Complete service manual with electrical wiring diagrams for Hitachi EX80U Excavators. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This Hitachi EX80U 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. 

FILE LIST:
TO196E-01 - Technical Manual (Operational Principle) EX80U.pdf
TT196E-01 - Technical Manual (Troubleshooting) EX80U.pdf
TT196E-01CIR - Circuit Diagram & Harness EX80U.pdf
W196E-01 - Workshop Manual EX80U.pdf

FORMAT: PDF
PAGES: 730
LANGUAGE: English

TABLE OF CONTENTS
to196e_01....4
  Intro....5
    INTRODUCTION....5
  T01....7
    SECTION 1 GENERAL....7
      Specifications....9
        SPECIFICATIONS....9
        WORKING RANGE AND TRANSPORTA-TION DIMENSIONS....10
        COMPONENT SPECIFICATION....11
      Component Layout....18
        MAIN COMPONENTS....18
        ELECTRICAL SYSTEM (Overall System)....19
        ELECTRICAL SYSTEM (Monitor and Switch)....21
        OTHERS....22
  T02....24
    SECTION 2 SYSTEM....24
      Control System....26
        OUTLINE....26
        ENGINE CONTROL....27
        PUMP CONTROL....30
        TRAVEL MODE CONTROL....31
      Hydraulic System....32
        OUTLINE....32
        MAIN CIRCUIT....33
        PILOT CIRCUIT....39
      Electrical System....42
        OUTLINE....42
        POWER CIRCUIT (KEY SWITCH: OFF)....43
        BULB CHECK CIRCUIT....44
        PREHEAT CIRCUIT....45
        ENGINE START CIRCUIT (Key Switch: START)....46
        CHARGING CIRCUIT (KEY SWITCH: ON)....48
        SURGE VOLTAGE PREVENTION CIRCUIT....51
        ACCESSORY CIRCUIT....52
        ENGINE STOP CIRCUIT....53
  T03....54
    SECTION 3 COMPONENT OPERATION....54
      Pump Device....56
        OUTLINE....56
        MAIN PUMPS (1 and 2)....58
        MAIN PUMP 3 AND PILOT PUMP....61
      Swing Device....62
        OUTLINE....62
        SWING MOTOR....63
        VALVE UNIT....65
        SWING REDUCTION GEAR....67
      Control Valve....68
        OUTLINE....68
        HYDRAULIC CIRCUIT....75
        FLOW COMBINER VALVE....79
        MAIN RELIEF SET PRESSURE CHANGE....80
        BOOM ANTI-DRIFT VALVE....81
        MAIN RELIEF VALVE....83
        OVERLOAD RELIEF VALVE....84
      Pilot Valve....86
        OUTLINE....86
        OPERATION....87
      Travel Device....96
        OUTLINE....96
        TRAVEL MOTOR....97
        TRAVEL BRAKE VALVE....104
        TRAVEL REDUCTION GEAR....106
      Others (Upperstructure)....108
        PILOT SHUT-OFF VALVE....108
        SHOCKLESS VALVE....109
        SOLENOID VALVE UNIT....113
        PILOT RELIEF VALVE....115
        EC MOTOR....115
      Others (Undercarriage)....116
        SWING BEARING....116
        CENTER JOINT....117
        TRACK ADJUSTER....118
  inde_to....120
    INDEX(TO)....120
tt196e_01....121
  Intro....122
    INTRODUCTION....122
  T04....124
    SECTION 4 OPERATIONAL PERFORMANCE TEST....124
      Introduction....126
        OPERATIONAL PERFORMANCE TESTS....126
        PREPARATION FOR PERFORMANCE TESTS....127
      Standard....128
        OPERATIONAL PERFORMANCE STANDARD TABLE....128
        MAIN PUMP P-Q DIAGRAM....131
        SENSOR ACTIVATING RANGE....132
      Engine Test....134
        ENGINE SPEED....134
        ENGINE COMPRESSION PRESSURE....135
        VALVE CLEARANCE ADJUSTMENT....137
        NOZZLE CHECK....139
        INJECTION TIMING....141
      Excavator Test....142
        TRAVEL SPEED....142
        TRACK REVOLUTION SPEED....143
        MISTRACK CHECK....144
        TRAVEL MOTOR LEAKAGE....145
        SWING SPEED....146
        SWING FUNCTION DRIFT CHECK....147
        SWING MOTOR LEAKAGE....148
        MAXIMUM SWINGABLE SLANT ANGLE....149
        SWING BEARING PLAY....150
        HYDRAULIC CYLINDER CYCLE TIME....151
        DIG FUNCTION DRIFT CHECK....153
        CONTROL LEVER OPERATING FORCE....154
        CONTROL LEVER STROKE....155
        BOOM RAISE/SWING COMBINED OPERATION CHECK....156
      Component Test....158
        PRIMARY PILOT PRESSURE....158
        SECONDARY PILOT PRESSURE....160
        MAIN RELIEF VALVE SET PRESSURE....161
        OVERLOAD RELIEF VALVE SET PRESSURE....167
        MAIN PUMP FLOW RATE MEASUREMENT....171
        SWING MOTOR DRAINAGE....175
        TRAVEL MOTOR DRAINAGE....177
      Adjustment....180
        ENGINE SPEED ADJUSTMENT AND ENGINE LEARNING....180
        BOOM LOWERING METHOD WHEN ENGINE STALLING....181
        CHECK OF GOVERNOR LEVER AND FUEL CUT LEVER POSITION....183
  T05....186
    SECTION 5 TROUBLESHOOTING....186
      General....188
        INTRODUCTION....188
        DIAGNOSING PROCEDURE....189
        Dr.EX OPERATION....191
        MAIN CONTROLLER FAULT CODE LIST....192
        MAIN CONTROLLER MONITORING ITEM LIST....192
        Dr.EX SPECIAL FUNCTION (SERVICE MODE)....193
        ADJUSTMENT DATA LIST....199
      Component Layout....200
        MAIN COMPONENTS....200
        ELECTRICAL SYSTEM (Overview)....201
        ELECTRICAL SYSTEM (Monitor and Switches)....203
        PUMP DEVICE....204
        SWING DEVICE....204
        TRAVEL DEVICE....204
        COMPONENT IN CONTROL VALVE....205
      Troubleshooting A....212
        TROUBLESHOOTING A PROCEDURE....212
        FAULT CODE LIST....213
        FAULT CODE 01....214
        FAULT CODE 07....215
      Troubleshooting B....216
        TROUBLESHOOTING B PROCEDURE....216
        RELATIONSHIP BETWEEN MACHINE TROUBLE SYMPTOMS AND RELATED PARTS....217
        CORRELATION BETWEEN TROUBLE SYMPTOMS AND PART FAILURES....221
        ENGINE SYSTEM TROUBLESHOOTING....227
        ALL ACTUATOR SYSTEM TROUBLESHOOTING....239
        FRONT ATTACHMENT SYSTEM TROUBLESHOOTING....241
        SWING SYSTEM TROUBLESHOOTING....245
        TRAVEL SYSTEM TROUBLESHOOTING....247
        BLADE SYSTEM TROUBLESHOOTING....251
      Troubleshooting C....254
        TROUBLESHOOTING C PROCEDURE....254
        MALFUNCTION OF COOLANT TEMPERATURE GAUGE....255
        MALFUNCTION OF FUEL GAUGE....257
        MALFUNCTION OF INDICATOR LIGHT CHECK SYSTEM....259
        MALFUNCTION OF ALTERNATOR INDICATOR....261
        MALFUNCTION OF ENGINE OIL PRESSURE INDICATOR....263
        MALFUNCTION OF OVERHEAT INDICATOR....265
        MALFUNCTION OF FUEL LEVEL INDICATOR....267
        MALFUNCTION OF AIR FILTER RESTRICTION INDICATOR....269
        MALFUNCTION OF ELECTROLYTE LEVEL INDICATOR....271
        MALFANCTION OF BUZZER....273
        MALFUNCTION OF HOUR METER....275
      Electrical System Inspection....276
        PRECAUTIONS FOR INSPECTION AND MAINTENANCE....276
        INSTRUCTIONS FOR DISCONNECTING CONNECTORS....278
        FUSE CONTINUITY TEST....279
        FUSIBLE LINK INSPECTION....281
        BATTERY VOLTAGE CHECK....282
        HOW TO TROUBLESHOOT ALTERNATOR MALFUNCTIONS....283
        CONTINUITY CHECK....284
        VOLTAGE AND CURRENT CHECK....285
        CHECK BY FALSE SIGNAL....288
        TEST HARNESS....289
  index_tt....290
    INDEX(TT)....290
  sa....291
    SAFETY....291
tt196e_cir....319
  EX80U CAB(E)....320
  EX80U CON(E)....321
  EX80U ELEC(E)....322
  EX80U ENG(E)....323
  EX80U HYD(E)....324
w196e_01....325
  Intro....326
    INTRODUCTION....326
  W01....328
    SECTION 1 GENERAL INFORMATION....328
      Precautions for Disassembling and Assembling....330
        PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING....330
      Tightening....336
        TIGHTENING TORQUE SPECIFICATIONS....336
        TORQUE CHART....337
        PIPING JOINT....340
        PERIODIC REPLACEMENT OF PARTS....344
  W02....346
    SECTION 2 UPPERSTRUCTURE....346
      Cab....348
        REMOVE AND INSTALL CAB....348
        DIMENSIONS OF CAB WINDOW GLASS....352
      Counterweight....354
        REMOVE AND INSTALL COUNTERWEIGHT....354
      Main Frame....360
        REMOVE AND INSTALL MAIN FRAME....360
      Pump Device....366
        REMOVE AND INSTALL PUMP DEVICE....366
        DISASSEMBLE PUMP DEVICE....369
        ASSEMBLE PUMP DEVICE....373
        MAINTENANCE STANDARD....379
        DISASSEMBLE AND ASSEMBLE PILOT PUMP....381
      Control Valve....384
        REMOVE AND INSTALL CONTROL VALVE1....384
        DISASSEMBLE CONTROL VALVE 1....388
        ASSEMBLE CONTROL VALVE 1....398
        REMOVE AND INSTALL CONTROL VALVE 2....409
        DISASSEMBLE CONTROL VALVE 2....411
        ASSEMBLE CONTROL VALVE 2....413
      Swing Device....416
        REMOVE AND INSTALL SWING DEVICE....416
        DISASSEMBLE SWING DEVICE....419
        ASSEMBLE SWING DEVICE....425
        DISASSEMBLE SWING MOTOR....433
        ASSEMBLE SWING MOTOR....437
        MAINTENANCE STANDARD....443
      Pilot Valve....444
        REMOVE AND INSTALL PILOT VALVE FOR FRONT ATTACHMENT AND SWING....444
        DISASSEMBLE PILOT VALVE FOR FRONT ATTACHMENT AND SWING....451
        ASSEMBLE PILOT VALVE FOR FRONT ATTACHMENT AND SWING....455
        REMOVE AND INSTALL PILOT VALVE FOR BOOM SWING....462
        DISASSEMBLE PILOT VALVE FOR BOOM SWING....465
        ASSEMBLE PILOT VALVE FOR BOOM SWING....467
      Pilot Shut-Off Valve....470
        REMOVE AND INSTALL PILOT SHUT-OFF VALVE....470
        DISASSEMBLE PILOT SHUT-OFF VALVE....473
        ASSEMBLE PILOT SHUT-OFF VALVE....475
      Shockless Valve....478
        REMOVE AND INSTALL SHOCKLESS VALVE....478
        DISASSEMBLE AND ASSEMBLE SHOCKLESS VALVE....480
      Solenoid Valve....484
        REMOVE AND INSTALL SOLENOID VALVE UNIT....484
        DISASSEMBLE PROPORTIONAL SOLENOID VALVE....487
        ASSEMBIE PROPORTIONAL SOLENOID VALVE....489
        DISASSEMBLE PILOT RELIEF VALVE....491
        ASSEMBLE PILOT RELIEF VALVE....493
  W03....496
    SECTION 3 UNDERCARRIAGE....496
      Swing Bearing....498
        REMOVE AND INSTALL SWING BEARING....498
        DISASSEMBLE SWING BEARING....501
        ASSEMBLE SWING BEARING....503
      Travel Device....506
        REMOVE AND INSTALL TRAVEL DEVICE....506
        DISASSEMBLE TRAVEL DEVICE....508
        ASSEMBLE TRAVEL DEVICE....513
        DISASSEMBLE TRAVEL MOTOR....521
        ASSEMBLE TRAVEL MOTOR....523
        DISASSEMBLE AND ASSEMBLE BRAKE VALVE....525
        MAINTENANCE STANDARD....527
      Center Joint....528
        REMOVE AND INSTALL CENTER JOINT....528
        DISASSEMBLE CENTER JOINT....531
        ASSEMBLE CENTER JOINT....533
        MAINTENANCE STANDARD....536
      Track Adjuster....538
        REMOVE AND INSTALL TRACK ADJUSTER....538
        DISASSEMBLE TRACK ADJUSTER....539
        ASSEMBLE TRACK ADJUSTER....545
      Front Idler....552
        REMOVE AND INSTALL FRONT IDLER....552
        DISASSEMBLE FRONT IDLER....553
        ASSEMBLE FRONT IDLER....555
        MAINTENANCE STANDARD....557
      Upper And Lower Roller....558
        REMOVE AND INSTALL UPPER ROLLER....558
        DISASSEMBLE AND ASSEMBLE UPPER ROLLER....561
        REMOVE AND INSTALL LOWER ROLLER....563
        DISASSEMBLE LOWER ROLLER....565
        ASSEMBLE LOWER ROLLER....567
        MAINTENANCE STANDARD....569
      Track....572
        REMOVE AND INSTALL RUBBER TRACK....572
        MAINTENANCE STANDARDS....574
  W04....576
    SECTION 4 FRONT ATTACHMENT....576
      Front Attachment....578
        REMOVE AND INSTALL FRONT ATTACHMENT....578
        MAINTENANCE STANDARD....585
        STANDARD DIMENSIONS FOR ARM AND BUCKET CONNECTION....588
      Cylinder....590
        REMOVE AND INSTALL CYLINDER....590
        DISASSEMBLE CYLINDER....606
        ASSEMBLE CYLINDER....613
        DISASSEMBLE BOOM SWING CYLINDER....621
        ASSEMBLE BOOM SWING CYLINDER....623
        DISASSEMBLE BLADE CYLINDER....627
        ASSEMBLE BLADE CYLINDER....629
        MAINTENANCE STANDARD....631
  W05....632
    SECTION 5 ENGINE AND ACCESSORY....632
      General....636
        Engine Specification.....637
        Identification....639
        Lubrication....640
      Inspection and Maintenance....642
        Engine Main Body....643
        Lubricating System....645
        Cooling System....646
        Fuel System....646
        Intake and Exaust System....654
        Electrical System....655
      Engine Servicing....656
        Manihold....657
        Rocker Cover....660
        Rocker Shaft....661
        Cylinder Head....664
        Gear Train....676
        Injection Pump....683
        Oil Pan....691
        Oil Cooler....693
        Oil Pump....693
        Water Pump....695
        Thermostat....695
      Engine Main Body Overhauling....698
        Precaution for Overhauling....699
        Engine Main Body Overhauling....701
      Service Data....720
        Engine Major Component Tightening Torque....721
        Engine Main Body Specifications....723
        Standard Tightening Torque....726
      Trouble Shooting....728
        Trouble Shooting Chart....729
        Hou to Use the Chart....729
  W2-1-4....738
  index_w....739
    INDEX(W)....739
  sa....740
    SAFETY....740

Hitachi EX80U Excavators Factory Service Manual