All-Inclusive Factory Service Technical manual for Hitachi Hydraulic Excavators Models EX1900-5.

This manuals will assist you in diagnosing, repairing, troubleshooting, repairing engine, maintaining, operating, assembling, and checking for your hydraulic excavator.
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Covered Models:
   EX1900-5

The manual comprises 22 documents, including three Workshop Manuals, two Troubleshooting Manuals, the Engine Technical Manual, Maintenance Manual, Operators Manual, Wiring Diagram, Assembly Manual, Training Text, and 11 Check Sheets

1. Workshop Manual: Swing Transmission (WSDSDE18C)
Format: PDF, 160 pages
Language: English

2. Workshop Manual (W18CE00)
Format: PDF, 521 pages
Language: English
Table of Contents:
   GENERAL INFORMATION
      Precautions for Disassembling and Assembling
      Tightening
      Bleeding Air from Hydraulic Oil Tank
   UPPERSTRUCTURE
      Cab
      Counterweight
      Main Frame
      Pump Device
      Control Valve
      Swing Device
      Pilot Valve
      Pilot Shut-Off Valve
      Shuttle Valve
      Shockless Valve
      Solenoid Valve
      Oil Cooler Fan Motor
      Compressor Drive Motor
      Air Conditioner
      Grease Pump
   UNDERCARRIAGE
      Swing Bearing
      Travel Device
      Travel Brake Valve
      Center Joint
      Adjuster Cylinder
      Front Idler
      Upper and Lower Roller
      Track Shoes
      Accumulator
      Welding Repair Procedure
   FRONT ATTACHMENT
      Front Attachment
      Cylinder
      Bushing and Point

3. Workshop Manual: Front Cylinder (WSDXFCE18C1)
Format: PDF, 178 pages
Language: English

4. Troubleshooting Manual (TT18CE01)
Format: PDF, 336 pages
Language: English
Table of Contents:
   OPERATIONAL PERFORMANCE TEST
      Introduction
      Standard
      Engine Test
      Excavator Test
      Component Test
   TROUBLESHOOTING
      General
      Cross Reference Table
      Component Layout
      Troubleshooting A
      Troubleshooting B
      Troubleshooting C
      Electrical System Inspection Procedure

5. Troubleshooting Manual (TO18CE01)
Format: PDF, 206 pages
Language: English
Table of Contents:
   GENERAL
      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)

6. Engine Technical Manual (KM927E04)
Format: PDF, 352 pages
Language: English
Table of Contents:
   COVER
   INTRODUCTION
   GENERAL CONTENTS
   GENERAL
   MAINTENANCE STANDARDS
   BASIC AND SPECIAL TOOLS
   OVERHAUL INSTRUCTIONS
   DISASSMBLY OF ENGINE MAIN PARTS
   INSPECTION AND REPAIR OF ENGINE MAIN PARTS
   REASSEBLY OF ENGINE MAIN PARTS
   FUEL SYSTEM
   LUBRICATION SYSTEM
   COOLING SYSTEM
   INLET AND EXHAUST SYSTEMS
   ELECTRICAL SYSTEM
   ADJUSTMENT, BREK-IN OPERATION AND PERFORORMANCE TESTS
   OTHERS
   ADJUSTING PROCEDURE OF ELECTRONIC GOVERNOR CONTROLS
   SERVICE MANUAL REVISION REQUEST FORM

7. Maintenance Manual: Recommended Service Program (KO30400)
Format: PDF, 42 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

8. Operators Manual (em18c11)
Format: PDF, 288 pages
Language: English
Table of Contents:
   COVER
   INTRODUCTION
   INDEX
   MACHINE NUMBERS
   SAFETY
   SAFETY SIGNS
   COMPONENTS NAME
   HANDLING LADDER / EMERGENCY ESCAPE DEVICE
   OPERATOR'S STATION
   BREAK-IN
   OPERATING THE ENGINE
   DRIVING THE MACHINE
   OPERATING THE MACHINE
   MAINTENANCE
   MAINTENANCE UNDER SPECIAL ENVIRONMENTAL CONDITIONS
   STORAGE
   TROUBLESHOOTING
   SPECIFICATIONS
   INDEX

9. Wiring Diagram (TT18CE00CIR)
Format: PDF, 6 pages
Language: English

10. Assembly Manual (KO29700)
Format: PDF, 294 pages
Language: English
Table of Contents:
   COVER
   Foreword
      LOADING SHOVEL
      BACKHOE
      EX1900-5 Assembly Process Chart LOADER FRONT
      EX1900-5 Assembly Process Chart BACKHOE FRONT
      1. Precautions
      2. Workers plan
      3. Parts check
      4. Preparations (loader front)
      4'. Preparations (backhoe front)
      5. Machines, apparatuses, tools, and materials necessary for assembly
      ASSEMBLY OF UNDERCARRIAGE
      ASSEMBLY OF UPPERSTRUCTURE
      MOUNTING PROCEDURES FOR LOADER FRONT-END ATTACHMENT
      MOUNTING PROCEDURES FOR BACKHOE FRONT-END ATTACHMENT
      CHECKS & PERFORMANCE STANDARDS
      BACK COVER

11. Training Text (TTLA0598EX)
Format: PDF, 79 pages
Language: English
Table of Contents:
   MATERIALS TOP
   GENERAL INFORMATION
      Specification
      Engine Left Bank
      Injection Pump
      Governor Actuator
      Starter Motor
      Alternator
      Intercooler
      Engine Oil Pressure Switch
      Engine Oil Level Switch
      Coolant Temperature Sensor
      Water Pump
      Engine Speed Sensors
      Boost Pressure Sensor
      Engine Right
      Turbochargers
      Air Cleaner Restriction Switch
      Coolant Level Switch 2
      Overheat Switch
      Engine Oil Filters
      Water Separators
      Fuel Tank
      Fuel Level Sensor
      Fuel Level Switch
      Coolant Reservoir
      Air Cleaners & Exhaust Pipes
      Batteries
      Hydraulic Oil Filters
      Hydraulic Oil Level Gauges
      Hydraulic Oil Level Switches
      Hydraulic Oil Temperature Sensors
      Main Pumps
      Main Pump Regulator
      Contamination Sensors
      High Pressure Strainers
      4-Unit Pump
      Pilot Filter
      Pump T/M Filter
      Pump Control Panel
      Control Valves
      Swing Motor (Front)
      Swing Reduction Box (Front)
      Breather For Rear Swing Reduction Box
      Center Joint
      Travel Motor (Left)
      Final Drive (Right)
      Track (Right)
      Travel Pilot Pressure Cut-Off Valve
      Pilot Pressure Selector Valve
      Swing Gear
      Undercarriage
      Accumulator
      Electrical Component Layout In The Cab
      Key Switch & Emergency Engine Stop Switch
      Engine Stop Switch
      Data Logging Unit Connector
      Hour Meter
      Engine Control Modulation
      Electrical Components
      Cover Switch (Ground Disconnector)
      Auto-Lubrication System
      Grease Pressure Switches
      A/C Compressors & A/C Drive Hyd. Motor
      Valve Limit Switches For Return Line
      Valve Limit Switch For Supply Line

12. Check Sheets: UT Inspection (Backhoe Front) (KO302B00)
Format: PDF, 49 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
      Track Frame
      Backhoe Boom 8.3 m
      Backhoe Arm 3.6m
   BACK COVER

13. Check Sheets: UT Inspection (Loader Front) (KO302L00)
Format: PDF, 47 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
      Track Frame
      Loader Boom
      Loader Arm
   BACK COVER

14. Check Sheets: UT Inspection (Backhoe front) (KO302LB00)
Format: PDF, 59 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
      Track Frame
      Backhoe Boom 10.5 m
      Backhoe Arm 5.5 m
   BACK COVER

15. Check Sheets: Visual Inspection (Backhoe Front) (KO303B00)
Format: PDF, 31 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
      Backhoe Boom 8.3m
      Seat: Screw (Backhoe Boom 8.3m)
      Backhoe Arm 3.6m
   BACK COVER

16. Check Sheets: Visual Inspection (Loader Front) (KO303L00_POD)
Format: PDF, 35 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
      Seat: Screw
   BACK COVER

17. Check Sheets: Visual Inspection (Backhoe Front) (KO303LB_105_00)
Format: PDF, 33 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
      Backhoe Boom 10.5m
      Seat: Screw (Backhoe Boom 10.5m)
      Backhoe Arm 5.5m
   BACK COVER

18. Check Sheets: Visual Inspection (Backhoe Front) (KO303LB_118_00)
Format: PDF, 33 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
      Backhoe Boom 11.8m
      Seat: Screw (Backhoe Boom 11.8m)
      Backhoe Arm 5.5m
   BACK COVER

19. Check Sheets: Diaily and Weekly Maintenance (KO29900)
Format: PDF, 5 pages
Language: English

20. Check Sheets: Monthly Maintenance (KO30000)
Format: PDF, 55 pages
Language: English
Table of Contents:
   COVER
      1. 50 TO 1250 HOURS
      2. 1500 TO 2500 HOURS
      3. 2750 TO 3750 HOURS
      4. 4000 TO 5000 HOURS
      5. 5250 TO 6250 HOURS
      6. 6500 TO 7500 HOURS
      7. 7750 TO 8750 HOURS
      8. 9000 TO 10000 HOURS
      9. 10250 TO 11250 HOURS
      10. 11500 TO 12500 HOURS
      11. 12750 TO 13750 HOURS
      12. 14000 TO 15000 HOURS
      13. 15250 TO 16250 HOURS
      14. 16500 TO 17500 HOURS
      15. 17750 TO 18750 HOURS
      16. 19000 TO 20000 HOURS

21. Check Sheets: Parts Visual Check (KO31000)
Format: PDF, 50 pages
Language: English
Table of Contents:
   INTRODUCTION
   INSPECTION PROCEDURE
   PRECAUTIONS FOR INSPECTION
   PRECAUTIONS IN USING THE PARTS VISUAL CHECK SHEET
   PIPING SYSTEM
   ELECTRIC PARTS
   FUNCTIONAL CHECK

22. Check Sheets: Complete Assembly (KO29800)
Format: PDF, 37 pages
Language: English
Table of Contents:
   COVER
      FOREWORD
      TABLE OF CONTENTS
      COMPLETED ASSEMBLY CHECK REPORT FOR THE EX1900-5
      UNDERCARRIAGE/SUPERSTRUCTURE EX1900-5
      FRONT-END ATTACHMENT FOR THE EX1900-5
      ELECTRICAL SYSTEM FUNCTION CHECK SHEETS FOR THE EX1900-5
      IMPLEMENTATION SPEED CHECK SHEETS FOR THE EX1900-5
      HOW TO USE THE EX1900-5 CHECK SHEETS
   BACK COVER