Hitachi EX80-5 User manual

Manual No. : KM-152E-NA
Vol.No. :TT152E-NA
TechnicalManual
(Troubleshooting)
EXBO-s
Excavator
Service Manual (Manual No. KM-152E-NA} consists of the following three separate volumes;
Technical Manual (Operational Principle} :Vol. No.T0152E-NA
Technical Manual (Troubleshooting)
Workshop Manual
:Vol.No.TT152E-NA
:Vol. No.W152E-NA
HITACHI

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INTRODUCTION
TO THE READER
• This manual is written for an experienced technician
to provide technical information needed to maintain
and repair this machine.
Be sure to thoroughly read this manual for correct
product information and service procedures.
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition
to this manual.
• The Operator's Manual
• The Parts Catalog
MANUAL COMPOSITION
• This manual consists of three portions:the Technical
Manual (Operational Principle), the Technical Man-
ual (Troubleshooting) and the Workshop Manual.
Information included in the Technical Manual
(Operational Principle):
technical information needed for redelivery and
delivery, operation and activation of all devices
and systems.
PAGE NUMBER
• Each page has a number, located on the center
lower part of the page, and each number contains
the following information:
T 1-3-5
If you have any questions or comments, at if you
found any errors regarding the contents of this
manual, please contact using "Service Manual
Revision Request Form" at the end of this man-
ual.
(Note: Donot tear off the form. Copy it for usage.):
Publications Marketing &Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: [phone]
FAX:[phone]
Operation Manual of the Engine
Parts Catalog of the Engine
Hitachi Training Material
Information included in the Technical Manual
(Troubleshooting):
technical information needed for operational per-
formance tests, and troubleshooting procedures.
• Information included in the Workshop Manual:
technical information neededfor maintenance and
repair of the machine, tools and devices needed
for maintenance and repair, maintenance stan-
dards, and removal/installation and assem-
ble/disassemble procedures.
Example: 11 : roo,oc••~ oage,,moo, fu, EachGro,p
Group Number
Section Number
'------ T:TechnicalManual W: Workshop Manual
IN-01
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INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and
signal words are used to alert the reader to the
potentialfor personal injuryof machine damage.
A This is the safety alert symbol. When you see this
symbol, be alertto the potentialfor personal injury.
Never fail to follow the safety instructions prescribed
along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to componenVpartweights.
To avoid injury and damage, be sure to use appropri-
ate lifting techniques and equipment when lifting heavy
parts.
UNITS USED
• SI Units (International System of Units) are used in
this manual.
MKSA system units and English units are also
indicatedin parenthhesesjust behind SI units.
Quantity To Convert Into Multiply By
From
Length mm in 0.03937
mm ft 0.003281
Volume L US qal 0.2642
L usqt 1.057
m" yd" 1.308
Weiaht kg lb 2.205
Force N kgf 0.10197
N lbf 0.2248
Torque N-m kgf-m 1.0197
N-m lbf-ft 0.7375
• AcAUTION:
Indicated potentially hazardous situation which could,
if not avoided, result in personal injury or death.
• IMPORTANT:
Indicates a situation which, if not conformed to the
instructions, could result in damage to the machine.
• {)NOTE
Indicates supplementary technical information or
know-how.
Example :24.5 MPa (250 kgf/cm2, 3560 psi)
A table for conversion from SI units to other system
units is shown below for reference purposees.
Quantity To Convert Into Multiply By
From
Pressure MPa kgf/cm' 10.197
MPa psi 145.0
Power kW PS 1.360
kW HP 1.341
Temperature oc OF °Cx1.8+32
Velocity km/h mph 0.6214
min·' rpm 1.0
Flow rate L/min USqpm 0.2642
ml/rev cc/rev 1.0
IN-02
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SAFETY
RECOGNIZE SAFETY INFORMATION
• This is the SAFETY ALERT SYMBOL.
When you see this symbol on your machine or in
this manual, be alert to the potential for personal
injury.
Follow recommended precautions and safe
operating practices.
0 □ 1"E'01A-0001
UNDERSTAND SIGNAL WORDS
• On machine safety signs, signal words designating
the degreeor level of hazard- DANGER,WARNING,
or CAUTION - are usedwith the safety alert symbol.
DANGER indicates an imminently hazardous
situationwhich, if not avoided, will result in death
or serious injury.
• WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
CAUTION indicates a potentially hazardous
situationwhich, if not avoided, may result in minor
or moderate injury.
DANGER or WARNING safety signs are located
near specific hazards. General precautions are
listedon CAUTION safety signs.
• CAUTION also calls attentionto safety messages in
this manual.
• Toavoid confusing machine protection with personal
safety messages, a signal word IMPORTANT
indicates a situation which, if not avoided, could
result in damage to the machine.
•tJNOTE indicates an additional explanation for an
elementof information.
□□ 2-ED1A-1223
SA-1
SA-001
A DANGER
A WARNING
A CAUTION
IMPORTANT
tJNOTE
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SAFETY
FOLLOW SAFETY INSTRUCTIONS
• Carefully read and follow all safety signs on the
machine and all safety messages in this manual.
• Safety signs should be installed, maintained and
replaced when necessary.
If a safety sign or operator's manual is damaged
or missing, replace itwith new one.
• Learn how to operate the machine and its controls
correctly and safely.
• Allow only trained, qualified, authorized personnel to
operate the machine.
• Keep your machine in properworking condition.
Unauthorized modifications of the machine may
impair its function and/or safety and affect
machine life.
• The safety messages in this SAFETY chapter are
intended to illustrate basic safety procedures of
machines. However it is impossible for these safety
messages to cover every hazardous situation you
may encounter. If you have any questions, you
should first consult your supervisor and/or your
authorized dealer before operating or performing
maintenance work on the machine.
PREPARE FOR EMERGENCIES
• Be prepared if a fire starts or if an accident occurs.
Keep a first aid kit and fire extinguisher on hand.
Thoroughly read and understand the label
attached on the fire extinguisher to use it properly.
Establish emergency procedure guidelines to
copewith fires and accidents.
Keep emergency numbers for doctors,
ambulance service, hospital, and fire department
posted nearyour telephone.
004-E01A-0437
SA-2
SA-003
SA-437
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SAFETY
WEAR PROTECTIVE CLOTHING
• Wear close fitting clothing and safety equipment
appropriate to thejob.
Youmay need:
A hard hat
Safety shoes
Safety glasses, goggles, or face shield
Heavygloves
Hearing protection
Reflective clothing
Wet weather gear
Respirator or filter mask.
Be sure to wear the correct equipment and clothing
for thejob. Do not take any chances.
Avoid wearing loose clothing, jewelry, or other
items that can catch on control levers or other
parts of the machine.
• Operating equipment safely requires the full
attention of the operator. Do not wear radio or music
headphoneswhile operating the machine.
D05--E01A-0438
PROTECT AGAINST NOISE
• Prolonged exposure to loud noise can cause
impairment or loss of hearing.
• Wear a suitable hearing protective devicesuch as
earmuffs or earplugs to protect against
objectionable or uncomfortably loud noises.
006-E01A-0434
INSPECT MACHINE
• Inspect your machine carefully each day or shift by
walking around it before you start it to avoid personal
injury.
In the walk-around inspection be sure to cover all
points described in the "PRE-START
INSPECTION" chapter in the operator's manual.
SA-3
SA-438
SA-434
SA-435
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SAFETY
USE HANDHOLDS AND STEPS
• Falling is one of the major causes of personal injury.
When you get on and off the machine, always
face the machine and maintain a three-point
contact withthe stepsand handrails.
Do not useany controls as hand-holds.
Neverjump on or off the machine. Never mount or
dismount a moving machine.
Be careful of slippery conditions on platforms,
steps, and handrailswhen leavingthe machine.
008-ED1A-0439
ADJUST THE OPERATOR'S SEAT
• A poorly adjusted seat for either the operator or for
the work at hand may quickly fatigue the operator
leading to misoperations.
The seat should be adjusted whenever changing
the operator for the machine.
The operator should be able to fully depress the
pedals and to correctly operate the control levers
with his back againstthe seat back.
If not, move the seat forward or backward, and
check again.
SA-4
SA-439
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SAFETY
FASTEN YOUR SEAT BELT
• If the machine should overturn, the operator rnay
become injured and/or thrown from the cab.
Additionally the operator may be crushed by the
overturning machine, resulting in serious injury or
death.
Prior to operating the machine, thoroughly
examinewebbing, buckleand attaching hardware.
If any item is damaged or worn, replace the seat
beltor component before operating the machine.
Be sure to remain seated with the seat belt
securely fastened at all times when the machine is
in operation to minimize the chance of injury from
an accident.
We recommend that the seat belt be replaced
every three years regardless of its apparent
condition.
010-E01A-0237
MOVE AND OPERATE MACHINE SAFELY
• Bystanderscan be run over.
Take extra care not to run over bystanders.
Confirm the location of bystanders before moving,
swinging, or operating the machine.
Always keep the travel alarm and horn in working
condition (if equipped). II warns people when the
machine starts to move.
Use a signal person when moving, swinging, or
operating the machine in congested areas.
Coordinate hand signals before starting the
machine.
011-E01A-0426
SA-5
SA-237
)
SA-426
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SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
• Inappropriate engine starting procedures may cause
the machine to runaway, possiblyresulting in serious
injury or death.
Start the engine only when seated in the
operator's seal.
NEVER start the engine while standing on the
track or on ground.
Do not start engine by shorting across starter
terminals.
Before starting the engine, confirm that all control
levers are in neutral.
012-E01B-0444
JUMP STARTING
• Battery gas can explode, resulting in serious injury.
If the engine must be jump started, be sure to
follow the instructions shown in the "OPERATING
THE ENGINE" chapter in the operator's manual.
The operator must be in the operator's seat so
that the machine will be under control when the
engine starts. Jump starting is a two-person
operation.
Never usea frozen battery.
Failure to follow correct jump starting procedures
could result in a battery explosion or a runaway
machine.
S013-E01A..(]D32
SA-6
SA-444
SA-032
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SAFETY
KEEP RIDERS OFF MACHINE
• Riders on machine are subject to injury such as
being struck by foreign objects and being thrown off
the machine.
• Only the operator should be on the machine.
Keep riders off.
Riders also obstruct the operator's view, resulting
in the machine being operated in an unsafe
manner.
014-E01B-0378
PROVIDE SIGNALS FOR FOBS INVOLV-
ING MULTIPLE NUMBERS OF MACHINES
• For jobs involving multiple numbers of machines,
provide signals commonly known by all personnel
involved.Also, appoint a signal person to coordinate
the job site. Make sure that all personnel obey the
signal person's directions.
018-E01A-0481
CONFIRM DIRECTION OF MACHINE TO
BE DRIVEN
• Incorrect travel pedal/lever operation may result in
serious injurydeath.
• Before driving the machine,confirm the positionof
the undercarriage in relation to the operator's po-
sition. If the travel motors are located in front of
the cab, the machine will move in reverse when
travel pedals/levers are operated to the front.
017-E01A-D491
SA-7
SA-379
SA-481
SA-491

SAFETY
DRIVE MACHINE SAFELY
• Before moving the machine, confirm which way to
move travel pedals/levers for the corresponding
direction youwish to go.
Pushingdown on the front of the travel pedals or
pushing the levers forward moves the machine
towards the idlers. (Refer to the Steering the
Machine Using Pedals/Levers section in the
operator'smanual for correct travel operation.)
• Traveling on a grade may cause the machine to slip
or to overturn, possibly resulting in serious injury or
death.
When traveling up or down a grade, keep the
bucket inthe direction of travel,approximately 200
to 300 mm(approximately 8 to 12 in)(A) above the
ground.
If machine starts to skid or becomes unstable,
lowerthe bucket immediately.
Traveling across the face of a slope may cause
the machineto skid or to turnover.When traveling
(ascending/descending) on a slope, be sure to
pointthe tracks uphill/downhill.
Turning on an incline may cause the machine to
tip over.
If turning on an incline is absolutely unavoidable,
do so at a place where the slope is gentle and the
surface isfirm.
S018-E02A-0590
SA-8
IWRONGI
\
SA-387
SA-388
SA-441
SA-589

SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS
• Death or serious injury may result if you attempt to
mount or stop a moving machine.
To avoid rollaways:
Select level ground when possible to park
machine.
Do not park the machine on a grade.
Lower the bucket and/or other work tools to the
ground.
Tum the auto-idle switch off.
Run the engine at slow idle speed without load for
5 minutes to cool down the engine.
Stop the engine and remove the key from the key
switch.
Pull the pilot control shut-off lever to LOCK
position.
Block both tracks and lower the bucket to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade.
Position the machine to prevent rolling.
Park a reasonable distance from other machines.
0:.-!O-E02A-0493
SA-9
SA-391
SA-392

SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
• If any person is present near the machine when
backing or swinging the upperstructure,the machine
may hit or run over that person, resulting in serious
injury or death.
To avoid back-over and swing accidents:
Always look around BEFORE YOU BACK UP
AND SWING THE MACHINE. BE SURE THAT
ALL BYSTANDERSARE CLEAR.
Keep the travel alarm in working condition (if
equipped).
ALWAYS BE ALERT FOR BYSTANDERS
MOVING INTO THE WORK AREA. USE THE
HORN OR OTHER SIGNAL TO WARN
BYSTANDERSBEFOREMOVING MACHINE.
USE A SIGNAL PERSON WHEN BACKING UP
IF YOUR VIEW IS OBSTRUCTED. ALWAYS
KEEPTHE SIGNAL PERSON INVIEW.
Use hand signals, which conform to your local
regulations,when work conditions require a signal
person.
No machine motions shallbe made unless signals
are clearly understood by both signalman and
operator.
Learn the meanings of all flags, signs, and
markings used on the job and confirm who has
the responsibility for signaling.
Keep windows, mirrors, and lights clean and in
good condition.
Dust, heavy rain, fog, etc., can reduce visibility.As
visibility decreases, reducespeed and use proper
lighting.
Read and understand all operating instructions in
the operator's manual.
S021-E01A-0494
SA-10
SA-383
SA-384

SAFETY
AVOID TIPPING
• DO NOT ATTEMPT TO JUMP CLEAR OF
TIPPING MACHINE--SERIOUS OR FATAL
CRUSHING INJURIESWILL RESULT
MACHINEWILL TIP OVER FASTERTHAN YOU
CAN JUMP FREE
FASTENYOUR SEATBELT
• The danger of tipping is always present when
operating on a grade, possibly resulting in serious
injuryor death.
Toavoidtipping:
• Be extra careful before operating on a grade.
Prepare machine operating area flat.
Keep the bucket low to the ground and close to
the machine.
Reduce operating speeds to avoid tipping or
slipping.
• Avoid changing direction when traveling on
grades.
NEVER attempt to travel across a grade steeper
than 15 degrees if crossing the grade is
unavoidable.
Reduceswing speedas necessarywhen swinging
loads.
• Be careful when working on frozen ground.
Temperature increases will cause the ground to
become soft and make ground travel unstable.
S025-E01B-0495
SA-11
SA-012
SA-440

SAFETY
AVOID POWER LINES
• Serious injury or death can result if the machine or
front attachments are not kept a safe distance from
electric lines.
When operating near an electric line, NEVER
move any part of the machine or load closer than
3 m (10 ft) plus twice the line insulator length.
Check and comply with any local regulations that
may apply.
Wet ground will expand the area that could cause
any person on it to be affected by electric shock.
Keep all bystanders or co-workers away from the
site.
029-E01A-0381
OBJECT HANDLING
• If a lifted load should fall, any person nearby may be
struck by the falling load or may be crushed
underneath ii, resulting in serious injuryor death.
When using the machine for craning operations,
be sure to comply with all local regulations.
Do not use damaged chains or frayed cables,
sables, slings, or ropes.
Before craning, position the upperstructure with
the travel motors at the rear.
Move the load slowly and carefully. Never move it
suddenly.
Keep all persons well awayfrom the load.
Never move a load over a person's head.
Do not allow anyone to approach the load until it is
safely and securely situated on supporting blocks
or on the ground.
Never attach a sling or chain to the bucket teeth.
They may come off, causing the load to fall.
SA-12
SA-381
SA-014

SAFETY
PROTECT AGAINST FLYING DEBRIS
• If flying debris hit eyes or any other part of the body,
serious injury may result.
Guard against injury from flying pieces of metal or
debris; wear goggles or safety glasses.
Keep bystanders away from the working area
before striking any object.
PARK MACHINE SAFELY
To avoid accidents:
Park machine on a firm, level surface.
Lower bucket to the ground.
Turn auto-idle switch off.
031-E01A-D432
Run engine at slow idle speed without load for 5
minutes.
Turn key switch to OFF to stop engine.
Remove the key from the keyswitch.
Pull the pilot control shut-off lever to the LOCK
position.
Close windows, roof vent, and cab door.
Lock all access doors and compartments.
033-E02B-0390
SA-13
SA-432
SA-390

SAFETY
HANDLE FLUIDS SAFELY-AVOID FIRES
• Handle fuel with care; it is highly flammable. If fuel
ignites, an explosion and/or a fire may occur,
possiblyresulting in serious injury or death.
Do not refuel the machinewhile smoking or when
near open flame or sparks.
Always stop the engine before refueling the
machine.
Fillthe fuel tank outdoors.
• All fuels, most lubricants, and some coolants are
flammable.
Store flammable fluids well away from fire
hazards.
Do not incinerate or puncture pressurized
containers.
Do not store oily rags; they can ignite and burn
spontaneously.
SA-14
SA-018
SA-019

SAFETY
SAFETY TRANSPORTING
• The danger of tipping is present when
loading/unloading the machine onto/from a truck or
trailer bed.
Be sure to observe local regulations when
transporting the machine on public roads.
Provide an appropriate truck or trailer for
transporting the machine.
Take the following precautions when loading /
unloadingthe machine:
1) Select firm levelground.
2) Be sure to use a loading dock or ramp.
3) Be sure to have a signal person when
loading/unloading the machine.
4) Always turn the auto-idle switch OFF when
loading or unloading the machine, to avoid
unexpected speed increase due to unintentional
operation of a control lever.
5) Always select the slow speed mode with the
travel mode switches. In the high speed mode,
travel speed may automatically increase.
6) Avoid steering while driving up or down the ramp
as it is extremely dangerous. If steering is
unavoidable, first move back to the ground or
flatbed, modify traveling direction, and begin to
drive again.
7) Do not operate any levers besides the travel
levers when driving up or down the ramp.
8) The top end of the ramp where it meets the
flatbed is a sudden bump. Take care when
traveling over it.
9) Prevent possible injury from machine tipping
while the upperstructure is rotating.
10) Keep the arm tucked under and rotate the
upperstructure slowlyfor best stability.
11) Securely fasten chain or cables to the machine
frame. Refer to "transporting" chapter in the
operator's manual for details.
S035-EOOA-0395
SA-15
SA-395

SAFETY
PRACTICE SAFE MAINTENANCE
Toavoid accidents:
Understand service procedures before doing
work.
Keep work area clean and dry.
Do not spray water or steam inside cab.
Never lubricate or service the machine while it is
moving.
Keep hands, feet and clothing away from power-
driven parts.
Before servicing the machine:
1) Park the machine on a level surface.
2) Lower the bucket to the ground.
3) Turn the auto-idle switch off.
4) Run the engine at slow idle speed without load
for 5 minutes.
5) Turn the key switch to OFF to stop engine.
6) Relieve the pressure in the hydraulic system by
moving the control levers several times.
7) Remove the key from the switch.
8) Attach a "Do Not Operate" tag on the control
lever.
9) Pull the pilot control shut-off lever to the LOCK
position.
10) Allow the engine to cool.
If a maintenance procedure must be performed
with the engine running, do not leave machine
unattended.
If the machine must be raised, maintain a 90 to
110 angle between the boom and arm. Securely
support any machine elements that must be
raised for service work.
Never work under a machine raised bythe boom.
Inspect certain parts periodically and repair or
replace as necessary. .Refer to the section
discussing that part in the "MAINTENANCE"
chapter in the operator's manual.
Keep all parts in good condition and properly
installed.
Fix damage immediately. Replaceworn or broken
parts. Remove any buildup of grease, oil, or
debris.
Disconnect battery ground cable (-) before
making adjustments to electrical systems or
before welding on the machine.
Illuminate your work area adequately but safely.
Use a portable safety light for working inside or
under the machine.
Make sure that the bulb is enclosed by a wire
cage.
The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
S500--E02B-0497
SA-16
SA-028
SA-527
SA-037