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Hitachi Ex2500-5 Excavator Technical Workshop Manual (W141-E-01) – PDF Download
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- Hitachi Ex2500-5 Excavator Technical Workshop Manual
- Part No:W141-E-01
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Description
Hitachi Ex2500-5 Excavator Technical Workshop Manual (W141-E-01)
File Details:
Hitachi Ex2500-5 Excavator Technical Workshop Manual (W141-E-01)
- Manual Language:English
- Pages: 518
- Size: 9.34 MB
- Downloadable:Yes
- Format:PDF
HITACHI EX2500-5 EXCAVATOR TECHNICAL WORKSHOP MANUAL (W141-E-01) – PDF DOWNLOAD:
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Description:
Hitachi Ex2500-5 Excavator Technical Workshop Manual (W141-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 Workshop Manual (W141-E-01)
INDEX........................................................................ 1 INTRODUCTION................................................................. 3 SAFETY....................................................................... 5 CONTENTS..................................................................... 31 SECTION 1 GENERAL INFORMATION................................................ 33 Precautions for Disassembling and Assembling............................. 35 PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING......................... 35 MAINTENANCE STANDARD TERMINOLOGY..................................... 41 Tightening............................................................... 43 TIGHTENING TORQUE SPECIFICATION...................................... 43 TORQUE CHART......................................................... 45 PIPING JOINT......................................................... 48 PERIODIC REPLACEMENT OF PARTS........................................ 52 Bleeding Air from Hydraulic Oil Tank..................................... 53 BLEEDING AIR FROM HYDRAULIC OIL TANK................................. 53 VACUUM............................................................... 54 SECTION 2 UPPERSTRUCTURE..................................................... 57 Cab...................................................................... 59 DIMENSIONS OF THE CAB GLASS.......................................... 59 Counterweight............................................................ 61 REMOVE AND INSTALL COUNTERWEIGHT..................................... 61 Main Frame............................................................... 65 REMOVE AND INSTALL MAIN FRAME........................................ 65 Pump Device.............................................................. 73 REMOVE AND INSTALL PUMP DEVICE....................................... 73 DISASSEMBLE MAIN PUMP................................................ 78 ASSEMBLE MAIN PUMP................................................... 88 MAINTENANCE STANDARD................................................. 96 DISASSEMBLE REGULATOR FOR MAIN PUMP.................................. 98 ASSEMBLE REGULATOR FOR MAIN PUMP.....................................104 COMPONENTS OF 4-SPOOL PUMP...........................................111 DISASSEMBLE OIL COOLER FAN DRIVE PUMP................................112 ASSEMBLE OIL COOLER FAN DRIVE PUMP...................................116 MAINTENANCE STANDARD.................................................122 DISASSEMBLE REGULATOR FOR OIL COOLER FAN DRIVE PUMP..................124 ASSEMBLE REGULATOR FOR OIL COOLER FAN DRIVE PUMP.....................130 DISASSEMBLE AIR COMPRESSOR DRIVE PUMP AND PILOT PUMP.................136 ASSEMBLE AIR COMPRESSOR DRIVE PUMP AND PILOT PUMP....................142 MAINTENANCE STANDARD.................................................146 DISASSEMBLE LUBRICATION PUMP FOR PUMP TRANSMISSION...................148 ASSEMBLE LUBRICATION PUMP FOR PUMP TRANSMISSION......................150 MAINTENANCE STANDARD.................................................152 Control Valve............................................................153 REMOVE AND INSTALL CONTROL VALVE.....................................153 DISASSEMBLE CONTROL VALVE............................................156 ASSEMBLE CONTORL VALVE...............................................164 DISASSEMBLE AND ASSEMBLE MAIN RELIEF VALVE, OVERLOAD RELIEF VALVE....168 MAKE-UP VALVE CONSTRUCTION...........................................170 Swing Device.............................................................171 REMOVE AND INSTALL SWING DEVICE......................................171 DISASSEMBLE SWING REDUCTION GEAR.....................................174 ASSEMBLE SWING REDUCTION GEAR........................................180 DISASSEMBLE SWING MOTOR..............................................188 ASSEMBLE SWING MOTOR.................................................192 MAINTENANCE STANDARD.................................................196 DISASSEMBLE AND ASSEMBLE VALVE UNIT..................................198 Pilot Valve..............................................................201 REMOVE AND INSTALL FRONT / SWING PILOT VALVE.........................201 REMOVE AND INSTALL TRAVEL AND BUCKET OPEN / CLOSE PILOT VALVE........203 PILOT LINE CONNECTION................................................206 DISASSEMBLE FRONT / SWING PILOT VALVE................................208 ASSEMBLE FRONT / SWING PILOT VALVE...................................210 DISASSEMBLE TRAVEL BUCKET OPEN / CLOSE PILOT VALVE...................214 ASSEMBLE TRAVEL BUCKET OPEN / CLOSE PILOT VALVE......................216 Pilot Shut-Off Valve.....................................................219 REMOVE AND INSTALL PILOT SHUT-OFF VALVE..............................219 DISASSEMBLE PILOT SHUT-OFF VALVE.....................................222 ASSEMBLE PILOT SHUT-OFF VALVE........................................224 Shuttle Valve............................................................227 REMOVE AND INSTALL SHUTTLE VALVE.....................................227 DISASSEMBLE AND ASSEMBLE SHUTTLE VALVE...............................229 Solenoid Valve...........................................................231 REMOVE AND INSTALL SOLENOID VALVE....................................231 SOLENOID VALVE CONSTRUCTION..........................................234 Oil Cooler Fan Motor.....................................................239 REMOVE AND INSTALL OIL COOLER FAN MOTOR..............................239 DISASSEMBLE OIL COOLER FAN MOTOR.....................................244 ASSEMBLE OIL COOLER FAN MOTOR........................................246 MAINTENANCE STANDARD.................................................248 Compressor Drive Motor...................................................249 REMOVE AND INSTALL COMPRESSOR DRIVE MOTOR............................249 DISASSEMBLE COMPRESSOR DRIVE MOTOR...................................252 ASSEMBLE COMPRESSOR DRIVE MOTOR......................................254 Air Conditioner..........................................................257 WORK AFTER REPLACING COMPONENT.......................................257 ADD COMPRESSOR OIL...................................................257 CHARGE AIR CONDITIONER WITH REFRIGERANT..............................258 SECTION 3 UNDERCARRIAGE......................................................269 Swing Bearing............................................................271 REMOVE AND INSTALL SWING BEARING.....................................271 Travel Device............................................................273 REMOVE AND INSTALL TRAVEL DEVICE.....................................273 DISASSEMBLE TRAVEL REDUCTION GEAR....................................276 ASSEMBLE TRAVEL REDUCTION GEAR.......................................286 DISASSEMBLE TRAVEL MOTOR.............................................294 ASSEMBLE TRAVEL MOTOR................................................302 DISASSEMBLE AND ASSEMBLE TRAVEL SPEED MODE SELECTOR VALVE............308 MAINTENANCE STANDARD.................................................310 Travel Brake Valve.......................................................313 REMOVE AND INSTALL TRAVEL BRAKE VALVE................................313 DISASSEMBLE TRAVEL BRAKE VALVE.......................................316 ASSEMBLE TRAVEL BRAKE VALVE..........................................318 Drive Tumbler............................................................321 REMOVE DRIVE TUMBLER.................................................321 INSTALL DRIVE TUMBLER................................................328 MAINTENANCE STANDARD.................................................338 Center Joint.............................................................341 REMOVE AND INSTALL CENTER JOINT......................................341 DISASSEMBLE CENTER JOINT.............................................344 ASSEMBLE CENTER JOINT................................................346 Adjuster Cylinder........................................................349 REMOVE AND INSTALL ADJUSTER CYLINDER.................................349 DISASSEMBLE ADJUSTER CYLINDER........................................354 ASSEMBLE ADJUSTER CYLINDER...........................................356 Front Idler..............................................................359 REMOVE AND INSTALL FRONT IDLER.......................................359 DISASSEMBLE FRONT IDLER..............................................364 ASSEMBLE FRONT IDLER.................................................366 MAITENANCE STANDARD..................................................368 Upper and Lower Roller...................................................369 REMOVE AND INSTALL UPPER/LOWER ROLLER................................369 DISASSEMBLE UPPER ROLLER.............................................374 ASSEMBLE UPPER ROLLER................................................376 DISASSEMBLE LOWER ROLLER.............................................378 ASSEMBLE LOWER ROLLER................................................380 MAINTENANCE STANDARD.................................................382 Track Shoes..............................................................385 REMOVE AND INSTALL TRACK SHOES.......................................385 DISASSEMBLE AND ASSEMBLE TRACK SHOES.................................390 MAINTENANCE STANDARD.................................................391 Accumulator..............................................................393 REMOVE AND INSTALL ACCUMULATOR.......................................393 DISASSEMBLE ACCUMULATOR..............................................396 ASSEMBLE ACCUMULATOR.................................................398 Welding Repair Procedure.................................................405 WELDING REPAIR PROCEDURE.............................................405 WELDING ROD SPECIFICATION............................................406 REPAIR TRACK SHOES (SHOE LUGS).......................................407 REPAIR ROLLERS.......................................................410 REPAIR DRIVE TUMBLER.................................................413 SECTION 4 FRONT ATTACHMENT...................................................419 Front Attachment.........................................................421 REMOVE AND INSTALL FRONT ATTACHMENT..................................421 Cylinder.................................................................451 REMOVE AND INSTALL CYLINDER..........................................451 DISASSEMBLE CYLINDER.................................................482 ASSEMBLE CYLINDER....................................................490 MAIN POINTS TO BLEED AIR.............................................498 MAINTENANCE STANDARD.................................................500 Bushing and Point........................................................503 REMOVE AND INSTALL BUSHING...........................................503 MAINTENANCE STANDARD.................................................506 SERVICE MANUAL REVISION REQUEST FORM.........................................517 THE ATTACHED PATTERN LIST....................................................518
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