PARKING BRAKE133
TRAVEL BRAKE VALVE134
TRAVEL REDUCTION GEAR136
Others (Upperstructure)138
PILOT SHUT-OFF VALVE138
SHOCKLESS VALVE139
9-UNIT SOLENOID VALVE145
SOLENOID VALVE UNIT147
OFFSET ANTI-DRIFT VALVE150
EC MOTOR153
Others (Undercarriage)154
SWING BEARING154
CENTER JOINT155
TRACK ADJUSTER156
index_tt158
INDEX158
INDEX(TT)158
INTRODUCTION158
SAFETY158
SECTION 4 OPERATIONAL PERFORMANCE TEST158
SECTION 5 TROUBLESHOOTING158
Intro159
INDEX159
INDEX(TT)159
INTRODUCTION159
SAFETY159
SECTION 4 OPERATIONAL PERFORMANCE TEST159
SECTION 5 TROUBLESHOOTING159
sa161
INDEX161
INDEX(TT)161
INTRODUCTION161
SAFETY161
SECTION 4 OPERATIONAL PERFORMANCE TEST161
SECTION 5 TROUBLESHOOTING161
T04189
INDEX189
INDEX(TT)189
INTRODUCTION189
SAFETY189
SECTION 4 OPERATIONAL PERFORMANCE TEST189
Introduction191
OPERATIONAL PERFORMANCE TESTS191
PREPARATION FOR PERFORMANCE TESTS192
Standard193
OPERATIONAL PERFORMANCE STANDARD TABLE193
MAIN PUMP P-Q DIAGRAM196
SENSOR ACTIVATING RANGE197
Engine Test199
ENGINE SPEED199
ENGINE COMPRESSION PRESSURE200
VALVE CLEARANCE202
NOZZLE CHECK204
INJECTION TIMING206
Excavator Test207
TRAVEL SPEED207
TRACK REVOLUTION SPEED208
MISTRACK CHECK209
TRAVEL MOTOR LEAKAGE210
SWING SPEED211
SWING FUNCTION DRIFT CHECK212
SWING MOTOR LEAKAGE213
MAXIMUM SWINGABLE SLANT ANGLE214
SWING BEARING PLAY215
HYDRAULIC CYLINDER CYCLE TIME216
DIG FUNCTION DRIFT CHECK218
CONTROL LEVER OPERATING FORCE220
CONTROL LEVER STROKE221
BOOM RAISE/SWING COMBINED OPERATION CHECK222
Component Test223
PRIMARY PILOT PRESSURE223
SECONDARY PILOT PRESSURE225
MAIN RELIEF VALVE SET PRESSURE226
OVERLOAD RELIEF VALVE SET PRESSURE232
MAIN PUMP FLOW RATE MEASUREMENT236
SWING MOTOR DRAINAGE240
TRAVEL MOTOR DRAINAGE242
Adjustment245
ENGINE SPEED ADJUSTMENT AND ENGINE LEARNING245
BOOM LOWERING METHOD WHEN ENGINE STALLING246
CHECK OF GOVERNOR LEVER AND FUEL CUT LEVER POSITION248
ASSEMBLY AND ADJUSTMENT OF LINK FOR ARM ANGLE SENSOR (EX75UR-5)250
INITIAL SETTING OF THE ANGLE SENSOR (EX75UR-5)251
INITIALIZING THE DEPTH LIMIT CONTROL SYSTEM (EX75UR-5)252
SECTION 5 TROUBLESHOOTING189
T05255
INDEX255
INDEX(TT)255
INTRODUCTION255
SAFETY255
SECTION 4 OPERATIONAL PERFORMANCE TEST255
SECTION 5 TROUBLESHOOTING255
General257
INTRODUCTION257
DIAGNOSTIC PROCEDURES258
DrEX OPERATION260
MAIN CONTROLLER FAULT CODE LIST261
AUTO-MARCCINO CONTROL UNIT FAULT CODE LIST (EX75UR-5)262
MAIN CONTROLLER MONITORING FUNCTION266
AUTO-MARCCINO CONTROL UNIT MONI-TORING FUNCTION (EX75UR-5)267
DrEX SPECIAL FUNCTION (Service Mode) (EX75UR-5)268
Component Layout277
MAIN COMPONENTS277
ELECTRICAL SYSTEM (OVERVIEW)278
ELECTRICAL SYSTEM (Monitor and Switches)280
PUMP DEVICE282
SWING DEVICE282
TRAVEL DEVICE282
COMPONENT IN CONTROL VALVE284
Troubleshooting A291
TROUBLESHOOTING A PROCEDURE291
FAULT CODE 01292
FAULT CODE 07293
Troubleshooting B295
TROUBLESHOOTING B PROCEDURE295
RELATIONSHIP BETWEEN MACHINE SYMPTOMS AND PROBLEM PARTS296
CORRELATION BETWEEN TROUBLE SYMPTOMS AND PART FAILURES302
ENGINE SYSTEM TROUBLESHOOTING308
ALL ACTUATOR SYSTEM TROUBLESHOOTING318
FRONT ATTACHMENT SYSTEM TROUBLESHOOTING320
SWING SYSTEM TROUBLESHOOTING326
TRAVEL SYSTEM TROUBLESHOOTING328
BLADE SYSTEM TROUBLESHOOTING331
Troubleshooting C333
TROUBLESHOOTING C PROCEDURE (Troubleshooting for Monitor)333
MALFUNCTION OF COOLANT TEMPERATURE GAUGE334
MALFUNCTION OF FUEL GAUGE336
MALFUNCTION OF INDICATOR LIGHT CHECK SYSTEM338
MALFUNCTION OF ALTERNATOR INDICATOR340
MALFUNCTION OF ENGINE OIL PRESSURE INDICATOR342
MALFUNCTION OF OVERHEAT INDICATOR344
MALFUNCTION OF FUEL LEVEL INDICATOR346
MALFUNCTION OF AIR FILTER RESTRICTION INDICATOR348
MALFUNTION OF BUZZER350
MALFUNCTION OF HOUR METER352
Troubleshooting D353
TROUBLESHOOTING D PROCEDURE (EX75UR-5)353
AUTO-MARCCINO CONTROL UNIT FAULT CODE LIST354
FAULT CODE 03 358
FAULT CODE 05, 06359
FAULT CODE 07, 08360
FAULT CODE 09361
FAULT CODE 11, 12, 13, 17362
FAULT CODE 14, 15, 16, 19, 20, 21, 22364
FAULT CODE 24366
FAULT CODE 40, 41368
FAULT CODE 43, 45, 47, 48369
FAULT CODE 50, 51, 52, 53370
FAULT CODE 60, 61, 62, 63372
FAULT CODE 80, 81, 82, 83373
FAULT CODE 90374
FAULT CODE 91375
Electrical System Inspection377
PRECAUTIONS FOR INSPECTION AND MAINTENANCE377
INSTRUCTIONS FOR DISCONNECTING CONNECTORS379
FUSE CONTINUITY TEST380
FUSIBLE LINK INSPECTION381
BATTERY VOLTAGE CHECK382
HOW TO TROUBLESHOOTING ALTERNATOR MALFUNCTIONS383
CONTINUITY CHECK384
VOLTAGE AND CURRENT CHECK386
CHECK BY FALSE SIGNAL389
TEST HARNESS390
EX75UR-5 CAB(E)391
EX75UR-5 CON(E)392
EX75UR-5 ELEC(E)393
EX75UR-5 ENG(E)394
EX75UR-5 HYD(E)395
EX75US-5 CAB(E)396
EX75US-5 CON(E)397
EX75US-5 ELEC(E)398
EX75US-5 ENG(E)399
EX75US-5 HYD(E)400
index_w401
INDEX401
INDEX(W)401
INTRODUCTION401
SAFETY401
SECTION 1 GENERAL INFORMATION401
SECTION 2 UPPERSTRUCTURE401
SECTION 3 UNDERCARRIAGE401
SECTION 4 FRONT ATTACHMENT401
SECTION 5 ENGINE AND ACCESSORY401
Intro402
INDEX402
INDEX(W)402
INTRODUCTION402
SAFETY402
SECTION 1 GENERAL INFORMATION402
SECTION 2 UPPERSTRUCTURE402
SECTION 3 UNDERCARRIAGE402
SECTION 4 FRONT ATTACHMENT402
SECTION 5 ENGINE AND ACCESSORY402
sa404
INDEX404
INDEX(W)404
INTRODUCTION404
SAFETY405
SECTION 1 GENERAL INFORMATION404
SECTION 2 UPPERSTRUCTURE404
SECTION 3 UNDERCARRIAGE404
SECTION 4 FRONT ATTACHMENT404
SECTION 5 ENGINE AND ACCESSORY404
W01432
INDEX432
INDEX(W)432
INTRODUCTION432
SAFETY432
SECTION 1 GENERAL INFORMATION432
Precautions for Disassembling and Assembling434
PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING434
Tightening440
TIGHTENING TORQUE SPECIFICATIONS440
TORQUE CHART441
PIPING JOINT444
PERIODIC REPLACEMENT OF PARTS448
SECTION 2 UPPERSTRUCTURE432
SECTION 3 UNDERCARRIAGE432
SECTION 4 FRONT ATTACHMENT432
SECTION 5 ENGINE AND ACCESSORY432
W02450
INDEX450
INDEX(W)450
INTRODUCTION450
SAFETY450
SECTION 1 GENERAL INFORMATION450
SECTION 2 UPPERSTRUCTURE450
Cab452
REMOVE AND INSTALL CAB452
DIMENSIONS OF THE CAB GLASS457
Counterweight460
REMOVE AND INSTALL COUNTERWEIGHT460
Main Frame466
REMOVE AND INSTALL MAIN FRAME466
Pump Device474
REMOVE AND INSTALL PUMP DEVICE474
DISASSEMBLE PUMP DEVICE477
ASSEMBLE PUMP DEVICE481
MAINTENANCE STANDARD487
DISASSEMBLE AND ASSEMBLE PILOT PUMP489
Control Valve492
REMOVE AND INSTALL CONTROL VALVE 1492
DISASSEMBLE CONTROL VALVE 1494
ASSEMBLE CONTROL VALVE 1504
REMOVE AND INSTALL CONTROL VALVE 2513
DISASSEMBLE CONTROL VALVE 2515
ASSEMBLE CONTROL VALVE 2517
Swing Device522
REMOVE AND INSTALL SWING DEVICE522
DISASSEMBLE SWING DEVICE525
ASSEMBLE SWING DEVICE531
DISASSEMBLE SWING MOTOR539
ASSEMBLE SWING MOTOR543
MAINTENANCE STANDARD549
Pilot Valve550
REMOVE AND INSTALL RIGHT PILOT VALVE (FOR FRONT ATTACHMENT)550
REMOVE AND INSTALL LEFT PILOT VALVE553
DISASSEMBLE RIGHT AND LEFT PILOT VALVES557
ASSEMBLE RIGHT AND LEFT PILOT VALVES561
REMOVE AND INSTALL TRAVEL PILOT VALVE568
DISASSEMBLE TRAVEL PILOT VALVE571
ASSEMBLE TRAVEL PILOT VALVE573
REMOVE AND INSTALL OFFSET PILOT VALVE578
DISASSEMBLE OFFSET PILOT VALVE581
ASSEMBIE OFFSET PILOT VALVE583
Pilot Shut-Off Valve586
REMOVE AND INSTALL PILOT SHUT-OFF VALVE586
DISASSEMBLE PILOT SHUT-OFF VALVE589
ASSEMBLE PILOT SHUT-OFF VALVE591
Shockless Valve594
REMOVE AND INSTALL SHOCKLESS USGVALVE594
DISASSEMBLE AND ASSEMBLE SHOCKLESS VALVE596
Solenoid Valve600
REMOVE AND INSTALL 9-SPOOL SOLENOID VALVE UNIT600
DISASSEMBLE AND ASSEMBLE 9-SPOOL SOLENOID VALVE UNIT603
DISASSEMBLE PROPORTIONAL SOLENOID VALVE605
ASSEMBLE PROPORTIONAL SOLENOID VALVE607
DISASSEMBLE AND ASSEMBLE ON-OFF SOLENOID VALVE609
REMOVE AND INSTALL SOLENOID VALVE UNIT611
DISASSEMBLE AND ASSEMBLE RELIEF VALVE613
DISASSEMBE AND ASSEMBLE UNLOAD VALVE615
Holding Valve618
REMOVE AND INSTALL HOLDING VALVE618
DISASSEMBLE HOLDING VALVE621
ASSEMBLE HOLDING VALVE623
SECTION 3 UNDERCARRIAGE450
SECTION 4 FRONT ATTACHMENT450
SECTION 5 ENGINE AND ACCESSORY450
W03626
INDEX626
INDEX(W)626
INTRODUCTION626
SAFETY626
SECTION 1 GENERAL INFORMATION626
SECTION 2 UPPERSTRUCTURE626
SECTION 3 UNDERCARRIAGE626
Swing Bearing628
REMOVE AND INSTALL SWING BEARING628
DISASSEMBLE SWING BEARING631
ASSEMBLE SWING BEARING633
Travel Device636
REMOVE AND INSTALL TRAVEL DEVICE636
DISASSEMBLE TRAVEL DEVICE638
ASSEMBLE TRAVEL DEVICE643
DISASSEMBLE TRAVEL MOTOR651
ASSEMBLE TRAVEL MOTOR653
DISASSEMBLE AND ASSEMBLE BRAKE VALVE655
MAINTENANCE STANDARD657
Center Joint658
REMOVE AND INSTALL CENTER JOINT658
DISASSEMBLE CENTER JOINT661
ASSEMBLE CENTER JOINT663
MAINTENANCE STANDARD666
Track Adjuster668
REMOVE AND INSTALL TRACK　ADJUSTER668
DISASSEMBLE TRACK ADJUSTER669
ASSEMBLE TRACK ADJUSTER675
Front Idler682
REMOVE AND INSTALL FRONT IDLER682
DISASSEMBLE FRONT IDLER683
ASSEMBLE FRONT IDLER685
MAINTENANCE STANDARD687
Upper And Lower Roller688
REMOVE AND INSTALL UPPER ROLLER688
DISASSEMBLE AND ASSEMBLE UPPER ROLLER691
REMOVE AND INSTALL LOWER ROLLER693
DISASSEMBLE LOWER ROLLER695
ASSEMBLE LOWER ROLLER697
MAINTENANCE STANDARD699
Track702
REMOVE AND INSTALL TRACKS702
MAINTENANCE STANDARD708
SECTION 4 FRONT ATTACHMENT626
SECTION 5 ENGINE AND ACCESSORY626
W04710
INDEX710
INDEX(W)710
INTRODUCTION710
SAFETY710
SECTION 1 GENERAL INFORMATION710
SECTION 2 UPPERSTRUCTURE710
SECTION 3 UNDERCARRIAGE710
SECTION 4 FRONT ATTACHMENT710
Front Attachment712
REMOVE AND INSTALL FRONT ATTACHMENT712
MAINTENANCE STANDARD721
Cylinder726
REMOVE AND INSTALL CYLINDER726
DISASSEMBLE CYLINDER743
ASSEMBLE CYLINDER753
MAINTENANCE STANDARD765
SECTION 5 ENGINE AND ACCESSORY710
W05766
INDEX766
INDEX(W)766
INTRODUCTION766
SAFETY766
SECTION 1 GENERAL INFORMATION766
SECTION 2 UPPERSTRUCTURE766
SECTION 3 UNDERCARRIAGE766
SECTION 4 FRONT ATTACHMENT766
SECTION 5 ENGINE AND ACCESSORY766
General Information768
General Repair Instructions769
Notes on the Format of This Manual769
Main Data and Specifications773
Tightening Torque Specifications769
Maintenance784
Model Identification785
Injiction Pump Identification785
Lubricating System785
Fuel System786
Cooling System789
Valve Clearance Adjustment790
Injection Timing791
Compression Pressure Measurement793
Recommended Lubricants794
Engine Repair Kit795
Engine Assembly 1796
General Description797
Disassembly798
Engine Assembly 2814
Inspection and Repair815
Engine Assembly 3848
Reassembly849
Lubricating System876
Main Data and Specification877
General Description878
Oil Pump881
Oil Filter with Built-in Oil Cooler884
Cooling System888
Main Data and Specification889
General Description890
Thermostat892
Fuel System894
Main Data and Specification895
General Description896
Injection Nozzle899
Injection Pump Calibration Data904
Engine Electricals908
Starter909
Alternator924
Troubleshooting936
Hard Starting938
Unstable Idling942
Insufficient Power945
Excessive Fuel Consumption949
Excessive Oil Consumption951
Overheating952
Whity Exhaust Smoke954
Darkish Exhaust Smoke955
Oil Pressure does not Rise956
Abnormal Engine Noise958
Special Tool List962
Special Tool List963
Repair Standards966
General Ruler966
Repair Standard Chart967
Conversion Table980
Length980
Area982
Volume982
Mass984
Pressure985
Torque986
Temperature987

HITACHI EX75UR-5 75US-5 EXCAVATOR OPERATIONAL PRINCIPLE TECHNICAL MANUAL – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]