Hi All, i could do with yet more advice on my father in laws ex60-2. i am doing my best to solve a number of electrical problems that have occured. the latest is after replacing the alternator and double checking that it is charging at 27.6 - 28 volts the battery light continues to be illuminated in the cab. the alt is definitely charging and if i connect a bulb in separate to the circuit this will light when ignition switched on and the go out as soon as engine running, however the light in the cab remains illuminated? the machine has worked around 5000 hrs and is good and tight, i am just concerned with the number of electrical issues, were the ex60-2 a good machine and ok or were they a problematic machine, when i was looking to buy one, i only heard good things about the reliabilty and build quality of all hitachi excavators, nothing bad at all, am i just a little unlucky at moment. any hepl very much appreciated
Don't we just love electrical gremlins.........not. Anyway I am having a few issues with my little ASV track loader, one of them seems to be that the battery is not getting charged. The alternator puts out 14v but there is not 14v at the battery, the way this machine is set up, it runs through a diode in the fuse box, 14v going into the diode but 12v going out, this may be the way it is supposed to be? A bit of creative wiring has now ensure that there is 14v going into the battery, will see what happens. Far as your issue goes, measure the voltage at the battery, measure the voltage at the light and see what the go is. I can only assume that your wiring is similar to my ASV, insofar as there are two circuits from the alternator, one feeds the battery and the other runs through the diode, however there are two wires running back into the in cab display http://www.compactpowercenter.com/media/pdf/manuals/ASV/RC-30/rc30-electrical schematic.pdf one from before the diode and one after, so that confuses me somewhat. This may be of help HeavyEquipmentForums Another possibility is that there is a short in the charging warning light circuit.
Does the hour meter work, does it read hour for hour? Also, does the battery relay work correctly, when you shut off the machine does it take approx. 3-4 second before the relay clicks off or does it click off imediately?
thank you for the quick response Hendrik and excavator. in response to Hendrik there is definitely a diode in the circuit, so possibly that is my problem. in response to Excavator. i believe the relay clicks off immediately but will check for sure tomorrow. the other strange thing since replacing the alternator is the machine now turns off with the key, prior to fitting the new alternator and making good all the corroded and damaged fusible links it would only stop if you pulled the manual stop under the seat.
If you have corrosion at the links, check your harness connections too. Corrosion will act like a resistor and cause all kinds of charging problems, if is just a poor connection and not an open one. I recommend using a multimetter and checking wires at each connection as some of the molded plugs will hide a bad connection. Good luck.
full story and as much info as i can remember ok thanks for all the suggestions. i am still having problems, the machine is 125 miles away so it's a 250 mile round trip to try something and then get back in time to type up the developments firstly my father in law has owned the machine for about year in all this time the machine has functioned fine to the best of my knowledge. stopping the machine has always been with the manual stop uner the seat, is this correct??? or should it stop by switching the machine off at the key?? it is an ex60-2 landy 24volt system. for about the last 3months the batteries had been goin flat while the machine was in use after about 30-40 mins, battery light would come on and sometimes machine would go into limp mode. so i did my research on the forum, applied some logic and common sense and decided the old girl could probably do with a new alternator. the batteries were not the best so i decided to treat her to two new batts as well. previous owner clearly did little or no maintenance as the connections etc were all very badly corroded. anyway firstly i cleaned all connections replaced fusible links and put on two new quality batteries, all good and machine start and runs fine. next after having alternator tested and told it has a weak and intermittent out put, i purchased a new alternator, pattern type not genuine Hitachi, it did have the important terminal which acts i am told as a rev counter signal. so i fitted alternator and much to my frustration the battery warning lamp is on and the alternator is not charging, however the machine turns off at the key, worse however is the fact that the air intake system is on constantly, the only way to stop it is to disconnect at the solenoid inside the rear door. any way towards the end of the day and raining hard, decide to remove new alternator have tested and return the following week. during removal of alternator forgot the golden rule and shorted alternator battery positive against chassis causing fuse link to blow :Banghead Returned to digger today with fully tested alternator that thankfully was undamaged, fitted alternator and started her up, battery light on and no charging voltage from batt positive terminal on alternator, air intake heat system on constantly unless i pull solenoid connection, heat system light in cab comes on and goes off after about 5 secs but QHS slenoid stays on also machine is still switching off at the key??? anyway i have checked all wiring, fuses and connections as best i can with a meter. on scouring the forums i have learned the 'T' shaped plug on the alternator has two purposes cross bar of 'T' is switched ignition feed and vertical connector is for the warning light, so to prove alternator is not faulty a competent auto electrican suggested connecting a separate lamp NOT led in the circuit by going from batt positive into lamp and other side of lamp into harness connection to lamp. when i do this the lamp lights as it should until engine running and then goes out and hey presto i have 27.8 - 28 volts from alternator and same charging voltage at the batteries. what is more the original light in the cab now goes out as well, however machine will only stop using manual stop under seat. so now i am really confused what is right or wrong and where to go, i have seen a number of diodes as refferred to earlier in the post by Hendrik, does any one no where i can buy these and possibly a couple of the green relays behind the seat?? any suggestions would be very much appreciated. i will summarise these issues in a new post i think as my brain is fried!!