Complete service manual with electrical wiring diagrams for Hitachi EX60-5, EX75UR-3, EX75URLC-3 Excavators. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This Hitachi EX60-5, EX75UR-3, 75URLC-3 Excavators service  manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices. 

TO152E-02 - Technical Manual (Operational Principle) EX60-5, EX75UR-3, 75URLC-3.pdf
TT152E-02 - Technical Manua (Troubleshooting) EX60-5, EX75UR-3, 75URLC-3.pdf
TT152E-02CIR - Circuit Diagram & Harness EX60-5, EX75UR-3, 75URLC-3.pdf
W152E-01 - Workshop Manual EX60-5, EX75UR-3, 75URLC-3.pdf

FORMAT: PDF
PAGES: 943
LANGUAGE: English

cir................2
index................3
to152e_02................4
  Intro................5
    INTRODUCTION................5
  T01................7
    SECTION 1 GENERAL................7
      Specifications................9
        SPECIFICATIONS................9
        WORKING RANGES AND MACHINE TRANSPORTATION DIMENSIONS................12
      Component Layout................15
        MAIN COMPONENTS................15
        ELECTRICAL SYSTEM (Overall System)................18
        ELECTRICAL SYSTEM (Monitor and Switches)................23
        Pump Device................27
        Swing Device................27
        Travel Device................28
      Component Specifications................29
        ENGINE................29
        ENGINE ACCESSORIES................32
        HYDRAULIC COMPONENT................32
        ELECTRICAL COMPONENT................35
  T02................37
    SECTION 2 SYSTEM................37
      Control System................39
        OUTLINE................39
        ENGINE CONTROL................40
        PUMP CONTROL................50
        PRECISE SWING MODE CONTROL (EX75UR-3 and EX75URLC-3)................54
      Front Control System................57
        OUTLINE................57
        FRONT FUNCTION CONTROL................58
        FRONT FUNCTION LIMIT CONTROL................68
      Hydraulic System................75
        OUTLINE................75
        PILOT CIRCUIT................76
        MAIN CIRCUIT................78
      Electrical System................87
        OUTLINE................87
        POWER CIRCUIT (Key Switch: OFF)................88
        BULB CHECK CIRCUIT................90
        PREHEAT CIRCUIT................92
        STARTING CIRCUIT (KEY SWITCH: START)................94
        CHARGING CIRCUIT (KEY SWITCH: ON)................98
        SURGE VOLTAGE PREVENTION CIRCUIT................102
        ACCESSORY CIRCUIT................104
        ENGINE STOP CIRCUIT................106
  T03................109
    SECTION 3 COMPONENT OPERATION................109
      Pump Device................111
        OUTLINE................111
        MAIN PUMP 1................112
        MAIN PUMP 2 AND PILOT PUMP................114
      Swing Device................115
        OUTLINE................115
        SWING MOTOR................116
        PARKING BRAKE SWITCH VALVE................118
        VALVE UNIT................120
        SWING REDUCTION GEAR................124
      Control Valve................125
        OUTLINE................125
        CONTROL VALVE LAYOUT................126
        HYDRAULIC CIRCUIT................136
        FLOW COMBINER VALVE................144
        MAIN RELIEF SET PRESSURE CHANGE................146
        BOOM ANTI-DRIFT VALVE (EX60-5)................148
        MAIN RELIEF VALVE................150
        OVERLOAD RELIEF VALVE................152
      Pilot Valve................153
        OUTLINE................153
        OPERATION................154
      Travel Device................163
        OUTLINE................163
        TRAVEL MOTOR................164
        PARKING BRAKE................166
        TRAVEL BRAKE VALVE................168
        TRAVEL REDUCTION GEAR................172
      Others (Upperstructure)................175
        PILOT SHUT-OFF VALVE................175
        SWING MODE CONTROL VALVE................176
        SHOCKLESS VALVE................178
        7-SPOOL SOLENOID VALVE UNIT................182
        PILOT RELIEF VALVE................184
        EC MOTOR................185
      Others (Undercarriage)................187
        SWING BEARING................187
        CENTER JOINT................188
        TRACK ADJUSTER................189
  index_to................191
    INDEX(TO)................191
tt152e_02................192
  Intro................193
    INTRODUCTION................193
  T04................195
    SECTION 4 OPERATIONAL PERFORMANCE TEST................195
      Introduction................197
        OPERATIONAL PERFORMANCE TESTS................197
        PREPARATION FOR PERFORMANCE TESTS................198
      Standard................200
        OPERATIONAL PERFORMANCE STANDARD TABLE................199
        MAIN PUMP P-Q DIAGRAM................208
        SENSOR ACTIVATING RANGE................210
      Engine Test................211
        ENGINE SPEED................211
        ENGINE COMPRESSION PRESSURE................212
        VALVE CLEARANCE................214
        NOZZLE CHECK................216
        INJECTION TIMING................218
      Excavator Test................219
        TRAVEL SPEED................219
        TRACK REVOLUTION SPEED................220
        MISTRACK CHECK................221
        TRAVEL MOTOR LEAKAGE................222
        SWING SPEED................223
        SWING FUNCTION DRIFT CHECK................224
        SWING MOTOR LEAKAGE................225
        MAXIMUM SWINGABLE SLANT ANGLE................226
        SWING BEARING PLAY................227
        HYDRAULIC CYLINDER CYCLE TIME................228
        DIG FUNCTION DRIFT CHECK................230
        CONTROL LEVER OPERATING FORCE................231
        CONTROL LEVER STROKE................232
        BOOM RAISE/SWING COMBINED OPERATION CHECK................233
        BUCKET/CAB COLLISION PREVENTION SYSTEM CHECK (EX75UR-3)................234
      Component Test................235
        PRIMARY PILOT PRESSURE................235
        SECONDARY PILOT PRESSURE................237
        MAIN RELIEF VALVE SET PRESSURE................238
        OVERLOAD RELIEF VALVE SET PRESSURE................244
        MAIN PUMP FLOW RATE MEASUREMENT................246
        SWING MOTOR DRAINAGE................250
        TRAVEL MOTOR DRAINAGE................252
      Adjustment................255
        ENGINE SPEED ADJUSTMENT AND ENGINE LEARNING................255
        BOOM LOWERING METHOD WHEN ENGINE STALLING................256
        CHECK OF GOVERNOR LEVER AND FUEL CUT LEVER POSITION................258
  T05................261
    SECTION 5 TROUBLESHOOTING................261
      General................263
        INTRODUCTION................263
        DIAGNOSTIC PROCEDURES................264
        DR.EX OPERATION................266
        MAIN CONTROLLER FAULT CODE LIST................267
        AUTO-MARCCINO CONTROL UNIT FAULT CODE LIST (EX75UR-3)................268
        MAIN CONTROLLER MONITORING FUNCTION................270
        AUTO-MARCCINO CONTROL UNIT MONITORING FUNCTION (EX75UR-3)................271
        Dr.EX SPECIAL FUNCTION (Service Mode) (EX75UR-3)................272
      Component Layout................279
        MAIN COMPONENTS................279
        ELECTRICAL SYSTEM (Overview)................282
        ELECTRICAL SYSTEM (Monitor and Switches)................289
        PUMP DEVICE................293
        SWING DEVICE................293
        TRAVEL DEVICE................294
        COMPONENT IN CONTROL VALVE................296
      Troubleshooting A................307
        TROUBLESHOOTING A PROCEDURE................307
        FAULT CODE 01................308
        FAULT CODE 07................310
      Troubleshooting B................313
        TROUBLESHOOTING B PROCEDURE................313
        RELATIONSHIP BETWEEN MACHINE TROUBLE SYMPTOMS AND SUSPECTED PARTS................314
        CORRELATION BETWEEN TROUBLE SYMPTOMS AND PART FAILURES................318
        ENGINE SYSTEM TROUBLESHOOTING................324
        ALL ACTUATOR CONTROL SYSTEM TROUBLESHOOTING................336
        FRONT ATTACHMENT CONTROL SYSTEM TROUBLESHOOTING................338
        SWING SYSTEM TROUBLESHOOTING................344
        TRAVEL SYSTEM TROUBLESHOOTING................348
        BLADE SYSTEM TROUBLESHOOTING ................351
      Troubleshooting C................353
        TROUBLESHOOTING C PROCEDURE (Troubleshooting for Monitor)................353
        MALFUNCTION OF COOLANT TEMPERATURE GAUGE................354
        MALFUNCTION OF FUEL GAUGE................356
        MALFUNCTION OF INDICATOR LIGHT CHECK SYSTEM................358
        MALFUNCTION OF ALTERNATOR INDICATOR................360
        MALFUNCTION OF ENGINE OIL PRESSURE INDICATOR................364
        MALFUNCTION OF OVERHEAT INDICATOR................368
        MALFUNCTION OF FUEL LEVEL INDICATOR (EX75UR-3, EX75URL-3)................372
        MALFUNCTION OF AIR FILTER RESTRICTION INDICATOR................374
        MALFUNCTION OF ELECTROLYTE LEVEL INDICATOR (EX75UR-3, EX75URLC-3)................378
        MALFUNTION OF BUZZER................380
        MALFUNCTION OF HOUR METER................384
      Troubleshooting D................387
        TROUBLESHOOTING D PROCEDURE................387
        AUTO-MARCCINO CONTROL UNIT SYSTEM FAULT CODE LIST................388
        FAULT CODE 03................390
        FAULT CODE 07................391
        FAULT CODE 08................391
        Fault Code 11, 12, 13................392
        Fault Code 14, 15, 16, 20................394
        Fault Code 40, 41, 42, 44................396
        Fault Code 43, 45, 47................397
        Fault Code 50, 51, 52................398
        Fault Code 60, 61, 62................400
        Fault Code 80, 81, 82................401
        Fault Code 90................402
      Electrical System Inspection................403
        PRECAUTIONS FOR INSPECTION AND MAINTENANCE................403
        INSTRUCTIONS FOR DISCONNECTING CONNECTORS................405
        FUSE CONTINUITY TEST................406
        FUSIBLE LINK INSPECTION................408
        BATTERY VOLTAGE CHECK................409
        HOW TO TROUBLESHOOT ALTERNATOR MALFUNCTIONS................410
        CONTINUITY CHECK................411
        VOLTAGE AND CURRENT CHECK................412
        CHECK BY FALSE SIGNAL................417
        TEST HARNESS................418
  index_tt................419
    INDEX(TT)................419
  sa................420
    SAFETY................420
tt152e_02cir................448
  EX60-5 CAB(E)................449
  EX60-5 CON(E)................450
  EX60-5 ELEC(E)................451
  EX60-5 ENG(E)................452
  EX60-5 HYD BLADE(E)................453
  EX60-5 HYD(E)................454
  EX75UR-3 CAB(E)................455
  EX75UR-3 CON(E)................456
  EX75UR-3 ELEC(E)................457
  EX75UR-3 ENG(E)................458
  EX75UR-3 HYD(E)................459
  EX75URLC-3 CAB(E)................460
  EX75URLC-3 CON(E)................461
  EX75URLC-3 ELEC(E)................462
  EX75URLC-3 ENG(E)................463
  EX75URLC-3 HYD(E)................464
w152e_01................465
  Intro................466
    INTRODUCTION................466
  W01................468
    SECTION 1 GENERAL INFORMATION................468
      Precautions for Disassembling and Assembling................470
        PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING................470
        MAINTENANCE STANDARD TERMINOLOGY................476
      Tightening................478
        TIGHTENING TORQUE SPECIFICATIONS................478
        TORQUE CHART................479
        PIPING JOINT................482
  W02................486
    SECTION 2 UPPERSTRUCTURE................486
      Cab................488
        REMOVE AND INSTALL CAB................488
        DIMENSIONS OF CAB WINDOW GLASS................494
      Counterweight................498
        REMOVE AND INSTALL COUNTERWEIGHT................498
      Main Frame................506
        REMOVE AND INSTALL MAIN FRAME................506
      Pump Device................520
        REMOVE AND INSTALL PUMP DEVICE................520
        DISASSEMBLE MAIN PUMP................525
        ASSEMBLE MAIN PUMP................531
        DISASSEMBLE AND ASSEMBLE PILOT PUMP (EX60-5)................539
        DISASSEMBLE AND ASSEMBLE GEAR PUMP (EX75UR-3, EX75URLC-3)................541
        MAINTENANCE STANDARD................543
      Control Valve................546
        REMOVE AND INSTALL CONTROL VALVE................546
        DISASSEMBLE CONTROL VALVE................554
        ASSEMBLE CONTROL VALVE ................564
        DISASSEMBLE BLADE CONTROL VALVE ................595
        ASSEMBLE BLADE CONTROL VALVE................597
      Swing Device................600
        REMOVE AND INSTALL SWING DEVICE................600
        DISASSEMBLE SWING REDUTION GEAR (EX60-5)................605
        ASSEMBLE SWING REDUCTION GEAR ................611
        DISASSEMBLE SWING MOTOR ................623
        ASSEMBLE SWING MOTOR................633
        MAINTENANCE STANDARD................649
      Pilot Valve................652
        REMOVE AND INSTALL RIGHT PILOT VALVE................652
        DISASSEMBLE PILOT VALVE FOR FRONT ATTACHMENT................669
        DISASSEMBLE OFFSET PILOT VALVE................673
        ASSEMBLE PILOT VALVE FOR FRONT ATTACHMENT................675
        ASSEMBLE OFFSET PILOT VALVE ................679
      Pilot Shut-Off Valve................682
        REMOVE AND INSTALL PILOT SHUT-OFF VALVE................682
        DISASSEMBLE PILOT SHUT-OFF VALVE................686
        ASSEMBLE PILOT SHUT-OFF VALVE ................689
      Shockless Valve................692
        REMOVE AND INSTALL SHOCKLESS VALVE................692
        DISASSEMBLE AND ASSEMBLE SWING SHOCKLESS VALVE................695
        DISASSEMBLE AND ASSEMBLE FRONT ATTACHMENT SHOCKLESS VALVE ................698
      Solenoid Valve................706
        REMOVE AND INSTALL SOLENOID VALVE UNIT (EX75UR-3 ONLY)................706
        DISASSEMBLE AND ASSEMBLE 7-SPOOL SOLENOID VALVE UNIT (EX75UR-3 ONLY)................709
        DISASSEMBLE PROPORTIONAL SOLENOID VALVE (EX75UR-3 ONLY)................711
        ASSEMBLE PROPORTIONAL SOLENOID VALVE (EX75UR-3 ONLY)................713
      Pilot Relief Valve Unit................716
        REMOVE AND INSTALL PILOT RELIEF VALVE UNIT................716
        DISASSEMBLE PILOT RELIEF VALVE................721
        ASSEMBLE PILOT RELIEF VALVE ................723
      Swing Mode Control Valve................728
        REMOVE AND INSTALL SWING MODE CONTROL VALVE UNIT (EX75UR-3, EX75URLC-3)................728
        DISASSEMBLE AND ASSEMBLE SWING MODE CONTROL VALVE (EX75UR-3, EX75URLC-3)................731
  W03................734
    SECTION 3 UNDERCARRIAGE................734
      Swing Bearing................736
        REMOVE AND INSTALL SWING BEARING................736
        DISASSEMBLE SWING BEARING................738
        ASSEMBLE SWING BEARING................740
      Travel Device................742
        REMOVE AND INSTALL TRAVEL DEVICE................742
        DISASSEMBLE TRAVEL DEVICE................745
        ASSEMBLE TRAVEL DEVICE................753
        DISASSEMBLE TRAVEL MOTOR................765
        ASSEMBLE TRAVEL MOTOR................769
        DISASSEMBLE AND ASSEMBLE BRAKE VALVE................775
        MAINTENANCE STANDARD................777
      Center Joint................780
        REMOVE AND INSTALL CENTER JOINT................780
        DISASSEMBLE CENTER JOINT................784
        ASSEMBLE CENTER JOINT................787
      Track Adjuster................790
        REMOVE AND INSTALL TRACK ADJUSTER................790
        DISASSEMBLE TRACK ADJUSTER................791
        ASSEMBLE TRACK ADJUSTER................797
      Front Idler................802
        REMOVE AND INSTALL FRONT IDLER................802
        DISASSEMBLE FRONT IDLER................803
        ASSEMBLE FRONT IDLER................805
        MAINTENANCE STANDARD................807
      Upper and Lower Roller................808
        REMOVE AND INSTALL UPPER ROLLER................808
        REMOVE AND INSTALL LOWER ROLLER................811
        DISASSEMBLE AND ASSEMBLE LOWER ROLLER................815
        MAINTENANCE STANDARD................817
      Track................820
        REMOVE AND INSTALL TRACKS (EX60-5, EX75URLC-3)................820
        MAINTENANCE STANDARD................826
        REMOVE AND INSTALL RUBBER TRACK  (EX75UR-3) ................828
        MAINTENANCE STANDARDS................831
  W04................834
    SECTION 4 FRONT ATTACHMENT................834
      Front Attachment................836
        REMOVE AND INSTALL FRONT ATTACHMENT................836
        MAINTENANCE STANDERD................845
        STANDARD DIMENSIONS FOR ARM AND BUCKET CONNECTION ................850
      Cylinder................852
        REMOVE AND INSTALL CYLINDER................852
        DISASSEMBLE CYLINDER................871
        ASSEMBLE CYLINDER................889
        MAINTENANCE STANDARD................903
  W05................904
    SECTION 5 ENGINE AND ACCESSORY................904
      General................908
        Engine Specification.................909
        Identification................911
        Lubrication................912
      Inspection and Maintenance................914
        Engine Main Body................915
        Lubricating System................917
        Cooling System................918
        Fuel System................918
        Intake and Exaust System................926
        Electrical System................927
      Engine Servicing................928
        Manihold................929
        Rocker Cover................932
        Rocker Shaft................933
        Cylinder Head................936
        Gear Train................948
        Injection Pump................955
        Oil Pan................963
        Oil Cooler................965
        Oil Pump................965
        Water Pump................967
        Thermostat................967
      Engine Main Body Overhauling................970
        Precaution for Overhauling................971
        Engine Main Body Overhauling................973
      Service Data................992
        Engine Major Component Tightening Torque................993
        Engine Main Body Specifications................995
        Standard Tightening Torque................998
      Trouble Shooting................1000
        Trouble Shooting Chart................1001
        Hou to Use the Chart................1001
  index_w................1010
    INDEX(W)................1010
  sa................1011