All-Inclusive Factory Service Technical manual for Hitachi Crawler Excavators Models EX750-5 and EX800H-5.

This manuals will assist you in diagnosing, repairing, troubleshooting, maintaining, operating, assembling, and checking for your crawler excavator.
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Covered Models:
   EX750-5
   EX800H-5

The manual comprises 17 documents, including two Workshop Manuals, the Troubleshooting Manual, Technical Manual, Maintenance Manual, three Operators Manuals, Wiring Diagram, Assembly Manual, and 7 Check Sheets

1. Workshop Manual (W162E00)
Format: PDF, 275 pages
Language: English
Table of Contents:
   GENERAL IMFORMATION
      Precautions for Disassembling and Assembling
      Tightening
   UPPERSTRUCTURE
      Cab
      Counterweight
      Pump Device
      Control Valve
      Swing Device
      Pilot Valve
      Pilot Shut-off Valve
      Shockless Valve
   UNDERCARRIAGE
      Swing Bearing
      Travel Device
      Center Joint
      Track Adjuster
      Front Idler
      Upper And Lower Roller
      Track
   FRONT ATTACHMENT
      Front Attachment
      Cylinder

2. Workshop Manual (Workshop_Manual)
Format: PDF, 313 pages
Language: English
Table of Contents:
   GENERAL IMFORMATION
      Precautions for Disassembling and Assembling
      Tightening
   UPPERSTRUCTURE
      Cab
      Counterweight
      Pump Device
      Control Valve
      Swing Device
      Pilot Valve
      Pilot Shut-off Valve
      Shockless Valve
   UNDERCARRIAGE
      Swing Bearing
      Travel Device
      Center Joint
      Track Adjuster
      Front Idler
      Upper And Lower Roller
      Track
   FRONT ATTACHMENT
      Front Attachment
      Cylinder

3. Troubleshooting Manual (TT162E01)
Format: PDF, 209 pages
Language: English
Table of Contents:
   OPERATIONAL PERFORMANCE TEST
      Introduction
      Engine Test
      Excavator Test
      Component Test
      Standard
   TROUBLESHOOTING
      Diagnosing Procedure
      Component Layout
      Troubleshooting A
      Troubleshooting B
      Troubleshooting C
      Electrical System Inspection
   REVISION REQUEST FORM

4. Technical Manual (T162E00)
Format: PDF, 355 pages
Language: English
Table of Contents:
   GENERAL
      Specifications
      Component Specifications
      Component Layout
   SYSTEM
      Control System
      Hydraulic System
      Electrical System
   COMPONENT OPERATION
      Pump Device
      Swing Device
      Control Valve
      Pilot Valve
      Travel Device
      Others (Upperstructure)
      Others (Undercarriage)
   OPERATIONAL PERFORMANCE TEST
      Introduction
      Engine Test
      Excavator Test
      Component Test
      Standard
   TROUBLESHOOTING
      Diagnosing Procedure
      Component Layout
      Troubleshooting A
      Troubleshooting B
      Troubleshooting C
      Electrical System Inspection
   EX750-5 EX800H-5 HYDRAULIC CIRCUIT DIAGRAM (BACKHOE)
   EX750-5 EX800H-5 HYDRAULIC CIRCUIT DIAGRAM (BACKHOE:C/W REMOVE/INSTALL DEVICE)
   EX750-5 EX800H-5 HYDRAULIC CIRCUIT DIAGRAM (LOADING SHOVEL)
   EX750-5 EX800H-5 ELECTRICAL CIRCUIT DIAGRAM1 (Serial No. A)
   EX750-5 EX800H-5 ELECTRICAL CIRCUIT DIAGRAM2 (Serial No. A)
   EX750-5 EX800H-5 ELECTRICAL CIRCUIT DIAGRAM 1 (Serial No. B)
   EX750-5 EX800H-5 ELECTRICAL CIRCUIT DIAGRAM 2 (Serial No. B)
   EX750-5 CAB HARNESS 1
   EX750-5 CAB HARNESS 2
   EX800H-5 CAB HARNESS 1
   EX800H-5 CAB HARNESS 2
   EX750-5 EX800H-5 CAB HARNESS 1
   EX750-5 EX800H-5 CAB HARNESS 2
   EX750-5 EX800H-5 ENGINE HARNESS
   EX750-EX800H-ENGINE HARNESS
   EX750-5 EX800H-5 ENGINE HARNESS
   EX750-5 RELAY HARNESS
   EX800H-5 RELAY HARNESS
   Return to EX750-5, EX800H-5 Contents
   EX750-5, EX800H-5 WM

5. Maintenance Manual: Recomended Service Program (KO21200)
Format: PDF, 74 pages
Language: English
Table of Contents:
   COVER
      INTRODUCTION
      MAJOR COMPONENTS PREVENTIVE SERVICE SCHEDULE
      HITACHI SCHEDULED DIAGNOSTIC SERVICE
      CHECK LISTS FOR PERFORMANCE AND COMPONENTS
      RECOMMENDATION OF PREVENTIVE SERVICE TO CUSTOMER
      RECOMMENDED PARTS LIST FOR PREVENTIVE SERVICE

6. Operators Manual (EM17C12)
Format: PDF, 326 pages
Language: English

7. Operators Manual (EM17C31)
Format: PDF, 319 pages
Language: English
Table of Contents:
   CONTENTS OVERVIEW
   FRONT COVER
   INTRODUCTION
   INDEX
   MACHINE NUMBERS
   SAFETY
   SAFETY SIGNS
   COMPONENTS NAME
   GETTING ON / OFF THE MACHINE
   OPERATOR'S STATION
   BREAK-IN
   PRE-START INSPECTION
   OPERATING THE ENGINE
   DRIVING THE MACHINE
   OPERATING THE MACHINE
   ASSEMBLING
   TRANSPORTING
   MAINTENANCE
   STORAGE
   TROUBLESHOOTING
   SPECIFICATIONS
   OPTIONAL ATTACHMENTS AND DEVICES
      HYDRAULIC BREAKER
   INDEX

8. Operators Manual (EM17C51)
Format: PDF, 328 pages
Language: English

9. Wiring Diagram (TT162E01CIR)
Format: PDF, 18 pages
Language: English
Table of Contents:
   EX750-5 EX800H-5 HYDRAULIC CIRCUIT DIAGRAM (BACKHOE)
   EX750-5 EX800H-5 HYDRAULIC CIRCUIT DIAGRAM (BACKHOE:C/W REMOVE/INSTALL DEVICE)
   EX750-5 EX800H-5 HYDRAULIC CIRCUIT DIAGRAM (LOADING SHOVEL)
   EX750-5 EX800H-5 ELECTRICAL CIRCUIT DIAGRAM1 (Serial No. A)
   EX750-5 EX800H-5 ELECTRICAL CIRCUIT DIAGRAM2 (Serial No. A)
   EX750-5 EX800H-5 ELECTRICAL CIRCUIT DIAGRAM 1 (Serial No. B)
   EX750-5 EX800H-5 ELECTRICAL CIRCUIT DIAGRAM 2 (Serial No. B)
   EX750-5 CAB HARNESS 1
   EX750-5 CAB HARNESS 2
   EX800H-5 CAB HARNESS 1
   EX800H-5 CAB HARNESS 2
   EX750-5 EX800H-5 CAB HARNESS 1
   EX750-5 EX800H-5 CAB HARNESS 2
   EX750-5 EX800H-5 ENGINE HARNESS
   EX750-EX800H-ENGINE HARNESS
   EX750-5 EX800H-5 ENGINE HARNESS
   EX750-5 RELAY HARNESS
   EX800H-5 RELAY HARNESS

10. Assembly Manual (KO17700)
Format: PDF, 178 pages
Language: English
Table of Contents:
   COVER
   Foreword
   BACKHOE FRONT
   LOADER FRONT
      1. Precautions
      2. Work Plan and Preparations
      3. Assembly of superstructure
      4. Backhoe front mounting procedure
      5. Loader front mounting procedure
      6. Extending and retracting the side frames
      7. Checks after completing the assembly
      8. Checking machine performance
      9. Appendix A. Lifting Diagrams
      10. Appendix B. Refrigerant Charging

11. Check Sheets: UT Inspection (Loader Front) (KO205L00)
Format: PDF, 40 pages
Language: English
Table of Contents:
   COVER
      INTRODUCTION
      DISTRIBUTION OF THE INSPECTION SHEET
      DEFINITION OF THE DEFECT LENGTH IN ULTRA-SONIC TESTING
      INSPECTION PROCEDURE
      EVALUATION OF DEFECT HEIGHT(H)BY DISTANCE CORRECTION TECHNIQUE AT INTERNAL BULKHEAD
      ULTRA-SONIC EXAMINATION REPORT FOR THE STRUCTURE
      Loader Boom
      Loader Arm

12. Check Sheets: Visual Inspection (Backhoe Front) (KO206B01)
Format: PDF, 37 pages
Language: English
Table of Contents:
   COVER

13. Check Sheets: Visual Inspection (Loader Front) (KO206L01)
Format: PDF, 36 pages
Language: English
Table of Contents:
   COVER
      INTRODUCTION
      COMPLETING AND SUBMITTING THE INSPECTION SHEETS
      INSPECTION PROCEDURE
      STRUCTURE VISUAL INSPECTION CHECK REPORT
      Track Frame
      Side Frame
      Main Frame
      Loader Boom
      Loader Arm
      Loader Bucket

14. Check Sheets: Daily And Weekly Maintenance (KO18700)
Format: PDF, 5 pages
Language: English

15. Check Sheets: Monthly Maintenance (KO18800)
Format: PDF, 54 pages
Language: English
Table of Contents:
   COVER
   CHECK POINTS
   PERIODIC REPLACEMENT OF PARTS
   INDEX
      1. 50 TO 1250 HOUR INTERVAL
      2. 1500 TO 2500 HOUR INTERVAL
      3. 2750 TO 3750 HOUR INTERVAL
      4. 4000 TO 5000 HOUR INTERVAL
      5. 5250 TO 6250 HOUR INTERVAL
      6. 6500 TO 7500 HOUR INTERVAL
      7. 7750 TO 8750 HOUR INTERVAL
      8. 9000 TO 10000 HOUR INTERVAL
      9. 10250 TO 11250 HOUR INTERVAL
      10. 11500 TO 12500 HOUR INTERVAL
      11. 12750 TO 13750 HOUR INTERVAL
      12. 14000 TO 15000 HOUR INTERVAL
      13. 15250 TO 16250 HOUR INTERVAL
      14. 16500 TO 17500 HOUR INTERVAL
      15. 17750 TO 18750 HOUR INTERVAL
      16. 19000 TO 20000 HOUR INTERVAL

16. Check Sheets: Completed Assembly (KO19200)
Format: PDF, 23 pages
Language: English
Table of Contents:
   COVER
   FOREWORD
   INDEX
      COMPLETED ASSEMBLY CHECK REPORT FOR THE EX750-5/EX800H-5
      UNDERCARRIAGE ASSEMBLY CHECK SHEET(TIGHTENING TORQUE)
      SUPERSTRUCTURE ASSEMBLY CHECK SHEET(TIGHTENING TORQUE)
      OIL LEVEL CHECK
      LOADER FRONT END ATTACHMENT ASSEMBLY CHECK SHEET
      BACKHOE FRONT END ATTACHMENT ASSEMBLY CHECK SHEET
      GREASE HOSE CONNECTION CHECK SHEET
      ELECTRICAL SYSTEM FUNCTION CHECK SHEET
      IMPLEMENTATION SPEED

17. Check Sheets: UT Inspection (Backhoe Front) (KO205B00)
Format: PDF, 48 pages
Language: English
Table of Contents:
   COVER
      INTRODUCTION
      DISTRIBUTION OF THE INSPECTION SHEET
      DEFINITION OF THE DEFECT LENGTH IN ULTRA-SONIC TESTING
      INSPECTION PROCEDURE
      EVALUATION OF DEFECT HEIGHT(H)BY DISTANCE CORRECTION TECHNIQUE AT INTERNAL BULKHEAD
      ULTRA-SONIC EXAMINATION REPORT FOR THE STRUCTURE
      Backhoe Boom(STD/HD)
      Backhoe Boom(BE)
      Backhoe Arm(STD/HD)
      Backhoe Arm(BE)
      Backhoe Arm(Semi-Long)
      Backhoe Arm(Long)