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Hitachi Ex2500-5 Excavator Technical Troubleshooting Manual (TT141-E-01) – PDF Download
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- Hitachi Ex2500-5 Excavator Technical Troubleshooting Manual
- Part No:TT141-E-01
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Description
Hitachi Ex2500-5 Excavator Technical Troubleshooting Manual (TT141-E-01)
File Details:
Hitachi Ex2500-5 Excavator Technical Troubleshooting Manual (TT141-E-01)
- Manual Language:English
- Pages: 292
- Size: 5.18 MB
- Downloadable:Yes
- Format:PDF
HITACHI EX2500-5 EXCAVATOR TECHNICAL TROUBLESHOOTING MANUAL (TT141-E-01) – PDF DOWNLOAD:
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Description:
Hitachi Ex2500-5 Excavator Technical Troubleshooting Manual (TT141-E-01)
TO THE READER
• This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
• Be sure to thoroughly read this manual for correct product information and service procedures.
• If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form at the end of this manual.
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition to this manual.
• The Operator’s Manual
• The Parts Catalog
• Operation Manual of the Engine
• Parts Catalog of the Engine
• Hitachi Training Material
MANUAL COMPOSITION
• This manual consists of three portions: the Technical Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual.
• Information included in the Technical Manual (Operational Principle): technical information needed for redeliver and delivery, operation and activation of all devices and systems.
• Information included in the Technical Manual (Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures.
• Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assemble/ disassemble procedures.
Table of Contents:
Hitachi Ex2500-5 Excavator Technical Troubleshooting Manual (TT141-E-01)
INDEX......................................................................................................................................................... 1 INTRODUCTION.................................................................................................................................................. 3 SAFETY........................................................................................................................................................ 5 CONTENTS...................................................................................................................................................... 35 SECTION 4 OPERATIONAL PERFORMANCE TEST........................................................................................................................ 37 Introduction.............................................................................................................................................. 39 OPERATIONAL PERFORMANCE TEST.......................................................................................................................... 39 PREPARATION FOR PERFORMANCE TESTS..................................................................................................................... 40 Standard.................................................................................................................................................. 41 OPERATIONAL PERFORMANCE STANDARD TABLE................................................................................................................ 41 Engine Test............................................................................................................................................... 45 ENGINE SPEED.......................................................................................................................................... 45 Excavator Test............................................................................................................................................ 47 TRAVEL SPEED.......................................................................................................................................... 47 TRACK REVOLUTION SPEED................................................................................................................................ 48 MISTRACK.............................................................................................................................................. 49 TRAVEL MOTOR DRIFT CHECK.............................................................................................................................. 50 SWING SPEED........................................................................................................................................... 51 SWING FUNCTION DRIFT.................................................................................................................................. 52 SWING MOTOR LEAKAGE................................................................................................................................... 54 MAXIMUM SWINGABLE SLANT ANGLE......................................................................................................................... 55 SWING BEARING PLAY.................................................................................................................................... 56 HYDRAULIC CYLINDER CYCLE TIME......................................................................................................................... 58 CYLINDER DRIFT........................................................................................................................................ 60 CONTROL LEVER OPERATING FORCE......................................................................................................................... 61 CONTROL LEVER STROKE.................................................................................................................................. 62 BOOM RAISE/SWING COMBINED OPERATION CHECK............................................................................................................. 63 Component Test............................................................................................................................................ 65 PILOT PRIMARY PRESSURE................................................................................................................................ 65 PILOT SECONDARY PRESSURE.............................................................................................................................. 66 MAIN RELIEF PRESSURE.................................................................................................................................. 68 OVERLOAD RELIEF PRESSURE.............................................................................................................................. 72 MAIN PUMP FLOW RATE MEASUREMENT....................................................................................................................... 74 OIL COOLER FAN PUMP FLOW RATE MEASUREMENT............................................................................................................. 82 SWING MOTOR DRAINAGE.................................................................................................................................. 88 TRAVEL MOTOR DRAINAGE................................................................................................................................. 90 SECTION 5 TROUBLESHOOTING.................................................................................................................................... 95 General................................................................................................................................................... 97 INTRODUCTION.......................................................................................................................................... 97 DIAGNOSING PROCEDURE.................................................................................................................................. 98 Component Layout..........................................................................................................................................101 MAIN COMPONENT LAYOUT.................................................................................................................................101 PILOT PANEL...........................................................................................................................................103 PUMP AND COMPONENTS...................................................................................................................................104 ELECTRICAL COMPONENT LAYOUT...........................................................................................................................105 ENGINE AND COMPONENTS ................................................................................................................................106 BATTERY COMPARTMENT...................................................................................................................................108 ELECTRICAL COMPONENT LAYOUT IN CAB....................................................................................................................110 ELECTRICAL EQUIPMENT BOX..............................................................................................................................112 CONTROL VALVE.........................................................................................................................................114 SWING DEVICE..........................................................................................................................................116 PILOT PIPING..........................................................................................................................................118 Troubleshooting A.........................................................................................................................................149 TROUBLESHOOTING A PROCEDURE...........................................................................................................................149 FAULT CODE INDICATION BY INDICATOR BLINKING PATTERN...................................................................................................150 CUMMINS ENGINE FAULT CODE INFORMATION.................................................................................................................152 ENGINE WARNING INDICATOR TROUBLESHOOTING..............................................................................................................156 Troubleshooting B.........................................................................................................................................159 TROUBLESHOOTING B PROCEDURE...........................................................................................................................159 MACHINE MALFUNCTIONS AND POSSIBLE CASES...............................................................................................................160 ENGINE SYSTEM.........................................................................................................................................166 ACTUATOR SYSTEM.......................................................................................................................................178 FRONT ATTACHMENT SYSTEM...............................................................................................................................186 SWING SYSTEM..........................................................................................................................................192 TRAVEL SYSTEM.........................................................................................................................................195 AUTO-LUBRICATION SYSTEM...............................................................................................................................202 WIPER OPERATING SYSTEM................................................................................................................................208 AIR CONDITIONER.......................................................................................................................................216 Troubleshooting C.........................................................................................................................................231 TROUBLESHOOTING C PROCEDURE...........................................................................................................................231 MALFUNCTION OF TACHOMETER.............................................................................................................................232 MALFUNCTION OF COOLANT TEMPERATURE GAUGE..............................................................................................................234 MALFUNCTION OF HYDRAULIC OIL TEMPERATURE GAUGE........................................................................................................236 MALFUNCTION OF FUEL GAUGE.............................................................................................................................238 MALFUNCTION OF ALTERNATOR INDICATOR...................................................................................................................240 MALFUNCTION OF AIR CLEANER RESTRICTION INDICATOR......................................................................................................241 MALFUNCTION OF ENGINE OIL PRESSURE INDICATOR (WARNING)................................................................................................242 MALFUNCTION OF OVERHEAT INDICATOR (WARNING)...........................................................................................................244 MALFUNCTION OF FUEL LEVEL INDICATOR (WARNING).........................................................................................................246 MALFUNCTION OF ENGINE STOP INDICATOR 1 (WARNING)......................................................................................................248 MALFUNCTION OF ENGINE STOP INDICATOR 2 (WARNING) MALFUNCTION OF ENGINE WARNING INDICATOR 1, 2 MALFUNCTION OF ENGINE PROTECTION INDICATOR (WARNING)....249 MALFUNCTION OF EMERGENCY ENGINE STOP INDICATOR........................................................................................................250 MALFUNCTION OF HYDRAULIC OIL LEVEL INDICATOR (WARNING)................................................................................................252 MALFUNCTION OF PUMP TRANSMISSION OIL PRESSURE INDICATOR (WARNING).....................................................................................254 MALFUNCTION OF PUMP CONTAMINATION INDICATOR (WARNING).................................................................................................256 MALFUNCTION OF STOP VALVE INDICATOR (WARNING).........................................................................................................258 MALFUNCTION OF LADDER POSITION INDICATOR (WARNING)....................................................................................................259 MALFUNCTION OF AUTO-LUBRICATION INDICATOR (WARNING)...................................................................................................260 MALFUNCTION OF FAST-FILLING PANEL INDICATOR (Option)..................................................................................................261 MALFUNCTION OF ENGINE OIL LEVEL INDICATOR.............................................................................................................262 MALFUNCTION OF COOLANT LEVEL INDICATOR (WARNING)......................................................................................................264 MALFUNCTION OF HYDRAULIC OIL LEVEL INDICATOR..........................................................................................................266 MALFUNCTION OF AUTO-IDLE INDICATOR....................................................................................................................267 MALFUNCTION OF FAST SPEED TRAVEL INDICATOR............................................................................................................268 MALFUNCTION OF SLOW SPEED TRAVEL INDICATOR............................................................................................................269 MALFUNCTION OF ENTRANCE LIGHT INDICATOR...............................................................................................................270 MALFUNCTION OF MAINTENANCE WORK LIGHT INDICATOR.......................................................................................................271 MALFUNCTION OF INDICATOR LIGHT CHECK SYSTEM...........................................................................................................272 MALFUNCTION OF HOUR METER.............................................................................................................................273 MALFUNCTION OF BUZZER.................................................................................................................................274 Electrical System Inspection Procedure....................................................................................................................275 PRECAUTIONS FOR INSPECTION AND MAINTENANCE............................................................................................................275 DISCONNECTION OF CONNECTOR............................................................................................................................277 BATTERY VOLTAGE CHECK.................................................................................................................................278 FUSIBLE LINK INSPECTION...............................................................................................................................279 FUSE CONTINUITY CHECK.................................................................................................................................280 ALTERNATOR CHECK......................................................................................................................................283 CONTINUITY CHECK......................................................................................................................................284 VOLTAGE CHECK.........................................................................................................................................285 5 VOLT CIRCUIT........................................................................................................................................286 CHECK USING FALSE SIGNAL..............................................................................................................................287 CIRCUIT CHECK BY LAMP HARNESS.........................................................................................................................288 SERVICE MANUAL REVISION REQUEST FORM..........................................................................................................................291 THE ATTACHED DIAGRAM LIST.....................................................................................................................................292
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