Hitachi EX35-2 Starting Issues and Troubleshooting

[MikePhua]

The Hitachi EX35-2 mini excavator is a versatile machine designed for use in a variety of construction and landscaping projects. However, like all machinery, it can experience starting issues that may disrupt operations. When an excavator like the EX35-2 refuses to start, it can be due to several factors ranging from simple electrical faults to more complex engine problems. This article will explore common starting issues faced by owners of the Hitachi EX35-2 and provide solutions to help troubleshoot and fix the problem.
Common Causes of Starting Problems in the Hitachi EX35-2
Starting issues in excavators like the Hitachi EX35-2 can stem from a variety of sources. Here are some of the most common causes:
1. Battery Problems
The first thing to check when an excavator won't start is the battery. A weak or dead battery is one of the most common reasons for starting failure. Batteries can lose charge over time, especially in colder weather, or if the machine has been idle for long periods.
Possible Issues:

• Battery voltage too low to crank the engine
  
• Corroded battery terminals or loose connections
  
• Faulty or damaged battery cables
  

Solution:

• Check the battery charge and ensure it's at the proper voltage (usually around 12 volts).
  
• Inspect and clean the battery terminals to ensure a secure connection.
  
• If the battery is old or damaged, consider replacing it with a new one.
  

2. Starter Motor and Solenoid Issues
The starter motor is responsible for turning over the engine. If the starter motor fails or the solenoid doesn't engage properly, the engine won’t start. This can happen due to wear and tear or issues with the electrical system.
Possible Issues:

• Faulty starter motor
  
• Damaged or faulty solenoid
  
• Loose or corroded starter wiring connections
  

Solution:

• Test the starter motor by bypassing the ignition switch to ensure it's functioning properly.
  
• Check the solenoid for continuity using a multimeter.
  
• Tighten or replace any loose or corroded wiring connections.
  

3. Fuel System Problems
A lack of fuel or a problem in the fuel delivery system can prevent the engine from starting. Common issues include a clogged fuel filter, air in the fuel lines, or a faulty fuel pump.
Possible Issues:

• Empty or low fuel tank
  
• Clogged or dirty fuel filter
  
• Faulty fuel pump
  
• Air in the fuel lines
  

Solution:

• Ensure there’s enough fuel in the tank.
  
• Replace or clean the fuel filter if it’s clogged.
  
• Check the fuel pump for functionality, and replace it if necessary.
  
• Bleed the fuel lines to remove any air and ensure smooth fuel delivery.
  

4. Electrical System and Fuses
The electrical system is vital to the starting process. A blown fuse or faulty wiring can cause electrical failures that prevent the machine from starting. In some cases, a malfunctioning relay can also prevent the proper flow of current to the starter motor or fuel system.
Possible Issues:

• Blown fuses or relays
  
• Faulty ignition switch
  
• Malfunctioning wiring or connections
  

Solution:

• Inspect the fuses and relays for any visible signs of damage or wear. Replace any blown fuses.
  
• Test the ignition switch to ensure it’s working properly.
  
• Check all wiring for signs of fraying or corrosion. Repair or replace damaged wires.
  

5. Glow Plugs and Cold Weather
If you are trying to start the Hitachi EX35-2 in cold weather, issues with the glow plugs can prevent the engine from starting. The glow plugs help warm the engine to a temperature that makes starting easier, especially in colder climates.
Possible Issues:

• Faulty or worn-out glow plugs
  
• Cold weather causing poor fuel ignition
  

Solution:

• Test the glow plugs with a multimeter to ensure they are heating up properly.
  
• Replace any faulty glow plugs.
  
• If cold weather is a consistent issue, consider using a block heater to help warm the engine before starting.
  

6. Engine or Compression Problems
In some cases, the problem could be more serious, such as engine damage or low compression. Low compression can prevent the engine from firing up properly and can result from worn-out piston rings or a faulty valve.
Possible Issues:

• Low compression due to worn engine components
  
• Damaged valve seals or pistons
  

Solution:

• Perform a compression test to check the engine's health.
  
• If compression is low, an engine overhaul may be necessary.
  
• Repair or replace worn-out parts as needed.
  

Troubleshooting Tips
When troubleshooting a starting issue with the Hitachi EX35-2, following a systematic approach can save time and help you pinpoint the problem more quickly. Here are some helpful troubleshooting steps:
Step 1: Check the Battery and Connections
Start with the basics by checking the battery charge and ensuring the terminals are clean and securely connected. A multimeter can be used to measure the voltage at the battery. If the voltage is below 12 volts, charge the battery or replace it if it’s old or damaged.
Step 2: Inspect the Fuel System
If the battery is in good condition, move on to checking the fuel system. Ensure the tank has enough fuel and inspect the fuel filter for clogs. If necessary, replace the fuel filter and check the fuel pump to ensure it’s delivering fuel properly to the engine.
Step 3: Examine the Starter Motor and Solenoid
If the engine still won’t start, inspect the starter motor and solenoid. Test the starter by bypassing the ignition switch. If the starter doesn’t engage, you may need to replace it or the solenoid.
Step 4: Check the Electrical System
Inspect fuses, relays, and wiring in the electrical system. A blown fuse or faulty relay can prevent the electrical components from receiving power. Replace any faulty parts and ensure the wiring is intact.
Step 5: Test the Glow Plugs
For cold weather issues, check the glow plugs. If the engine is cranking but not firing, faulty glow plugs could be the cause. Test the glow plugs for continuity and replace any that are not functioning properly.
Conclusion
Starting issues in the Hitachi EX35-2 can be frustrating, but with the right knowledge and a systematic approach to troubleshooting, most problems can be identified and resolved quickly. Whether the issue is a dead battery, faulty starter motor, or clogged fuel system, taking the time to check the machine’s key components will help get your excavator back up and running smoothly. Regular maintenance and inspections are essential to prevent future issues and extend the life of your equipment.