Hitachi EX100-2 Excavator: Comprehensive Overview and Troubleshooting Guide

[MikePhua]

   

Introduction
The Hitachi EX100-2 is a mid-sized hydraulic crawler excavator that gained popularity in the 1990s for its reliability and versatility in construction, demolition, and utility applications. Manufactured by Hitachi Construction Machinery, the EX100-2 was part of the EX series, which was known for its robust design and efficient performance. Over time, the EX100-2 has become a sought-after model in the used equipment market due to its durability and cost-effectiveness.
Technical Specifications

• Operating Weight: Approximately 19,200 lbs (8,700 kg)
  
• Engine: Isuzu 4BG1T turbocharged diesel engine
  
• Engine Power: Approximately 85 hp (63 kW)
  
• Hydraulic System: Open-center hydraulic system with a variable displacement pump
  
• Travel Speed: High: 3.0 km/h; Low: 1.8 km/h
  
• Swing Speed: 10.5 rpm
  
• Bucket Capacity: 0.4 m³ (standard)
  
• Dimensions:
  • Length: Approximately 7.11 m
    
  • Width: Approximately 2.46 m
    
  • Height: Approximately 3.4 m
    
• Maximum Digging Depth: Approximately 4.2 m
  
• Maximum Reach: Approximately 7.43 m
  

Common Issues and Troubleshooting

1. Hydraulic Power Loss
   A common issue reported by operators is a loss of hydraulic power, particularly when attempting to dig or operate attachments. This can be caused by several factors:
   • Clogged or Worn Hydraulic Filters: Over time, filters can become clogged with debris, restricting fluid flow and reducing system pressure.
     
   • Faulty Hydraulic Pump: A failing pump may not generate adequate pressure, leading to sluggish or unresponsive hydraulics.
     
   • Internal Leaks: Leaks within the hydraulic system can cause a drop in pressure, affecting performance.
     
   Solution: Regular maintenance, including timely replacement of filters and inspection of the hydraulic pump, can help prevent these issues.
   
2. Travel Motor Problems
   Issues with the travel motor can manifest as the machine not moving, moving slowly, or exhibiting uneven movement. Potential causes include:
   • Worn or Damaged Final Drive: The final drive unit, which transmits power from the engine to the tracks, can wear out over time.
     
   • Low Hydraulic Fluid Levels: Insufficient fluid can impair the operation of the travel motor.
     
   • Contaminated Hydraulic Fluid: Dirt or debris in the fluid can cause internal damage to the motor.
     
   Solution: Regularly check and replace hydraulic fluid, and inspect the final drive for signs of wear or damage.
   
3. Electrical System Failures
   Electrical issues can affect various components, including the starter motor, alternator, and control systems. Common problems include:
   • Corroded Battery Terminals: Corrosion can impede electrical flow, leading to starting issues.
     
   • Faulty Wiring: Worn or damaged wires can cause intermittent electrical failures.
     
   • Defective Sensors: Sensors that monitor engine and hydraulic system parameters can fail, leading to incorrect readings or system shutdowns.
     
   Solution: Regular inspection and cleaning of electrical connections, along with timely replacement of faulty components, can mitigate these issues.
   
4. Undercarriage Wear
   The undercarriage, comprising tracks, rollers, and sprockets, is subject to significant wear, especially in challenging operating conditions. Excessive wear can lead to:
   • Uneven Track Tension: Uneven wear can cause tracks to become misaligned.
     
   • Increased Fuel Consumption: Worn components can increase rolling resistance, leading to higher fuel usage.
     
   • Reduced Stability: A compromised undercarriage can affect the machine's stability and safety.
     
   Solution: Regular inspection and maintenance of the undercarriage, including timely replacement of worn components, are essential for optimal performance.
   

Maintenance Tips

• Regular Fluid Checks: Monitor hydraulic fluid levels and quality, and replace filters as per the manufacturer's recommendations.
  
• Scheduled Inspections: Conduct routine inspections of the engine, hydraulic system, and undercarriage to identify potential issues early.
  
• Use OEM Parts: Whenever possible, use original equipment manufacturer (OEM) parts for replacements to ensure compatibility and reliability.
  
• Operator Training: Ensure that operators are trained in the proper use and maintenance of the excavator to prevent misuse and premature wear.
  

Conclusion
The Hitachi EX100-2 excavator, with its robust design and reliable performance, remains a valuable asset in various construction applications. By adhering to regular maintenance schedules and promptly addressing any issues, operators can ensure the longevity and efficiency of the machine. Understanding common problems and their solutions is key to maximizing the EX100-2's operational lifespan and minimizing downtime.