HITACHI EX100 EX100M EXCAVATOR SERVICE MANUAL

Save significantly on repair costs with our comprehensive HITACHI EX100 EX100M EXCAVATOR SERVICE MANUAL. This detailed guide empowers you to handle maintenance and repairs with ease, offering step-by-step instructions and expert insights. Whether you're a professional mechanic or a DIY enthusiast, this manual will help you extend the life of your equipment while minimizing downtime and expenses.

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📑 Table of Contents:

- EX100 EX100M 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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🚙 All Models, Engines, Trims, and Transmissions Covered:

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