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The Hitachi EX135 is a popular model of mini-excavators known for its durability and versatility in various construction and digging tasks. One of the critical components that ensure the smooth operation of this excavator is the hydraulic pump, which powers the machine’s hydraulic systems, including the boom, arm, and tracks. However, like all hydraulic systems, the pump can sometimes experience issues, leading to decreased performance or complete failure. This article explores common problems with the hydraulic pump in the Hitachi EX135, how to diagnose these issues, and how to properly maintain the system to avoid costly repairs.
Understanding the Hydraulic Pump System
The hydraulic pump is responsible for generating the hydraulic pressure needed to operate the various hydraulic functions of the excavator. It uses engine power to convert mechanical energy into hydraulic energy, which is then used to move fluids under high pressure. The key components of the hydraulic pump system include:
Common Hydraulic Pump Problems
Several common issues can arise with the hydraulic pump in the Hitachi EX135, each affecting the performance of the machine in different ways. Below are some of the most frequent problems and their symptoms:
When experiencing issues with the hydraulic pump, it is important to systematically diagnose the problem before attempting repairs. The following steps can help identify the underlying issue:
Proper maintenance is key to avoiding pump failures and extending the lifespan of the hydraulic system. Here are some preventive maintenance tips:
A construction company in Texas faced a significant issue when the hydraulic pump in their Hitachi EX135 mini-excavator failed during an important earthmoving project. The machine had been experiencing slow response times and erratic arm movements for several days before the failure occurred.
After performing a diagnostic test, the crew found that the hydraulic fluid level was low, and the filters had not been replaced in over 500 hours of operation. The pump had also shown signs of excessive wear, which had contributed to the problem. To resolve the issue, the company drained and replaced the hydraulic fluid, installed new filters, and replaced the worn-out pump. After performing a system bleed and pressure test, the excavator was back in operation, performing at full capacity.
This incident highlights the importance of regular maintenance and timely repairs. By addressing the issue before it caused a complete pump failure, the company was able to minimize downtime and avoid costly repairs.
Conclusion
The hydraulic pump in the Hitachi EX135 is a vital component that ensures the excavator operates efficiently. Understanding the common issues that can arise, as well as implementing preventive maintenance practices, can help operators keep the hydraulic system running smoothly and extend the life of the equipment. Regular inspections, proper fluid levels, and timely repairs are key to maintaining a reliable hydraulic system. By staying proactive, operators can prevent expensive pump failures and maximize the productivity of their machines.
Understanding the Hydraulic Pump System
The hydraulic pump is responsible for generating the hydraulic pressure needed to operate the various hydraulic functions of the excavator. It uses engine power to convert mechanical energy into hydraulic energy, which is then used to move fluids under high pressure. The key components of the hydraulic pump system include:
- Hydraulic Pump: The core component that generates pressure.
- Hydraulic Fluid: The medium through which energy is transferred.
- Hydraulic Valves: Direct the flow of hydraulic fluid to different parts of the machine.
- Filters: Clean the hydraulic fluid and prevent contaminants from entering the system.
Common Hydraulic Pump Problems
Several common issues can arise with the hydraulic pump in the Hitachi EX135, each affecting the performance of the machine in different ways. Below are some of the most frequent problems and their symptoms:
- Loss of Hydraulic Power:
- Symptoms: The excavator may struggle to lift heavy loads or the boom may move slowly.
- Possible Causes:
- Air trapped in the hydraulic system.
- Low hydraulic fluid levels.
- Clogged or damaged filters.
- Worn-out pump components.
- Air trapped in the hydraulic system.
- Symptoms: The excavator may struggle to lift heavy loads or the boom may move slowly.
- Overheating:
- Symptoms: The hydraulic system becomes excessively hot, with a noticeable drop in performance.
- Possible Causes:
- Insufficient hydraulic fluid.
- Contaminated hydraulic fluid.
- Failed cooling system or blocked cooling lines.
- Low fluid flow due to worn-out or malfunctioning pump.
- Insufficient hydraulic fluid.
- Symptoms: The hydraulic system becomes excessively hot, with a noticeable drop in performance.
- Erratic Movements or Slow Response:
- Symptoms: The excavator’s arms, boom, or tracks may move inconsistently, or the response time may be delayed.
- Possible Causes:
- Hydraulic fluid leaks.
- Damaged pump or valves.
- Contaminants in the hydraulic system causing improper fluid flow.
- Hydraulic fluid leaks.
- Symptoms: The excavator’s arms, boom, or tracks may move inconsistently, or the response time may be delayed.
- Unusual Noises:
- Symptoms: The hydraulic pump or system may produce a high-pitched or grinding noise.
- Possible Causes:
- Cavitation (air trapped in the hydraulic fluid).
- Worn or damaged pump components.
- Lack of lubrication within the system.
- Cavitation (air trapped in the hydraulic fluid).
- Symptoms: The hydraulic pump or system may produce a high-pitched or grinding noise.
When experiencing issues with the hydraulic pump, it is important to systematically diagnose the problem before attempting repairs. The following steps can help identify the underlying issue:
- Check Fluid Levels:
- Ensure the hydraulic fluid is at the proper level. Low fluid can cause the pump to malfunction or overheat. Always use the correct type of hydraulic fluid recommended by the manufacturer.
- Ensure the hydraulic fluid is at the proper level. Low fluid can cause the pump to malfunction or overheat. Always use the correct type of hydraulic fluid recommended by the manufacturer.
- Inspect for Leaks:
- Inspect the entire hydraulic system for any visible signs of fluid leaks. Leaks can lead to a drop in pressure and cause the pump to lose efficiency.
- Inspect the entire hydraulic system for any visible signs of fluid leaks. Leaks can lead to a drop in pressure and cause the pump to lose efficiency.
- Examine the Filters:
- A clogged filter can restrict the flow of hydraulic fluid, reducing the pump’s performance. Replace the hydraulic filters as part of regular maintenance to ensure smooth operation.
- A clogged filter can restrict the flow of hydraulic fluid, reducing the pump’s performance. Replace the hydraulic filters as part of regular maintenance to ensure smooth operation.
- Check for Air in the System:
- If air is trapped in the hydraulic system, it can cause the pump to lose pressure and lead to cavitation. Bleeding the system can remove air and restore proper fluid flow.
- If air is trapped in the hydraulic system, it can cause the pump to lose pressure and lead to cavitation. Bleeding the system can remove air and restore proper fluid flow.
- Test the Pump Pressure:
- Use a pressure gauge to check the output pressure of the hydraulic pump. Low pressure can indicate that the pump is worn or damaged. If the pressure is too high, it could be a sign of a malfunctioning relief valve.
- Use a pressure gauge to check the output pressure of the hydraulic pump. Low pressure can indicate that the pump is worn or damaged. If the pressure is too high, it could be a sign of a malfunctioning relief valve.
- Inspect the Pump for Wear:
- Over time, the hydraulic pump’s internal components can wear down. Signs of excessive wear include unusual noises or reduced performance. In this case, the pump may need to be rebuilt or replaced.
- Over time, the hydraulic pump’s internal components can wear down. Signs of excessive wear include unusual noises or reduced performance. In this case, the pump may need to be rebuilt or replaced.
- Examine the Cooling System:
- Overheating is a common issue with hydraulic pumps. Ensure that the cooling system, including the radiator and cooling lines, is functioning properly and free from blockages.
- Overheating is a common issue with hydraulic pumps. Ensure that the cooling system, including the radiator and cooling lines, is functioning properly and free from blockages.
Proper maintenance is key to avoiding pump failures and extending the lifespan of the hydraulic system. Here are some preventive maintenance tips:
- Regular Fluid Checks:
- Monitor hydraulic fluid levels regularly. Low fluid can cause significant damage to the pump and other hydraulic components. It’s also important to check the quality of the fluid to ensure it is clean and free of contaminants.
- Monitor hydraulic fluid levels regularly. Low fluid can cause significant damage to the pump and other hydraulic components. It’s also important to check the quality of the fluid to ensure it is clean and free of contaminants.
- Frequent Filter Replacements:
- Filters should be replaced at regular intervals based on the manufacturer’s guidelines. Dirty filters can clog the system and reduce fluid flow, leading to decreased pump performance.
- Filters should be replaced at regular intervals based on the manufacturer’s guidelines. Dirty filters can clog the system and reduce fluid flow, leading to decreased pump performance.
- Monitor Pump Temperature:
- Keep an eye on the temperature of the hydraulic fluid. If the system starts to overheat, investigate the cause, which could include low fluid levels, blocked cooling lines, or a malfunctioning pump.
- Keep an eye on the temperature of the hydraulic fluid. If the system starts to overheat, investigate the cause, which could include low fluid levels, blocked cooling lines, or a malfunctioning pump.
- Lubrication:
- Regularly lubricate all moving parts in the hydraulic system to reduce friction and wear. This includes the pump’s bearings and seals.
- Regularly lubricate all moving parts in the hydraulic system to reduce friction and wear. This includes the pump’s bearings and seals.
- Fluid Contamination Prevention:
- Keep the hydraulic system free from debris, dirt, and water, as contaminants can cause internal damage to the pump and other components. Always use high-quality filters and ensure that the system is properly sealed.
- Keep the hydraulic system free from debris, dirt, and water, as contaminants can cause internal damage to the pump and other components. Always use high-quality filters and ensure that the system is properly sealed.
- System Bleeding:
- After any repair work or fluid change, ensure the hydraulic system is properly bled to remove any air trapped within the lines. Air in the system can cause erratic movements and damage the pump.
- After any repair work or fluid change, ensure the hydraulic system is properly bled to remove any air trapped within the lines. Air in the system can cause erratic movements and damage the pump.
- Scheduled Inspections:
- Conduct regular inspections of the hydraulic system, including the pump, hoses, and valves. Early detection of wear or damage can prevent more serious issues from developing.
- Conduct regular inspections of the hydraulic system, including the pump, hoses, and valves. Early detection of wear or damage can prevent more serious issues from developing.
A construction company in Texas faced a significant issue when the hydraulic pump in their Hitachi EX135 mini-excavator failed during an important earthmoving project. The machine had been experiencing slow response times and erratic arm movements for several days before the failure occurred.
After performing a diagnostic test, the crew found that the hydraulic fluid level was low, and the filters had not been replaced in over 500 hours of operation. The pump had also shown signs of excessive wear, which had contributed to the problem. To resolve the issue, the company drained and replaced the hydraulic fluid, installed new filters, and replaced the worn-out pump. After performing a system bleed and pressure test, the excavator was back in operation, performing at full capacity.
This incident highlights the importance of regular maintenance and timely repairs. By addressing the issue before it caused a complete pump failure, the company was able to minimize downtime and avoid costly repairs.
Conclusion
The hydraulic pump in the Hitachi EX135 is a vital component that ensures the excavator operates efficiently. Understanding the common issues that can arise, as well as implementing preventive maintenance practices, can help operators keep the hydraulic system running smoothly and extend the life of the equipment. Regular inspections, proper fluid levels, and timely repairs are key to maintaining a reliable hydraulic system. By staying proactive, operators can prevent expensive pump failures and maximize the productivity of their machines.
