All-Inclusive Factory Service Technical manual for Hitachi Crawler Excavators Models EX2500-6.

This manuals will assist you in diagnosing, repairing, operating, troubleshooting, assembling, and checking for your crawler excavator.
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Covered Models:
   EX2500-6

The manual comprises 20 documents, including 6 Workshop Manuals, two Operational Principle Manuals, two Operators Manuals, the Wiring Diagram, Assembly Manual, and 7 Check Sheets

1. Workshop Manual: Travel Transmission (WSDTDE186)
Format: PDF, 148 pages
Language: English

2. Workshop Manual: Swing Transmission (WSDSDE186)
Format: PDF, 146 pages
Language: English

3. Workshop Manual: Pump Transmission (WSDPDE186)
Format: PDF, 110 pages
Language: English

4. Workshop Manual: Pump Transmission (WSDPDE18Y2)
Format: PDF, 108 pages
Language: English

5. Workshop Manual: Travel Motor (M3B) (WSDTME1861)
Format: PDF, 196 pages
Language: English

6. Workshop Manual (W18LE00)
Format: PDF, 570 pages
Language: English
Table of Contents:
   SECTION 1 GENERAL
      Group 1 Precautions for Disassembling and Assembling
      Group 2 Tightening
      Group 3 Painting
      Group 4 Bleeding Air from Hydraulic Oil Tank
   SECTION 2 UPPERSTRUCTURE
      Group 1 Cab
      Group 2 Counterweight
      Group 3 Pump Device
      Group 4 Control Valve
      Group 5 Swing Device
      Group 6 DQR Valve
      Group 7 Shuttle Valve
      Group 8 8-Spool Solenoid Valve Unit
      Group 9 Oil Cooler Fan Motor
      Group 10 Compressor Drive Motor
      Group 11 Air Conditioner
      Group 12 Lift Cylinder (Filling System)
      Group 13 Lift Cylinder (Sliding Fold-In Ladder)
   SECTION 3 UNDERCARRIAGE
      Group 1 Swing Bearing
      Group 2 Travel Device
      Group 3 Travel Brake Valve
      Group 4 Drive Tumbler
      Group 5 Center Joint
      Group 6 Adjuster Cylinder
      Group 7 Front Idler
      Group 8 Upper and Lower Roller
      Group 9 Track
      Group 10 Accumulator
      Group 11 Welding Repair Procedure
   SECTION 4 FRONT ATTACHMENT
      Group 1 Front Attachment
      Group 2 Cylinder
      Group 3 Bushing and Point
   THE ATTACHED PATTERN LIST
      Track Shoe Pattern (A)
      Track Shoe Pattern (B)
      Upper Roller Pattern
      Lower Roller Pattern
      Drive Tumbler Pattern (A)
      Drive Tumbler Pattern (B)

7. Operational Principle Manual (TO18LE00)
Format: PDF, 270 pages
Language: English
Table of Contents:
   GENERAL
      Specifications
      Component Layout
      Component Specifications
   SYSTEM
      Controller
      Control System
      ELU System
      Hydraulic System
      Electrical System
   COMPONENT OPERATION
      Pump Device
      Swing Device
      Control Valve
      Control Equipment
      DQR Valve
      Travel Device
      Others (Upperstructure)
      Others (Undercarriage)

8. Operational Principle Manual (TO186E01)
Format: PDF, 212 pages
Language: English
Table of Contents:
   GENERAL
      Specifications
      Component Layout
      Component Specifications
   SYSTEM
      Control System
      Hydraulic System
      Electrical System (24V)
      Electrical System (6600 V)
   COMPONENT OPERATION
      Pump Device
      Swing Device
      Control Valve
      Pilot Valve
      Travel Device
      Others (Upperstructure)
      Others (Undercarriage)

9. Operators Manual: Visual Inspection (Loader Front) (KO44001)
Format: PDF, 248 pages
Language: English
Table of Contents:
   VISUAL INSPECTION EX2500-6/EX2600-6 LOADER FRONT
      COMPLETING AND SUBMITTING THE INSPECTION SHEETS
      SAFETY
      Inspection procedure
      Noting the cracks
      0 hour to 250 hours
      251 hours to 500 hours
      501 hours to 750 hours
      751 hours to 1000 hours
      1001 hours to 1250 hours
      1251 hours to 1500 hours
      1501 hours to 1750 hours
      1751 hours to 2000 hours
      2001 hours to 2250 hours
      2251 hours to 2500 hours
      2501 hours to 2750 hours
      2751 hours to 3000 hours
      3001 hours to 3250 hours
      3251 hours to 3500 hours
      3501 hours to 3750 hours
      3751 hours to 4000 hours
      4001 hours to 4250 hours
      4251 hours to 4500 hours
      4501 hours to 4750 hours
      4751 hours to 5000 hours
      5001 hours to 5250 hours
      5251 hours to 5500 hours
      5501 hours to 5750 hours
      5751 hours to 6000 hours
      6001 hours to 6250 hours
      6251 hours to 6500 hours
      6501 hours to 6750 hours
      6751 hours to 7000 hours
      7001 hours to 7250 hours
      7251 hours to 7500 hours
      7501 hours to 7750 hours
      7751 hours to 8000 hours
      8001 hours to 8250 hours
      8251 hours to 8500 hours
      8501 hours to 8750 hours
      8751 hours to 9000 hours
      9001 hours to 9250 hours
      9251 hours to 9500 hours
      9501 hours to 9750 hours
      9751 hours to 10000 hours
   BACK COVER

10. Operators Manual: Quick Visual Inspection (Backhoe Front) (KO41001)
Format: PDF, 248 pages
Language: English
Table of Contents:
   VISUAL INSPECTION EX2500-6/EX2600-6 BACKHOE FRONT
      COMPLETING AND SUBMITTING THE INSPECTION SHEETS
      SAFETY
      Inspection procedure
      Noting the cracks
      0 hour to 250 hours
      251 hours to 500 hours
      501 hours to 750 hours
      751 hours to 1000 hours
      1001 hours to 1250 hours
      1251 hours to 1500 hours
      1501 hours to 1750 hours
      1751 hours to 2000 hours
      2001 hours to 2250 hours
      2251 hours to 2500 hours
      2501 hours to 2750 hours
      2751 hours to 3000 hours
      3001 hours to 3250 hours
      3251 hours to 3500 hours
      3501 hours to 3750 hours
      3751 hours to 4000 hours
      4001 hours to 4250 hours
      4251 hours to 4500 hours
      4501 hours to 4750 hours
      4751 hours to 5000 hours
      5001 hours to 5250 hours
      5251 hours to 5500 hours
      5501 hours to 5750 hours
      5751 hours to 6000 hours
      6001 hours to 6250 hours
      6251 hours to 6500 hours
      6501 hours to 6750 hours
      6751 hours to 7000 hours
      7001 hours to 7250 hours
      7251 hours to 7500 hours
      7501 hours to 7750 hours
      7751 hours to 8000 hours
      8001 hours to 8250 hours
      8251 hours to 8500 hours
      8501 hours to 8750 hours
      8751 hours to 9000 hours
      9001 hours to 9250 hours
      9251 hours to 9500 hours
      9501 hours to 9750 hours
      9751 hours to 10000 hours
   BACK COVER

11. Wiring Diagram (TT18LE00_circuit)
Format: PDF, 11 pages
Language: English
Table of Contents:
   EX2500-6 ELECTRICAL CIRCUIT DIAGRAM 1/3
   EX2500-6 ELECTRICAL CIRCUIT DIAGRAM 2/3
   EX2500-6 ELECTRICAL CIRCUIT DIAGRAM 3/3
   EX1900-6, EX2500-6, EX3600-6 ELECTRICAL CIRCUIT DIAGRAM (CAB)
   EX1900-6, EX2500-6, EX3600-6 ELECTRICAL CIRCUIT DIAGRAM (ELECTRICAL EQUIPMENT BOX 1/2)
   EX1900-6, EX2500-6, EX3600-6 ELECTRICAL CIRCUIT DIAGRAM (ELECTRICAL EQUIPMENT BOX 2/2)
   EX1900-6, EX2500-6, EX3600-6, EX5500-6 CONNECTORS
   EX2500-6 HYDRAULIC CIRCUIT DIAGRAM (LOADING SHOVEL)
   EX2500-6 HYDRAULIC CIRCUIT DIAGRAM (BACKHOE)

12. Assembly Manual (KO32502)
Format: PDF, 341 pages
Language: English
Table of Contents:
   1. Precautions
      1-1 Safety precautions for servicemen
      1-2 How to use a power wrench
      1-3 Work precautions
   2. Workers plan
   2'. Workers plan
      2-1 Transportation of Loader Front
      2-1' Transportation of Backhoe Front
   3. Parts check
      3-1 Check
   4. Preparations (loader front)
   4'. Preparations (backhoe front)
   5. Machines, apparatus, tools, and materials necessary for assembly
   6. Assembly of Undercarriage
      6-1 Preparation
      6-2 Connection of track frame and side frames
      6-3 Connection of travel motor hoses and adjuster hoses
      6-4 Assembly of motor covers and steps
      6-5 Disassembly procedures for shipment (Procedure, Track)
      6-6 Assembly of motor guards and mission guards (Option)
   7. Connection of undercarriage and superstructure
      7-1 Preparations before connection
      7-2 Preparation of undercarriage
      7-3 Preparation of base machine
      7-4 Connection of undercarriage and base machine
      7-5 Connection of piping to center joint
      7-6 Assembly of fuel tank
      7-7 Assembly of cab
      7-8 Assembly of fenders, steps, handrails, beam, box, and covers
      7-9 Assembly of engine unit
      7-10 Mounting the counterweight & Installation the reserve tank
      7-11 Assembly of air-intake unit / exhaust unit and head lamps, mirror, wroking lamp, etc.
      7-12 Connection
      7-13 Checking the stop valves and stopcocks
      7-14 Final check of superstructure
      7-15 Releasing air from main pumps
      7-16 Trial operation of superstructure
      7-17 Disassembly procedures for shipment
      7-18 Assembly of option parts
   8. Mounting procedures for loader front-end attachment
      8-1 Preparation
      8-2 Mounting of loader front
      8-3 Mounting the bucket1
      8-4 Adjustment of track link tension
      8-5 Final trial operation check
      8-6 Disassembly procedures for shipment
   8'. Mounting procedures for backhoe front-end attachment
      8'-1 Preparation
      8'-2 Mounting of boom
      8'-3 Installation of arm
      8'-4 Mounting of bucket
      8'-5 Adjustment of track link tension
      8'-6 Final trial operation check
      8'-7 Assembly of option parts
      8'-8 Disassembly procedures for shipment
   9. Checks after completing the assembly
   10. Checking machine performance

13. Check Sheets: Visual Inspection (Backhoe Front) (KO360B01)
Format: PDF, 42 pages
Language: English

14. Check Sheets: Daily Visual Inspection (KO366B00)
Format: PDF, 6 pages
Language: English
Table of Contents:
   EX2500-6 DAILY VISUAL INSPECTION BACKHOE FRONT
      Backhoe Boom

15. Check Sheets: Weekly Visual Inspection (KO372B00)
Format: PDF, 20 pages
Language: English
Table of Contents:
   EX2500-6 WEEKLY VISUAL INSPECTION BACKHOE FRONT
   Main Frame
   Backhoe Boom
   Backhoe Arm

16. Check Sheets: Daily and Weekly Maintenance (KO33100)
Format: PDF, 4 pages
Language: English
Table of Contents:
   COVER
      DAILY AND WEEKLY CHECK SHEETS FOR THE EX2500-6
      EX2500-6 CHECK POINTS
   BACK COVER

17. Check Sheets: Completed Assembly (KO39400)
Format: PDF, 61 pages
Language: English
Table of Contents:
   COVER
      FOREWORD
      TABLE OF CONTENTS
      COMPLETED ASSEMBLY CHECKREPORT FOR THE EX2500-6
      ASSEMBLY CHECK SHEETSFORUNDERCARRIAGE EX2500-6
      ASSEMBLY CHECK SHEETSFORSUPERSTRUCTURE EX2500-6
      ASSEMBLY CHECK SHEETSFORFRONT-END ATTACHMENT EX2500-6
      ELECTRICAL SYSTEM FUNCTIONFORCHECK SHEETS EX2500-6
      IMPLEMENTATION SPEEDCHECK SHEETSFOR EX2500-6
   BACK COVER

18. Check Sheets: Visual Inspection (Loader Front) (KO360L01)
Format: PDF, 32 pages
Language: English

19. Check Sheets: Monthly Maintenance (KO33200)
Format: PDF, 55 pages
Language: English
Table of Contents:
   CHECK SHEETS FOR EX2500-6
      1 50 HOURS to 1250 HOURS
      2 1500 HOURS to 2500 HOURS
      3 2750 HOURS to 3750 HOURS
      4 4000 HOURS to 5000 HOURS
      5 5250 HOURS to 6250 HOURS
      6 6500 HOURS to 7500 HOURS
      7 7750 HOURS to 8750 HOURS
      8 9000 HOURS to 10000 HOURS
      9 10250 HOURS to 11250 HOURS
      10 11500 HOURS to 12500 HOURS
      11 12750 HOURS to 13750 HOURS
      12 14000 HOURS to 15000 HOURS
      13 15250 HOURS to 16250 HOURS
      14 16500 HOURS to 17500 HOURS
      15 17750 HOURS to 18750 HOURS
      16 19000 HOURS to 20000 HOURS
      EX2500-6 CHECK POINTS : 1
      EX2500-6 CHECK POINTS : 2
      FOR EX2500-6 PERIODIC REPLACEMENT OF RUBBER HOSES
      HOW TO USE THE EX2500-6 SHEETS