Part of the Hitachi Repair Manuals.
Every one of the 676 pages in this Hitachi EX80-5 Workshop Manual PDF (OEM #TT152E-NA) exists for one job: putting your hydraulic excavator back to work. Inside you get full electrical circuit diagrams with engine and cab harness routing, hydraulic schematics that trace the pump device, control valve, swing and travel circuits, plus a fat troubleshooting section built around Hitachi's own diagnosing procedures. Teardown and assembly steps run through the whole machine: cab, main frame, swing bearing, track adjuster, cylinders, boom, bucket, and the engine itself, backed by factory torque charts. Set main relief pressure at 26 MPa (265 kgf/cm2), then torque the overload relief valve lock nut to 59 to 69 N-m, straight from Hitachi's test standards. No more chasing a pressure drop on forum hearsay. Bookmarked chapters, keyword search, opens on any device; download it and walk back to the machine.
What's Inside This Manual
| System | Pages | Key Topics |
|---|---|---|
| EX80-5 Service Manual | 1 | |
| Circuit Diagram and Harness | 2-9 | Electrical Circuit Diagram, Engine Harness, Cab Harness |
| Safety | 10-35 | Safety Alert Symbol, Protective Clothing, Rollaway Accidents, Tipping, Power Lines, Maintenance |
| General | 36-49 | Specifications, Working Ranges, Component Layout, Electrical System, Monitor and Switch Panels |
| System | 50-85 | Control System, Hydraulic System, Electrical System |
| Component Operation | 86-135 | Pump Device, Swing Device, Control Valve, Pilot Valve, Travel Device |
| Operational Performance Test | 136-185 | Engine Test, Excavator Test, Component Test, Standard |
| Troubleshooting | 186-277 | Diagnosing Procedure, Troubleshooting a, Troubleshooting B, Troubleshooting C, Electrical System Inspection |
| Workshop Manual | 278-306 | |
| General Information | 307-324 | Precautions for Disassembling and Assembling, Tightening Torque, Torque Chart, Piping Joint, Periodic Replacement of Parts |
| Upperstructure | 325-446 | Cab, Counterweight, Main Frame, Pump Device, Control Valve, Swing Device |
| Undercarriage | 447-524 | Swing Bearing, Travel Device, Center Joint, Track Adjuster, Front Idler, Tracks |
| Front Attachment | 525-570 | Cylinder, Arm, Bucket, Boom |
| Engine and Accessory | 571-676 | Engine Main Body, Lubricating System, Cooling System, Fuel System, Intake and Exhaust System |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Plug tightening torque | 24.5 N·m (2.5 kgf·m, 18 lbf·ft) | p. 165 |
| Overload relief valve lock nut tightening torque | 59 to 69 N·m | p. 172 |
| Main relief pressure | 26 MPa (265 kgf/cm²) | p. 234 |
| Overheat Switch - Coolant Temperature (OFF) | Lower than 105 °C (221 °F) | p. 261 |
| Overheat Switch - Coolant Temperature (ON) | 105 °C (221 °F) or more | p. 261 |
| Tightening torque for 30° male union nut (19 mm) | 59 N·m | p. 319 |
| Engine Rated Output | 41 kW | p. 38 |
| Swing Speed | 15.0 min-1 | p. 38 |
| Travel Speed (Fast) | 4.8 km/h | p. 182 |
| Main Relief Pressure (Front and Swing) | 26.0 MPa | p. 42 |
| Main Relief Pressure (Travel) | 31.4 MPa | p. 42 |
| Blade Cylinder Stroke | 145 mm | p. 43 |
