1986–2003 Hitachi EX60-3 Excavator Technical & Workshop Manual Set

The technical portion explains system operation, performance testing, and troubleshooting. The workshop portion supplies the corresponding component repair procedures, tools, and maintenance standards, supporting fault tracing and preparation for disassembly.

Bookmarked PDF and Wiring Detail

Page navigation and small labels: Embedded bookmarks cover both portions, including individual procedures. Text search is limited to the two revision-request forms; the manual content is accessed through bookmarks. Small wiring labels, connector numbers, and dense harness tables require zooming.

One printable English PDF contains 718 pages total, including three wiring/harness sheets and two revision-request forms. Original section dividers and blank pages are included in the publication totals above.

Hydraulic Testing, Component Repair, and Engine Overhaul

These selected topics are supplemented by cab-glass dimensions and reference dimensions for mounting replacement buckets.

• Hydraulic components: Pump-device and KVMM-80 control-valve removal, disassembly, reassembly, and inspection, including the optional blade control valve.

• Swing and travel: Step-by-step procedures for swing motors, HMC070 radial piston travel motors, two-stage planetary reduction gears, and parking-brake assemblies.

• Undercarriage: Swing-bearing replacement, center-joint overhaul, track-adjuster service, roller and idler repair, and track-link removal with wear standards.

• Front attachment: Boom, arm, bucket, blade, and offset-cylinder service, including seal replacement and pin-and-bushing inspection.

• Engine repair: BD3004 cylinder-head service, gear-train inspection, injection-system work, and internal engine overhaul with component measurements and service limits.

• Performance testing: Pilot-pressure and main-pump-flow tests, relief-valve checks, cylinder cycle-time measurements, travel and swing tests, and drift checks.

• Electrical diagnosis: EPC fault codes, Dr.EX monitoring, EC motor adjustment, monitor troubleshooting, wiring diagrams, and harness-continuity tests.

Hitachi identifies experienced technicians as the intended readers; the component overhaul and hydraulic test sections call for the measuring equipment, presses, and lifting gear specified in the procedures.

Hydraulic and Mechanical Systems Overview

Chapters explain the pump device’s constant horsepower control and two-stage maximum flow-rate regulation. Neutral, parallel, and confluence circuit descriptions show how the flow combiner valve manages oil delivery during combined travel and attachment operation.

Construction drawings cover the main control valve, pilot valve, flow-regulating solenoid valve, pilot shut-off valve, and shockless valve. Swing-device coverage explains brake valves, negative-type parking brakes, and delayed parking-brake application.

The workshop procedures extend into internal inspection, seal replacement, assembly orientation, and component-specific tightening specifications. Travel-reduction section views and exploded assembly drawings support parts identification during teardown.

Center-joint assembly notes warn that rapid spindle insertion can damage the internal seals. The center-joint drawings also distinguish the sealing arrangements used with and without a blade.

Performance Tests and EPC Fault Isolation

The diagnostic charts connect operating symptoms with pilot-system, pump, valve, and motor checks. This gives technicians a structured way to distinguish control faults from component faults before committing to an overhaul.

Dr.EX coverage includes fault-code retrieval, code clearing, and real-time signal monitoring. Connector-voltage tables support EPC checks, while separate procedures address EC sensor positioning, EC motor installation adjustments, and auto-idle operation.

The electrical tests identify the ST 7125 two-lamp harness for EC motor checks and the ST 7129 test harness for EC sensor signals. The Electrical Circuit, Engine Harness Diagram, and Cab Harness Diagram complement connector-location views and hydraulic circuit drawings.

Engine and Front-Attachment Workshop Detail

The engine chapter includes piston and cylinder-liner grade selection, cylinder-head gasket identification, bearing-clearance measurement, and injection-pump calibration data. Fuel-system bleeding and nozzle-testing procedures accompany cooling-system and lubrication-system service information.

Front-attachment sections distinguish standard and offset arrangements and include blade-cylinder service. Cylinder assembly notes explain seal orientation and warn that misaligned piston-rod insertion can damage the sealing rings.

Observe the manual’s precautions for residual hydraulic pressure, supporting raised attachments, and lifting heavy assemblies.

Selected Hot-Engine and Refill Specifications

For BD3004 valve adjustment, the engine specifications list 0.35 mm (0.0138 in) clearance for both intake and exhaust valves with the engine hot. The overhaul sections separately identify standard dimensions and service limits for component inspection.

The machine refill table lists 10 L (2.6 US gal) for the complete cooling system and 135 L (35.7 US gal) for the fuel tank, keeping whole-machine capacities distinct from engine-only specifications.