Part of the Hitachi Repair Manuals.
Wrenching on a Hitachi EX75UR-5 or 75US-5? This 587-page workshop manual PDF (OEM W197E-00) covers both hydraulic excavator variants with the factory procedures Hitachi wrote for its own techs. You get a full pump and hydraulic component teardown section, page after page of step-by-step removal and installation work, tightening torque tables for every fitting size, and a troubleshooting section that traces failures back to the root cause. Metric-to-imperial conversion charts sit in the back, so you can work in either unit system. Set the 30-degree union joint (19 mm wrench) to 59 N·m and the 37-degree female fitting to 44 N·m; check plunger-to-cylinder-block clearance at 0.060 mm during pump rebuilds. Your excavator is down. Get the factory numbers, not forum guesses. Bookmarked PDF: search any spec by keyword and pull it up on any device in the shop.
What's Inside This Hitachi EX75UR-5, 75US-5 Manual
| System | Pages | Key Topics |
|---|---|---|
| Length | 580-581 | Millimeters to Inches, Feet to Meters |
| Area | 582-583 | Square Inches to Square Centimeters, Gallons to Liters |
| Mass | 584 | Pounds to Kilograms |
| Pressure | 585 | Pounds per Square Inch to Kilograms per Square Centimeter |
| Torque | 586 | Foot Pounds to Kilogram Meters |
| Temperature | 587 | Fahrenheit to Centigrade |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Pump suction hose replacement interval | Every 2 years | p. 48 |
| Pump delivery hose replacement interval | Every 2 years | p. 48 |
| Union joint 30° male 19mm wrench size torque | 59 N·m | p. 44 |
| Union joint 37° female 19mm wrench size torque | 44 N·m | p. 44 |
| Clearance between plunger outer diameter and cylinder block inner diameter | 0.060 mm | p. 87 |
| End play between plunger and shoe | 0.2 mm | p. 87 |
| Overload relief valve tightening torque | 49 to 54 N·m | p. 91 |
| Control valve 1 hose connection tightening torque (17 mm) | 9.8 N·m | p. 93 |
| Drum (28) weight | 29 kg (64 lb) | p. 246 |
| Bearing (2) inner race heating temperature | 50 to 70 °C (122 to 158 °F) | p. 246 |
| Upper Roller A Standard | 43 mm (1.7 in) | p. 299 |
| Upper Roller B Standard | 90 mm (3.5 in) | p. 299 |
Hitachi EX75UR-5, 75US-5 Common Problems This Manual Covers
Hitachi EX75UR-5 hydraulic functions weak and slow after warm-up, boom and arm lag under load
Check hydraulic oil level and filter condition before opening anything. If flow stays weak, pull the pump and measure plunger-to-cylinder-block clearance against the 0.060 mm limit on page 87, then check plunger-to-shoe end play against 0.2 mm. Anything over spec means a worn rotating group; replace those parts as a matched set.
Manual Section: Troubleshooting Procedures p. 87Hydraulic oil weeping from pump suction hose fittings and O-rings, wet film on tank side
Wipe every fitting dry, then run the machine and find the live leak. Retorque 19 mm union joints to 59 N·m per page 44 before condemning a hose. Replace any hose past the 2 year interval listed on page 48, and always fit fresh O-rings; a hardened suction O-ring pulls air and ruins the pump.
Manual Section: Service Procedures p. 48Boom drifts down and bucket won't hold position with control levers in neutral
Swap the overload relief valves side to side and watch whether the drift follows. If it moves with the valve, clean or replace it and torque to 34 to 39 N·m per page 120. If drift stays put, reseal that cylinder, then reconnect 22 mm hose ends at 39 N·m and 27 mm ends at 93 N·m per page 341.
Manual Section: Service Procedures p. 120Engine runs hot and coolant temperature climbs during sustained digging in warm weather
Check fan belt deflection first: press mid-span and confirm 8 to 12 mm per page 576, then tighten or replace a glazed belt. Clean the radiator core with low pressure air from the fan side. Verify coolant level, thermostat opening, and cap sealing before you blame the water pump.
Manual Section: Overheating p. 576Track travel weak on one side and machine pulls when driving straight
Measure undercarriage wear before tearing into a final drive. Compare lower roller tread against the 45 mm standard on page 300 and upper rollers against 43 mm on page 299; replace any roller past its allowable limit. Drain the final drive, inspect the oil for metal, and refill with 2.3 L of gear oil.
Manual Section: Service Procedures p. 300Frequently Asked Questions
How do I check the torque specifications for the swing bearing bolts on a Hitachi EX75UR-5?
The swing bearing mounting bolts to the upperstructure and to the undercarriage require a torque of 265 N⋅m (27 kgf⋅m, 195 lbf⋅ft). These bolts should be tightened using a 24 mm wrench. p. 40
What are the replacement specifications for hydraulic hoses?
All hydraulic hoses, including pump suction, delivery, swing, and cylinder line hoses, should be replaced every 2 years to ensure safe operation and prevent fire hazards. p. 48
What is the specified tightening torque for the cylinder head bolts on the A-4JG1 engine?
The cylinder head bolts should be tightened in three steps. The first step is 44-54 N⋅m (4.5-5.5 kgf⋅m), followed by a second step of 60-75 degrees, and a final third step of 60-75 degrees. p. 377
What is the standard valve clearance for the A-4JG1 engine?
The standard valve clearance for both intake and exhaust valves on the A-4JG1 engine is 0.40 mm (0.016 in) when measured at cold engine temperature. p. 391
What is the standard compression pressure for the A-4JG1 engine?
The standard compression pressure for the A-4JG1 engine is 3.04 MPa (31 kgf/cm², 441 psi) at 200 rpm. The limit for compression pressure is 2.2 MPa (22 kgf/cm², 313 psi). p. 394
What do I get after purchasing this Hitachi EX75UR-5 manual?
Immediate download of the complete 587-page searchable Workshop Manual. Access it on any device, from a laptop at your desk to a phone in the field.
Is this Hitachi EX75UR-5 Workshop Manual printable?
Absolutely. No DRM or copy protection. Print the whole manual or just the pages you need. Any home or office printer works.
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