Part of the Hitachi Repair Manuals.
All 762 pages of this Hitachi EX80u service manual PDF focus on one machine: the EX80u hydraulic excavator, from pilot valve to final drive. You get full electrical wiring diagrams, complete hydraulic circuit schematics, and a troubleshooting section that walks electrical system inspection step by step. Workshop chapters take you through pump device, control valve, swing and travel device removal, every boom, arm, bucket, and blade cylinder, plus a full engine section covering fuel, cooling, and lubricating systems. Run the operational performance tests with real factory numbers: set main relief at 26.0 MPa for front and swing, 31.4 MPa for travel, and confirm the main pump flows 60 L/min at 2.0 MPa. No more chasing hydraulic faults with a gauge and a guess. Bookmarked and keyword-searchable; jump straight to the spec and get back under the boom.
What's Inside This Manual
| System | Pages | Key Topics |
|---|---|---|
| Service Manual | 1 | Operational Principle, Troubleshooting, Circuit Diagram, Harness, Workshop Manual |
| Circuit Diagram and Harness | 2 | Hydraulic Circuit Diagram, Electrical Circuit Diagram, Connectors, Engine Harness, Cab Harness |
| Technical Manual Operational Principle | 3-5 | Introduction |
| General | 6-22 | Specification, Working Ranges, Machine Transportation Dimensions, Component Specification, Component Layout |
| System | 23-52 | Control System, Hydraulic System, Electrical System |
| Component Operation | 53-118 | Pump Device, Swing Device, Control Valve, Pilot Valve, Travel Device |
| Technical Manual Troubleshooting | 119-149 | Safety |
| Operational Performance Test | 150-211 | Operational Performance Tests, Engine Test, Excavator Test, Component Test, Adjustment |
| Troubleshooting | 212-320 | Troubleshooting a, Troubleshooting B, Troubleshooting C, Electrical System Inspection |
| Workshop Manual | 321-370 | General Information |
| Upperstructure | 371-520 | Cab, Counterweight, Main Frame, Pump Device, Control Valve, Swing Device |
| Undercarriage | 521-600 | Swing Bearing, Travel Device, Center Joint, Track Adjuster, Front Idler, Upper and Lower Roller |
| Front Attachment | 601-656 | Cylinder, Boom Cylinder, Arm Cylinder, Bucket Cylinder, Boom Swing Cylinder, Blade Cylinder |
| Engine and Accessory | 657-762 | Engine Specification, Identification, Lubrication, Engine Main Body, Lubricating System, Cooling System, Fuel System, Intake and Exhaust System |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Main relief pressure (Front and swing) | 26.0 MPa (265 kgf/cm2, 3770 psi) | p. 13 |
| Main relief pressure (Travel) | 31.4 MPa (320 kgf/cm2, 4550 psi) | p. 13 |
| Main Pump Flow Rate at 2.0 MPa (20 kgf/cm2) | 60 L/min | p. 157 |
| Pump Control Solenoid Valve current | 400 mA | p. 267 |
| T-Bolt Type Band Clamp tightening torque | 4.4 N·m | p. 366 |
| Worm Gear Type Band Clamp tightening torque | 5.9 to 6.9 N·m | p. 366 |
| Mounting bolts (3) torque | 88 N·m (65 lbf·ft) | p. 393 |
| Hose/pipe connection torque (19 mm) | 29 N·m (21.5 lbf·ft) | p. 393 |
| Clearance between plunger outer diameter and cylinder block inner diameter | 0.060 mm | p. 404 |
| End play between plunger and shoe | 0.2 mm | p. 404 |
| Oil filter capacity | 0.7 L (5/8 Imp qt) | p. 366 |
| Operating Weight | 8100 kg | p. 8 |
