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This complete service repair workshop manual PDF download for the EX400-5 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.
TABLE OF CONTENTS :
GENERAL INFORMATION
UPPERSTRUCTURE
UNDERCARRIAGE
FRONT ATTACHMENT
ENGINE AND ACCESSORY
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Total Pages : 638
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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INTRODUCTION
SAFETY
SECTION 1 GENERAL INFORMATION
GROUP 1 Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING
MAINTENANCE STANDARD TERMINOL-OGY
GROUP 2 Tightening
TIGHTENING TORQUE SPECIFICATIONS
TORQUE CHART
PIPING JOINT
PERIODIC REPLACEMENT OF PARTS
SECTION 2 UPPERSTRUCTURE
GROUP 1 Cab
REMOVE AND INSTALL CAB
DIMENSIONS OF THE CAB GLASS
GROUP 2 Counterweight
REMOVE AND INSTALL COUN-TERWEIGHT
REMOVE AND INSTALL COUNTER-WEIGHT (WITH COUNTERWEIGHT RE-MOVAL DEVICE)
GROUP 3 Main Frame
REMOVE AND INSTALL MAIN FRAME
GROUP 4 Pump Device
REMOVE AND INSTALL PUMP DEVICE
DISASSEMBLE PUMP TRANSMISSION
ASSEMBLE PUMP TRANSMISSION
REMOVE AND INSTALL MAIN PUMP
DISASSEMBLE MAIN PUMP
ASSEMBLE MAIN PUMP
MAINTENANCE STANDARD
DISASSEMBLE REGULATOR
ASSEMBLE REGULATOR
DISASSEMBLE AND ASSEMBLE PILOT PUMP
GROUP 5 Control Valve
REMOVE AND INSTALL CONTROL VALVE
DISASSEMBLE CONTROL VALVE 1
ASSEMBLE CONTROL VALVE 1
DISASSEMBLE CONTROL VALVE 2
ASSEMBLE CONTROL VALVE 2
DISASSEMBLE CONTROL VALVE 3
ASSEMBLE CONTROL VALVE 3
DISASSEMBLE CONTROL VALVE 4
ASSEMBLE CONTROL VALVE 4
DISASSEMBLE CONTROL VALVE 5
ASSEMBLE CONTROL VALVE 5
GROUP 6 Swing Device
REMOVE AND INSTALL SWING DEVICE
DISASSEMBLE SWING DEVICE
ASSEMBLE SWING DEVICE
DISASSEMBLE SWING MOTOR
ASSEMBLE SWING MOTOR
MAINTENANCE STANDARD
GROUP 7 Pilot Valve
REMOVE AND INSTALL RIGHT PILOT VALVE (FRONT ATTACHMENT)
REMOVE AND INSTALL LEFT PILOT VALVE (FRONT ATTACHMENT)
REMOVE AND INSTALL TRAVEL PILOT VALVE
DISASSEMBLE FRONT ATTACHMENT PILOT VALVE
ASSEMBLE FRONT ATTACHMENT PILOT VALVE
DISASSEMBLE TRAVEL PILOT VALVE
ASSEMBLE TRAVEL PILOT VALVE
BUCKET OPEN / CLOSE AND BREAKER PILOT VALVE
ASSEMBLE BUCKET OPEN / CLOSE AND BREAKER PILOT VALVE
GROUP 8 Pilot Shut-off Valve
REMOVE AND INSTALL PILOT SHUT-OFF VALVE
DISASSEMBLE PILOT SHUT-OFF VALVE
ASSEMBLE PILOT SHUT-OFF VALVE
GROUP 9 Shockless Valve
REMOVE AND INSTALL FRONT ATTACH-MENT SHOCKLESS VALVE
DISASSEMBLE AND ASSEMBLE FRONT ATTACHMENT SHOCKLESS VALVE
REMOVE AND INSTALL TRAVEL SHOCK-LESS VALVE
DISASSEMBLE AND ASSEMBLE TRAVEL SHOCKLESS VALVE
Solenoid Valve
REMOVE AND INSTALL THREE-SPOOL SOLENOID VALVE
DISASSEMBLE AND ASSEMBLE THREE-SPOOL SOLENOID VALVE
SECTION 3 UNDERCARRIAGE
GROUP 1 Swing Bearing
REMOVE AND INSTALL SWING BEARING
DISASSEMBLE SWING BEARING
ASSEMBLE SWING BEARING
GROUP 2 Travel Device
REMOVE AND INSTALL TRAVEL DEVICE
DISASSEMBLE TRAVEL DEVICE
ASSEMBLE TRAVEL DEVICE
DISASSEMBLE TRAVEL MOTOR
ASSEMBLE TRAVEL MOTOR
DISASSEMBLE BRAKE VALVE
ASSEMBLE BRAKE VALVE
MAINTENANCE STANDARD
GROUP 3 Center Joint
REMOVE AND INSTALL CENTER JOINT
DISASSEMBLE CENTER JOINT
ASSEMBLE CENTER JOINT
MAINTENANCE STANDARD
GROUP 4 Track Adjuster
REMOVE AND INSTALL TRACK AD-JUSTER
DISASSEMBLE TRACK ADJUSTER
ASSEMBLE TRACK ADJUSTER
GROUP 5 Front Idler
REMOVE AND INSTALL FRONT IDLER
DISASSEMBLE FRONT IDLER
ASSEMBLE FRONT IDLER
MAINTENANCE STANDARD
GROUP 6 Upper And Lower Roller
REMOVE AND INSTALL UPPER ROLLER
REMOVE AND INSTALL LOWER ROLLER
DISASSEMBLE UPPER ROLLER
ASSEMBLE UPPER ROLLER
DISASSEMBLE LOWER ROLLER
ASSEMBLE LOWER ROLLER
MAINTENANCE STANDARD
GROUP 7 Track
REMOVE AND INSTALL TRACKS
MAINTENANCE STANDARD
SECTION 4 FRONT ATTACHMENT
GROUP 1 Front Attachment
REMOVE AND INSTALL FRONT ATTACHMENT
REMOVING AND INSTALLING CYLINDER
GROUP 2 Cylinder
REMOVE AND INSTALL BOOM CYLINDER
HYDRAULIC CIRCUIT PRESSURE RELEASE PROCEDURE
DISASSEMBLE CYLINDER
ASSEMBLE CYLINDER
DISASSEMBLE CYLINDER
ASSEMBLE CYLINDER
AIR BLEEDING PROCEDURE
MAINTENANCE STANDARD
GROUP 3 Bushing and Point
REMOVE AND INSTALL BUSHING
MAINTENANCE STANDARD
SECTION 5 ENGINE AND ACCESSORY
General Information
GENERAL REPAIR INSTRUCTIONS
NOTES ON THE FORMAT OF THIS MANUAL
MAIN DATA AND SPECIFICATIONS
PERFORMANCE CURVE
ENGINE EXTARNAL VIEW
DESIGN FEATURES AND GGENERAL OUTLINES
TIGHTENING TORQUE SPECIFICATIONS
ANGULAR NUT AND BOLT TIGHTENING METHOD
MAJOR PARTS FIXING NUTS AND BOLTS
IDENTILFICATIONS
Maintenance
LUBRICATING SYSTEM
FUEL SYSTEM
COOLING SYSTEM
VALVE CLEARANCE ADJUSTMENT
INJECTION TIMING
COMPRESSION PRESSURE MEASUREMENT
TURBOCHARGER INSPECTION
ENGINE REPAIR KIT
RECOMMENDED LUBRICANTS
ENGINE OIL VISCOSITY CHART
Engine Assembly I (Disassembly)
GENERAL DESCRIPTION
DISASSEMBLY 1ST STEP
DISASSEMBLY 2ND STEP
DISASSEMBLY 3RD STEP
CYLINDER HEAD DISASSEMBLY STEP
PISTON AND CONNECTING ROD DISASSEMBLY STEP
ROCKER ARM AND SHAFT DISASSEMBLY STEP
CAMSHAFT AND GEAR DISASSEMBLY STEP
CRANKSHAFT DISASSEMBLY STEP
Engine Assembly II (Inspection & Repair)
CYLINDER HEAD
VALVE GUIDE
VALVE AND VALVE SEAT INSERT
VALVE SPRING
TAPPET
PUSH ROD
ROCKER ARM SHAFT AND ROCKER ARM
IDLER GEAR AND IDLER GEAR SHAFT
CAMSHAFT
CYLINDER BODY AND LINER
PISTON AND PISTON RING
PISTON PIN
CONNECTING ROD
CRANKSHAFT AND BEARINGS
FLYWHEEL AND FLYWHEEL HOUSING
TIMING GEAR CASE COVER
Engine Assembly III (Reassembly)
PISTON AND CONNECTING ROD REASSEMBLY STEP
CYLINDER HEAD REASSEMBLY STEP
ROCKER ARM AND ROCKER ARM SHAFT REASSEMBLY STEP
REASSEMBLY 1ST STEP
REASSEMBLY 2ND STEP
REASSEMBLY 3RD STEP
ENGINE TURNING OPERATION
Lubricating System
GENERAL DESCRRIPTION
OIL PUMP
OIL COOLER
Cooling System
GENERAL DESCRIPTION
WATER PUMP
THERMOSTAT
Fuel System
GENERAL DESCRIPTION
INJECTION NOZZLE
INJECTION PUMP CALIBRATION DATA
Turbocharger
GENERAL DESCRIPTION
TURBOCHARGER IDENTIFICATION
ROTOR SHAFT PLAY INSPECTION
Engine Electricals
STARTER MOTOR IDENTIFICATION
STARTER MOTOR MAIN DATA AND SPECIFICATIONS
STARTER MOTOR SECTIONAL VIEW
STARTER MOTOR EXPLODED VIEW
ALTERNATOR IDENTTIFICATION
MAIN DATA AND SPECIFICATIONS
ALTERNATOR SECTIONAL VIEW
ALTERNATOR EXPLODED VIEW
INTAKE HEATER
Troubleshooting
HARD STARTING
UNSTABLE LOW IDLING
INSUFFICIENT POWER
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION
OVERHEATING
WHITE EXHAYST SMOKE
DARK EXHAUST SMOKE
OIL PRESSURE DOES NOT RISE
ABNORMAL ENGINE NOISE
Special Tool List
SPECIAL TOOL LIST
Rerpair Standards
GENERAL RULES
REPAIR STANDARDS CHART
Conversion Table
LENGTH
AREA
VOLUME
MASS
PRESSURE
TORQUE
TEMPERATURE
REVISION REQUEST FORM
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