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This complete service repair workshop manual PDF download for the EX100 & EX100M Hitachi Hydraulic Excavator has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.
APPLICABLE MODELS :
Hitachi Hydraulic Excavator EX100
Hitachi Hydraulic Excavator EX100M
TABLE OF CONTENTS :
SECTION 01 HOW TO USE
SECTION 02 SPECIFICATIONS
SECTION 03 GENERAL
SECTION 04 SUPERSTRUCTURE
SECTION 05 UNDERCARRIAGE
SECTION 06 FRONT-END ATTACHMENT
SECTION 07 HYDRAULIC SYSTEM
SECTION 09 ELECTRICAL SYSTEM
SECTION 10 TROUBLSHOOTING
SECTION 11 ENGINE
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Total Pages : 1014
This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.
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EX100 HYDRAULIC EXCAVATOR SERVICE MANUAL
SECTION 01 HOW TO USE
Group 01 Section & Group Contents
Group 02 Introduction
Introduction
Care of the Handling
Symbols
Group 03 Features of This Manual
Construction
Tab
Page
Contents
Group 04 Safty Informations
SECTION 02 SPECIFICATIONS
Group 01 General Specifications
Dimensions
Weights and Ground Pressure
Capability
Backhoe Attachments
Other Attachments
Working Ranges
Lifting Capacities
Group 02 Components Specifications
Engine
Main Pump
Pilot Pump
Control Valve
Swing Motor
Travel Motor
Center Joint
Pilot Valve (for Travel)
Pilot Valve (for Swing,Boom,Arm,Bucket)
Control Neutralizer Valve
Shockless Valve
Accumulator
Hydraulic Tank
Suction Filter
Full-Flow Filter
Air Breezer
Bypass Check Valve
Pilot Filter
Oil Cooler
Restriction Valve
Solenoid Valve
Mode Selection Cylinder
Boom Cylinder
Arm Cylinder
Bucket Cylinder
Group 03 Torque Reference
Group 04 Others
maintenance Intervals
Group 05 Conversion Table
SECTION 03 GENERAL
Group 01 Introduction
Group 02 Construction
Group 03 Hydraulic System
Hydraulic System
Main Hydraulic Circuit
Pilot Hydraulic Circuit
Group 04 Electric System
Main Circuit
Control System
Monitor System
Group 05 Maintenance
Removal and Instrallation (Cab,Front Attachment,Superstructure)
Maintenance
Name Plate
SECTION 04 SUPERSTRUCTURE
Group 01 Superstructure
Main Frame and Counter-Weight
Engine
Hydraulic Oil Tank
Fuel Tank
Swing Device
Electric Parts
Cab Heater
Engine Control Lever
Main Piping
Oil Cooler Piping
Cover
Main Pump
Control Box
Cab Group
Pilot Piping
Control Lever
Group 02 Hydraulic Pump Device
O/P, Hydraulic Pump
Outline
Function
Operation
D/A, Main Pump
Disassembly
Assembly
Parts List
Group 03 Control Valve
O/P, CV-22M Control Valve
General
Construction and Function
D/A, CV-22M Control Valve
Disassembly
Inspection
Assembly
Group 04 Swing Device
O/P, Swing Motor
Outline
Function
D/A, Swing Motor
Disassembly
Inspection
Assembly
Special Tools
D/A, Swing Reduction Device
Disassembly
Assembly
Group 05 Pilot Valve
O/P, Pilot Valve
Outline
Function
D/A, HV Type Pilot Valve (Front-End Attachment)
Disassembly
Assembly
D/A, HV Type Pilot Valve (Travel)
Disassembly
Assembly
Group 06 Control Neutralizer Valve
O/P, Control Neutralizer Valve
Outline
Function
D/A, Control Neutralizer Valve
Disassembly
Assembly
Group 07 Shockless Valve
O/P, Shockless Valve
Outline
Function
D/A, Shockless Valve
Disassembly
Inspection
Assembly
Group 08 Accumulator
O/P, Accumulator
Outline
Function
Group 09 Solenoid Valve
O/P, Solenoid Valve
Outline
Function
D/A, Solenoid Valve
Disassembly
Inspection
Assembly
Group 10 Mode Selection Cylinder
D/A, Mode Selection Cylinder
Disassembly
Assembly
SECTION 05 UNDERCARRIAGE
Group 01 Undercarriage
Track Frame
Swing Bearing
Travrl Device and Piping
Front Idler
Adjuster
Upper Roller and Lower Roller
Track Link
Center Joint
Group 02 Travel Devece
O/P, Travel Motor (EX100)
Outline
Travel Motor
Brake Valve Assembly
D/A, Travel Motor (EX100)
Disassemble Travel Motor
Inspect Travel Motor
Assemble Travel Motor
Special Tools
Disassemble Brake Valve
Assemble Brake Valve
Special Tools
D/A, Travel Divice (EX100)
Dissembly
Assembly
Special Tools
O/P, Travel Motor (EX100M)
Outline
Travel Motor
Brake Valve Assembly
D/A, Travel Motor Travel Device (EX100M)
Disassemble Travel Motor
Inspect Travel Motor
Assenmble Travel Motor
Disassemble Travel Device
Assemble Travel Device
Special Tools
Group 03 Center Joint
O/P, Center Joint
Outline
D/A, Center Joint
Disassembly
Assembly
Special Tools
SECTION 06 FRONT-END ATTACHMENT
Group 01 FRONT-END ATTACHMENT
Boom Assembly
Arm Assembly
Bucket Assembly
Front Pipings
Group 02 Hydraulic Cylinder
Operational Principle
Construction and Function
Disassembly and Assembly
Disassembly
Inspection
Assembly
Special Tools
Group 03 Pin and Bushing
Specifications
Group 04 Point and Side Cutter
Maintenance
SECTION 07 HYDRAULIC SYSTEM
Group 01 Outline
Group 02 Main Hydraulic Circuit
Suction Circuit and Delivery Circuit
Return Circuit
Drain Circuit
Group 03 Pilot Circuit
Suction,Delivery and Return Circuit
Accumulator
Control Neutralizer Valve
Pump Displacement Control Circuit
Relief pressure Change Circuit
Switch Valve Circuit
Heat-Run Circuit
Swing Parking Brake Circuit
Group 04 Single Operation
Boom Raise Circuit Operation
Boom Lower Circuit Operation
Arm Roll-In Circuit Operation
ArmRoll-Out Circuit Operation
Bucket Circuit Operation
Swing Circuit Operation
Swing Operation
Travel Circuit Operation
Travel Forward and Reverse Operation
Group 05 Combined Operation
Outline
Combined Swing and Boom Operation
Combined Swing and Arm Operation
Combined Swing and Bucket Operation
Combined Swing, Boom, Arm and Buket Operation
Combined Swing and Travel Operation
Combined Boom and Travel Operation
Combined Arm and Travel Operation
Combined Bucket and Travel Operation
Group 06 Extra Control Circuit
Outline
Single Operation
Combined Extra and Arm Roll-In Operation
Combined Extra and Arm Roll-Out Operation
SECTION 09 ELECTRICAL SYSTEM
Group 01 Safety Precautions
Safety Precautions
Group 02 Specifications
Battery, Starter, Safety, Relay, Alternator, Regulator, Headlight, Wiper Motor, Speaker, Fuse
Group 03 Construction and Function
Construction of Electrical System
Monitor
Control (E-P Control) System
Function of Seneors and Relays
Group 04 Circuit Operations
Characteristics of Electrical Circuit
Electrical Circuit
Battery Circuit
Preheat Circuit
Starting Circuit
Charging Circuit
Safety Circuit
Accessory Circuit
Gauge Panel Circuit
Control Circuit
Group 05 Maintenance
Replacing Panel Gauge Parts
Assembly and Adjustment of Engine Control Device
SECTION 10 TROUBLSHOOTING
Group 01 Introduction
General Information
Notes on Performance Measurement
Group 02 Diagnose Malfunctions
Malfunctions Phenomena
Hydraulic System
Electric System
Group 03 Ezcavator Performance Test
Introduction
Engine Performance Measurement
Travel Performance Measurment
Swing Performance Measurement
Front-end Attachment
Control Level Performance Measurement
Group 04 Components Performance Standard
Introduction
Pilot Relief Valve
Main Relief Valve
Overlord Relief Valve
Swing Crossover Relief Valve
Travel Crossover Relief Valve
Main Hydraulic Pump
Travel Motor
Swing Motor
Group 05 Electrical System Test
Commom Circuit Test
Articles Necessary for Electric Circuit Test
Measurement Procedure
Measurement Standard
SECTION 11 ENGINE
Group 01 General Instructions
General Repair Instructions
Notes on the Format of this Manual
Main Data and Specifications
Design Features and General Outline
Tightening Torque Specifications
Anglular Nut and Bolt Tightening Method
Major Parts Fixing Nut and Bolts
Identifications
Group 02 Maintenance
Lubricating System
Fuel System
Cooling System
Valve Clearance and Adjustment
Injection Tinming
Compression Pressure Measurement
Turbocharger Inspection
Engine Repair Kit
Recommended Lubricants
Engine Oil Viscosity Chart
Group 03 Engine Disassemble
Exterminal Parts
Major Components
Rocker Arm and Rocker Arm Shaft
Cylinder Head
Piston and Connecting Rod
Group 04 Inspection and Repair
Cylinder Head
Valve Guide
Valve Spring
Tappet
Push Rod
Rocker Arm Shaft and Rocker Arm
Idler Gear and Idler Gear Shaft
Cam Shaft
Cylinder Body and Liner
Piston and Piston Ring
Piston Pin
Connecting Rod
Crank Shaft
Fly Wheel and Fly Wheel Housing
Timing Gear Case Cover
Group 05 Engine Assembly
Piston and Connecting Rod
Cylinder Head
Rocker Arm and Rocker Arm Shaft
Major Components
External Parts
Engine Tuning Operation
Engine Section View
Group 06 Lubricating System
General Description
Oil Pump
Main Oil Pump
Oil Cooler
Group 07 Cooling System
General Description
Water Pump
Thermostat
Group 08 Fuel System
General Description
Fuel Filter
Injection Nozzle
Group 09 Turbocharger
General Description
Identification
Roter Shaft Play Inspection
Group 10 Engine Electricals
Starter Motor
Alternator
Group 11 Troubleshooting
Head Starting
Unstable Low Idling
Insufficient Power
Excessive Fuel Consumption
Overheating
White Exhaust Smoke
Darkish Exhaust Smoke
Not Rising Oil Pressure
Abnormal Engine Noise
Group 12 Special Tool List
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