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 Hitachi EX100-5 to EX110M-5 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 | 59 kW/2100 min-1 | p. 39 |
| EX100M-5 | ||
| Engine Rated Output | 60 kW/2200 min-1 | p. 39 |
Hitachi EX100-5 to EX110M-5 Common Problems This Manual Covers
Hitachi EX100-5 hydraulic pressure drops under load, arm and bucket respond slow and weak
Check hydraulic oil level and inspect the suction filter for clogging before condemning the pump. Test main relief valve pressure against the 34.3 MPa (350 kgf/cm2, 4977 psi) spec on page 45. If pressure is low in all circuits, suspect the relief valve or pump; if only one circuit, follow the flow charts starting on page 281.
Manual Section: Troubleshooting B p. 281Engine cranks slowly or won't start in cold weather after machine sits overnight
Load test both 12 V batteries; each is rated 55 Ah, and the pack should read its rated system voltage at the terminals with the key off. Clean and tighten the ground cables at the frame. If voltage checks pass, pull the starter and inspect it using the Engine Electricals procedures starting on page 892.
Manual Section: Engine Electricals p. 892Engine stalls under load or loses power, restarts after sitting a few minutes
Replace the fuel filter and bleed the system; hand-tighten the new filter until the gasket seats, then turn it in an additional 2/3 of a turn with the filter wrench, page 765. Check the tank pickup and lines for restriction, then work through the injection pump and nozzle checks in the Fuel System section on page 865.
Manual Section: Fuel System p. 865Swing motor groans under load and upper structure swings slowly in both directions
Time a full 360 degree swing at full throttle; the spec is 13.5 min-1 for all models, page 39. Run the operational performance tests starting on page 179 to separate pump supply problems from swing motor wear. Check the swing reduction gear oil for metal flakes before retesting.
Manual Section: Operational Performance Test p. 179Loose tracks derail on slopes, machine mistracks and pulls to one side
Measure track sag and adjust tension at the grease valve before replacing parts. Inspect idlers and rollers for flat spots and oil leaks; front idler oil fill follows the quantity in the undercarriage section, and page 672 gives the plug and yoke torques. When replacing lower rollers, torque the mounting bolts to 304 N·m (31 kgf·m, 224 lbf·ft), page 678.
Manual Section: Troubleshooting C p. 678Frequently Asked Questions
What are the hydraulic pressure specifications for the Hitachi EX100-5?
The main relief pressure for the EX100-5 is 34.3 MPa (350 kgf/cm², 4977 psi) at 80 L/min. The overload relief pressure for the boom raise/lower, arm roll-in, and bucket roll-in is 37.3 MPa (380 kgf/cm², 5404 psi) at 50 L/min, while for arm roll-out and bucket roll-out it is 39.2 MPa (400 kgf/cm², 5688 psi) at 50 L/min. p. 45
What are the replacement specifications for hydraulic hoses?
Rubber hoses containing flammable fluids under pressure must be replaced periodically due to aging, fatigue, and abrasion. Refer to the 'Periodic replacement of parts' page in the operator's manual for the specific replacement schedule. p. 29
What is the standard valve clearance for the 4BG1 engine?
The standard valve clearance for both the intake and exhaust valves on the 4BG1 engine is 0.40 mm (0.016 in) when the engine is cold. p. 800
What is the torque specification for the main bearing cap bolts on the engine?
The main bearing cap bolts should be tightened to a torque of 23–25 kgf·m (166–181 lb·ft). p. 817
What is the standard injection timing for the 4BG1 engine?
The standard injection timing for the 4BG1 engine is 14 degrees before Top Dead Center (BTDC). p. 738
What do I get after purchasing this Hitachi EX100-5 manual?
All 934 pages arrive as one searchable PDF at checkout. Read it at the desk, then take the phone out to the machine.
Are there any print restrictions on this Hitachi EX100-5 manual?
You can. The PDF is unlocked and carries no copy protection, so print the sections you want and keep the file as your backup.
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