Part of the Hitachi Repair Manuals.
Wrenching on a Hitachi EX45? This 568-page Hitachi EX45 service manual PDF (OEM #KM510E-01) combines the full Technical Manual and Workshop Manual for the compact excavator, and it covers the EX12, EX15, EX22, EX25, and EX30 too. You get complete wiring diagrams and hydraulic schematics, a full troubleshooting section for electrical and hydraulic faults, and torque tables for the upperstructure, undercarriage, front attachment, and engine. Page after page of teardown procedures and exploded views walk you through pump, swing, and travel work bolt by bolt. Before you condemn a pump, run the operational performance test: measure relief valve pressure, cylinder cycle times, and swing speed against the factory tables. No more chasing wiring faults with a multimeter and a prayer. Bookmarked and text-searchable; download it, pull it up on your phone next to the machine, and get to work.
What's Inside This Hitachi EX45 Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 6-19 | Safety Alert Symbols, Emergency Procedures, Operating and Maintenance Precautions, Decals |
| Technical Manual - Specifications | 20-45 | Machine Specifications, Working Ranges, Component Layout, Weights and Dimensions, Serial Numbers |
| Technical Manual - Upperstructure | 46-95 | Hydraulic Pump and Regulator, Control Valve, Swing Device, Pilot Valves, Cylinders, Swivel Joint Operation |
| Technical Manual - Undercarriage | 96-117 | Travel Device and Reduction Gear, Track Frame, Rollers and Idlers, Track Adjuster Operation |
| Technical Manual - Electrical and Hydraulic Systems | 118-125 | Electrical Component Layout, Monitor and Sensors, Wiring Schematics, Hydraulic Main and Pilot Circuits |
| Operational Performance Test | 126-153 | Engine Speed, Compression Pressure, Hydraulic Pressure and Flow Tests, Cycle Times, Standard Values and Adjustment |
| Technical Manual - Troubleshooting | 154-215 | Diagnosing Procedure, Engine Faults, Hydraulic and Electrical Troubleshooting Charts, Sensor Checks |
| Workshop Manual - Specifications and Precautions | 216-225 | Disassembly and Assembly Precautions, Tightening Torques, Sealants and Adhesives |
| Workshop Manual - Upperstructure | 226-309 | Counterweight and Canopy, Hydraulic Pump, Control Valve, Swing Motor and Reduction Gear, Cylinders, Swivel Joint Disassembly and Assembly |
| Workshop Manual - Undercarriage | 310-365 | Travel Motor and Reduction Gear Disassembly, Track Frame, Rollers, Idler and Track Adjuster, Wear Limits |
| Workshop Manual - Front Attachment | 366-395 | Boom, Arm and Bucket Removal, Pins and Bushings, Wear Limits and Clearances |
| Workshop Manual - Special Tools | 396-401 | Special Tool List, Puller and Press Fixtures, Measuring Equipment |
| Engine and Accessories - Full Repair Section (Bundled Engine Manual) | 402-568 | Engine Specifications, Disassembly and Reassembly, Cylinder Head and Valves, Piston, Rod and Crankshaft, Lubrication and Cooling Systems, Fuel Injection Pump and Nozzles, Starter and Alternator, Wear Limits and Torque Values |
Every system also includes contents, an index, specifications, undercarriage, and upperstructure.
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Hydraulic System | SECTION 05 | p. 2 |
| Engine Test | Group 02 | p. 4 |
| Replace full-flow filter element | 1 | p. 38 |
| Fuel filter | monthly | p. 89 |
| Main relief pressure | 23 ± 0.98 MPa (235 ± 10 kgf/cm²) | p. 150 |
| Clearance between the outside diameter of the piston and the inside diameter of the rotor | D-d≤0.050 mm | p. 247 |
| Clearance between the piston and the shoe | δ≤0.2 mm | p. 247 |
| Clearance between the piston and piston shoe | δ≤0.2 mm | p. 334 |
| Point A Standard | 135 (5.31) | p. 375 |
Hitachi EX45 Common Problems This Manual Covers
Hitachi EX45 hydraulic pressure low, bucket won't lift and all functions feel slow under load
Check main relief valve pressure first; standard is 23 ± 0.98 MPa per the test procedure on page 150. If pressure checks low, verify pilot oil pressure at the pilot valve outlet reads 4 ±0.5 MPa as shown on page 162. Replace the full-flow hydraulic filter element before condemning the pump, then retest.
Manual Section: Hydraulic System Troubleshooting (Actuators) p. 160Engine overheating during operation, coolant temperature gauge climbs into the red after an hour of digging
Check the radiator core for clogging; page 87 notes a lit overheat indicator or power loss points straight to a blocked core. Verify coolant level, then run the engine at fast idle, 2350 ± 50 rpm, and watch the gauge. Work the flowchart on page 557 to rule out the radiator cap, thermostat, and water pump.
Manual Section: Engine Troubleshooting p. 557One track dead or machine pulls to one side, travel motor weeping oil around the drive area
Inspect the travel motor internals before buying a complete motor. Measure clearance between the piston and piston shoe; anything over 0.2 mm per page 334 means replacement. Check the rotor sliding surface for scratching deeper than 0.03 mm (0.001 in.), the limit on page 335, and install a new seal kit while it is apart.
Manual Section: Undercarriage (Workshop Manual) p. 334Boom drops slowly under load with the control lever in neutral, arm drifts down overnight
Test the overload relief valve in the control valve; it should hold 24 ±0.98 MPa per page 151. Verify pilot oil pressure at the pilot valve outlet is 4 ±0.5 MPa as detailed on page 162. If both pressures pass, pull the boom cylinder and replace the piston seals, checking wear against the 0.05 mm limit on page 395.
Manual Section: Hydraulic System Troubleshooting (Front Attachments) p. 162Engine hard to start, cranks fine but stumbles and dies at idle
Replace the cartridge-type fuel filter; hand-tighten it 1/3 to 2/3 of a turn after the gasket seats, per the procedure on page 420. Bleed the fuel system, then inspect the air cleaner element and clean or replace it if clogged. Verify slow idle settles at 1000 ± 70 rpm before releasing the machine.
Manual Section: Engine and Accessories (Workshop Manual) p. 420Frequently Asked Questions
What are the torque specifications for Hitachi EX45 engine bolts?
For the Hitachi EX45 engine, the Cylinder Head Bolts (new) require a 1st step torque of 4.0 ± 1.0 kg-m (39.0 ± 9.8 N-m) and a 2nd step torque of 8.7 ± 0.5 kg-m (85.3 ± 4.9 N-m). The Rocker Arm Shaft Bracket Bolts should be tightened to 5.5 ± 0.5 kg-m (53.9 ± 4.9 N-m). p. 411
What are the replacement specifications for the hydraulic filter?
The full-flow hydraulic filter element should be replaced for the first time only. The hydraulic oil should be replaced every 250 hours. This ensures the hydraulic system maintains optimal performance. p. 38
What are the replacement specifications for the engine air filter?
The manual indicates that the air cleaner has an electronic indicator system. The filter element should be replaced when the indicator, located in the operator’s cab, lights up, signaling that the filter is clogged. p. 87
What is the recommended engine oil change interval for the Hitachi EX45?
The recommended engine oil change interval for the Hitachi EX45 is every 250 hours. This is a standard maintenance procedure to ensure engine longevity and performance. p. 37
What is the standard valve clearance for the Hitachi EX45 engine?
The standard valve clearance for the Hitachi EX45 engine is 0.4mm (0.016 in) when the engine is cold. This clearance should be measured and adjusted as part of regular maintenance. p. 88
What format is this manual in?
Instant PDF download. You get the full 568-page searchable Service Manual immediately after payment. Open it on your laptop, tablet, or phone right in the shop.
Is this Hitachi EX45 Service Manual printable?
Yes, print as many copies as you want, and there are no restrictions. Many mechanics print the section they need and bring it to the shop floor.
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