All-Inclusive Factory Service Technical manual for Hitachi Crawler Excavators Models EX2500-5.

This manuals will assist you in diagnosing, repairing, troubleshooting, operating, assembling, and checking for your crawler excavator.
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Covered Models:
   EX2500-5

The manual comprises 19 documents, including five Workshop Manuals, two Troubleshooting Manuals, the Operational Principle Manual, Operators Manual, Wiring Diagram, Assembly Manual, and 8 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 (W141E01)
Format: PDF, 527 pages
Language: English
Table of Contents:
   GENERAL INFORMATION
      Precautions for Disassembling and Assembling
      Tightening
      Bleeding Air from Hydraulic Oil Tank
   UPPERSTRUCTURE
      Cab
      Counterweight
      Main Frame
      Pump Device
      Control Valve
      Swing Device
      Pilot Valve
      Pilot Shut-Off Valve
      Shuttle Valve
      Solenoid Valve
      Oil Cooler Fan Motor
      Compressor Drive Motor
      Air Conditioner
   UNDERCARRIAGE
      Swing Bearing
      Travel Device
      Travel Brake Valve
      Drive Tumbler
      Center Joint
      Adjuster Cylinder
      Front Idler
      Upper and Lower Roller
      Track Shoes
      Accumulator
      Welding Repair Procedure
   FRONT ATTACHMENT
      Front Attachment
      Cylinder
      Bushing and Point

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

6. Troubleshooting Manual (TT141E01)
Format: PDF, 304 pages
Language: English
Table of Contents:
   OPERATIONAL PERFORMANCE TEST
      Introduction
      Standard
      Engine Test
      Excavator Test
      Component Test
   TROUBLESHOOTING
      General
      Component Layout
      Troubleshooting A
      Troubleshooting B
      Troubleshooting C
      Electrical System Inspection Procedure
   SERVICE MANUAL REVISION REQUEST FORM
   THE ATTACHED DIAGRAM LIST
      HYDRAULIC CIRCUIT DIAGRAM (BACKHOE )
      HYDRAULIC CIRCUIT DIAGRAM (LOADING SHOVEL )
      ELECTRICAL CIRCUIT DIAGRAM 1/3 (Up to Machine Serial No. 523)
      ELECTRICAL CIRCUIT DIAGRAM 1/3 (Machine Serial No. 524 and Up)
      ELECTRICAL CIRCUIT DIAGRAM 2/3 (Up to Machine Serial No. 523)
      ELECTRICAL CIRCUIT DIAGRAM 2/3 (Machine Serial No. 524 to 551)
      ELECTRICAL CIRCUIT DIAGRAM 2/3 (Machine Serial No. 552 and Up)
      ELECTRICAL CIRCUIT DIAGRAM 3/3 (Up to Machine Serial No. 507)
      ELECTRICAL CIRCUIT DIAGRAM 3/3 (Machine Serial No. 508 to 523)
      ELECTRICAL CIRCUIT DIAGRAM 3/3 (Machine Serial No. 524 and Up)
      CONNECTORS (Up to Machine Serial No. 523)
      CONNECTORS (Machine Serial No. 524 and Up)

7. Troubleshooting Manual: Recommended Service Program (KO16801)
Format: PDF, 39 pages
Language: English
Table of Contents:
   COVER
   INTRODUCTION
   MAJOR COMPONENTS PREVENTIVE SERVICE SCHEDULE
   HITACHI SCHEDULED DIAGNOSTIC SERVICE
   CHECK LISTS FOR PERFORMANCE AND COMPONENTS
   RECOMMENDATION OF PREVENTIVE SERVICE TO CUSTOMER
   RECOMMENDED PARTS LIST FOR PREVENTIVE SERVICE

8. Operational Principle Manual (TO141E01)
Format: PDF, 178 pages
Language: English
Table of Contents:
   GENERAL
      Specifications
      Component Layout
      Component Specifications
   SYSTEM
      Control System
      Hydraulic System
      Electrical System
   COMPONENT OPERATION
      Pump Device
      Swing Device
      Control Valve
      Pilot Valve
      Travel Device
      Others (Upperstructure)
      Others (Undercarriage)
   SERVICE MANUAL REVISION REQUEST FORM

9. Operators Manual (em18611)
Format: PDF, 294 pages
Language: English

10. Wiring Diagram (TT141E00_circuit)
Format: PDF, 6 pages
Language: English

11. Assembly Manual (KO27800_POD)
Format: PDF, 225 pages
Language: English
Table of Contents:
   COVER
   Foreword
   EX2500-5 Assembly Process Chart LOADER FRONT
   EX2500-5 Assembly Process Chart BACKHOE FRONT
      1. Precautions
      2. Workers plan
      2'. Workers plan
      3. Parts check
      4. Preparations (loader front)
      4'. Preparations (backhoe front)
      5. Machines, apparatus, tools, and materials necessary for assembly
      ASSEMBLY OF UNDERCARRIAGE
      ASSEMBLY OF SUPERSTRUCTURE
      MOUNTING PROCEDURES FOR LOADER FRONT-END ATTACHMENT
      MOUNTING PROCEDURES FOR BACKHOE FRONT-END ATTACHMENT
      CHECKS & PERFORMANCE STANDARDS
   BACK COVER

12. Check Sheets: Mothly Maintenance (KO28100)
Format: PDF, 55 pages
Language: English
Table of Contents:
   1. 50 TO 1250 HOURS
   2. 1500 TO 2500 HOURS
   3. 2750 TO 3750 HOURS
   4. 4000 TO 5000 HOURS
   5. 5250 TO 6250 HOURS
   6. 6500 TO 7500 HOURS
   7. 7750 TO 8750 HOURS
   8. 9000 TO 10000 HOURS
   9. 10250 TO 11250 HOURS
   10. 11500 TO 12500 HOURS
   11. 12750 TO 13750 HOURS
   12. 14000 TO 15000 HOURS
   13. 15250 TO 16250 HOURS
   14. 16500 TO 17500 HOURS
   15. 17750 TO 18750 HOURS
   16. 19000 TO 20000 HOURS

13. Check Sheets: Visual Inspection (Loader Front) (KO170L01)
Format: PDF, 32 pages
Language: English

14. Check Sheets: UT Inspection (Backhoe Front) (KO175B01)
Format: PDF, 76 pages
Language: English
Table of Contents:
   COVER
   INTRODUCTION
   DISTRIBUTION OF THE INSPECTION SHEET
   DEFINITION OF THE DEFECT LENGTH IN ULTRA-SONIC TESTING
   INSPECTION PROCEDURE
   ULTRA-SONIC EXAMINATION REPORT FOR THE STRUCTURE
   Track Frame
   Backhoe Boom
   Backhoe Arm

15. Check Sheets: UT Inspection (Loader Front) (KO175L01)
Format: PDF, 58 pages
Language: English

16. Check Sheets: Parts Visual Check (KO16601)
Format: PDF, 53 pages
Language: English
Table of Contents:
   COVER
   INTRODUCTION
   INSPECTION PROCEDURE
   PRECAUTIONS FOR INSPECTION
   DISTRIBUTION OF THE INSPECTION SHEET
   PIPING SYSTEM
   ELECTRIC PARTS
   IMPORTANT CHECKS

17. Check Sheets: Visual Inspection (Backhoe Front) (KO170B02)
Format: PDF, 42 pages
Language: English

18. Check Sheets: Daily and Weelkly Maintenance (ko28000)
Format: PDF, 7 pages
Language: English

19. Check Sheets: Completed Assembly (KO27900_POD)
Format: PDF, 40 pages
Language: English
Table of Contents:
   COVER
      FOREWORD
      TABLE OF CONTENTS
      COMPLETED ASSEMBLY CHECKREPORT FOR THE EX2500-5
      UNDERCARRIAGE/SUPERSTRUCTURE EX2500-5
      FRONT-END ATTACHMENT FOR THE EX2500-5
      ELECTRICAL SYSTEM FUNCTION CHECK SHEETS FOR THE EX2500-5
      IMPLEMENTATION SPEED CHECK SHEETS FOR THE EX2500-5
      HOW TO USE THE EX2500-5 CHECK SHEETS
   BACK COVER