INTRODUCTION TO THE READER ‘© This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine. Be sure to thoroughly read this manual for correct product information and service procedures. if you have any questions or comments regarding the contents of this manual. please contact: Technical Document Center Hitachi Construction Machinery Co. Lid. TEL: 81-298-32-7173 FAX: 81-298-31-1162 ADDITIONAL REFERENCES Please refer to the materials listed below in addition to this manual. “The Operator's Manual ‘The Parts Catalog + Operation Manual of the Engine Parts Catalog of the Engine + Hitachi Training Material MANUAL COMPOSITION © This manual consists of two portions: the T/M (Technical Manual) portion and the W/M (Workshop Manual) portion. At the beginning of each section, a tab fixed separator is inserted to help in opening sections needed. Green tabs are used for the sections in the T/M portion and yellow tabs for those in the WIM portion. Information included in the T/M portion: technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and ‘troubleshooting procedures. Information included in the W/M portion: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removai/installation and assemble/disassemble procedures. PAGE NUMBER © Each page has a number, located on the center lower part of the page, and each number contains the following information: Example: T 01-03-05 '—> Group Number ‘———* Section Number T: Technical Manual ‘Consecutive Page Number for Each Group W: Workshop Manual IN-O1INTRODUCTION SAFETY ALERT SYMBOL AND HEAD- LINE NOTATIONS In this manual, the following safety alert symbol and signal words are used to alert the reader to the poten- tial for personal injury or machine damage. AA Tris is the safety alert symbol. When you see this symbol, be alert to the potential for personal in- jury. Never fail to follow the safety instructions prescribed along with the safety alert symbol The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropri- ate lifting techniques and equipment when lifting heavy parts. « & cauTion: incicates a potentially hazardous situation which could, if not avoided, result in personal injury or death. © IMPORTANT: indicates a situation which, if not avoided, could result in damage to the machine. © NOTE: indicates supplementary technical informa- tion or know-how. UNITS USED ‘¢ SI Units (International System of Units) are used in this manual MKSA system units and English units are also indi- cated in parentheses just behind SI units. Example: 24.5 MPa (250 kgf/cm’, 3 560 psi) A table for conversion from Si units to other system units is shown below for reference purposes. To Convert Multiply To Convert Multiply Quantity | From Into By Quantity | From Into By mim in. 0039 37, a MPa Kate” [70.197 ae mm ft 0,003 267 Pressure MPa psi [745.0 L US gal_| 0.2642 Tower kW. PS) 1.360, Volume cE US gt 7.057 kW. HP. 1.341 ria iF 7,308 [[Temperature [°C SF [0x1 Bae Weight iq ib 2.205 Velocity Tn moh 1621 4 Force N kf 0.101 97, min tpm. 1.0 N To (0.2248 || Flow rate Lin | “US qom | 0.2642 Torque Nem kgf 4.0197 mUjrev_| — ccjrev 1.0. Nem Toff 0.7375 IN-02SAFETY FOLLOW SAFE PROCEDURES © Safety First This safety-alert symbol AM warns you of the potential for personal injury. Be sure to take all recommended precautions seriously and follow safe operating procedures and practices, Be sure to thoroughly read, understand and comply with the safety precautions of this manual and of the ‘operator's manual. sx003 PRECAUTIONS FOR SERVICE WORK © Prepare for Emergencies + Be prepared if a fire starts or if an accident occurs. © Wear Protective Clothing Wear close fitting clothing and safe equipment appropriate for the job. Do not wear a necktie, scart, loose clothing, or eckiace when you work near machine tools or moving parts. If these items get caught in the machine, severe injury could result. “Remove rings and other jewelry, to help avoid electrical shocks and entanglement in moving parts, © Protect Against Noise Prolonged exposure to loud noise can cause impairment or loss of hearing, Wear a suitable hearing protective device, such as earmuffs or earplugs, to protect against constant or uncomfortably loud noise. Protect Against Flying Debris Flying pieces of metal or debris are very dangerous, and can cause serious personal injury. + Be sure to wear goggles or safety glasses before performing any service work in which flying pleces of metal or debris are anticipated, especially before removing/installing pins. SA-01SAFETY PREPARATIONS FOR SERVICE WORK Before working on the machine: Park the machine on a firm, level surface. + Lower the bucket to the ground Run the engine at slow idle without load for 3 minutes. Tum the key switch to the OFF position to stop the a engine. Remove the key ffom the switch. Pull the pilot control shut-off lever to the LOCK position. Allow the engine to cool down. ¢ Warn Others of Service Work Unexpected machine movement can result in serious injury. Before performing any work on the excavator, attach a clearly visible “Do Not Operate” tag on the control levers andjor on the cab door. snows ‘© Support the Machine Properly “Always lower the attachment or implement to the ground before you work on the machine. I you must work on a lifted machine or a raised attachment, be sure to securely support the machine or the attachment, using the provided cylinder supports or solid wooden blocks. If the machine must be jack-up, Keep a 90 to 110° angle between the boom and arm. If you must park the machine on a slope, take the following measures in addition to the ordinary parking procedure: Before servicing the travel system Block both tracks and lower the bucket to the ground, thrusting the bucket teeth into the ground, as shown. Before servicing the swing system s Position the front attachment down the slope’ and lower the blade and bucket to the ground, thrusting the bucket teeth and blade into the ground, as shown, so as to prevent the upperstructure from swinging downhill unexpectedly. SA-02SAFETY PRACTICE SAFE MAINTENANCE © Fully understand the procedures of the service to be e done before starting work. Also, make sure that your co-workers understand the service procedures as welt ¢ Prepare and Clean the Work Area Select a firm, level surface, protected trom wind and provided. shoes Before starting any service work, clean the work area. Remove any objects that may be a safety hazard to the service personal or bystanders. Remove any buildup of grease, oil, paints, or debris. ‘ Park the Machine Safely Refer to the PREPARATION FOR SERVICE WORK section on the previous page. © Beware of Exhaust Fumes Engine exhaust fumes can cause sickness or death + If you must operate inside a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes, or open doors and windows to bring enough outside air into the area. ¢@ Iluminate Work Area Safely illuminate your work area adequately but safely. Use a portable safety light for working inside or Under the machine. Make sure that the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can gy ignite spilled fuel or cr '® Allow the engine and the hydraulic oil-to cool before starting any service work. © Disconnect the battery ground cable (—) before servicing the electrical system or welding on the machine. SA-03SAFETY USE HANDHOLDS AND STEPS «Falling is one of the major causes of personal injury When getting on and off the machine, always maintain a three-point contact with the steps and handrails, and face the machine. Do not use any controls as handholds + Never jump on or off the machine. Never mount or dismount a moving machine. S | Be careful of slippery conditions on platforms, steps, and handrails when getting on or off the machine, PRECAUTIONS FOR MACHINE OPERATION @ Never lubricate or service the machine while it is moving. if a maintenance procedure must be performed with the engine running, do not leave the machine unattended, © Take precautions when operating the machine - Be sure to start the engine only while seated in the operator's seat. —_= - Always be alert for bystanders moving into the work area. Use the horn or other signal to warn bystanders before starting the engine and before moving the machine. Machines experiencing trouble may move in unexpected ways. Be sure to operate the machine slowly while observing machine movements closely. Use a signal person when backing up, if your view is obstructed. Always keep the signal person in view. sxoor + Learn the meaning of all flags, signs, and markings used on the job, and confirm who has the responsibilty fr signaling Be sure to remain seated in the operator's seat while operating the machine. ‘© Keep riders off the machine. Only allow the operator on the machine, SA-04SAFETY USE TOOLS PROPERLY 4 Use tools appropriate for the work to be done. a, Makeshift tools, parts, and procedures can create safety hazards. For loosening and tightening hardware, use the correct size tools to avoid injury caused by slipping wrenches. Use only recommended replacement part. (See the parts catalog.) sao STAY CLEAR OF MOVING PARTS. d © Entanglement in moving parts can cause serious lo injury. Never attempt to touch any moving parts with your hands. To prevent accidents, use extra care and take a necessary safety measures when working around moving parts. AVOID HIGH-PRESSURE FLUIDS @ If escaping fluid under pressure penetrates the skin, or if it is splashed into the eyes, serious personal a injury may result. “Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines. Be sure to retighten all connections before reapplying pressure. + Search for leaks with a piece of cardboard, not your hands. Protect all body parts from high pressure a fluids, Be sure to wear a face shield or goggles to protect your eyes from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed whe within a few hours or gangrene may result. SA-05SAFETY HANDLE FLUIDS SAFELY - AVOID FIRES ‘© Handle fuel with care; it is highly flammable. Also, be sure to handle fiammable lubricants safely. Do not smoke while refueling the machine. Do not refuel near open flame or sparks. Always stop the engine before refueling the ‘machine, Fill the fuel tank outdoors. + Store flammable fluids well away from fire hazards. Make sure the machine is clean of trash, grease, and debris. Do not store oily rags; they can ignite and burn spontaneously. sacte HANDLE BATTERIES SAFELY © Prevent battery explosions. Keep sparks, lighted matches, and flame away from the top of battery. Battery gas can explode. Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer. Do not attempt to charge a frozen battery; it may explode. Warm the battery to 16 °C (60 F°) first. Sulfuric acid in battery electrolyte is poisonous. Fil batteries in a well-ventilated area. Wear eye protection and rubber gloves. ‘Avoid breathing fumes when adding electrolyte. Avoid spilling or dripping electrolyte, ‘© Follow proper jump start procedures. Refer to the jump start section of the Operator's Manual. SA-06SAFETY SERVICE COOLING SYSTEM SAFELY ‘© Explosive release of fluids from the pressurized cooling system can cause serious burns. ~ Always run the engine at slow idle for a few minutes before shutting off the engine. Only remove the radiator cap when it is cool enough to touch with the bare hands. + Be sure to loosen the radiator cap to release system pressure before removing it. REMOVE PAINT BEFORE WELDING OR HEATING ‘# Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all welding or heating work outside or in a well ventilated area. Dispose of paint and solvent property. Avoid potentially toxic fumes and dust. ‘@ Remove paint before welding or heating + If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. aaa Hf you use solvent or paint stripper, remove stripper with soap and water before welding, Remove solvent or paint stripper container and other flammable material from area. Allow fumes to disperse for at least 15 minutes before welding or heating AVOID HEATING NEAR PRESSURIZED FLUID LINES © Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. © Do not heat by welding, soldering, or using a torch near pressurized fiuid lines or other flammable materials. © Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire-resistant guards to protect hoses or other materials. SA-07SAFETY USE PROPER LIFTING EQUIPMENT © Lifting heavy components incorrectly can result in severe injury or machine damage. Refer to the component weights listed in this manual before lifting heavy components. When using a crane, confirm that the lifting capacity of the crane and hoisting accessories to be used ate appropriate for the work to be done, and that the crane is maintained in good condition. DISPOSE OF FLUIDS PROPERLY «Improper disposal of fluids can harm the environment and the ecology. Use proper containers when draining fluids. DO NOT pour oil into the ground, down a drain, or into a stream, pond, or lake, © Observe all relevant environmental protection regulations when disposing of oil, fuel, coolant, brake fluid, fiters, batteries, and other harmful waste. REPLACE SAFETY SIGNS © Maintain all safety signs, so that they are intact and legible. Replace any missing safety signs. + If safety signs are damaged, replace them with new ones. See the machine Operator's Manual for correct safety sign placement. A009 BEFORE RETURNING THE MACHINE TO THE CUSTOMER Alter maintenance or repair work is complete, confirm that: The machine is functioning properly, especially the safety systems. Worn or damaged parts have been repaired or replaced SA-08Ex2008 SECTION 01 SPECIFICATIONS CONTENTS, Group 01- General Information Group 03- Interchangeability Foreword... eeeececcceeseeses TO1-01-01 Interchangeability sees. TO1-03-01 ‘Specifications To1-01-02 Installation of Attachments... To1-03-02 Working Ranges Transportation «2.2... 01-01-03 Group 04- Machine Numbers ‘Shoe Types and Applications ..., 01-01-04 Machine Numbers - T01-04-01 Weight sevsese TO1-01-06 Group 05- Components Specifications Group 02- Fuels and Lubricants Engine ....... . 701-05-01 Service Refill Capacities ......... T01-02-01 Engine Accessories =. T01-05-04 FUG eee ececeeeeeeseeceeees TO102-01 Hydraulic Devices TO1-05-04 Greasing 2... To1-02-02 Electrical Equipment. T01-05-06 Engine Ol... eeeceeeeceeseeess T01-02-08 Gear Oil secseses TO1-02-04 Hydraulic System .............., T01-02-05 Cooling System 2... seeeeee. TO1-02-06 1377-01-01Ex2003 137T-01-02SPECIFICATIONS / General Information FOREWORD The hydraulic excavator consists of three main ‘components. They are the FRONT ATTACHMENT, UPPERSTRUCTURE and UNDERCARRIAGE. Z ~~ = 1 Bucket Cylinder 7 Cab 13— Main Pump 18— Travel Device 2— Arm cylinder 14— Engine 19— Swing Bearing 3~ Boom Cylinder 15— Radiator 20— Center Joint 4— Boom 18— OllCooler 21~ Shoes 6— Arm 11— Hydraulic O1| Tank 17— Battery 22— Upper Roller 6— Bucket 42— Main Control Valve 23— Lower Roller 24— Track Adjuster 25~ Front Idler T01-01-01SPECIFICATIONS / General Information SPECIFICATIONS Mode! 1EX200-3 Hydraulic Excavator EX200LC.s Hydraulic Excavator ‘Arm Length 291 m(9 ft7 in) Arm Bucket Capacity (Heaped) PCSA0.8 m(1.05 ye), CECEO.7 m Operating Weight 18500 kg (40 800 Ib) 19.000 kg (41 900 Ib) Basic Machine Weight 15000 kg (33 100 Ib) 15500 kg (34200 Ib) Engine 99 kW (135 PS) | 2050 min (tpm) ‘A: Overall Width 2850 mm(9 ft4 in) 2990 mm(9f70 in) (Excluding back mirrors) B: Cab Height 2850 mm(9 f4 in) (C: Rear End Swing Radius 2750 mm(9 RO in) D: Minimum Ground Clearance ‘450 mm (18 in) (Excluding shoe lug) E: Counterweight Clearance 1.030 mm (3 tS in) (Excluding shoe lug) F: Engine Cover Height G: Overall Width of Upperstructure 2110 mm(7 RO in) 2660 mm( (Excluding shoe lug) @ ft9 in) H: Undercarriage Length 4170 mm (143 #8 in) 4460 mm (14 118 in) I: Undercarriage Width 2800 mm(9 ft2 in) 2990 mm(9 ft10 in) ‘J: Sprocket Center to Idler Center 3370 mm (11 1 in) ‘3660 mm (12 0 in) K:_ Track Shoe Width ‘600 mm (24 in) (Grouser shoe) Ground Pressure ‘41 kPa (0.42 kgtfom®, 6.0 psi) 39 _kPa (0.40 kgtlom®, 5.7 psi) ‘Swing Speed 41.0 min= (rpm) Travel Speed (fast/medium/siow) 5.7/3.7/2.2 kmjh (3.5/2.3/1.4 mph) Gradeability 35° (tan0=0.70) ‘Arm Digging Force: 89 kN (9 100 kgf) Bucket Digging Force 113 KN(AT ‘500 kgf) NOTE: The dimensions do not include the height of the shoe lug. T01-01-02SPECIFICATIONS / General Information WORKING RANGES - TRANSPORTATION Backhoe usoraseoe Face shovel noraaoa (Reversed hoe bucket) Working Range (EX200-s, EX200LC-3) 2.22 m(7 ft in) Arm 2.91 m(9 ft7 in) Arm — Category | aackhoe Shovel Backhoe Shovel mm | tin | mm | tin | mm | tin | mm | fein ‘A: Maximum Digging Reach 9.250] 30'4*| 9390| 3010") 9910] 32'6"| 10060] 33'0” 8: Maximum Digging Depth *5 980] *19'0"| “6 120| *20'0"| *6670"21' 11"| *6 820] 22'5" C: Maximum Cutting Height *9 170 *30'0"| *9.450) *31'0"| *9.600| *31'6"| 9.850] *32'4" D: Maximum Dumping Height 6 390| *21'0"| *6 290] *20'8"| *6 780] *22'3"| *6720| *22'1" E: Transport Height 3030] 9'11*] 3030] 9'11"| 2890] 9'6"| 2890] 9'6" F: Overall Transport Length 9.560] 31°4"| 9560] 3174"| 9490] 3172"| 9490] 31'2” G: Minimum Swing Radius 3530] 11°7"| 3530] 11'7"| 3540] 11°7"| 3540] 11'7" NOTE: * The dimensions do not include the height of the shoe lug. T01-01-03SPECIFICATIONS / General Information SHOE TYPES AND APPLICATIONS ex2003 [600 mm (24") ]700 mm (28") [200 mm ¢31~) [600 mm (24")] 900 mm (35") | B00 mm (24°) sroewitn (Re 2 eos Saran Sue rn ren Se [eee mons rena Favors] Fore | Forweok | ForPare | Forweax | ForPaod Sea | oot | tno | Cron | conen | cron Gpairawaon va} veo | osm | sexo] 1oso0 | veamo | — rea | casey | cen | deton | deem | asso | ermn | catty | acecy | aim | cern | ean | asa Cont wm | 2050 | 20m | ao] em | 200 | — 2000 (ftin) (4") (4") v4") 94") 97") 5") w|i [we | ee | | oe |e a doen | aay | asen [aoe | asm | cow tml en | om | om | om | we | on (0.42 kgtfom®, |(0.37 kgficm”, |(0.33 kgtiem®, (0.44 kgi/em?, | (0.31 kgtfcm’, | (0.43 kgt/cm’, col es el cr ones ees no ee NOTE (1) The spectoton fr fortond a (9) Te dimension do rt nde te tachment are for 2.22 m(7 t3 in) height of the shoe lug. arm or 2.91 m(9 ft7 in) arm with PCSA 0.8 m? (1.05 yo? ) bucket. (2) 700, 800 mm ( 28, 31 in ) grouser ‘shoe, 600 mm (24 in) flat shoe and 900mm ( 35 in ) triangular shoe should not be used on gravel or rocky ground. T01-01-04Pp SPECIFICATIONS / General Information EX200LC-3 ror eco man ooo may] 7 [600 mm (24")|700 mm (28") [800 mm (31°) }600 mm (24")} 800 mm (35*) | 808 mm (24°) eee lGrouser Shoe |Grouser Shoe Grouser Shoe} Flat Shoe Triangular Shoe | Shoo” ov" ‘Application For Ordinary | ForWeak | ForWeak | ForPaved | ForWeak | For Paved Ground | Footing | Footing Road Footing Road (Standard) | (Option) | (Option) | (Option) (Option) (Option) ‘Operating Weight xg | 19.000 19400 19700 20.000 20 500 19.400 ty) | (41900) | (42800) | (43.400) | 44 100) (45 200) (42 £00) Basic Machine Weight kg | 15500 15900 16 100 16.400 16900 15.900 (tb) | (4200) | (95100) | 5500) | (6200) (37 300) (35 100) ‘Cab Height mm | 2850 2850 2850 2860 2920 2.880 (fein) | 4") oa") er) ee) e7") 5") Minimun Ground 450 450 94450 2490 450 500 Clearance (em | (18") (18*) (18°) a9") (8) as") Undercarriage mm | 4480 4460 4460 4480 4570 4820 Length (fein) | 148") (148) cae) | ase wait (14:10") Undercariage Wicth mm | 2990 3080 3190 2900 3290 2990 fein) | 14") (102) (106) ee") (100°) (oa) Ground Pressure sokPa | 34kPa | goKPa | 41 kPa 28 KPa 40 KPa (0.40 kgtlem?, (0.95 katfom?, |(0.31 kgtfem?, (0.42 katlem?,| (0.29 kgticm?, | (0.44 katfom?, 57 psi) | 50psi) | 44ps) | 6.0ps) 4.1 psi) 5.8 psi) NOTE: (1) The specifications for the front-end at- (8) 3% The dimensions do not include the tachment are for 2.22 m(7 ft3 in} height of the shoe lug arm or 2.91 m(9 ft7 in) arm with PCSA 0.8 m® (1.05 yd!) bucket. (2) 700, 800 mm (28 f31_ in) grouser shoe, 600 mm ( 24 in) flat shoe and 900mm ( 35 in ) trlangular shoe should not be used on gravel or rocky ground. 01-01-05SPECIFICATIONS / General Information WEIGHT nit kg Model EX2003 EX200LC-5 Applicable Serial No. 14C-78001— 1140-78001 — Upperstructure 7580 (16 710) < Main Frame 1.340 (2 955) = Engine Assembly 575 (1270) = ‘Main Pump Assembly 140 (310) = Main control valve 180 (395) - Swing Device 230 (608) < Hydraulic Oil Tank 100 (220) < Fuel Tank 85 (185) = Counter Weight 3.900 (6 600) < Cab 230 (605) < Undercarriage 3.980 (8 755) 4 280 (9 440) Track Frame 2.020 (4 455) 2 250 (4 960) ‘Swing Baring 220 (485) = Travel Device 315 (695)%2 - Center Joint 25 (55) < Track Adjuster 100 (220)x2 < Front Idier 140 (245)%2 < Upper Roller 20 (46)x4 < Lower Roller 35 (75)*14 35 (75)*16 Track-link Assembly (600 mm Grouser shoe ) 1.300 (2 865)x2 1 385 (3 055)x2 Feameeean Ses woe 251 mA | sees - 5.68 m Boom 1 265 (2790) - 2.91 mAnm 585 (1 290) = 2.22 m Arm 500 (1105) < 0.8 m? Bucket (POSA heaped ) 640 (1 410) = Boom Cylinder 170 (975)>2 < ‘Arm Cylinder 255 (560) < Bucket Cylinder 135 (300) < Bucket Link A 70 (155) - an Right Side 15 (85) < Left Side 20 (45) = T01-01-06B SPECIFICATIONS / Fuels and Lubricants SERVICE REFILL CAPACITIES Description liters US gal Reference Fuel Tank 310 82 Engine Coolant 21 55 Engine Oil 25 66 Pump Transmission 4.0 |(1.1 USat) ‘Swing Reduction Gears 82 22 Travel Reduction Gears 552 1.52 Hydraulic System 200 528 Hydraulic Oil Tank 130 34.3 ‘Swing Gear 8 2A : 7 Engine Oil SAE No.30 Front Idier 0.265% 2 | 0.070x2 {cD Glass) Upper Roller 0854 | 0.022%4 t Ex2003 | 0.27014 | 0.07114 t Lower Roller Ex200LCs | 027016 | 0.07116 t FUEL Tank capacity 310 iters (82 US gal) Interval (hours) sooo uantiy [aso [0 | 250 | 500] 1000 [2000 1__Drain Fuel Tank Sump 1 eal 2._Check Water Separator 1 Bae 3._Replace Fuel Filter 1 ae 4. Clean Feed Pump Strainer 1 See Recommended Fuel Use high quality DIESEL FUEL only (JIS K-2204) (ASTM 2D). Kerosene must NOT be used, IMPORTANT: Be careful not to allow dust, dirt, water of other foreign materials into the fuel system. 01-02-01SPECIFICATIONS / Fuels and Lubricants GREASING Interval (hours) Parts Quantity [50 | 100 | 250 | 500 | 1.000 | 2000 Boom Pr reer Front Joint] Boom Guinier i ee Bottom En lee Bucket ard Link a Oihers 7 FP ~ ee 2 Swing Beanng 2 Ea ‘Swing Internal Gear 1 Le Where to be applied Manufacturer Hitachi Genuine Caltex Oil Mobil Oil ‘Shell OF NOTE: The machine Brand Names of Recommended Grease British Petroleum “Esso Tdemitsu Kosan ‘Nippon Of | %* Grease every 8 hours for first 100 hours +k Maintenance required when operating in water or mud. Bucket, Arm and Boom, Swing Gear, Swing Bearing, ete. =20 10.40 °C ( —410 104 °F) Doubrex. HK* Multifax, EP2 M107-07-074 Beacon, EP2. Daphne Coronex Grease _EP2 Mobilux_ EP2 Epinoc Grease AP2 Shell Alvaria z EP Grease shipped from the factory is filed with lubricants marked with ». T01-02-02SPECIFICATIONS / Fuels and Lubricants ENGINE OIL. interval (hours) fom Co @_] 80 | 100 | 250 | 500 [1000 | 2000 T_Engine O1_ Oi Level Check 7 a 2._Engine Oil | Change 2501 G6US ga) we 3. Engine Ol | Replacement 7 ee Main Filter oa Engine Oi | Replacement 7 ee Bypass Filter a Recommended Engine Oil Depending upon the expected air temperature range between oil changes, use the oil viscosity shown on the ‘temperature chart below. API CD Class ‘SAE 30 or equivalent (both summer and winter) High temperature areas, SAE 40 or equivalent Low temperature areas, SAE 10W or equivalent Brand Names of Recommended Engine Oi Kind of Oil Engine Oil Application | Engine Grank Case Fuet Injection Pump and ji Governor ir emp: | —20100°C | -10t035°C | 25t0 40°C eed (410927) | (14t095°F) | 7710 108-7) British Petroleum BP Vanellus C3 tow 30 40 Caltex Oi iPM DELO 300 Ol tow 30 40 Esso Essolube 0-3 tow 30 40 Idemitsu Kosan ‘Apol oll diesel mote $310 $-330 8-340 ~15 to 40 °C (6 to 104 °F) ‘poll oil custom wide 15W-40 Apoll oil super wide 15W-40 Mobil Oil Mobil Delvac 1310 1330 1340 Nippon Oil Hidiese! $3 -2010.95°0 (61095°F) |-1010.40°C (140 108 °F) | 10W-30 15W-40 Shell Oi Rymia zoll white pilot super tow 30 40 + The machine shipped from the factory is filled with lubricants marked with «. T01-02-03SPECIFICATIONS / Fuels and Lubricants GEAR OIL awa our) pane cua 8 50 100 | 250 | 500 | 1 000 | 2000 1. Pump sion [Dil bevel Check ~ a Change TO Litt Usa) as 2 Gag, , | Oiteve Check = = ee cre TEES WS a ae 3. Travel il Level Check = oe FeSebion __ oe change TEU eae aE Brand Names of Recommended Gear Oil Kind of Oi Application Gear oil Travel Reduction Gears ~201040 °C( —410 104 °F) Manufacturer British Petroleum —_| BP Gear oll ‘SAEQOEP Caltex Oil Universal Thuban SAE 90 Esso Esso Gear Oil 80W-90, 85W-90 Idemitsu Kosan | Apollo Gear HESO Mobil Oil Mobilube GXx90 Nippon Oil Gear Lube ‘SPO Gear Lube SPBOW-90+ (Pump) Shell Oil Shell Spirax EP90 APIGL 4 Class ‘The machine shipped from the factory i filled with olf marked Remarks Pump Transmission and Swing and (Swing andTravel) T01-02-04ao SPECIFICATIONS / Fuels and Lubricants HYDRAULIC SYSTEM interval (hours) noe Guantty [8-80] 100 [250 | 500 [1 000] S00] 000] 500 1 Check Hydrauie Of Level i Le 2_Drain Hydraulic Ol Tank Sump 1 me 3._ Change Hydraulic Oi 2001 (62.8 US gal), ul “ Suoton Filter Cleaning 7 When changing hydraulic of 3._Replace Hydraulic Tank Oi Fiter 7 o3 {Replace Pilot Oi Fiter 1 rz Brand Names of Recommended Hydraulic Oil 1% Hydraulic oil changing intervals differ according to kind of hydraulic oils used. ‘See recommended oil chart ing of ebricant Hydra 01 ‘Where tobe appied Hydra Sytem Change ew 2500 hows 1 500 Roars wiorarore vronmenia] —2070 40°C | -101040°C | -20040°C | -10040°C Manutactor? 10 104°) | (1410 104 °F) [(~410 108°F) | (1410 108°F) iderisu Kosan ne Suber [Daphne Super Pyare Labi Hvar twee Bash Poole Barren Ava6 Sate OF [Rando OF HOAs Toxaco NG. [Rando on Hes Ghewon USAING. [Ghevion AWas a InuTorae * Use proper hydraulic oll in accordance with the atmospheric temperature, MOBO loreas Shot OH Telus ORAS [fetus O48 + The machine shipped trom the factory ony Soecae ea een is filled with lubricants marked with +. Tot- 02-05,SPECIFICATIONS / Fuels and Lubricants COOLING SYSTEM Interval (Hours) Ga) Quantity 8 50 100 | 250 | 500 | 1 000 | 2000 1,_Check Coolant Level 1 co 2._Check and Adjust Fan Beit Tension 7 FAL '3._ Change Coolant 21L(5.5US gal) | Twice a year Ky “4,_Clean Radiator Core (outside) 1 Lae 3._Clean Radiator Interior 1 ‘When changing coolant 6. Clean Oil Cooler Front Screen 1 ‘2 | 4K: First time only NOTE: >; Before leaving the Hitachi factory, the cooling system is filled with a mixture of water and long-life coolant, Hitachi Genuine Long-Lite Coolant. As long as Hitachi Genuine Long-Life Coolant is used, the service intervals between changing the coolant is once every two years (in autumn), or every 4 000 hours, whichever comes first. Xe Shorten the maintenance interval when the machine is operated in dusty areas. 41. Coolant: Fill the radiator with soft, pure tap or bottled water. . Ant-rust agent: ‘Add approximately 0.42 L (0.11 US gal ) of anti-rust agent to the new coolant when the coolant is changed It is not necessary to add anti-rust agent when antifteezed is used. 3. Antifreeze: If the air temperature is expected to fall be- low 0 °C ( 32 °F), fill the cooling system with an antifreeze and soft water mix. As a general rule, the ratio of antifreeze should Tange between 30 % and 60 % as shown in the table below. If the ratio is below 30 %, the system may develop rust, and if it is above 60 % the engine may overheat. Antifreeze Mixing Table Mixing Refill capacities Air temperature ratio Antitreezes Soft water °C °F, % Tiers: US gal Titers: US gal =T 30 30 63 1.68 147; ~SC«O BB -4 25 30 63 1.66 4700) 3.88 -7 19 30 63 1.68 14700 | 3.88 -11 12 30 63 1.66 147 3.88 -15 =F 5 35 74 1.94 137 3.60 -20 | -4 40 84 2.22 126 0 333 -25 -13 45 95 2.49 116 3.05 -30 ~22 50 105 277 105 277 50 =58 60 126 3.33 84 2.22 T01-02-06% SPECIFICATIONS / Fuels and Lubricants A caution: (1) Antifreeze is poisonous; if ingested, it @) Mf anti can cause serious injury or death. Induce vomiting and get emergency for 10 to 15 @) jeeze is accidentally splashed in the eyes, flush the eyes with water utes and get emer- ‘medical attention immediately. gency medical attention. When storing antifreeze be sure to keep it in a clearly marked container (4) When storing or disposing of anti- freeze, be sure to comply with all lo- with tight closing lid. Always keep cal regulations. antifreeze out of the reach of chil- dren. T01-02-07SPECIFICATIONS / Fuels and Lubricants 01-02-08o SPECIFICATIONS / Interchangeability INTERCHANGEABILITY INTERCHANGEABILITY OF EX200-3 AND EX200.2 Interchangeable X: Exclusive A: Slight modification required nae interchangeabi lity Engine ° Pump device x The transmission has been separated Main control valve x ‘An arm-bottom pressure sensor mounting hole has been added, and two swing spool stroke adjusters have been added. ‘Swing device x The swing motor has been Upperstructure changed. Front attachment pilot vaive A The different types of return springs have been consolidated into a single type of spring. Travel pilot valve ° Front attachment shockless valve x ‘An boom-pilot pressure sensor mounting hole has been added. Travel shockiess valve x Joined with the travel shuttle valve. Travel device x Interchangeable with that of the X.2, only when both the right and left travel devices are replaced at the same time. ‘Swing bearing ° Undercarriage | Center joint ° Track adjuster ° Front idler ° Upper roller ° Lower roller ° Track link assembly ° Boom ° Arm ° Front attachment | Bucket ° Boom cylinder ° ‘Arm cylinder ° Bucket oylinder ° T01-03-01SPECIFICATIONS / Interchangeability INSTALLATION OF ATTACHMENTS Reference dimensions are for installation of buckets other than those produced by Hitachi. Attachments that meet the basic dimensions can be mounted on machine. Hitachi cannot be held responsible for any damage or problems encountered when any attachment other than those produced by Hitachi is installed on machine, HS fet NOTE: 1 mm=0.039 37 in SECTIONA SECTIONS Unt E2005 ExX2002 EX2007 a 450) = = b 0 = < € 604, = 600 d 580 = S e t 7460 = a 433 = = fh 326 = 324 7 20 SI = i a5 = #70. K 3 = 43 1 452 < 233 m 307 SS S a 30 = = © 37 = 20" 2 ar = 20" a 449 = = T01-03-02a SPECIFICATIONS / Machine Numbers MACHINE NUMBERS MACHINE TYPE AND SERIAL NUMBER Tyre: 5 MFG. NO. LLL LG) ENGINE TYPE AND SERIAL NUMBER TYPE: MEG. NO, TRAVEL MOTOR TYPE AND SERIAL NUMBER, TYPE: MFG. NO. SWING MOTOR TYPE AND SERIAL NUMBER, TYPE: MFG. NO, TO1-04-01SPECIFICATIONS / Machine Numbers HYDRAULIC PUMP TYPE AND SERIAL NUMBER TYPE: MFG. NO. T01-04-02SPECIFICATIONS / Components ENGINE MAIN SPECIFICATIONS Model Type Cyl. No.-bore * stroke Piston displacement Rated output Compression ratio Dry weight Firing order Rotation direction COOLING SYSTEM Cooling fan Fan pulley ratio Thermostat {under atmosphere prossur) Water pump LUBRICATION SYSTEM Lubrication pump type ...... Oil fiter Oilcooler STARTING SYSTEM Motor Voltage - Output... PRE-HEAT SYSTEM Heating method ENGINE STOP SYSTEM ‘Stop method ALTERNATOR Type .. Voltage utp ‘SUPERCHARGING SYSTEM Type : FUEL SYSTEM Injection pump model Governor .......... Injection nozzle ISUZU 6BD1TPJ Diesel 4 cycle, vertical, 6-cylinder inline, water-cooled, direct injection type 6-102 mmxt18 mm 5785 cm? 99.3 kW } 2050 min-' (135 PS / 2050 rpm) 175 467 kg 1-5-3-6-2-4 Clockwise (viewed from fan side) Dia. 600 mm, 8 blades, draw-in type Engine rpm «0.97 Cracking temp.: 82 °C Full open temp.: 95. °C Centrifugal type, bett driven Gear pump Full-flow paper element type with bypass function Water-cooled, builtin Magnetic pinion shift system, reduction type 24-45 kW Glow plug Fuel cut AC type (with regulator) 24-30 A Exhaust-gas-turbo type Bosch A type Centrifugal all speed control RSV Muttihole nozzle T01-05-01SPECIFICATIONS / Components PERFORMANCE Lubrication oil consumption .... Less than 50 mU/h (New engine, at rated horsepower) Fuel consumption ratio. ........... Less than 231 g/kW'h (170 gIPSh) Injection timing .. secsese 16° before T.D.C. Rated output : 5 99.3 KW (135 PS) at 2050 min~" Max. output torque Disses 461 Nem (47 kgfm) or more at 1 600 min~* Injection pressure... ese 18.1 MPa (185 kalfom?) Cylinder compression tosses 2:94 Mpa (30 kgffom? ) at 200 min~" Valve clearance (inlet/exhaust) ........ 0.4/0.4 mm (when cool) No load min. speed ceeseses 800820 min”? No load max. speed ..... foe 221578 min? T01-05-02SPECIFICATIONS / Component Spe: ENGIN PERFORMANCE CURVE (68D1TP1) Test Conditions: 1. In conformity with JIS 01005 (Performance test method for diesel engines used for construction machinery), under standard atmospheric pressure. 2. With fan and generator. T Torque 1 + 487-470 kw PS aa 110 vo | " 0 0-| 7 | +109] my 4 7 i) eo} af | 1 | jf Horse roel Power i | 50 1 Consumption Lo Rate j++} | 0 | : 200-270 T |-250 ah 180 | | [7 L230 20. 1 107 10 2 — 140-190 — { 1 alpen gikwh ol |_| 01000 120014004600 1600 2000-2200 Engine Speed min~ (rpm) T01-05-03SPECIFICATIONS / Components ENGINE ACCESSORIES RADIATOR ASSEMBLY Type eee eeeseee Weight Weight Capacity Airtight testing pressure Cap opening pressure . BATTERY Capacity Voltage . Weight Radiator/Oil cooler tandem- type assembly 67 kg (148 Ib) Radiator Oil cooler 23.5 kg (51.8 Ib) 26 kg (57.3 Ib) 58 L(1.53 US gal) 44 L(1.16 US gal) 68.6 kPa 981 kPa (0.7 kgtlom?, 9.95 psi) (10 kgtjom?, 142 psi) 49 kPa - (0.5 kgtfcm, 7.11 psi) 96 Ah (6 hours) 120 Ah (20 hours) 12V 33 kg (72.8 Ib)x2 HYDRAULIC DEVICES MAIN PUMP. Model Type Max. flow PILOT PUMP. Model Hyoer Max. flow CONTROL VALVE Model Type eee eeeceeees Main relief pressure Overload relief pressure... 2... ‘SWING DEVICE Type . ‘SWING MOTOR Model Type ‘SWING BRAKE VALVE eee Relief pressure HPVOSTEW Variable displacement plunger pump: regulator attached type 187 L (49.4 US gai )x2 HY/ZFS Fixed displacement type gear pump 34.4 L(8.09 US gal) KVMX-25 Pilot pressure operated type (4-spool+3-spool) 34.3 Mpa (350 kgtiom?, 4977 psi) at 80 min (21.4 US gpm) 36.3 Mpa (370 kgtlom?, 5 261 psi) at 50 min (13.2 US gpm) Two-stage planetary reduction type M2xX1208, ‘Swash-plate type, fixed-displacement plunger motor Non counter balance valve type 30.9 MPa (315 katfom?, 4.479 psi) at 100. Yimin (26.4 US gpm) TO1-05-04SPECIFICATIONS / Components SWING PARKING BRAKE Type Cracking pressure for release SWING DAMPENER VALVE Normal pressure Peak pressure TRAVEL DEVICE Model Type TRAVEL MOTOR Model Type - TRAVEL BRAKE VALVE eee Relief pressure TRAVEL PARKING BRAKE Type Cracking pressure for release | CYLINDER Rod Dia Cylinder Bore Stroke Fully retracted length Plating thickness FRONT ATTACHMENT PILOT VALVE Mode! ee TRAVEL PILOT VALVE Model. ACCUMULATOR Model Type Capacity Gas intlating pressure OIL COOLER BYPASS CHECK VALVE Cracking pressure RESTRICTION VALVE Cracking pressure Muttiple-wet-plate negative type 1.27 MPa (13 kgl/om?, 18.1 psi) 34.3 Mpa (350 kgl/om?, 497 psi) 41.2 Mpa ( 420 kgffom?, 5 972 psi) HMGF33DA Three-stage planetary reduction gear HMV116EF Bent-axis type, variable displacement plunger motor Counter balance valve type 34.8 MPa (355 kgf/or’, 5 048 psi) Muttiple-wet-plate negative type 0.95 to 1.02 MPa (9.7 to 10.4 kal/em, 198 to 148 psi) Boom Arm Bucket 85 mm(3.35") 95 mm(3.74") 75 mm( 2.95") 420 mm(4.72") 130 mm(5.12") 410 mm( 4.33" ) 1221 mm(4') 1630 mm(5'4") 1060 mm(3'6") 1758 mm(5'9") 2230 mm(7'4") 1590 mm (5'3") 30 wm (1.18 pin) 30 pm (1.18 pin) 30 pm(1.18 pin) or more or more or more HvP04B, HVPO4A muro Nitrogen-gas-enclosed, bladder type 300 mL 2.4 MPa (24 kgtlem?, 341 psi) 490 kPa (5 kgflom?, 71.1 psi) atS L/min (1.32 US gpm ) 196 kPa(2 kgl/cm*, 28.4 psi) atS L/min (1.32 US gpm) T01-05-05SPECIFICATIONS / Components ELECTRICAL EQUIPMENT ENGINE OIL LEVEL SWITCH Type Normal close type, float switch ENGINE OIL PRESSURE SWITCH Type socscessees Normal close type Operating pressure range 80 to 50 kPa (0.3100.5 kgtfom, 4.27 107.11 psi) OVERHEAT SWITCH Type cecteseeseeeees Notmnal open type Activation temperature 101 °C (214 °F) COOLANT TEMPERATURE SENSOR ‘Operating temperature range .......... 500110 °C (12210 230 °F) COOLANT LEVEL SWITCH Type cecscscsee Normal close type, float switch AIR RESTRICTION SWITCH Type Normal open type Activation pressure ......... +. 6.23 kPa( 635 mmAg, 0.90 psi) FUEL SENDING UNIT Resistance value Empty: 90 9 / Full: 10 @ LOW FUEL LEVEL SWITCH Type . Normal open type, float switch ENGINE CONTROL MOTOR (EC MOTOR) Model... KPS56RM2G_ Coitresistance ......... fees BTM Operating angle 80° HORN Specifications s. 24-3 A, 11010 125 dB(A) UGHT Specifications ......... Work lights: halogen 24 V-70 W Domne light: 24 V-10 W HYDRAULIC OIL LEVEL SWITCH Type Normal close type, float switch HEATER, Model (CH235-HKA Specification DC 24 V-130 W Heating Capacity . : 14700 x 10° Jjmin (3.500 kealfmin ) Maximum air blow volume 4.5m? min (19 ft/min ) TO1-05-06x2003 UPPERSTRUCTURE SECTION 02 CONTENTS, Group 01- Layout Group 05- Control Valve Layout of Upperstructure To2-01-01 Outing oo eee 02-05-01 Main Relief System. 02-05-04 Group 02- Tank Overload Relief Valve 02-05-08 Hydraulic Oil Tank .. 02-02-01 Variable Pressure Fuel Tank 02-02-01 Compensated Valve ..... T02-05-10 Shuttle Valve T02-05-11 Group 03- Pump Device Differential Pressure Sensor 02-05-12 Outline. 02-03-01 Levers in Neutral 02-05-13 Main Pump 02-03-02 Travel or Swing Operation 02-05-15 Pilot Pump T02-03-06 Boom or Arm Operation 02-05-16 Engine Speed Sensor 02-03-06 Pressure Sensor . T02-03-06 Group 06- Pilot Valve Pump Displacement Angle Sensor 02-03-06 Outline T02-06-01 Operation 702-06-05 Group 04- Swing Device Cuiting ee eee T02-04-01 Group 07- Others ‘Swing Motor . 02-04-02 Pilot Shut-off Valve T02.07-01 Brake Valve 02-04-04 Shockless Valve 02-07-02 Swing Parking Brake 02-04-07 Accumulator 02-07-03 ‘Swing Dampener Valve To2-04-08 Solenoid Valve 02-07-04 ‘Swing Reduction Gear To2-04-10 Pump Displacement Solenoid Valves we 02-07-04 ‘Swing Dampener Valve T02-07-05 Solenoid Valve Assembly 02-07-05 Proportional Solenoid Valve .... 02-07-06 Directional Solenoid Valve T02-07-07 Reducing Valve 702-07-08 Pilot Relief Valve 7102-07-08 2 137T-02-01Ex2003, 1977-02-02UPPERSTRUCTURE / Layout LAYOUT OF THE UPPERSTRUCTURE The upperstructure consists of main frame (13), en- gine (9), fuel tank (5), hydraulic oil tank (6), hydraulic ‘components [pump device (8), control valve (4), swing device (3).etc.], operator's cab (1), and coun- terweight (12) Counterweight (12) is bolted to the rear end of main frame (13) and balances the machine. The front attachment is attached to main frame (13). 1 Operator's Cab 5~ Fuel Tank 2 Swing Bearing 6~ Hydraulic Ol Tank 3~ Swing Device 7—Muttlee 4~ Control Valve 8— Pump Devices 9 Engi 10—Radiator 11-Oil Cooler 12—Counterweight 13-Main frame 14—Battery 15-Alr Cleaner T02-01-01UPPERSTRUCTURE / Layout T02-01-02UPPERSTRUCTURE / Tank HYDRAULIC OIL TANK 1 Hydraulic O1 Tank 2- Cap 3~ Suction Filter 4 Suction Pipe 5~ Full Flow Filter 7= Hydraulic OU Level Switch 8 Pilot Return 9— Level Gauge 10- n icone FUEL TANK eo” eet poeanseaeme con g2 3 Fuel Tank 6— Level Gauge T02-02-01UPPERSTRUCTURE / Pump device OUTLINE The pump device consists of a transmission, main pump, and pilot pump. Transmission receives engine power via coupling (2), then divides and transmits the power to front pump (5), rear pump (6), and pilot pump (1). The gear ratio of the three pumps is 1:1. 1— Pilot Pump 4— Pump Displacement Angle Sensor (A Sensor) 2— Coupling 5~ Front Pump 3 Engine Speed Sensor (N'Sensor) The transmission lubricates with gear oil ‘The main pump is a variable displacement, bent-axis plunger-type pump. It consists of front pump (5) and rear pump (6), cov- ered by a housing, ‘The pilot pump is a gear-type pump. ‘Oo 6— Rear Pump '8— Pump displacement Solenoid Valve No.2 9~ Pressure Sensor ( Sensor) 7— Pump displacement Solenoid Valve No.t T02-03-01UPPERSTRUCTURE / Pump device MAIN PUMP In this manual, the assembly of the front pump and This cylinder block rotation causes the plungers to the rear pump is defined as the main pump. reciprocate in the cylinder bores, thus discharging ln each pump, the shaft is connected to the seven- hydraulic oil to the hydraulic circuit. plunger-inserted cylinder block. Thus, as the shaft rotates, the cylinder block rotates, 7 2 g a 7 g De 8 Mi & 1 ytinderBlock Rear «3 Shat 5 valve Plate — 2 hous 7— Pump Displacement Solenoid Valve No.1 4— Cylinder Block: Front 6 Plunger 8— Pump Displacement Pump Solenoid Valve No.2 02-03-0227 UPPERSTRUCTURE / Pump device Operation The engine drives cylinder block (3) via shatt (1) and plungers (2) to slide on valve plate (4). Plungers (2) move in and out of their bores in cylinder block (3) to alternatively suck, and deliver hydraulic oil. 1= Shatt 2 Plunger 3— Cylinder Block 4— Valve Plate T02-03-03UPPERSTRUCTURE / Pump device Increasing and Decreasing Main Pump Output The delivery quantity of the main pump is controlled by changing the stroke lengths of plungers (2) with servo piston (6) Servo piston (6) is jointed to valve plate (4) with pin (@). thus up and down movernent of the servo piston changes the position of vaive plate (4) Position at the maximum displacement angle As the face of rotating cylinder block (3) is held in contact with the valve plate surface, the position change of valve plate (4) results in change of the displacement angle of cylinder block (3), causing the stroke lengths of plungers (2) to change. Position at the minimum displacement angle (Allowable position) 2— Plunger 4— Valve Plate 3 Cylinder Block s- Pin 6— Servo Piston T02-03-04UPPERSTRUCTURE / Pump device Main Pump Control Circuit Various sensing signals (12) from pressure sensor (P sensor) (4), pump displacement angle sensor (A sensor) (8), engine speed sensor (N sensor) (9) are input into controller (11) Opening ar closing of pump displacement vaives. No.1 (6) and No.2 (5) regulates the position (pump displacement angle) of servo piston (7), as shown in the table below. Based on the sensing signals received, controller (11) judges the current pump delivery quantity, de- cides whether it is to be increased or decreased, and sends out appropriate control signals (10) to ump displacement solenoid valves No.1 (6) and No.2 (6). Pump displacement solenoid Open Close Close valve No.1 (8) Pump displacement solenoid Close Open Close valve No.2 (5) Pump displacement angle Decrease Increase Retention Pump delivery quantity Decrease Increase Constant Engine 4 Pressure Sensor T= Servo Piston 10—Control Signals (P sensor) 2— Main Pump 5 8 Pilot Pump 11—Controller Pump Displacement 6— Small Diameter 9~ Engine Speed Sensor —-12~Sensing Signals Angle Sensor (A (N sensor) sensor) Valve (No.1) T02-03-05UPPERSTRUCTURE / Pump device PILOT PUMP. Drive gear(1) is rotated by the engine through the main pump crive gear train. Driven gear (2) is rotated by drive gear (1) 1— Drive Gear Dativery Port 2 Driven Gear ENGINE SPEED SENSOR (N SENSOR) The N sensor monitors the engine speed, which is es- sential information for various operation controls. The N sensor is installed so that its tip is positioned close to the disk drive gear tooth tops. The engine speed is monitored by the number of gear teeth passing by the tip of the N sensor and converting that information into pulse signals. 1= cot 2— Magnet 3~ Disk Drive (Gear) 4— Output Terminal 5~ Power Source (SV) terminal PRESSURE SENSOR (P SENSOR) The P sensor detects oil pressure, which is essential in- formation for various operation controls. When dia- phragm (4) receives oil pressure, it deforms. The de- gree of diaphragm deformation is converted into an electric signal i= Earth 2— Output Terminal 3~ Power Source (SV) terminal 4— Diaphragm (pressure-recelving area) PUMP DISPLACEMENT ANGLE SENSOR (A SENSOR) The A sensor detects the pump displacement angle by checking the movement of shaft (2), and converts it into an electric signal. t= Lever 4— Pump Displacement ‘Angle Sensor (Asensor) 2 Shatt 5- Pin 3 Bushing 02-03-064 UPPERSTRUCTURE / Swing device OUTLINE The swing device consists of brake valve unit(1), swing motor unit (2), and swing reduction gear unit (3) 1 Brake Valve Unit 2— Swing Motor Unit 3~ Swing Reduction Gear Unit T02-04-01UPPERSTRUCTURE / Swing device SWING MOTOR ‘The swing motor is a swash-plate-type axial plunger mo- tor. ‘The major parts of the motor are: fixed-type swash plate @). cylinder block (9), piungers (8), valve plate (3), mo- tor housing (6), and the parking brake. The parking brake is a wet-lype multiple disc brake, consisting of center plates (1) and friction plates (2). ‘Shoes (4) are caulked to each plunger (8) and nine plungers with shoes are provided in cylinder block (9). Cylinder block (9) is installed onto shaft (7) with a spline coupling, QA 1— Conter Plate 2 Friction Plate 3 Valve Plate 4— Shoe 6— Motor Housing 5~ Fixed-type Swash Plate 7— Shaft 8~ Plunger 9— Cylinder Block 02-04-0220 UPPERSTRUCTURE / Swing device ‘Swing speed varies depending on the amount of oil Turning force is transmitted to the swing reduction delivered from the pump. From port (A), high pres- gear unit via shatt (6). The return oil flows to outlet sure oil is fed so that plunger (3) is moved upward por (B) and returns to the hydraulic ol tank. from the bottom dead center to the top dead center. When pressure oil is fed to port (B), the motor ro- Shoe (4) then slides along swash plate (5), develop- tates in the opposite direction. ing turning force. 1= Valve Plate 3~ Plunger 5~ Swash Plate 2 Cylinder Block 4 Shoe 6 Shaft T02-04-03UPPERSTRUCTURE / Swing device BRAKE VALVE The brake valve consists of the make-up valve and the relief valve. Reliet Valve Make-up Valve When swing is stopped, if the upperstructure tends to keep rotating due to swing inertia force, causing the swing motor to continue rotating further, and to begin sucking oil from the pump, developing cavitation in the motor. The make-up valve sucks hydraulic oil through the re- — pore turn circuit (port C) to compensate for the lack of oil and prevent cavitation he Make-up Valve Control Valve Control Valve T02-04-04a UPPERSTRUCTURE / Swing device Relief Vaive ‘When starting or stopping swing operation, oil pressure in the swing circuit becomes high. The relief vaive pre- vents the circuit pressure from rising higher than the specified pressure. Plunger (5) is pushed to the left by pressure Pp at port (P) and pressure-receiving area A2. However, plunger (5) is also pushed back to the right by spring (8) force and pressure Pg at chamber (g) and pressure-receiving area A3. Chamber (g) is routed to port (P) through orifice (m). When force acting on the left is higher than that on the right, the relief vaive operates, 1 Spring 4— Piston 1 7— Housing (Body) 2~ Ball Check Valve 5— Plunger 8~ Spring 3 Sleeve 6 Seat ‘Pressure Increasing Operation When pressure Pp at port (P) increases, pressure Pg in chamber (g) also increases, as chamber (9) is opened to port (P) through orifice (m) in plunger (5).Therefore, this increased pressure acts on pressure-receiving area A4 of piston 2 (10). When force pushing piston 2 (10) to the left exceeds spring (1) force, piston 2 (10) moves to the left, reduc- ing pressure Pg in chamber (9) to lower than pressure Pp. Then, plunger (5) moves to the left, opening port (P) to port (R), decreasing pressure at port (P). When pressure at port (P) decreases, plunger (5) moves back to the right, and the opening between ports (P) and (R) is closed, increasing pressure Pp at port (P) and pressure Pg in chamber () until piston 2 (10) begins to move further to the left. This operation is repeated until piston 2 (10) reaches its stroke end. As piston 2 (10) moves to the left, oll behind piston 2 (10) is pushed out through orifice (n) and gradually re- tums 10 port (R), smoothly raising relief pressure. Pressure change at this stage is shown in the P1 to P2 range found in the reliet pressurejtime diagram on the next page. Toren.o4o19| 9 Adjusting Plug 10~ Piston2 T02-04-05UPPERSTRUCTURE / Swing device When piston 2 (10) reaches its stroke end, piston 1 (4) starts to move to the right due to force developing on pressure receiving area A1 by pressure Pg in chamber ). as a result compressing spring (8). When piston 1 @) begins to move to the right, oil trapped in chamber (@) leaks through oil grooves (h) provided on the sliding surface between adjusting plug (9) and piston 1 (4). Accordingly, pressure Pg in chamber (g) smoothly in- creases until piston 1 (4) reaches the stepped bore end of adjusting plug (9). As spring (8) is compressed, its spring force increases. Then, relief pressure P smoothly increases from P2 to Ps, as illustrated. When piston 7 (4) reaches the stepped bore end of adjusting plug (9), piston 1 (4) cannot move further to the right so that pressure in chamber (g) comes to equal specified pres- sure Ps. After this point, steady relief operation starts In summary, as movements of piston 2 (10) and piston 1 (4), and spring (8) force change, it takes a certain amount of time (!) to reach the specified relief pressure Ps, thus reducing shocks during swing operation, #Pressure Lowering Operation When pressure Pp at port (P) is reduced, pressure Pg in chamber (g) is also reduced to oil tank pressure. Then, plunger (5) moves to the right, closing seat (6). Piston 1 (4) is pushed by spring (8) to the left, to its original location. Piston 2 (10) is moved by spring (1) to the right. At the same time, ball check valve in- stalled in sleeve (3) opens to supply oil from port (R), preventing vacuum from occurring behind piston 2 (10), helping piston 2 (10) to return without a time lag D) () ai A 7 aw Ey = 2 ae Oe 8 Relief pressure P * Pa ’, tt Time )» € 4 D\OaE z = P 3 g 8 T02-04-06a UPPERSTRUCTURE / Swing device SWING PARKING BRAKE The parking brake is a wet-type multiple disc brake. The brake Is released only when brake release pressure S| enters into brake piston chamber (b), (negative type brake). When swing and/or arm rollin operation is made (that is, when solenoid valve (9) is not magnetized), brake release pressure SI is supplied from pilot pump (10), During operations other than swing andjor arm rollin, or while the engine is stopped, brake release pressure SI is routed to the hydraulic oil tank and the parking brake is automatically applied by spring (1). ‘While the brake is “ON" (except when swing andjor arm rollin function is operated): Signals from swing pressure switch (7) andfor arm roll in pressure switch (8) are not sent to the pump and valve controller PVC, keeping solenoid vaive (9) mag- netized (ON). While solenoid valve (9) is magnetized, brake release pressure SI is released to the tank port, allowing the force of spring (1) to apply downward via piston (2), to keep center plates (3) engaged with the circumferential part of cylinder block (6) and friction plates (4) en- gaged with the internal side of motor housing (6). By friction force equivalent to this thrust load, center plates (3) and cylinder block (6) are braked. ‘@While the brake is "OFF" (swing andjor arm roll-in function operated): Signals from swing pressure switch (7) andjor arm roll- in pressure switch (8) are sent to pump and valve con troller PVC, which in tum demagnetizes solenoid valve (2), Then, brake release pressure SI moves piston (2) up- ward against spring (1), breaking contact between cen- ter plates (3) and friction plates (4), releasing the brake. 1— Spring 6— Cylinder Block 2= Piston 7 Swing Pressure Switch 3— Center Plate 8 Arm Rollin Pressure Switch 4— Friction Plate 9~ Solenoid valve 5— Motor Housing 10— Pilot Valve While brake is "ON" oy sh] ctl ort + f= Puch eerie st @ f O-—® T02-04-07UPPERSTRUCTURE / Swing device SWING DAMPENER VALVE When returning the swing control lever to the neutral position to stop swing operation, the return oil circuit from the swing motor is blocked and oil pressure in the relurn circuit increases. At the same time, swing inertia force of the upperstructure drives the swing motor so that the swing motor sucks oil from its inlet port (re- ferred to as pumping function of a motor), decreasing pressure at the inlet port. Then, when the motor stops rotating, the motor is push- fed back from the stop position by high oll pressure ap- peared at the return port. Until pressures at both the in- let port and the return port become balanced, the swing motor repeats to swing clockwise and counterclockwise, The swing dampener vaive functions to quickly con- verge this swinging action of the motor. The swing dampener vaive consists of valves (5, 6, and 7) and solenoid valve (8). Ports (AM1 and BM1) are connected to the swing motor. Pilot pressure oil to regu- late vaive (5) is fed to port (Ps). Solenoid valve (8) is actuated by signal from engine controller (EC). Any ES Lonny 1— ‘Swing Dampener Valve 2— Swing Motor 5 Valve 6 Valve 3 Hydraulic Ol! Tank 4 Solenoid Valve Assembly 7 Valve 8 Solenoid Valve T02-04-083 UPPERSTRUCTURE / Swing device ‘¢When swing operation is stopped (when the swing control lever is returned to the neutral position): When the swing control lever is in neutral (the swing pressure switch is OFF), and hydraulic oil temperature is higher than 20 °C (68 °F) at the T sensor, engine controller (EC) does not send out a signal to magnetize solenoid valve (8). so that sole- Then, valve (5) is opened to operate swing damp- ener function. ‘Swing pressure switch Hydraulic oil temperature noid valve (8) is closed. Pvc (Controller) I+ EC ‘Swing dampener valve (Controller) "(Solenoid valve) sensor (T sensor) When the motor rotating in the arrow direction is stopped, high braking pressure arises at port AM side. This braking pressure enters into chamber (n) through passage (h), and passages (m) in valves (7, and 8). Then, plunger (12) and seat (10) are moved against spring (9) to the left by pressure force in chamber (n). When swing inertia force of the upperstructure disappears, high braking pres- sure at port AM acts to rotate the motor in the re- verse ditection, decreasing pressure at port AM. 6~ valve 10~ Seat 7 Valve 11 Spring 9 Spring 12— Plunger While swinging: When the swing control lever is operated (the swing pressure switch is ON), or hydraulic oil tem- perature is lower than 20 °C (68°F) at the T sen- sor, engine controller (EC) sends out signals to magnetize solenoid valve (8) so that solenoid valve (@) is opened. Thus, plunger (12) is returned to the right by spring (9) force and seat (10) is also returned to the right. However, orifice (q) restricts oll flow from chamber (u) 80 that seat (10) cannot be returned along with plunger (12). Then, seat (10) is opened to allow Pressure oil at port AM to flow out to port BM through port (). Accordingly, oil pressure at both Ports AM and BM become equal, and minimizing ‘swinging action of the motor to the extent possible. Then, pilot oil (Ps) is routed to valve (6) to close it, canceling swing dampener valve function and re- covering normal swing operation. T02-04-09UPPERSTRUCTURE / Swing device SWING REDUCTION GEAR ‘The swing reduction gear is a two-stage planetary gear type. Ring gears (2 and 4) in the first and sec: cond stages are provided on the inside of the hous- ing, The housing is bolted to the main frame so that ring gears (2 and 4) are held stationary Motor output shaft (10) of the swing motor drives first stage sun gear (9). Then, rotary power is transmitted to second stage sun gear (7) via first stage planetary gear (1) and cartier (8). Second stage sun geat (7) rotates drive shaft (5) via second stage planetary gear (3) and cartier (6). As drive shaft (6) meshes with the internal gear of the swing bearing bolted to the undercarriage, the Uupperstructure is rotated. I= First Stage Planetary Gear 4— Second Stage Ring Gear 5— Drive Shaft (Output Shaft) 6~ Second Stage Carrier 2— First Stage Ring Gear 3~ Second Stage Planetary Gear 7— Second Stage Sun Gear 8 First Stage Car ‘9— First Stage Sun Gear 10— Motor Output Shaft T02-04-10