Hitachi ZAXIS 75US Excavator Operational Principle+Troubleshooting+Workshop Manual
FILE DETAILS:
Hitachi ZAXIS 75US Excavator Operational Principle+Troubleshooting+Workshop Manual
This Listing includes all of the manuals mentioned below:
- Hitachi ZAXIS 75US Hydraulic Excavator Operational Principle Technical Manual
- Hitachi ZAXIS 75US Hydraulic Excavator Troubleshooting Technical Manual
- Hitachi ZAXIS 75US Hydraulic Excavator Workshop Manual
- Hitachi ZAXIS 75US Hydraulic Excavator Circuit Diagram & Harness
DESCRIPTION:
Hitachi ZAXIS 75US 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 Excavator Operational Principle+Troubleshooting+Workshop Manual
- Hitachi ZAXIS 75US Hydraulic Excavator Workshop Manual
SECTION 1
GENERAL INFORMATION
CONTENTS
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 Specification W1-2-1
Torque Chart W1-2-2
Piping Joint W1-2-5
Periodic Replacement of Parts W1-2-9
Group 3 Painting
Painting W1-3-1
SECTION 2
UPPERSTRUCTURE
Group 1 Cab
Remove and Install Cab W2-1-1
Dimensions of the Cab Glass W2-1-9
Group 2 Counterweight
Remove and Install Counterweight W2-2-1
Group 3 Main Frame
Remove and Install Main Frame W2-3-1
Group 4 Pump Device
Remove and Install Pump DeviceW2-4-1
Disassemble Pump Device W2-4-4
Assemble Pump DeviceW2-4-8
Disassemble and
Assemble Valve Block W2-4-12
Disassemble and
Assemble Control PistonW2-4-14
Maintenance Standard W2-4-16
Disassemble and Assemble Pilot
Pump W2-4-18
Group 5 Control Valve
Remove and Install Control Valve 1 W2-5-1
Disassemble Control Valve 1 W2-5-5
Assemble Control Valve 1 W2-5-15
Remove and Install Control Valve 2 W2-5-24
Disassemble Control Valve 2 W2-5-26
Assemble Control Valve 2 W2-5-28
Group 6 Swing Device
Remove and Install Swing Device W2-6-1
Disassemble Swing Device W2-6-4
Assemble Swing Device W2-6-10
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 Right Pilot Valve W2-7-1
Remove and Install Left Pilot Valve W2-7-5
Remove and Install Travel
Pilot Valve W2-7-9
Remove and Install
Blade Pilot Valve W2-7-13
Disassemble Right and Left
Pilot Valves W2-7-16
Assemble Right and Left
Pilot Valves W2-7-20
Disassemble Travel Pilot Valve W2-7-24
Assemble Travel Pilot Valve W2-7-28
Disassemble Blade Pilot Valve W2-7-34
Assemble Blade Pilot Valve W2-7-36
Group 8 Pilot Shut-Off Valve
Remove and Install Pilot Shut-Off
Valve W2-8-1
Disassemble Pilot Shut-Off Valve W2-8-4
Assemble Pilot Shut-Off Valve W2-8-6
SECTION 3
UNDERCARRIAGE
Group 1 Swing Bearing
Remove and Install Swing Bearing W3-1-1
Disassemble Swing Bearing W3-1-4
Assemble Swing BearingW3-1-6
Group 2 Travel Device
Remove and Install Travel Device W3-2-1
Disassemble Travel Device W3-2-4
Assemble Travel Device W3-2-8
Disassemble Travel Motor W3-2-12
Assemble Travel Motor W3-2-16
Disassemble Travel Brake Valve W3-2-20
Assemble Travel Brake Valve W3-2-22
Maintenance Standard W3-2-24
Group 3 Center Joint
Remove and Install Center Joint W3-3-1
Disassemble Center Joint W3-3-4
Assemble Center Joint W3-3-6
Maintenance Standard W3-3-9
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 Idler W3-5-4
Maintenance Standard W3-5-6
Group 6 Upper and Lower Roller
Remove and Install Upper Roller W3-6-1
Disassemble and Assemble
Upper Roller W3-6-4
Remove and Install Lower Roller W3-6-6
Disassemble and Assemble
Lower Roller W3-6-8
Maintenance StandardW3-6-10
Group 7 Track
Remove and Install Track W3-7-1
Maintenance StandardW3-7-7
SECTION 4
FRONT ATTACHMENT
Group 1 Front Attachment
Remove and Install Front Attachment W4-1-1
Maintenance Standard W4-1-6
Standard Dimensions for
Arm and Bucket Connection W4-1-9
Group 2 Cylinder
Remove and Install Cylinder W4-2-1
Disassemble Cylinder W4-2-14
Assemble Cylinder W4-2-22
Maintenance Standard W4-2-34
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 7
SECTION 2
Maintenance
Model Identification 18
Injiction Pump Identification 18
Lubricating System 18
Fuel System 19
Cooling System 22
Valve Clearance Adjustment 23
Injection Timing 24
Compression Pressure
Measurement 26
Recommended Lubricants 27
Engine Repair Kit 28
SECTION 3
Engine Assembly 1 (Disassembly)
General Description 30
Disassembly 31
SECTION 4
Engine Assembly 2
(Inspection and Repair)
Inspection and Repair 48
SECTION 5
Engine Assembly 3 (Reassembly)
Reassembly 82
SECTION 6
Lubricating System
Main Data and Specification 110
General Description111
Oil Pump 114
Oil Filter with Built-in Oil Cooler 117
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 137
SECTION 9
Engine Electricals
Starter 142
Alternator 157
- Hitachi ZAXIS 75US Hydraulic Excavator Troubleshooting Technical Manual
SECTION 4
OPERATIONAL
PERFORMANCE TEST
Group 1 Introduction
Operational Performance Tests T4-1-1
Preparation for Performance Tests T4-1-2
Group 2 Engine Test
Engine SpeedT4-2-1
Engine Compression Pressure T4-2-3
Valve Clearance AdjustmentT4-2-4
Nozzle Check T4-2-6
Injection TimingT4-2-8
Group 3 Excavator Test
Travel SpeedT4-3-1
Track Revolution Speed T4-3-2
Mistrack Check T4-3-3
Travel Parking Function CheckT4-3-4
Swing Speed T4-3-5
Swing Function Drift Check T4-3-6
Swing Motor LeakageT4-3-7
Swing Bearing Play T4-3-8
Maximum Swingable Slant AngleT4-3-9
Hydraulic Cylinder Cycle Time T4-3-10
Dig Function Drift Check T4-3-12
Control Lever Operating Force T4-3-14
Control Lever Stroke T4-3-15
Combined Boom Raise/Swing
Function Check T4-3-16
Group 4 Component Test
Primary Pilot PressureT4-4-1
Secondary Pilot Pressure T4-4-3
Solenoid Valve Set Pressure T4-4-4
Main Pump Delivery PressureT4-4-6
Main Relief Valve Set PressureT4-4-7
Overload Relief Valve Set PressureT4-4-12
Main Pump Flow Rate Measurement T4-4-16
Swing Motor Drainage T4-4-20
Travel Motor Drainage T4-4-22
Group 5 Standard
Operational Performance Standard
Table T4-5-1
Main Pump P-Q DiagramT4-5-3
Injection Pump T4-5-4
DrEX Monitor Indicating ValuesT4-5-5
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 T5-1-7
Dr EX Monitoring Item List T5-1-8
Dr EX Special FunctionT5-1-10
Dr EX Service Mode T5-1-12
Adjustment Data List T5-1-21
Group 2 Component Layout
Main Components T5-2-1
Electrical Component (Overall System) T5-2-2
Electrical System
(Monitors and Switches) T5-2-4
Control ValveT5-2-6
Others T5-2-14
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 04T5-3-3
Fault Code 06T5-3-4
Fault Code 07T5-3-5
Fault Code 10T5-3-6
Fault Code 16, 18T5-3-7
Sensor Activating Range T5-3-8
Group 4 Troubleshooting B
Troubleshooting B Procedure T5-4-1
Relationship between Machine Trouble
Symptoms and Related PartsT5-4-2
Correlation between Trouble
Symptoms and Part FailuresT5-4-8
Engine System Troubleshooting T5-4-15
All Actuator System Troubleshooting T5-4-24
Front Attachment System
Troubleshooting T5-4-26
Swing System TroubleshootingT5-4-30
Travel System TroubleshootingT5-4-33
Blade System Troubleshooting T5-4-38
Other System Troubleshooting T5-4-40
Engine Speed Adjustment and
Engine Learning T5-4-58
Exchange Inspection T5-4-60
Emergency Boom Lowering
ProcedureT5-4-62
- Hitachi ZAXIS 75US Hydraulic Excavator Operational Principle Technical Manual
SECTION 1
GENERAL
Group 1 Specification
SpecificationsT1-1-1
Working Ranges and Machine
Transportation Dimensions T1-1-2
Group 2 Component Layout
Main Components T1-2-1
Electrical System (Overall System)T1-2-2
Electrical System
(Monitor and Switches) T1-2-4
Others T1-2-6
Group 3 Component Specifications
EngineT1-3-1
Engine Accessories T1-3-4
Hydraulic Component T1-3-5
FilterT1-3-7
Electrical Component T1-3-7
SECTION 2
SYSTEM
Group 1 Control System
Outline T2-1-1
Engine Control T2-1-2
Pump Control T2-1-11
Valve ControlT2-1-16
Arm Flow Combining Control T2-1-18
Other ControlsT2-1-20
Group 2 Hydraulic System
Outline T2-2-1
Pilot CircuitT2-2-2
Main Circuit T2-2-4
Group 3 Electrical System
Outline T2-3-1
Main Circuit T2-3-2
Electric Power Circuit (Key Switch: OFF)T2-3-3
Indicator Light Check Circuit
(Key Switch: ON) T2-3-4
Accessory Circuit T2-3-5
Preheat Circuit (Key Switch: Heat)T2-3-6
Starting Circuit (Key Switch: Start)T2-3-8
Charging Circuit (Key Switch: ON) T2-3-10
Serge Voltage Prevention Circuit T2-3-13
Engine Stop CircuitT2-3-15
SECTION 3
COMPONENT OPERATION
Group 1 Pump Device
Outline T3-1-1
Main Pumps (1 and 2) T3-1-3
Main Pump 3 and Pilot Pump T3-1-6
Group 2 Swing Device
Outline T3-2-1
Swing Motor T3-2-2
Valve UnitT3-2-4
Swing Reduction GearT3-2-6
Group 3 Control Valve
Outline T3-3-1
Hydraulic Circuit T3-3-10
Flow Combiner ValveT3-3-14
Main Relief Set Pressure ChangeT3-3-15
Boom Anti-Drift Valve T3-3-16
Main Relief ValveT3-3-18
Overload Relief Valve T3-3-19
Group 4 Pilot Valve
Outline T3-4-1
Operation T3-4-2
Group 5 Travel Device
Outline T3-5-1
Travel Motor T3-5-2
Parking BrakeT3-5-8
Travel Brake Valve T3-5-10
Travel Reduction GearT3-5-15
Group 6 Others (Upperstructure)
Pilot Shut-Off Valve T3-6-1
Shockless Valve T3-6-2
Solenoid Valve Unit T3-6-8
EC MotorT3-6-10
Group 7 Others (Undercarriage)
Swing Bearing T3-7-1
Center JointT3-7-2
Track Adjuster T3-7-3
VIDEO PREVIEW OF THE MANUAL:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME MANUAL used by the dealerships to diagnose your vehicle
- No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
- Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
- So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com