Part of the Hitachi Repair Manuals.
All 934 pages of this Hitachi EX100-5, EX100M-5, EX110-5, EX110M-5 service manual PDF cover one machine family: the 100M-5, 110-5, and 110M-5 hydraulic excavators, from pilot valve to final drive. Open to the full electrical circuit and harness diagrams (cab, engine, relay), the complete hydraulic circuit diagram, and Dr.EX fault code diagnostics with sensor operating ranges. You also get page after page of troubleshooting flow charts, operational performance tests with pass and fail standards, and full engine teardown procedures for the cylinder head, crankshaft, and turbocharger. Torque the front idler plug to 20 N·m and confirm 26 to 28 V at the battery with the engine running before you condemn the alternator. Your machine is down; get factory numbers, not forum guesses. Bookmarked and keyword-searchable: jump straight to the spec, fix the machine.
What's Inside This Manual
| System | Pages | Key Topics |
|---|---|---|
| Circuit Diagram and Harness | 2-7 | Electrical Circuit Diagram, Engine Harness, Cab Harness |
| Introduction | 8-10 | Technical Manual Introduction, How to Read the Manual |
| Safety | 11-36 | Safety Alert Symbol, Protective Clothing, Tipping, Power Lines, Maintenance Precautions |
| General | 37-54 | Specifications, Machine Dimensions, Component Layout, Electrical System, Pump Components |
| System | 55-90 | Control System, Hydraulic System, Electrical System, Engine Control, Valve Control |
| Component Operation | 91-178 | Pump Device, Swing Device, Control Valve, Pilot Valve, Travel Device, Undercarriage Components |
| Operational Performance Test | 179-238 | Operational Performance Tests, Engine Test, Excavator Test, Component Test, Performance Standards |
| Diagnosing Procedure | 239-276 | Dr.EX, Fault Codes, Monitoring Function, Service Mode, Harness Check |
| Troubleshooting a | 277-280 | Flow Charts, Fault Code List, Sensor Operating Range |
| Troubleshooting B | 281-336 | Machine Trouble Symptoms, Engine Troubleshooting, Actuator Control System, Swing System, Travel System, Blade System |
| Troubleshooting C | 337-362 | Diagnosing Procedure, Component Test |
| Electrical System Inspection | 363-376 | Component Checks |
| Harness Check | 377-378 | |
| Workshop Manual - Introduction and Safety | 379-413 | Introduction, Safety Alert Symbol, Precautions for Disassembling and Assembling, Bleeding Air From Hydraulic System, Floating Seal Precautions |
| General Information - Tightening Torque | 414-423 | Tightening Torque, Torque Chart, Pilot Valve |
| Upperstructure | 424-583 | Cab, Counterweight, Main Frame, Pump Device, Control Valve, Swing Device, Pilot Valve, Pilot Shut-Off Valve, Shockless Valve, Solenoid Valve, Pilot Relief Valve Unit |
| Undercarriage | 584-729 | Swing Bearing, Travel Device, Center Joint, Track Adjuster, Front Idler |
| Engine and Accessory | 730-850 | Engine Assembly, Cylinder Head, Camshaft, Piston, Connecting Rod, Crankshaft |
| Lubricating System | 851-856 | Oil Pump, Oil Cooler |
| Cooling System | 857-864 | Water Pump, Thermostat |
| Fuel System | 865-880 | Injection Nozzle, Injection Pump, Fuel Filter |
| Turbocharger | 881-884 | General Description, Turbocharger Identification, Inspection and Repair |
| Air Compressor | 885-891 | General Description, Disassembly Steps, Inspection and Repairs, Reassembly Steps |
| Engine Electricals | 892-934 | Starter Motor Identification, Starter Main Data and Specifications, Alternator Identification, Main Data and Specifications, Alternator Sectional View, Alternator Exploded View |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Battery Capacity | 55 Ah (5 hours) | p. 45 |
| Battery Voltage | 12 V | p. 45 |
| Upper roller weight EX100M-5 | 20 kg (44 lb) | p. 675 |
| Upper roller weight EX100-5 | 11 kg (24 lb) | p. 675 |
| Front idler plug tightening torque | 20 N·m (2 kgf·m, 15 lbf·ft) | p. 672 |
| Front idler yoke bolt tightening torque | 206 N·m (21 kgf·m, 152 lbf·ft) | p. 672 |
| Fuel filter turn-in | 2/3 of a turn | p. 765 |
| Depth of undercut mica standard | 0.5-0.8 mm (0.020-0.031 in.) | p. 894 |
| Swing Speed | 13.5 min-1 | p. 39 |
| Main Relief Valve Pressure | 34.3 MPa | p. 45 |
| EX100-5 | ||
| Engine Rated Output, EX100-5 | 59 kW/2100 min-1 | p. 39 |
| EX100M-5 | ||
| Engine Rated Output, EX100M-5 | 60 kW/2200 min-1 | p. 39 |
