Hitachi EX60-5 / EX60LC-5 Hydraulic Excavator 1987–1997 Workshop Manual, (P/N 152W-1-1)

• 670-page PDF set — Technical Manual: 271 pages; Workshop Manual: 399 pages — covering the Hitachi EX60-5 and EX60LC-5 excavators.
• Configuration data covers standard and blade-equipped machines, backhoe and face-shovel working ranges, and standard- and long-arm dimensions.
• Hydraulic and electronic diagnosis includes Dr.EX monitoring and service functions, MC fault codes, adjustable data, engine learning, pump-flow testing, pilot and relief-pressure checks, and operational performance standards.
• Upperstructure repair procedures cover the main pump, pilot and blade pumps, control valves, swing device and swing motor, pilot valves, pilot shut-off valve, and swing/front-attachment shockless valves.
• Undercarriage and attachment repair extends to the travel device and motor, brake valve, swing bearing, center joint, track adjuster, idlers, rollers, tracks, front attachment, and boom, arm, bucket, and blade cylinders.
• Nissan A-BD30 diesel material covers inspection, servicing, internal overhaul, fuel and injection equipment, cooling and lubrication systems, electrical components, service data, and engine troubleshooting.

Built around the EX60-5 and EX60LC-5 rather than a generic excavator platform, this two-manual set combines system operation and fault diagnosis with component-level workshop repair. Hitachi expressly states that the material was written for an experienced technician. The hydraulic measurements, dedicated service tools, heavy-component lifting work, and internal engine procedures make it best suited to technicians or owners with equivalent shop experience and equipment.

System Operation and Diagnosis

The Technical Manual explains how the engine, pump, hydraulic, and electrical control systems interact before moving into individual component operation. Dedicated sections describe the main and pilot hydraulic circuits, engine and pump control, power and charging circuits, engine starting and stopping, preheat operation, and surge-voltage protection.

Operational testing covers engine speed and compression, valve-clearance adjustment, injection timing, nozzle checks, travel and swing performance, hydraulic-cylinder cycle times, drift and leakage checks, and control-lever force and stroke. Component tests address pump flow, pilot circuits, relief valves, and swing- and travel-motor drainage. Results can be compared with the included operational performance tables and main-pump P-Q data.

Troubleshooting is organized into Dr.EX-assisted diagnosis and symptom-based Troubleshooting A, B, and C procedures. Coverage includes the engine, actuator controls, front attachment, swing, travel, blade system, monitor gauges, warning indicators, buzzer, hour meter, alternator, fuses, fusible links, and harness circuits. Electrical inspection procedures include continuity, voltage/current, false-signal, and circuit checks.

Workshop Repair Coverage

The Workshop Manual provides removal and installation instructions for the cab, counterweight, main frame, pump device, control valve, swing device, travel components, front attachment, and hydraulic cylinders. Internal repair sections then cover disassembly, inspection, reassembly, and maintenance standards for the pumps, valves, swing motor and reduction unit, travel motor and reduction unit, brake valve, center joint, track adjuster, idlers, rollers, and cylinders.

The Nissan A-BD30 chapter is a true engine repair section, not just a specification sheet. It covers the cylinder head, rocker shaft, gear train, injection pump, oil pan, oil cooler and pump, water pump, thermostat, manifolds, and the engine main body. Overhaul precautions, component tightening data, dimensional specifications, and an engine troubleshooting chart support internal inspection and reassembly.

Factory diagrams and views include the main and pilot hydraulic circuits, control-valve hydraulic circuit, main-pump P-Q diagram, overall electrical and monitor/switch layouts, swing and travel reduction-gear exploded views, and the engine troubleshooting chart. Maintenance-standard tables provide component-specific torque data, allowable wear limits, fits, clearances, and adjustment specifications without limiting the material to routine maintenance.

Named service equipment includes the ST 4920 track-adjuster fixture, ST 5908 cylinder service stand, ST 7099 pilot-valve installation guide, and ST 7924 valve-holder assembly. Electrical circuit work is supported by lamp and test harnesses P/N 4283594 (ST 7126), P/N 4274589 (ST 7125), and P/N 4284347 (ST 7129).

Several assembly cautions are specific enough to prevent expensive repeat repairs. The manual warns that trapped air can damage the hydraulic pump, motors, or cylinders after installation, while the cylinder procedures identify seal direction, staggered slide-ring gaps, and rod-insertion hazards that can damage seals and sliding surfaces. It also cautions against disturbing the main-pump locknut and adjusting screw because doing so changes the factory flow setting.

High-pressure hydraulic work must be performed only after stored pressure is relieved, and the cab, counterweight, main frame, and front attachment require properly rated lifting equipment and the manual’s stated support procedures. The Operator’s Manual, machine and engine Parts Catalogs, and separate engine operation material are listed as additional references and are not part of this two-file set.