Hitachi Ex2500-5 Excavator Technical Troubleshooting Manual (TT141-E-01) – PDF Download

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Hitachi Ex2500-5 Excavator Technical Troubleshooting Manual (TT141-E-01)

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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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