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 Hitachi EX80-5 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 |
Hitachi EX80-5 Common Problems This Manual Covers
Hitachi EX80-5 hydraulic oil level dropping, wet hoses under the boom, bucket and arm getting weak
Check the hydraulic oil level before every shift and trace each hose for kinks, rub marks, and weeping fittings; use cardboard, never your hand, to find pinhole leaks. Retighten 19 mm union nuts to 59 N·m and 22 mm O-ring seal joints to 98 N·m per the torque charts on pages 319 and 320. Replace all hydraulic hoses every 2 years per page 323, cracked or not.
Manual Section: General Information p. 319Hydraulics slow and noisy after an oil change, pump whines and cylinders shudder at idle
Check the tank sight gauge on level ground first; a low level pulls air into the suction line and makes the pump growl. Fill to spec, then cycle every cylinder slowly to full stroke several times to purge trapped air. If functions stay weak afterward, test main relief pressure against the 26 MPa (265 kgf/cm²) standard on page 234.
Manual Section: Troubleshooting p. 234Boom or arm cylinder drifts down under load, front functions feel weak while digging
Test main relief pressure before pulling anything apart; front circuits should hold 26.0 MPa (265 kgf/cm², 3770 psi), spec on page 42. Inspect the overload relief valve on the affected circuit and torque its lock nut to 59 to 69 N·m after any adjustment, page 172. If drift continues, reseal the cylinder using the Front Attachment procedures starting on page 525.
Manual Section: Front Attachment Control System Troubleshooting p. 234Engine overheats in warm weather, coolant temperature gauge climbs into the red during heavy digging
Check coolant level cold and inspect the radiator core for packed mud; blow it out from the fan side. Test the thermostat in heated water; the industrial-use valve must begin opening at 71°C (160°F), spec on page 636. Remember the overheat switch does not trip until 105°C (221°F), page 261, so a silent buzzer does not mean the engine is running cool.
Manual Section: Engine and Accessory p. 636Track shoe bolts working loose, shoes rattling over rock, machine mistracks on flat ground
Torque track shoe mounting bolts to 245 N·m per the chart on page 315; loose shoes wallow out their bolt holes fast in rocky work. Check track sag and service the track adjuster using the Undercarriage procedures starting on page 447. If mistracking continues, compare sides in fast mode; both tracks should pull an even 4.8 km/h, spec on page 182.
Manual Section: Undercarriage p. 447Frequently Asked Questions
How do I reset the buzzer on a Hitachi EX80-5?
To cancel the buzzer, use the buzzer cancel switch located on the monitor panel. The buzzer cancel switch is identified as item 25 on the switch panel. p. 48
How do I troubleshoot low engine oil pressure on a Hitachi EX80-5?
If the engine oil pressure indicator does not come on when the key switch is turned to the ON position, check if the indicator comes on when the harness side PLUS terminal (lightgreen/red line) is grounded to the vehicle. If the indicator stays on after the engine is started, check if the indicator goes OFF when the engine oil pressure switch is disconnected. p. 257
What is the valve clearance specification for the Hitachi EX80-5 engine?
The valve clearance for both the intake and exhaust valves on a hot engine is 0.35 mm (0.0138 in). p. 582
What is the tightening torque for the cylinder head bolts on the Hitachi EX80-5 engine?
The cylinder head bolts must be tightened in three steps: first to 4.0 - 4.5 kg-m (29 - 33 ft-lb), second to 5.5 - 6.0 kg-m (40 - 43 ft-lb), and third by the angular method of 90 degrees ± 10 degrees. p. 607
What is the capacity of the engine oil pan for the Hitachi EX80-5?
For automotive use, the oil pan capacity is 7.5 L (6-5/8 Imp qt) for the high level and 6 L (5-1/4 Imp qt) for the low level. For industrial use, it is 10 L (8-3/4 Imp qt) for the high level and 8 L (7 Imp qt) for the low level. p. 580
What format is this Hitachi EX80-5 manual in?
Straight to your device: 676 pages of searchable Workshop Manual, downloadable the moment payment goes through.
Am I free to print this Hitachi EX80-5 Workshop 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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