Expert Hitachi EX60, EX60-2, EX60-3, EX60-5, EX60L, EX60LC Excavator Technical & Workshop Manual - Comprehensive Repair & Maintenance Guide (1986-2003)

Hitachi EX60-3 Excavator Technical & Workshop Manual - 1991-1997

Technical performance and mechanical longevity are secured through the application of factory-standard maintenance protocols detailed in this twin-portion manual. High-pressure hydraulic circuits are protected from cavitation damage by the integrated make-up valve logic, which ensures a constant oil supply during inertia-driven swing deceleration. This documentation provides the precise calibration data for the Nissan A-BD30 engine and the complex AP2D36L variable displacement pump systems to maintain peak operational ROI.

Technical Applicability & Chassis Configurations

• Standard Crawler Series (Steel/Rubber): EX60-3 configured with 1.62 m standard arms and 0.25 m³ bucket capacities.
• Blade-Equipped Variants: Models featuring 2300 mm blade widths and 24-degree blade angle capabilities for stabilization.
• Offset Front Configurations: Specialized chassis designed for maximum digging reaches of 6310 mm and 1150 mm offset distances.
• Interchangeability Reference: Cross-compatibility mapping for components shared with EX60, EX60-2, and UH025-7 series.

Operational ROI & System Integrity

• Diagnostic troubleshooting for the 40.5 kW Nissan diesel engine minimizes unscheduled downtime through precise fuel injection pump governor settings.
• Hydraulic system protection is maintained via relief valves set at 26.0 MPa for front/swing functions and 28.5 MPa for travel operations.
• Operational safety is enhanced by the negative-type wet multiple-disc parking brakes which engage automatically upon engine shutdown.

Document Metadata

• Print Number: 132T-01-01
• Total Page Count: 718 Pages
• File Format: Searchable Digital PDF

Technical Depth & Factory Benchmarks

• Engine Performance: Nissan BD3004 rated at 40.5 kW (55 PS) at 2200 rpm with a compression ratio of 18.5.
• Hydraulic Relief Pressures: Main relief (Travel) at 28.5 MPa (4,123 psi); Main relief (Front/Swing) at 26.0 MPa (3,768 psi).
• Electrical Thresholds: Overheat switch activation at 105±2 °C (221±3.6 °F); Oil pressure switch range 30 to 50 kPa.
• Swing Calibration: Relief pressure set at 25 MPa (3,626 psi) at 63 L/min; parking brake release pressure at 1.5 MPa.

Visual Navigation Aids

• Hydraulic Schematics: Detailed layout of the 5-spool and 4-spool control valve blocks including neutral and parallel circuit flow.
• Upperstructure Layout: Component mapping for main pump, control valve, swing device, and cooling tandem-type assembly.
• Undercarriage Architecture: Exploded views of two-stage planetary reduction gears and radial-piston travel motors.
• Pilot System Diagrams: Operation of the pilot shut-off valve, shockless valve, and solenoid-controlled pump flow rate adjustments.

Table of Contents

• Section 01: Specifications (General Info, Lubricants, Interchangeability, Component Specs)
• Section 02: Upperstructure (Pump Device, Swing Device, Control Valve, Pilot Valve)
• Section 03: Undercarriage (Travel Device, Swing Bearing, Center Joint, Track Adjuster)
• Section 04: Electrical System (Main Circuit, Control System, Monitor Panel, Inspection)

Operational Limits & Specifications

• Torque Sequences: Specified for bucket link pins, boom pivots, and undercarriage track frame mounting.
• Fluid Capacities: Fuel Tank (135 L), Hydraulic System (90 L), Engine Oil (12.5 L), Cooling System (10 L).
• Lubricant Standards: Hydraulic system requires ISO VG46 anti-wear oil; gear oil must meet API GL-4 SAE 90 specifications.
• Maintenance Intervals: Engine oil change every 500 hours; Hydraulic oil change every 2,500 hours (1,500 hours for severe duty).