Hitachi Zaxis 75US-A 75UR Excavator Operational Principle+Troubleshooting+Workshop Manual
FILE DETAILS:
Hitachi Zaxis 75US-A 75UR Excavator Operational Principle+Troubleshooting+Workshop Manual
This Listing includes all of the manuals mentioned below:
- Hitachi Zaxis 75US-A 75UR Excavator Operational Principle Technical Manual
- Hitachi Zaxis 75US-A 75UR Excavator Troubleshooting Technical Manual
- Hitachi Zaxis 75US-A 75UR Excavator Workshop Manual
- Hitachi Zaxis 75US-A 75UR Excavator Electrical Circuit Diagram
DESCRIPTION:
Hitachi Zaxis 75US-A 75UR Excavator Operational Principle+Troubleshooting+Workshop Manual
INTRODUCTION:
TO THE READER:
• This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
• Be sure to thoroughly read this manual for correct product information and service procedures.
• If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual.
ADDITIONAL REFERENCES:
• Please refer to the materials listed below in addition to this manual.
• The Operator’s Manual
• The Parts Catalog
• The Engine Manual
• Parts Catalog of the Engine
• Hitachi Training Material
MANUAL COMPOSITION:
• This manual consists of three portions: the Technical Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual.
• Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems.
• Information included in the Technical Manual (Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures.
• Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assemble/ disassemble procedures.
TABLE OF CONTENTS:
Hitachi Zaxis 75US-A 75UR Excavator Operational Principle+Troubleshooting+Workshop Manual
- Hitachi Zaxis 75US-A 75UR Excavator Workshop Manual
SECTION 1
GENERAL
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling W1-1-1
Maintenance Standard Terminology W1-1-7
Group 2 Tightening Torque
Tightening Torque Specifications W1-2-1
Torque Chart W1-2-2
Piping JointW1-2-5
Periodic Replacement of PartsW1-2-9
Group 3 Painting
Painting (ZAXIS75UR) W1-3-1
Painting (ZAXIS75US-A)W1-3-3
Group 4 Bleeding Air from Hydraulic Oil
Tank
Bleeding Air from Hydraulic Oil tank W1-4-1
SECTION 2
UPPERSTRUCTURE
Group 1 Cab
Remove and Install CabW2-1-1
Dimensions of the Cab Glass W2-1-5
Group 2 Counterweight
Remove and Install Counterweight W2-2-1
Group 3 Main Frame
Remove and Install Main FrameW2-3-1
Group 4 Pump Device
Remove and Install Pump Device W2-4-1
Disassemble Main Pumps 1 and 2W2-4-4
Assemble Main Pumps 1 and 2W2-4-10
Disassemble Main Pump 3W2-4-18
Assemble Main Pump 3W2-4-22
Maintenance StandardsW2-4-28
Disassemble and Assemble Pilot
Pump W2-4-30
Group 5 Control Valve
Remove and Install Control ValveW2-5-1
Disassemble Control ValveW2-5-4
Assemble Control Valve W2-5-15
Group 6 Swing Device
Remove and Install Swing Device W2-6-1
Disassemble Swing Reduction Gear W2-6-4
Assemble Swing Reduction GearW2-6-10
Disassemble Swing Motor W2-6-18
Assemble Swing Motor W2-6-22
Disassemble and Assemble
Valve Block W2-6-26
Maintenance Standard W2-6-28
Group 7 Pilot Valve
Remove and Install Front/Swing
Pilot ValveW2-7-1
Remove and Install Travel
Pilot ValveW2-7-3
Remove and Install
Blade Pilot Valve W2-7-5
Remove and Install Offset
Pilot Valve W2-7-7
Disassemble Right and Left
Pilot Valves W2-7-10
Assemble Right and Left
Pilot Valves W2-7-14
Disassemble Travel Pilot Valve W2-7-18
Assemble Travel Pilot ValveW2-7-22
Disassemble Blade Pilot ValveW2-7-28
Assemble Blade Pilot Valve W2-7-30
Group 8 Pilot Shut-Off Valve
Remove and Install Pilot Shut-Off
ValveW2-8-1
Disassemble Pilot Shut-Off ValveW2-8-4
Assemble Pilot Shut-Off Valve W2-8-6
SECTION 3
UNDERCARRIAGE
Group 1 Swing Bearing
Remove and Install Swing BearingW3-1-1
Disassemble Swing Bearing W3-1-4
Assemble Swing Bearing W3-1-6
Group 2 Travel Device
Remove and Install Travel DeviceW3-2-1
Disassemble Travel Reduction GearW3-2-4
Assemble Travel Reduction Gear W3-2-8
Disassemble Travel Motor W3-2-12
Assemble Travel Motor W3-2-16
Disassemble Brake Valve W3-2-24
Assemble Brake ValveW3-2-28
Maintenance Standard W3-2-32
Group 3 Center Joint
Remove and Install Center Joint W3-3-1
Disassemble Center Joint W3-3-2
Assemble Center JointW3-3-4
Maintenance Standard W3-3-8
Group 4 Track Adjuster
Remove and Install Track Adjuster W3-4-1
Disassemble Track Adjuster W3-4-2
Assemble Track Adjuster W3-4-8
Group 5 Front Idler
Remove and Install Front Idler W3-5-1
Disassemble Front Idler W3-5-2
Assemble Front IdlerW3-5-4
Maintenance Standard W3-5-6
Group 6 Upper and Lower Roller
Remove and Install Upper RollerW3-6-1
Remove and Install Lower Roller W3-6-4
Disassemble and Assemble
Lower Roller W3-6-6
Maintenance Standard W3-6-8
Group 7 Track
Remove and Install Track W3-7-1
Maintenance Standard W3-7-7
SECTION 4
FRONT ATTACHMENT
Group 1 Front Attachment
Hydraulic Circuit Pressure
Release ProcedureW4-1-1
Remove and Install Front AttachmentW4-1-2
Maintenance Standard W4-1-10
Standard Dimensions for
Arm and Bucket Connection W4-1-15
Group 2 Cylinder
Hydraulic Circuit Pressure
Release ProcedureW4-2-1
Remove and Install CylinderW4-2-2
Disassemble Cylinder W4-2-18
Assemble CylinderW4-2-28
Maintenance Standard W4-2-42
Group 3 Holding Valve
Hydraulic Circuit Pressure
Release ProcedureW4-3-1
Remove and Install Holding Valve W4-3-2
Structure of Holding ValveW4-3-3
SECTION 5
ENGINE AND ACCESSORY
SECTION 1
General Information
General Repair Instructions 2
Notes on the Format of
This Manual 2
Main Data and Specifications 6
Tightening Torque Specifications 11
SECTION 2
Maintenance
Model Identification 22
Injiction Pump Identification 22
Lubricating System 22
Fuel System 23
Cooling System 25
Valve Clearance Adjustment 26
Injection Timing 28
Compression Pressure
Measurement 29
Recommended Lubricants 30
Engine Repair Kit 31
SECTION 3
Engine Assembly 1 (Disassembly)
General Description 34
Disassembly 35
SECTION 4
Engine Assembly 2
(Inspection and Repair)
Inspection and Repair 52
SECTION 5
Engine Assembly 3 (Reassembly)
Reassembly 84
SECTION 6
Lubricating System
Main Data and Specification 112
General Description 113
Oil Pump 116
SECTION 7
Cooling System
Main Data and Specification 122
General Description 123
Thermostat 125
SECTION 8
Fuel System
Main Data and Specification 128
General Description 129
Injection Nozzle 132
Injection Pump Calibration Data 138
SECTION 9
Engine Electricals
Starter 144
Alternator 159
- Hitachi Zaxis 75US-A 75UR Excavator Troubleshooting Technical Manual
SECTION 4
OPERATIONAL
PERFORMANCE TEST
Group 1 Introduction
Operational Performance TestsT4-1-1
Preparation for Performance
TestsT4-1-2
Group 2 Standard
Operational Performance
Standard TableT4-2-1
Main Pump1 and 2 P-Q Diagram T4-2-4
Main Pump 3 P-Q Diagram T4-2-5
Injection PumpT4-2-6
DrEX Monitor Indicating ValuesT4-2-7
Sensor Activating RangeT4-2-9
Group 3 Engine Test
Engine Speed T4-3-1
Engine Compression Pressure T4-3-3
Valve Clearance Adjustment T4-3-4
Nozzle Check T4-3-6
Injection Timing T4-3-8
Group 4 Excavator Test
Travel Speed T4-4-1
Track Revolution SpeedT4-4-2
Mistrack CheckT4-4-3
Travel Parking Function Check T4-4-4
Swing SpeedT4-4-5
Swing Function Drift CheckT4-4-6
Swing Motor Leakage T4-4-7
Maximum Swingable
Slant Angle T4-4-8
Swing Bearing PlayT4-4-9
Hydraulic Cylinder Cycle Time T4-4-10
Dig Function Drift Check T4-4-12
Control Lever Operating ForceT4-4-14
Control Lever Stroke T4-4-15
Boom Raise/Swing Combined
Operation Check T4-4-16
Group 5 Component Test
Primary Pilot Pressure T4-5-1
Secondary Pilot PressureT4-5-3
Travel Speed Changeover Solenoid Valve
Set Pressure T4-5-4
Main Pump Delivery Pressure T4-5-6
Main Relief Valve Set Pressure T4-5-7
Overload Relief Valve Set Pressure T4-5-12
Main Pumps 1 and 2 Flow Rate
MeasurementT4-5-14
Main Pump 3 Flow Rate MeasurementT4-5-18
Swing Motor DrainageT4-5-22
Travel Motor Drainage T4-5-24
SECTION 5
TROUBLESHOOTING
Group 1 General
Introduction T5-1-1
Diagnosing Procedure T5-1-2
Built-In Diagnosing System Operation T5-1-4
Built-In Diagnosing Function Display List T5-1-5
Dr EX Operation T5-1-6
Dr EX Fault Code List (MC) T5-1-8
Dr EX Fault Code List
(Auto-MARCCINO Controller) T5-1-10
Dr EX Monitoring Item List (MC) T5-1-14
Dr EX Monitoring Item List
(Auto-MARCCINO Controller) T5-1-15
Dr EX Special Function T5-1-16
Dr EX Service Mode (MC) T5-1-18
Dr EX Service Mode Adjustment
Data List (MC) T5-1-26
Dr EX Service Mode
(Auto-MARCCINO Controller) T5-1-27
Group 2 Component Layout
Main Components T5-2-1
Electrical System (Overall System) T5-2-2
Electrical System (Front Attachment) T5-2-4
Electrical System
(Monitor and Switches) T5-2-5
Electrical System (Battery) T5-2-9
Electrical System (Pressure Sensor) T5-2-9
Solenoid Valve T5-2-10
Pump Device T5-2-11
Travel DeviceT5-2-11
Swing DeviceT5-2-11
Control Valve T5-2-13
Group 3 Troubleshooting A
Troubleshooting A Procedure T5-3-1
Fault Code List T5-3-2
Fault Code 01, 02, 03 T5-3-3
Fault Code 04 T5-3-3
Fault Code 06 T5-3-4
Fault Code 07 T5-3-5
Fault Code 18 T5-3-7
Group 4 Troubleshooting B
Troubleshooting B Procedure T5-4-1
Relationship between Machine Trouble
Symptoms and Related Parts T5-4-2
Correlation between Trouble
Symptoms and Part Failures T5-4-8
Engine System Troubleshooting T5-4-17
All Actuator System Troubleshooting T5-4-28
Front Attachment System
Troubleshooting T5-4-31
Swing System Troubleshooting T5-4-38
Travel System Troubleshooting T5-4-41
Blade System Troubleshooting T5-4-48
Other System Troubleshooting T5-4-50
Exchange Inspection T5-4-68
Emergency Boom Lowering
Procedure T5-4-69
- Hitachi Zaxis 75US-A 75UR Excavator Operational Principle Technical Manual
SECTION 1
GENERAL
Group 1 Specification
Specifications T1-1-1
Working Ranges and Machine
Transportation Dimensions T1-1-3
Group 2 Component Layout
Main Components T1-2-1
Electrical System (Overall System) T1-2-2
Electrical System (Front Attachment) T1-2-4
Electrical System
(Monitor and Switches) T1-2-5
Electrical System (Battery) T1-2-9
Electrical System (Pressure Sensor) T1-2-9
Solenoid Valve T1-2-10
Contorl Valve T1-2-11
Pump Device T1-2-12
Swing Device T1-2-12
Travel Device T1-2-12
Group 3 Component Specifications
Engine T1-3-1
Engine Accessories T1-3-4
Hydraulic Component T1-3-5
Filter T1-3-7
Electrical Component T1-3-7
SECTION 2
SYSTEM
Group 1 Control System
Outline T2-1-1
Engine Control T2-1-2
Valve Control T2-1-14
Other Controls T2-1-16
Group 2 Front Contorl System
Outline T2-2-1
Front Movement Control T2-2-2
Group 3 Hydraulic System
Outline T2-3-1
Pilot Circuit T2-3-2
Main Circuit T2-3-4
Group 4 Electrical System
Outline T2-4-1
Main Circuit T2-4-2
Electric Power Circuit (Key Switch: OFF) T2-4-4
Indicator Light Check Circuit
(Key Switch: ON) T2-4-6
Accessory Circuit T2-4-8
Preheat Circuit (Key Switch: Heat) T2-4-10
Starting Circuit (Key Switch: Start) T2-4-12
Charging Circuit (Key Switch: ON) T2-4-16
Serge Voltage Prevention Circuit T2-4-20
Engine Stop Circuit T2-4-21
SECTION 3
COMPONENT OPERATION
Group 1 Pump Device
Outline T3-1-1
Main Pumps (1, 2 and 3) T3-1-2
Reducing Valve T3-1-5
Pilot Pump T3-1-6
Group 2 Swing Device
Outline T3-2-1
Swing Motor T3-2-2
Swing Parking Brake T3-2-3
Make-Up Valve T3-2-4
Relief Valve T3-2-5
Swing Reduction Gear T3-2-6
Group 3 Control Valve
Outline T3-3-1
Hydraulic Circuit T3-3-6
Flow Combiner Valve T3-3-10
Main Relief Set Pressure Change T3-3-12
Boom Anti-Drift Valve T3-3-14
Main Relief Valve T3-3-16
Overload Relief Valve T3-3-17
Group 4 Pilot Valve
Outline T3-4-1
Operation (4-Port Pilot Valve) T3-4-4
Operation (2-Port Pilot Valve) T3-4-11
Group 5 Travel Device
Outline T3-5-1
Travel Motor T3-5-2
Parking Brake T3-5-10
Travel Brake ValveT3-5-11
Travel Reduction Gear T3-5-13
Group 6 Others (Upperstructure)
Pilot Shut-Off Valve T3-6-1
Shockless Valve T3-6-2
Solenoid Valve Unit T3-6-9
Offset Anti-Drift Valve T3-6-13
Pilot Relief Valve T3-6-15
EC Motor T3-6-15
Engine Fan Clutch T3-6-16
Group 7 Others (Undercarriage)
Swing Bearing T3-7-1
Center Joint T3-7-2
Track Adjuster T3-7-3
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]