Hitachi EX60-5 / EX60LC-5 Excavator Technical & Workshop Manual Set, 1987–1997

The Technical Manual supports fault diagnosis and comparison with factory performance standards. The Workshop Manual provides the corresponding component removal, inspection, and repair procedures.

The referenced Operator’s Manual, machine and engine Parts Catalogs, and separate engine operation manual are not included.

PDF Search, Bookmarks and Diagram Detail

Search and navigation: Text search works in parts of both PDFs. Character-encoding problems affect much of the Technical Manual and the Workshop Manual’s track section; the BD30 engine section has no searchable text. Both files have bookmarks, but some index and return links point to files absent from the ZIP. Small electrical terminal labels and dense component callouts require zooming in the checked illustrations.

ZIP download containing two printable English PDFs, 670 pages total. This includes one cover per file, 19 pages marked blank in the Technical Manual, 21 in the Workshop Manual, and one duplicated engine page in the Workshop Manual.

Hydraulic Diagnosis and Component Repair

The overview presents selected contents; further workshop topics include cab-window glass dimensions and installation methods.

• Machine configurations: Specification and working-range tables distinguish standard and blade-equipped machines, backhoe and face-shovel arrangements, and standard and long arms.

• Hydraulic testing: Main-pump flow tests, pilot and relief-pressure checks, swing- and travel-motor drainage measurements, and operational performance standards.

• Electronic diagnosis: Dr.EX monitoring and service functions, MC fault codes, adjustable data, engine learning, and symptom-based troubleshooting.

• Upperstructure repair: Cab, counterweight, and main-frame removal; main, pilot, and blade pumps; control valves, swing device, pilot valves, pilot shut-off valve, and shockless valves.

• Undercarriage and attachment: Travel device, brake valve, swing bearing, center joint, track adjuster, idlers, rollers, tracks, front attachment, and boom, arm, bucket, and blade cylinders.

• Nissan diesel engine: BD30 inspection, servicing, internal overhaul, fuel and injection equipment, cooling, lubrication, electrical components, service data, and engine troubleshooting.

Hitachi wrote these manuals for experienced technicians; owners using them need equivalent shop experience and equipment.

System Operation and Performance Tests

Controls and circuits: Explanations connect engine and pump control with the main and pilot hydraulic circuits. Electrical coverage follows power distribution, charging, engine starting and stopping, preheat operation, and surge-voltage protection.

Engine and machine checks: Tests address engine speed and compression, valve-clearance adjustment, injection timing, and nozzle condition. Travel and swing measurements, cylinder cycle times, drift and leakage checks, and control-lever force and stroke are supported by operational-performance tables and main-pump P-Q data.

Dr.EX and Electrical Fault Isolation

Troubleshooting A follows reported MC fault codes; Troubleshooting B addresses abnormal operation without a displayed code; Troubleshooting C addresses monitor faults. This structure helps distinguish electrical control problems from hydraulic or mechanical faults before component teardown.

Monitor diagnosis covers gauges, warning indicators, the buzzer, and hour meter. Electrical inspection adds alternator checks, fuse and fusible-link testing, harness continuity, voltage/current measurements, false-signal tests, and circuit checks.

Workshop Disassembly and Reassembly

Step-by-step procedures cover component removal, internal inspection, reassembly, and installation. Maintenance tables distinguish standard dimensions, allowable wear, fits, clearances, adjustment specifications, and component-specific tightening data.

Swing reduction-gear repair includes bearing-preload adjustment. Front-attachment material provides pin and bushing inspection standards and arm-to-bucket connection dimensions.

Undercarriage procedures extend into travel-motor and reduction-unit repair, brake-valve and center-joint service, swing-bearing assembly, track-adjuster rebuilding, and idler and lower-roller repair. The upper roller is specified for replacement as an assembly.

The hydraulic assembly cautions explain how trapped air can damage pumps, motors, or cylinders, and how incorrect seal direction, slide-ring gap positioning, or rod insertion can damage cylinder seals and sliding surfaces. Pump-disassembly warnings also identify the locknut and adjusting screw that affect the factory flow setting.

Stored hydraulic pressure must be relieved before service. Cab, counterweight, main-frame, and front-attachment work requires rated lifting equipment and the manual’s specified support procedures.

BD30 Engine Repair

Engine procedures progress through cylinder-head and rocker-shaft work, gear-train service, injection-pump removal and installation, and main-body overhaul. Separate material addresses manifolds, the oil pan, oil cooler and pump, water pump, and thermostat.

Overhaul precautions, component tightening data, dimensional inspection tables, and engine troubleshooting charts support internal inspection and reassembly. The included BD30 reference material distinguishes automotive and industrial specifications; these configurations must be kept separate when selecting service data.

Schematics, Views and Service Tools

Electrical support includes Engine Start Circuit and Charging Circuit schematics, overall-system layouts, and monitor/switch-panel views. Main and pilot hydraulic circuit drawings, control-valve hydraulic circuits, the main-pump P-Q diagram, and swing/travel reduction-gear exploded views support the corresponding tests and repairs.

Tool references identify the ST 4920 track-adjuster fixture, ST 5908 cylinder service stand, ST 7099 plate installation guide for pilot valves, and ST 7924 valve-holder assembly. Electrical circuit tests specify harnesses P/N 4283594 (ST 7126), P/N 4274589 (ST 7125), and P/N 4284347 (ST 7129).

Examples of BD30 Engine Inspection Limits

The BD30 engine service data lists crankshaft journal oil clearance at 0.035–0.081 mm as standard, with a 0.15 mm service limit.

Cylinder-head distortion has a 0.2 mm service limit. These values accompany the internal inspection and overhaul material, which distinguishes standard dimensions from limits requiring corrective work.