Manual No. : KM-587E Vol.No. — : T587E-0" Technical Manual EXle-2 E€EX30-2 EX15-2 €X35-2 €X18-2 €X40-2 E€Xee-2 €X45-2 E€X25-2 Service Manual (Manual No. KM-587E} lowing two separate volumes; Technical Manual Vol. No. T587E Workshop Mant wal Vol. No. W5B7E HITACHIINTRODUCTION O 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, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form’ at the end of this man- val (Note: Do not tear off the form. Copy it for usage.) Publications Marketing & Product Support Hitachi Construction Machinery Co. Ltd TEL: 81-298-32-7173 FAX: 81-298-31-1162 + The following abbreviations of the serial numbers are used in this manual. Model Type A Type B ExX12-2 | 02001 to02812_| 02613 and up Ex15.2 | 01501 to.02175_| 02176 and up Ex18-2 | 00101 to00532_| 00533 and up &x22-2 | 02001 to02653_| 02654 and up Ex25-2 | 01501 to.02204 | 02205 and up Ex30-2_| 03501 to 05699 _| 05700 and up Ex36-2 | 02001 to 03404 _| 03405 and up EX40-2_| 003501 to 004842 | 004843 and up Ex45-2 | 001001 to 001593 | 001594 and up 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 Technical Manual and the Workshop Manual. Use the manuals according to purpose. + Information included in the Technical Manual: 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 Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance stan- dards, and removallinstallation and assem- ble/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 Group Number Section Number L Consecutive Page Number for Each Group T. Technical Manual W: Workshop Manual IN-04INTRODUCTION SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage. Ai This is the safety alert symbol. When you see this ‘symbol, be alert to the potential for personal injury 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 componentipart weights. To avoid injury and damage, be sure to use appropri- ate lifting techniques and equipment when lifting heavy parts. + Acaution: Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death. * IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine. + Pnore: Indicates supplementary technical information or know-how. UNITS USED ‘* SI Units (International System of Units) are used in this manual. MKSA system units and English units are also indicated in parenthheses just behind SI units. Example ; 24.5 MPa (250 kgf/cm”, 3560 psi) A table for conversion from SI units to other system units is shown below for reference purposes. Quantity | Te emE | into | utiply By | Quantity | FONT | into | Mutipty By Length mm in| 0.03937 | Pressure MPa__|_kgfiem” [10.197 rm ft [0.003287 MPa psi__| 145.0 Volume L US gal [0.2642 ___| Power KW. PS [1.360 L US qt__| 1.057 KW HP [4.341 m ye 71.308 Temperature °C. oF °Cx1.8+32 Weight kg tb _| 2.205 Velocity kmh mph | 0.6214 Force N kgf | 0.10197 min” rpm | 1.0 N tof 0.2248 | Flow rate Umin | US gpm_|0.2642 Torque Nm kofm | 1.0197 mUrev | colrev | 4.0 Nm tft | 0.7375 IN-02SAFETY RECOGNIZE SAFETY INFORMATION * This is the SAFETY ALERT SYMBOL. + When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. + Follow recommended precautions and safe oper- ating practices. UNDERSTAND SIGNAL WORDS: + on asi sate sas, wots seagwicg AAS WO DUN] od 2 the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol + DANGER indeates an imminenty hazardous A WARNING or senous uy + WARNING indicates a potentially hazardous situa- tion which, if not avoided, could result in death or serous ny + CAUTION indicates a potentially hazardous situa- tion which, if not avoided, may result in minor or I M PO RT ANT moderate injury. + DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. ‘* CAUTION also calls attention to safety messages in sane this manual ‘* To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indi- cates a situation which, if not avoided, could result in damage to the machine. * @ NOTE indicates an additional explanation for an element of information. SA-1SAFETY FOLLOW SAFETY INSTRUCTIONS «a * Carefully read and follow all safety signs on the —_— machine and all safety messages in this manual * Safety signs should be installed, maintained and replaced when necessary. + If 2 safety sign or operator's manual is damaged ‘or missing, replace it with new one. correctly and safely. sxe ‘+ Allow only trained, qualified, authorized personnel to operate the machine, ‘* Keep your machine in proper working condition. + Unauthorized modifications of the machine may impair its function and/or safety and affect ma- chine life. ‘The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of ma- chines. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor and/or your authorized dealer before operating or performing maintenance work on the machine PREPARE FOR EMERGENCIES — ‘* Be prepared if a fie starts or if an accident occurs. —_ + Keep a first aid kit and fire extinguisher on hand. + Thoroughly read and understand the label at- ee" tached on the fire extinguisher to use it properly. + Establish emergency procedure guidelines to cope with fires and accidents. + Keep emergency numbers for doctors, ambu- lance service, hospital, and fire department posted near your telephone, SA-2SAFETY WEAR PROTECTIVE CLOTHING ‘© Wear close fitting clothing and safety equipment appropriate to the job. You may need: Abard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear exe Respirator or filter mask Be sure to wear the correct equipment and clothing for the job. Do not take any chances, 98 «3D + Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine © Operating equipment safely requires the full atten- tion of the operator. Do not wear radio or music headphones while operating the machine. PROTECT AGAINST NOISE * Prolonged exposure to loud noise can cause im- pairment or loss of hearing, + Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objection able or uncomfortably loud noises. SA-3SAFETY USE HANDHOLDS AND STEPS «Falling is one of the major causes of personal injury. + When you get on and off the machine, always face the machine and maintain a three-point con- tact with the steps and handrails. + Do not use any controls as hand-holds. + Never jump on or off the machine. Never mount or dismount a moving machine. + Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine. LF, ADJUST THE OPERATOR'S SEAT * A poorly adjusted seat for either the operator or for the work at hand may quickly fatigue the operator leading to misoperations. + The seat should be adjusted whenever changing the operator for the machine. + The operator should be able to fully depress the pedals and to correctly operate the control levers with his back against the seat back + If not, move the seat forward or backward, and check again FASTEN YOUR SEAT BELT(IF EQUIPPED) ‘*If the machine should overturn, the operator may become injured and/or thrown from the cab. Addi- tionally the operator may be crushed by the overturn- ing machine, resuiting in serious injury or death + Prior to operating the machine, thoroughly exam- ine webbing, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine, + Be sure to remain seated with the seat belt se- curely fastened at all times when the machine is in ‘operation to minimize the chance of injury from an accident. + We recommend that the seat belt be replaced every three years regardless of its apparent condi- tion SA-4SAFETY OPERATE ONLY FROM OPERATOR'S SEAT « Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death. + Start the engine only when seated in the opera- tors seat + NEVER start the engine while standing on the track or on ground + Do not start engine by shorting across starter ter- minals. shee + Before starting the engine, confirm that all control levers are in neutral. JUMP STARTING ‘* Battery gas can explode, resulting in serious injury. + If the engine must be jump started, be sure to follow the instructions shown in the “OPERATING THE ENGINE” chapter in the operator's manual + The operator must be in the operator's seat so that the machine will be under control when the engine starts. Jump starting is a two-person op- eration. + Never use a frozen battery Failure to follow correct jump starting procedures shox could result in @ battery explosion or a runaway machine. KEEP RIDERS OFF MACHINE * Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine. * Only the operator should be on the machine. Keep riders off + Riders also obstruct the operator's view, resulting in the machine being operated in an unsafe manner, SA5SAFETY PROVIDE SIGNALS FOR FOBS INVOLV- ING MULTIPLE NUMBERS OF MACHINES ‘© For jobs involving multiple numbers of machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person's directions. CONFIRM DIRECTION OF MACHINE TO BE DRIVEN «Incorrect travel pedaV/ever operation may result in serious injury death. + Before driving the machine, confirm the position of the undercarriage in relation to the operator's po- sition, If the travel motors are located in front of the cab, the machine will move in reverse when travel pedais/levers are operated to the front. SA-6SAFETY DRIVE MACHINE SAFELY ‘* Before moving the machine, confirm which way to move travel pedals/ievers for the corresponding direction you wish to go. + Pushing down on the front of the travel pedals or pushing the levers forward moves the machine towards the idlers. (Refer to the Steering the Machine Using Pedals/Levers section in the operator's manual for correct travel operation.) ‘* Traveling on a grade may cause the machine to slip or to overtum, possibly resulting in serious injury or death. + When traveling up or down a grade, keep the bucket in the direction of travel, approximately 200 to 300 mm (approximately 8 to 12 in)(A) above the ground, + If machine starts to skid or becomes unstable, lower the bucket immediately. + Driving across the face of a slope or steering on a slope may cause the machine to skid or turnover. If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation. SA-7SAFETY AVOID INJURY FROM ROLLAWAY ACCIDENTS © Death or serious injury may result if you attempt to ‘mount or stop a moving machine. To avoid rollaways: + Select level ground when possible to park machine. + Do not park the machine on a grade. + Lower the bucket and/or other work tools to the ground. + Tum the auto-idle switch off. + Run the engine at slow idle speed without load for 5 minutes to coo! down the engine + Stop the engine and remove the key from the key switch, + Pull the pilot control shutoff lever to LOCK position. * Block both tracks and lower the bucket to the ground. Thrust the bucket teeth into the ground if you must park on a grade. sae + Position the machine to prevent rolling. + Park a reasonable distance from other machines. SA-8SAFETY AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS ‘+ If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death. To avoid back-over and swing accidents: * Always look around BEFORE YOU BACK UP AND SWING THE MACHINE. BE SURE THAT ‘ALL BYSTANDERS ARE CLEAR. + Keep the travel alarm in working condition ALWAYS BE ALERT FOR BYSTANDERS MOV- ING INTO THE WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE. - USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN VIEW. Use hand signals, which conform to your local regulations, when work conditions require a signal person + No machine motions shall be made unless signals are clearly understood by both signalman and op- erator, * Learn the meanings of all flags, signs, and mark- ings used on the job and confirm who has the re- sponsibility for signaling + Keep windows, mirrors, and lights clean and in {good condition. + Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting, + Read and understand all operating instructions in the operator's manual SA-9SAFETY AVOID TIPPING + DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE—SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT + MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE + FASTEN YOUR SEAT BELT ‘* The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death. To avoid tipping: ‘+ Be extra careful before operating on a grade. + Prepare machine operating area flat. + Keep the bucket low to the ground and close to the machine + Reduce operating speeds to avoid tipping or slipping. + Avoid changing direction when traveling on grades + NEVER attempt to travel across a grade steeper than 15 degrees if crossing the grade is unavoidable. + Reduce swing speed as necessary when swinging loads. ‘© Be careful when working on frozen ground. + Temperature increases will cause the ground to become soft and make ground travel unstable. AVOID POWER LINES * Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines. + When operating near an electric line, NEVER move any part of the machine or load closer than 3m (10 ft) plus twice the line insulator length. + Check and comply with any local regulations that may apply. + Wet ground will expand the area that could cause any person on it to be affected by electric shock Keep all bystanders or co-workers away from the site, SA-10SAFETY PROTECT AGAINST FLYING DEBRIS. * If fying debris hit eyes or any other part of the body, serious injury may result + Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses. + Keep bystanders away from the working area before striking any object PARK MACHINE SAFELY To avoid accidents: + Park machine on a firm, level surface. + Lower bucket and/or other work tools to the ground, + Tum auto-idle switch off. + Run engine at slow idle speed without load for minutes. + Tur key switch to OFF to stop engine. + Remove the key from the key switch. + Pull the pilot control shut-off lever to the LOCK om position, + Close windows, roof vent, and cab door. * Lock all access doors and compartments. HANDLE FLUIDS SAFELY—AVOID FIRES ‘¢ Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possi- bly resulting in serious injury or death. * Do not refuel the machine while smoking or when near open flame or sparks. + Always stop the engine before refueling the ma- chine + Fill the fuel tank outdoors. © All fuels, most lubricants, and some coolants are flammable. * Store flammable fluids well away from fire haz~ ards. + Do not incinerate or puncture pressurized con- tainers. + Do not store oily rags; they can ignite and bur spontaneously. SA-11SAFETY SAFETY TRANSPORTING ©The danger of tipping is present when loading/unloading the machine ontoffrom a truck or trailer bed. + Be sure to observe local regulations when transporting the machine on public roads. + Provide an appropriate truck or trailer for transporting the machine. Take the following precautions when loading / unloading the machine: 1) Select firm level ground. 2) Be sure to use a loading dock or ramp. 3) Be sure to have a signal person when Joading/unloading the machine. 4) Always tum the auto-idle switch (if equipped) OFF when loading or unicading the machine, to avoid unexpected speed increase due to Unintentional operation of a control lever. 5) Always select the slow speed mode with the travel mode switches. In the high speed mode, travel speed may automatically increase. 6) Avoid steering while driving up or down the ramp as it is extremely dangerous. If steering is unavoidable, first move back to the ground or flatbed, modify traveling direction, and begin to drive again. 7) Do not operate any levers besides the travel levers when driving up or down the ramp. 8) The top end of the ramp where it meets the flatbed is a sudden bump. Take care when traveling over it 9) Prevent possible injury from machine tipping while the upperstructure is rotating 40) Keep the arm tucked under and rotate the upperstructure slowly for best stabil 41) Securely fasten chain or cables to the machine frame. Refer to “transporting” chapter in the operator's manual for details. SA-12SAFETY PRACTICE SAFE MAINTENANCE To avoid accidents: Understand service procedure before starting work. Keep the work area clean and dry. Do not spray water or steam inside a cab. Never lubricate or service the machine while it is moving. Keep hands, feet and clothing away from power- driven parts. Before servicing the machine: 4. Park machine on a solid, level surface. 2. Lower the boom to the ground. If the boom cannot be fully lowered, secure the boom with Quy ropes to prevent the boom from being blown by wind. 3. Run the engine at slow idle speed without load for 5 minutes. ‘Apply all brakes and locks. ‘Tum the key switch OFF to stop the engine, Remove the key from the switch Move the pilot shut-off lever to the LOCK posi- tion, Attach a “Do Not Operate” tag on the cab door. Noose If a maintenance procedure must be performed with the engine running, do not leave machine un- attended, Securely support any machine elements that must be raised for service work. If the machine must be raised, place supporting blocks under the frame. Inspect certain parts periodically and repair or replace as necessary. Refer to the section dis- cussing that part in the “MAINTENANCE” chapter of the operator's manual. + Keep all parts in good condition and properly in- stalled. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil or de- brs. + Disconnect battery ground cable (-) before mak- ing adjustments to electrical systems or before performing welding on the machine. 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 ignite spilled fuel or cil SA43SAFETY WARN OTHERS OF SERVICE WORK ‘* Unexpected machine movement can cause serious injury. + Before performing any work on the machine, at- DO tach a "Do Not Operate" tag on the control lever. NOT OPERATE SUPPORT MACHINE PROPERLY securing the machine first. + Always lower the attachment to the ground before you work on the machine. + If you must work on a lifted machine or attach- ment, securely support the machine or attach- ment. Do not support the machine on cinder blocks, hollow tires, or props that may crumble under continuous load. Do not work under a ma- chine that is supported solely by a jack sas SA-14SAFETY STAY CLEAR OF MOVING PARTS ‘* Entanglement in moving parts can cause serious injury, + To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts. PREVENT PARTS FROM FLYING ‘¢ Grease in the track adjuster is under high pressure. Failure to follow the precautions below may result in serious injury, biindness, or death. + Do not attempt to remove GREASE FITTING or VALVE ASSEMBLY. + As pieces may fly off, be sure to keep body and face away from valve. ‘Travel reduction gears are under pressure. + As pieces may fly off, be sure to keep body and face away from AIR RELEASE PLUG to avoid injury. GEAR OIL is hot + Wait for GEAR OIL to cool, then gradually loosen AIR RELEASE PLUG to release pressure. STORE ATTACHMENTS SAFELY ‘Stored attachments such as buckets, hydraulic hammers, and biades can fall and cause serious injury or death + Securely store attachments and implements to prevent falling, Keep children and bystanders away from storage areas, SA-15,SAFETY USE TOOLS PROPERLY ** Use tools appropriate for the work to be done. + Makeshift tools, parts, and procedures can create safety hazards. + For loosening and tightening hardware, use the correct size tools to avoid injury caused by slip- ping wrenches, + Use only recommended replacement parts. (See the parts catalog.) PREVENT BURNS Hot spraying fluids: ‘© After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. ‘Skin contact with escaping hot water or steam can cause severe bums. + To avoid possible injury from hot spraying water. DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap. + The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap. Hot fluids and surfaces: ‘Engine oil, gear oil and hydraulic cil also become hot during operation The engine, hoses, lines and other parts become hot as well + Wait for the oil and components to cool before starting any maintenance or inspection work. “Gul Gi SA-16SAFETY REPLACE RUBBER HOSES PERIODICALLY * Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone. + Periodically replace the rubber hoses. (See the page of “Periodic replacement of parts” in the operator's manual.) * Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment fo fall on @ person nearby, which may result in severe bums, gangrene, or otherwise serious injury or death (SZ AVOID HIGH-PRESSURE FLUIDS ‘* Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing ‘serious injury, blindness or death. + Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard; take care to protect hands and body from ‘high- pressure fluids. Wear a face shield or goggles for eye protection. + if an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within 2 few hours or gangrene may result SA-17SAFETY PREVENT FIRES. Check for Oil Leaks: * Fuel, hydraulic oll and lubricant leaks can lead to fires + Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the cil-cooler, and loose oil- ‘cooler flange bolts. + Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil- ‘cooler fiange bolts. + Do not bend or strike high-pressure lines, + Never install bent or damaged lines, pipes, or hoses. Check for Shorts: ‘© Short circuits can cause fires. + Clean and tighten all electrical connections. + Check before starting work for loose, kinked, hardened or frayed electrical cables and wires. + Check before starting work for missing or dam- aged terminal caps. + DO NOT OPERATE MACHINE if cable or wires are loose, kinked, ete. Clean up Fiammables: * Spilled fuel and oil, and trash, grease, debris, accu- mulated coal dust, and other flammables may cause fires. + Prevent fires by inspecting and cleaning the ma- chine daily and by removing spilled or accumu- lated flammable immediately Check Key Switch: * If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting. + Always check key switch function before operat- ing the machine every day: 1) Start the engine and run it at slow idle. 2) Tum the key switch to the OFF position to con- firm that the engine stops. + If any abnormalities are found, be sure to repair them before operating the machine. (SZ SA-18SAFETY Check Heat Shields: ‘* Damaged or missing heat shields may lead to fires. + Damaged or missing heat shields must be re- paired or replaced before operating the machine. EVACUATING IN CASE OF FIRE ‘If a fire breaks out, evacuate the machine in the following way: + Stop the engine by turning the key switch to the OFF position if there is time. + Use a fire extinguisher if there is time. + Exit the machine, ‘In an emergency, if the cab door andlor the front window cannot be opened, break the front or rear window panes with the emergency evacuation hammer to escape from the cab Refer to the explanation page on “EMERGENCY EXIT" (Cab-Equipped Machines Only) in Operator's Manual BEWARE OF EXHAUST FUMES © Prevent asphyxiation. Engine exhaust fumes can cause sickness or death + If you must operate in 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. SA-19SAFETY 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 fluid lines or other flammable materials. + Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. In- stall temporary fire-resistant guards to protect hoses or other materials before engaging in weld- ing, soldering, ete. AVOID APPLYING HEAT TO LINES CON- TAINING FLAMMABLE FLUIDS * Do not weld or flame cut pipes or tubes that con- tain flammable fluids. + Clean them thoroughly with nonflammable solvent before welding or flame cutting them. SA-20SAFETY REMOVE PAINT BEFORE WELDING OR HEATING ‘* Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness + Avoid potentially toxic fumes and dust. + Do alll such work outside or in a well-ventilated area, Dispose of paint and solvent properly + Remove paint before welding or heating: 4) If you sand or grind paint, avoid breathing the dust. ‘Wear an approved respirator. 2) Ifyou use solvent or paint stripper, remove strip- per with soap and water before welding. Re- move solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating, PREVENT BATTERY EXPLOSIONS « Battery gas can explode. + Keep sparks, lighted matches, and flame away from the top of battery. + Never check battery charge by placing a metal object across the posts. Use @ voltmeter or hy- drometer. + Do not charge a frozen battery, it may explode. Warm the battery to 16 °C ( 60 °F ) first ** Battery electroiyte is poisonous. If the battery should explode battery electrolyte may be splashed into eyes, possibly resulting in blindness. + Be sure to wear eye protection when checking electrolyte specific gravity SA-21SAFETY SERVICE AIR CONDITIONING SYSTEM SAFELY © If spilled onto skin, refrigerant may cause a cold contact bum. + Refer to the freon container for proper use when servicing the air conditioning system, + Use a recovery and recycling system to avoid venting freon into the atmosphere. + Never let the freon stream make contact with the skin HANDLE CHEMICAL PRODUCTS SAFELY * Direct exposure to hazardous chemicals can cause ‘serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paints, and adhesives. + A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and ‘emergency response techniques. ‘Check the MSDS before you start any job using a hazardous chemical. That way you will know ex- actly what the risks are and how to do the job safely. Then follow procedures and use recom- mended equipment. SA-22SAFETY DISPOSE OF WASTE PROPERLY ‘* Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, fiters, and batteries. + Use leakproof containers when draining fluids. Do not use food or beverage containers that may mis- lead someone into drinking from them, Do not pour waste onto the ground, down a drain, or into any water source. Air conditioning refrigerants escaping into the ait can damage the Earth's atmosphere. Govern- ment regulations may require a certified air condi- tioning service center to recover and recycle used air conditioning refrigerants, Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center. OY O BEFORE RETURNING THE MACHINE TO THE CUSTOMER ‘* After maintenance or repair work is complete, con- firm that: + The machine is functioning property, especially the safety systems. + Worn or damaged parts have been repaired or replaced SA-23SAFETY (Blank) SA-24SECTION AND GROUP CONTENTS TECHNICAL MANUAL All information, illustrations and speci- fications in this manual are based on the latest product information available at the time of publication. The right is reserved fo make changes at any time without notice. COPYRIGHT(C)1999, Hitachi Construction Machinery Co., Ltd “Tokyo. Japan All rights reserved SECTION 1 GENERAL Group 1 Specification | Group 2 Component Layout | SECTION 2 SYSTEM Group 1 Hydraulic System | SECTION 3 COMPONENT OPERATION Group 1 Pump Device Group 2 Swing Device Group 3 Control Valve Group 4 Pilot Valve Group 5 Travel Device Group 6 Others(Upperstructure) Group 7 Others(Undercarriage) SECTION 4 OPERATIONAL PER- FORMANCE TEST Group 1 Introduction Group 2 Engine Test Group 3 Excavator Test Group 4 Component Test Group 5 Standard SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Group 2 Troubleshooting A Group 3 Troubleshooting B Group 4 Electrical System InspectionWORKSHOP MANUAL SECTION 1 GENERAL INFORMA- TION SECTION 3 UNDERCARRIAGE Group 1 Swing Bearing Group 1 Precautions for Disassem- Group 2 Travel Device bling and Assembling Group 2 Tightening Torque SECTION 2 UPPERSTRUCTURE Group 1 Cab Group 2 Counterweight Group 3 Pump Device Group 4 Control Valve Group 5 Swing Device Group 6 Pilot Valve Group 7 Solenoid Valve Group 3 Center Joint Group 4 Track Adjuster Group 5 Front Idler Group 6 Upper and Lower Roller Group 7 Track SECTION 4 FRONT ATTACHMENT Group 1 Front Attachment Group 2 Cylinder SECTION 5 ENGINE EX15-2EX18-2-EX22-2° EX25-2-EX30-2-EX35-2 SECTION 6 ENGINE EX40-2-EX45-2SECTION 1 GENERAL —CONTENTS— Group 1 Specification Specifications. T1414 Working Range Transportation 14-4 Engine Specification T14-6 Interchangeabilty. T14-8 Group 2 Component Layout Main Components. T1244 Electrical System (Overall System) 1123 Electrical System (Relays) 112-5 Electrical System (Monitor and Switches) 11-27 587T-1-1(Blank) 587T-1-2GENERAL / Specifications SPECIFICATIONS Unit EXt22 EX152 EXi82 Canopy [Gab | Canopy [Cab | Canopy | Cab Front Attachment = ‘Boom Swing Type _| Boom Swing Type | Boom Swing Type Bucket Capacity 7 PCSA: 0.041 PCSA: 0.046 PCSA: 0.05 (Heaped) CECE: 0.035 CECE: 0.04 CECE: 0.045 7250 | 1350 | 1350 ] 1450 | 1700 | 1600 Operating Weight k9(®) | (2760) | 2980) | (2980) | (3200) | (3750) | (3970) 7020 | 1120 | 1080 | 1180 | 1420 | 1820 Base Machine Weight *9() | (2250) | 2470) | (2380) | (2600) | (3130) | (3350) KUBOTA D1105 | KUBOTAD1105 | KUBOTAD1105 Engine - 12.1 KW/2000 min” | 12.9 kW/2100 min | 12.1 kW/2000 min (16.5 PS/2000 rpm) | (17.5 PS/2100 rpm) | (16.5 PS/2000 rpm) ‘A Overall Width mm (tin) _|1020(3'4")] 1055(3°6")]1020(34")]1055(3'6")]1300(43")| 1300(4'3") B_Cab Height mim (Rein) |2200(7'3")]2280(7°6")[2200(7'3")|2280(7'6")|2320(7°7")2400(7 10") c: fear End Swing R&- | men (fin) 1070 (3'6") © « D: Minimum Ground 7 7 tiewmum mm (ftin) 2365 (9") + 325 (11) E Gounterweiaht | mrm tiny | 448 (75° - 565 (710") F_ Engine Cover Height |_mm (Rin) 7170 S10) = 1275 (42) Underage Tmt) | 19756) - 1775 66") Ti Underearriage Width | _mm (fin) 36032) 7000 SS) 7300143") 1. Sprocket Center to a 5" Idler Center mm (ft in) 1025 (3'4”) . 1350 (4°5") T_Track Shoe Width | _mm (fin) BOG} = 20 kPa Ea 6 % 27 235 | 245 Ground Pressure (kgtiem?, psi) | (0.25) | (0.26) | (0.26) | (0.28) | (024) | (0.25) ‘Swing Speed min” (pm) as 3.0 10 Travel Speed (atvsiow) krrvh (mph) 2.2(1.37) 2.3 (1.44) « Gradeabiity % (deg) 58 G0) = = c F le T1-1-1GENERAL / Specifications Un EXE EXI52 EXS02 " ‘Canopy Cab Canopy, Cab ‘Canopy Cab Front Attachment = ‘Boom Swing Type | Boom Swing Type | Boom Swing Type Bucket Capacity 7 PCSA: 0.068 PCSA: 0.08 PSA: 0.092 (Heaped) CECE: 0.06 CECE: 0.07 CECE: 0.08 2260 | 2360 | 2400 | 2530 | 2760 | 2680 Operating Weight kab) | (4s60) | (250) | (5290) | (5580) | (6060) | (6350) 1750 | 1880 | 1860) 1980 | 2140 | 2270 Base Machine Weight | kab) | (3a60)_| cargo) _| (4100) | (4390) _| 4720) | (5000) KUBOTAD1105 | KUBOTAD1105 | _ KUBOTAD1505 Engine - 43.6 kW/2200 min" | 14.7 KW/2400 min’ | 17.3 KW/2000 min’ (48.5 PS/2200 rpm) |_(20 PS/2400 rpm)_| (23.5 PS/2000 rpm) Overall Width mm (fin) _[1450(4'9")|1460(410|T450@S [i404 1071470470] — B. Cab Height ‘mm (fein) [2340(7'8")[2430(712")|2340(7'6")[2430(7 12")] 2360(79") | 244078) G: Rear End Swing R&T nm (fin) 1250 (4'1") « 4370 (4°6") D: am Ground | ram (ftin) 325 (1'1") « 330 (1°1") E Counterweight mm (ft in) 555 (1'10") « 565 (1°10") F Engine Cover Haight | mm (Win) 7355 (5) = TaE0 FED S'Unsercaage Tram tin) | _1785 (6107) 1390 (62°) 2020 6") HE Undercarriage Width |_mm (Rin) T4007} 7450 (497) TEE F Berocket Center 101 mm fin) 1350 (4'5") 4465 (410") 1590 (5'3") Track Shoe Width [mm (Rin) 25010) 3001) = Ground Pressure kPa 30 32 5 77 Ea a tkgticm’. psi] 31) | (033) | 0.25) | (027) | @26 | (027) Swing Speed min” (tpm) 30) 35 20 Travel Speed (Fast/Siow) kmh (mph) | 3.7/2.2(2.3/1.4) | 4.0/2.4(25/1.5) 4513.0 (2.8/1.9) Gradeabilly % (deg) 3830) = = T1-1-2GENERAL / Specifications Unt EXS52 Ex402 EX52 Canopy | Cab | Canopy | Cab | Canopy | Cab Front Alachment = Boom Swing Type | Boom Swing Type _| Boom Swing Type: Bucket Capacity PCSA: 0.11 PCSA: 0.14 PCSA: 0.16 (Heaped) CECE: 0.10 CECE: 0.13 CECE: 0.14 3100 | 3230 | 4000 ] 4180 | 4300 | 4450 Operating Weight kg (lb) (6830) _| (7120) | (e820) | (9150) | (9480) | (9810) , 2440 | 2570 | 3410 | 3560 | 3660 | 3810 Base Machine Weight kg (Ib) (5380) | (5670) | (7520) | (7850) | (8070) | (8400) KUBOTA D1505 | KUBOTA V2203 | _ KUBOTA V2203 Engine - 19.1 KW/2100 min | 26.5 kW/2100 min” | 26.5 kW/2100 min™ (26 PS/2100 rpm) _| “(36 PS/2100 rpm)_| (36 PS/2100 rpm) % Overal Width mmm Tarot <— [esos] eo Y B:_Cab Height mim (fin) | 2350(79") | 2440(6) [2520(6'3")|2505(66")|2520(8'3")| 2505(66") ©: Rear End Swing RE |r niny | 1980 (@°7) 1445 (49 - D: Minimum Ground a 7 amon mm (fin) 330 (1"1") 365 (1'2") « E: Counterweight 0" 7 Gounterwe mm (fin) 565 (1"10") 635 (2'1") « F Engine Cover Height |_mm (tin) 1360 (46) 75358) = © tengo mm (fin) 2030 (6'8") 2440 (8°) e FE Undercarriage Width | _mm (tin) 75205) FESO ET) < E Sprocket Center to 3 3 erro mmm (fin) 1590 (5'3") 1930 63") < Track Shoe Widih [mm (Rin) 3001) 400 (14°) < kPa 2 30 26 | 245 | 24 | 265 Ground Pressure katicr ps)! (0.30) _| 31) | 24 | (25) | @26 | (27 Swing Speed min (rpm) 2.0 10 = Travel ‘Speed (awvSiow) kmih (mph) | 4.6/3.1(2.9/1.9) | 45/28 (2.8/1.8) « ‘Gradeabilty % (dea) 38 30) = = 71-1-3GENERAL / Specifications WORKING RANGE: TRANSPORTATION Moder EX122 EX152 EXi82 Ex222 Item Canopy | Cab | Canopy | Cab | Canopy | Cab | Canopy | Cab % Maximum Digging Reach | 3430 | 3680) | so70 | | 4360 | mm (tin) | _(11°3") a2) 13!) q's") B Maximum Digging Depth [1900 | | 2170 | | | 2200 | | 2440 | mm (tin) |_(6'3") ry 73) (8) © Maximum Cutting Height |~3430 | 3120 | 3620 | 3260 | 3880 | 3476 | 4465 | 4215 mmitin | v3") | to") | ary | Gow) | a2 | ary | carey | 3107 D: Maximum Dumping 2450 | 2190 | 2650 | 2330 | 2920 | 2560 | 3245 | 3020 Height mini) | (81) | (72) | 8) | 7s) | 97) | ws) | Gos) | or) E Transport Height 2220 | 2280 | 2200 | 2280 | 2320 | 2400 | 2340 | 2430 mmiti | (73) | (76) | 73) | ey | 77) | cio | sy | @) F: Overall Transport Length | 3620 [ | 3630 [ | | 3800 | | 4245 [ mm i) |_(19"7") ava") 126") 311") GMinimum Swing Radius | 1270 | 1450 | 1270 | 1660 | 1560 | 1700 | 1430 | 1595 mm (fin) |_(4'2") (4'9") (42") (S'1") {5'1") (57°) (4'8") (5'3") Hi Minimum Swing Radius 945 | 1240 | 960 | 1340 | 1160 | 1430 | 1075 | 1280 with Maximum Boom oe on > 8) . "3 2 Swing Angie mein | 7) | 4) | BZ) | 5) | C10) | ey | CS) | 42) T Blade Bottom Highest | 180 ~ 7 300 7 380 . Position sm nin) |_(8") = ) a3) T Blade Bottom Lowest] 220 7 a . 290 7 355 . Position mm ini | (9°) a") 12") K Maximum Boom Swing | L90° | L7o* | Lao | L7o | Lao | L70 | Leo | Lao Angle o| Rs |e < « « < < « 1 Offset Distance T4001 < < << [ursrm] << ~slasoam | mmm tiny [R520(79" | Ra90(177) | 520119" | Re90(179 | RE2O(20" |RSBO(1'119] REsO2"1")|_RE2O2) Q@ NOTE: “E: Transport Height” do not include the height of shoe lug. cu Let L. Right L | Hy |} | Mf LOC ells a AS qr S A ‘ ) vet kK\ TES J, renovate Right k T1-1-4GENERAL / Specifications EX252 EXa02 EXS52 Exa52 Canopy [Cab | Canopy | Cab | Canopy | Cab Canopy | Cab ‘4600 “4810 5145 5920 as | © | ase) | © [ae | o ags) | 2745 2885 3140 3585 (9) < (6) = | aos | fare | | ary | 4605 | 4330 | 4745 5145 5805 5940 as) | 4's) | 157") © tae | fae | 196") = 3400 | 3155 | 3418 3805 ans 4250 (42) | aoa) | (127) - (12°6") © (13'6") - (13'11") - 2340 | 2430 | 2360 | 2440 | 2350 | 2440 | 2520 | 2595 | 2520 | 2595 (78) (8) (7'9") (8) (7'9") (8) (8'3") (sé) _} (83°) (8'6") 4475 “4680 4985, ‘5430 ‘5555 (14'8") - (15'4") - (16'4") - (17°10) = (18'3") - 1430 1715, 1560 1570 1930 . 1930 as) | 68) | er) | © | 62) | * | ea) ea) | 1265 | 1450 | 1285 | 1455 | 1265 a2) | @) | @3) | 4 | 2 1080 | 1385 | 1185 | 1285 67") (a7) | (3't") | 4's") 300 430 3") « (rs) < « © « « « 365 400 410(1'4") (r2") < a") < - <_ |365(1'2")| - - Leo | Leo | Lac | Leo | Leo | Leo | Loo [ Leo | Leo | La R50 | « © < < < < < < Lasor7) | < < © << usm) — fusrm| — Reso(2't")| R620(2 | 630121") | Re2012) | Rs3012"1")|_RE20%2) |R7702"7)| REO) | R776] — @ NOTE: *E: Transport Height” do not include the height of shoe lug. Lem Light T1-GENERAL / Specifications ENGINE SPECIFICATION item Mode!) ext22, Ex182 EXt52 EX22.2 “Engine —__ KUBOTA = a = 01105-BHH-7 “DiT0S BAAS “Dii05-BH-AS water cooled, swirl cam- rf OOPS ens 3.78 mmx76.4 mm “42.9 KWI2100 min’ __(17.5 PS/2100 rpm), Rotation direction Ciockwise (viewed from fan side) ‘Starling system "Redicion ype ive KW Voltage" Ouiput Alternator Type. Voltage ° Output 71-1-6GENERAL / Specifications Ex252 EX35.2 Ex40.2, EX452 KUBOTA vertical, water cooled, swirl cam- ber type - 78.4 4.423 L_ 14.7 kwr2400 _(20,PS/2400 rpm) _ cep BTL "36.5 KWi2100 min _(96.0 PS/2100 rpm) _ 23 _ “48.7 KWi2200 min® (26.0 PS/2200 rp Giockwise (viewed trom fan side) 12V-1.4 kW ‘AC type (with requiator) 12 V-40 A T1-1-7GENERAL / Specifications INTERCHANGEABILITY IMPORTANT: Part interchangeability is changed when the part is modif ied. Be sure to check update interchangeability re- ferring to the current parts catalog. Interet hangeable Model tem EX12-2 | EX15-2 | EX18-2 | £x22-2 | EX25-2 Exa0-2 EX45-2 Upperstructure Pot Valve ‘Boom Swing Cylinder Undercarriage Travel Device “Swing Bearing _ Center Joint Track, Adjuster _Front tdler “Upper Roller Lower| Roller “Rubber ‘Crawier ‘Blade Blade Cylinder Front Attachment = “Am Bucket ‘Boom Cy Cylinder : Arm Cynder Bucket Cylinder T1-1-8GENERAL / Component Layout MAIN COMPONENTS EX12-2, EX15-2, EX18-2 Q@NOTE: The components depends on the serial number. Refer to INTRODUCTION (IN-01) for the corresponding serial numbers. 4 Bucket Cynder 6- Radiator 11 Control Valve 16- Blade Cylinder 2- Arm Cylinder 7 Engine 12- Pilot Shut-Of Vatve (Type A) 17 - Pilot Valve ‘Solenoid Valve (Type 8) 3- Boom Cylinder 8- Pilot Pump 43- Center Joint ‘4- Boom Swing Cylinder 9 Main Pump 14 Swing Device 5- Hydraulic Ol! Tank 40- Travel Device 15 Fuel Tank 71-2-1GENERAL / Component Layout EX22-2, EX25-2, EX30-2, EX35-2, EX40-2, EX45-2 @ NOTE: The components depends on the serial number. Refer to INTRODUCTION (IN-01) for the corresponding serial numbers. 1" exroraneo1 10 1 Bucket Cylinder 6- Radiator 11 - Control Valve 16 - Blade Cyinder 2- Am Cylinder 7- OiCooler 12- Pilot Shut-Of Valve (Type A) 17 - Pict Valve 3 Boom Cylinder B- Engine 13 Swing Device 4 Boom Swing Cylinder 9- Main Pump 14- Center Joint 5- Hydraulic OW Tank 10- Travel Device 15- Solenoid Valve (Type A) Fuel Tank 2.Unit Solenoid Valve Type 5 71-2-2GENERAL / Component Layout ELECTRICAL SYSTEM (Overall System) EX12-2, EX15-2, EX18-2 Q@ NOTE: The components depends on the serial number. Refer to INTRODUCTION (IN-01) for the corresponding serial numbers. Refer to 71-255 “Electrical System (Relays)". 9 17 1 Work Light 6- Fuse Box 11- Glow Pug 15- Fuel Sensor 2- Hom Switch 7 Alternator 12+ Engine Stop Solenois ~ Solenoid Valve (Type 8) 3° Hour Meter 8- Overheat Switch 13 Coolant Temperature 17 Pilot Shut-Off Switch (Type ‘Sensor 8) 4 Battery 9 Fuel Pump 14- Staner 18 Horn 5 Key Switch 40- Engine Oi Pressure Switch 71-2-3GENERAL / Component Layout EX22-2, EX25-2, EX30-2, EX38-2, EX40-2, EX45-2 Q@ NOTE: The components depends on the serial number. Refer to INTRODUCTION (IN-01) for the corresponding serial numbers. Refer to T1-2-5 “Electrical System (Relays)" 1 Work Light 7 Fuel Sensor 13 Engine Stop Solenoid 17 - Plot Shut-O# Switch (Type 8) 2+ Hom Switch 8- Aterator 14- Coolant Temperature 18- Travel Speed Change ‘Sensor Switch 3+ Hour Meter 9- Engine Oil Pressure Switch 15 Starter 49- Horn 4 Fusibie Link 10- Ovemeat Switch 16- AirFiter Restrcton Switch 20 Solenoid Vatve (Type A) 2.Unit Solenoid Valve (Type 8) 5- Battery 11 Fuel Pump 6- Key Switch 12- Glow Plug 71-2-4GENERAL / Component Layout ELECTRICAL SYSTEM (Relays) EX12-2, EX15-2, EX18-2 @NoTE: The components depends on the serial number. Refer to INTRODUCTION (IN-01) for the corresponding serial numbers. Type A 10 SS 1+ Fusibe Link 4+ Work Light Relay 7+ Starter Relay 2 40- Starter Relay 1 27 Plot ShutOffRelay Type 5- Hom Relay 8 Glow Timer 5) 3- Hour Meter Relay 6 Timer Unit 9- Buzzer T1-2-5GENERAL / Component Layout EX22-2, EX25-2, EX30-2, EX36-2, EX40-2, EX45-2 Q@NOTE: The components depends on the serial number. Refer to INTRODUCTION (IN-01) for the corresponding serial numbers. ype 2 2 3 9) ° 3 1 1 4 4 7 Ke) 5 5 e& 7 CI 6 8 oor 8 ° ° Lu ” ZA sf RE = Eft] 1 Timer Unit a> Buzzer 7 stoner Rely 10- Travel Speed Change Re- ay 2- Fuse Box 5+ Glow Timer 8 Hom Reay 11 Hour Meter Relay 3 Starter Relay 2 8 Piet ShutOM Relay Type 9 Work Light Relay 8) T1-2-6GENERAL / Component Layout ELECTRICAL SYSTEM (Monitor and Switches) 1+ Auto-die Switeh (©2222 to 45.2: Option) 2- Work Light Switch Wiper Switch (Option) NAVY ‘EEE aye OB T ct 4 yet 4- Engine Oil Pressure Ind 7 cator 5- Altemator Indicator 8. 6- Fuel Level Indicator 9. ll Preheat Indicator ‘Ait Fiter Restriction Ind- cator (E222 to 45.2) Overneat Indicator (©x222 to 452) 10- Fast Speed Travel indicator (©x222 10.452) 11 Fuel Gauge 12 Coolant Temperature Gauge 11-2-7GENERAL / Component Layout (Blank) 71-2-8MEMO—CONTENTS— Group 1 Hydraulic System Outline... T2414 Main Circuit 724-2 Pilot Circuit 124-8 587T-2-1(Blank) 587T-2-2SYSTEM / Hydraulic System OUTLINE The hydraulic system consists of the main circuit and pilot circuit Main Circuit: This circuit controls pressure oil from the main pump by the control valve, and actuates the cylinders and motors. Pilot Circuit: This circuit supplies pressure oil from the pilot pump into the operation circuit and the travel speed changeover circuit T2-4-1SYSTEM / Hydraulic System MAIN CIRCUIT EX12-2, EX15-2, EX18-2 @ NOTE: Boom section and bucket section are re- placed with EX12-2 (Serial number 02001 to 02058) and EX15-2 (Serial number 01501 to 01541) Main pumps (P1, P2) draw hydraulic oil from the hy- draulic oil tank and discharge pressure oil to the con- trol valve. (Refer to “Control Valve group in “COMPONENT OPERATION’ section.) The pressure oil from main pump (P1) flows to the spools of blade (9), swing (8), arm (7) and right travel (@) in the control valve. The pressure oil from main pump (P2) flows to the spools of left travel (1), bucket (2), boom swing (3), boom (4) and auxiliary (5) in the control valve. ‘The pressure oil in the control valve, depending on which spools are selected, flows to the cylinders or motors actuating them. The return oil from cylinders or motors retums to con- trol valve and flows through the vaive. The return oil from the control valve flows through the oil cooler, then returns to the hydraulic oil tank. When the temperature of the hydraulic oil is low (viscosity is high), hydraulic oil restriction increases in the oil cooler passages. Therefore, a bypass check valve opens to return the hydraulic oil directly to the hydraulic oil tank. Q@ NOTE: Retum circuit from the control valve is only T2 circuit with EX18-2 T2-1-2SYSTEM / Hydraulic System @ nore: The illustration shows the EX12-2 (Serial number 02059 and up) and EX15-2 (Serial number 01542 and up). Boom section and bucket section are re- placed with EX12-2 (Serial number 02001 to 02058) and EX15-2 (Serial number 01501 to 01541). 00m am Biage 00m ing Buck Travel Motor (R) Travel Motor (L)———Gytnaer—Gyder yer Gylinder Cylinder ‘Swing Motor Hydraulic O1 Tank 1 Bypass Check Valve 1+ Left Travel 4 Boom 6- Right Travel 8- Swing 2- Bucket 5 Auxiliary 7 Am 9- Blade 3 Boom Swing 72-1-3SYSTEM / Hydraulic System EX22-2,EX25-2,EX30-2,EX35-2 Main pumps (P1, P2) draw hydraulic oil from the hy- Boom 2 11: Blade 3° Boom Swing 6- Right Travel 9 Amt T2-1-7SYSTEM / Hydraulic System PILOT CIRCUIT EX12-2, EX15-2, EX18-2 The pressure oil from the pilot pump is supplied to the following circuits: + Operation Circuit This circuit controls pressure oil from the pilot pump by pilot vaive, and moves the spools in the control valve. + Valve Control Circuit This circuit switches the flow combiner valve by ‘pening or closing the pilot signal circuit ‘Swing Parking Brake Release Circuit (Refer to “Swing Device" group in "COMPONENT OPERA- TION" section) This circuit releases the swing parking brake when the pilot signal circuit in the control valve closes. T2-1-8@ Note: ‘Swing Motor SYSTEM / Hydraulic System The illustration shows type B. Type A series machines are equipped with a manual-operated pilot shut-off valve from which the pilot relief vaive is separated. Refer to INTRODUCTION (IN-01) for the corresponding serial numbers. Pilot Valve (L) Pilot Valve (R) Contro! Valve Flow Combiner Valve OO# € 5 Type B Pilot Shut-Oft Pilot Pilot Relief Shut-off Valve Vale T2-1-9SYSTEM / Hydraulic System EX22-2, EX25-2, EX30-2, EX35-2 ‘The pressure oil from the pilot pump is supplied to the following circuits: + Operation Circuit This circuit controls pressure cil from the pilot pump by pilot valve, and moves the spools in the control valve. + Valve Control Circuit This circuit switches the flow combiner valve by ‘opening or closing the pilot signal circuit Travel Speed Changeover Circuit (Refer to “Travel Device" group in “COMPONENT OPERATION’ section) Travel speed changeover solenoid valve is switched ON-OFF by the travel speed change switch (fast speed travel pedal) to deliver travel speed changeover pressure to the travel motor. + Swing Parking Brake Release Circuit (Refer to “Swing Device® group in COMPONENT OPERA- TION” section) This circuit releases the swing parking brake when the pilot signal circuit in the control valve closes. T2-1-10@ NOTE: The illustration shows type B. SYSTEM / Hydraulic System Pilot shut-off valve with type A is manually operated. Refer to INTRODUCTION (IN-01) for the corresponding serial numbers. ‘Swing Motor Travel Motor Pict Signal Cireut Flow Combiner Valve Pilot Vaive (R) Travel Speed Change Sole- oid Valve. Pilot Shut-off Solenoid Valve Pilot Reliet Valve T2-1-11SYSTEM / Hydraulic System EX40-2, EX45-2 The pressure oil from the pilot pump is supplied to the following circuits: + Operation Circuit This circuit controls pressure oil from the pilot pump by pilot vaive, and moves the spools in the control valve. + Valve Control Circuit This circuit switches the flow combiner valve by ‘opening or closing the pilot signal circuit + Travel Speed Changeover Circuit (Refer to “Travel Device" group in “COMPONENT OPERATION’ section) Travel speed changeover solenoid valve is switched ON-OFF by the travel speed change switch (fast speed travel pedal) to deliver travel speed changeover pressure to the travel motor. + Swing Parking Brake Release Circuit (Refer to “Swing Device" group in “COMPONENT OPERA- TION’ section) This circuit releases the swing parking brake when the pilot signal circuit in the control valve closes. + Main Relief Pressure Shift Circuit (Refer to "Control Valve” group in “COMPONENT OPERATION’ section) When the travel function is operated, the pilot sig- nal circuit in the control valve is closed, increasing the relief set pressure of the main relief valve, 72-1-12SYSTEM / Hydraulic System @ NOTE: The ilustration shows type B. Pilot shutoff valve with fype A is manuelly ‘operated. Refer to INTRODUCTION (IN-01) for the corresponding serial numbers. ‘Travel Motor Pilot Valve (R) Pilot Valve (L) ‘Swing Motor Pit Stal Great Flow Combiner Valve “Travel Speed Pilot Change Soie-—ays— _.Fiter nogvave (0 i ; at Gl) Pict Shi. Soleo Valve ce) a u (6 u T2-1-13SYSTEM / Hydraulic System (Blank) 72-41-14MEMOCOMPONENT OPERATION SECTION 3 En —CONTENTS— Group 1 Pump Device Group 4 Pilot Valve Outline. T3-4-1 Outline..... T34-1 Main Pump 131-5 Operation. T3-4-2 Pilot Pump. T3-1-10 Group 5 Travel Device Group 2 Swing Device Outline Outline. 73-2-1 Travel Motor ‘Swing Motor. 73-22 Travel Brake Valve Parking Brake Changeover Valve 73-23 Travel Reduction Gear Valve Unit, 132-4 owing Reduaion Gear 3-2-7 Group 6 Others (Upperstructure) 3 “ Pilot Shut-Off Valve 13-64 r 5. Group 3 Control Valve Solenoid Valve 1362 Outline. ~ T3-3-1 Group 7 Others (Undercarriage) Hydraulic Circuit. 13-34 ‘Swing Bearing TTA Flow Combiner Valve 13-313 Center Joint. 137-2 Main Relief Valve... 13-3-14 Track Adjuster. 137-4 Overload Relief Valve 133-15 Make-up Valve. T3-3-17 587T-3-1(Blank) 587T-3-2COMPONENT OPERATION / Pump Device OUTLINE © EX122, EX152 Main pumps (1 and 2) and the pilot pump are sepa- rately installed. Main pumps (1 and 2) are engine- direct-driven pumps. The pilot pump is driven from the power take-off (PTO) of the engine. Main pumps (1 and 2) are tandem gear type pumps. ‘They supplys high pressure oil to the control valves. The pilot pump is a gear type pump. It supplies pressure oil to the pilot circuit Main Pump wh Ma Pilot Pump Pump 1 Pump 2 Delivery Port Suction Port seasencor | xtnary Por = 1 T 4 ‘Suction Port T3-1-1COMPONENT OPERATION / Pump Device + EX182 Main pumps (1 and 2) and the pilot pump are sepa- rately installed. Main pumps (1 and 2) are engine- direct-driven pumps. The pilot pump is driven from the power take-off (PTO) of the engine. Main pumps (1 and 2) are variable displacement ax- jal plunger pump swash plate type. They supplys high pressure oil to the control valves, The pilot pump is a gear type pump. It supplies pressure oil to the pilot circuit Main Pump Pilot Pump 4 Delivery Port SI on [bd Suction Port = | sssen Pon Delivery Port (Main Pump 1) Delivery Port ‘(Main Pump 2) 3-1-2COMPONENT OPERATION / Pump Device 1 EX222, EX25.2, EX302, EX35.2, EX40.2, EX45.2 Main pump (1 and 2) and the pilot pump are engine- direct-driven pumps. Main pumps (1 and 2) are variable displacement ax- ial plunger pump swash plate type. They supplys high pressure oil to the control valves. The pilot pump is 2 gear type pump. It supplies pressure oil tothe pilot circuit EX22.2, EX25-2 EX30-2, EX35-2, EX40-2, EX45-2 Main Pump 1:2 Plot Pump Main Pump 1-2 Pilot Pump 5 Ht Li Ly He oy jo Oo | J ‘Suction Port ‘Suction Por — ATT cl Lory Delvery Por Delivery Port A in Por) CJ (Main Pump 2) Delivery Port oo ‘ot Pama) H WAS otnesy ron tain Bore) Delvery Por (tain Prop 1) T3-1-3COMPONENT OPERATION / Pump Device (Blank) T3-1-4COMPONENT OPERATION / Pump Device MAIN PUMP © EX122, EX152 ‘The drive gear is mounted on the shaft engaged with the driven gear. Engine rotation drives the shaft directly, and it ro- tates along with the drive gear. When the drive gear rotates, the driven gear also ro- tates. The hydraulic oil from the suction port fills the spaces between the gears, then it flows along the inner surfaces of housing and discharges through the delivery ports. Suction Port 4 Driven Gear Driven Gear Drive Gear Drive Gear 3-1-5,COMPONENT OPERATION / Pump Device © EX182 X45. The shaft is splined to the cylinder block, and plung- ers are inserted in the cylinder block. ‘The engine rotation drives the shaft directly, and it rotates the cylinder block and plungers together. The plungers slide on the shoe plate, and reciprocate in the cylinder block by the tit of the swash plate. In the cylinder block, suction/delivery ports are placed on the inside and outside of the cylinder block alternately. Also, there are delivery ports on each side (inside and outside) of valve plate (there is only one suction port) ‘The dual outlet port design allows one pump to func- tion like two pumps having equal oil displacement. Ex22-2, EX26-2, EX302, EX35.2, EX402, EX182 shat Plunger Delivery Port aside? ( Suction Port (G “Valve Plate Suction-Deliver Port (Outside) ‘Suction: Delivery Port (Inside) Cylinder Block Cylinder Block ‘Swash Plate Valve Plate T3-1-6COMPONENT OPERATION / Pump Device EX22-2, EX25-2 Shaft Plunger Cylinder Block Swash Plate Valve Plate Teesecazoo EX30-2, EX35-2, EX40-2, EX45.2 Shaft Plunger Cylinder Block Swash Plate Valve Plate 13-1-7COMPONENT OPERATION / Pump Device ion Horsepower Control Oper © EX18.2, EX22.2, EX25-2 To prevent the loading of main pumps (1 and 2) from ‘As the discharged pressure from the pump exceeding the engine torque, pumps (1 and 2) regu- creases, the plungers press the swash plate by dis- late the delivery flow rate. charged pressure from the pump. The swash plate ‘The swash plate can be tited around the ball center. is moved to decrease the swash plate tilt unti it bal- ances with spring force. As a result of this movement, delivery flow rate from pump decreases so the load of pump decreases. EX18.2 Plunger Spring Ball —_Swash Plate serene EX22.2, EX252 Plunger Spring Ball Swash Plate T3-1-8COMPONENT OPERATION / Pump Device + EX30.2, EX35.2, EX40-2, EX45.2 To prevent the loading of main pumps (1 and 2) from ‘exceeding the engine torque, pumps (1 and 2) regu- late the delivery flow rate. The discharged pressure from each main pump is directed to the control pin through a passage in the housing. The control pin is pressed toward the ‘swash plate by the springs installed on the opposite side of control pin EX30.2, EX36.2, EX40-2, EX45.2 Plunger ‘As the discharged pressure from the pump in- ‘creases, the load on the pump also increases. At this time, the control pin moves the swash plate slightly by discharged pressure from the pump. The ‘swash plate is moved to decrease the swash plate {it unti it balances with spring force. ‘As a result of this movement, delivery flow rate from the pumps decreases so the loading on the pumps also decreases. Cylinder Block ‘Swash Plate Control Pin 13-1-9COMPONENT OPERATION / Pump Device PILOT PUMP The drive gear is mounted on the shaft engaged with the driven gear. Engine rotation (EX12-2, EX15-2, EX18-2 are driven by the power take-off (PTO) of the engine) drives the shaft directly, and it rotates along with the drive gear. When the drive gear rotates, the driven gear also ro- tates. The hydraulic oil from the suction port fills the spaces between the gears, then it flows along the inner surfaces of housing and discharges through the deliv- ery ports. Suction Port Driven Gear Drive Gear Delivery Port seonezoson2 T3-1-10COMPONENT OPERATION / Swing Device OUTLINE The swing device consists of the valve unit, parking brake changeover valve, swing motor and swing re- duction gear. ‘The valve unit prevents cavitation and overload in the swing circuit ‘The parking brake changeover valve controls the The swing motor is a swash-plate-type axial plunger motor incorporating a parking brake. The swing motor, driven by pressure oil from the pump, transmits the rotation force to the swing reduction gear. ‘The swing reduction gear converts the swing motor rotation power to a slow but large torque which rotates brake release pressure. It switches the brake the upperstructure. changeover. EX40-2, EX452 EX12.2, EX152, EX182 —_ i a valve Unit Valve Unit 0° —~ rm A Swing Motor i fi Swing Motor ‘fe Packing Parking Brake Ul Brake Changeover [ Changeover Vawve Vaive’ swing Reauc- = tion Gear cre A om vepeene fe! LJ tion Gear snr] — i EX22.2, EX252, EX30-2, EX36. — — lVaive Unit oo {|___J vssvenescor J ra [| swing motor Packing Brake Changeover ic Valve swing Rese. mn Gear ‘ ) F shat F] | — T3-2-1COMPONENT OPERATION / Swing Device SWING MOTOR The inner rotor is splined to the shaft, and the plunger is inserted in the rotor. When the pump supplies pressure oil to the swing mo- tor, the plungers are pushed down by pressure oil while sliding along the swash plate, developing turning force. As the shaft is splined to the first stage sun gear in the ‘swing reduction gear, the rotor torque is transmitted to the swing reduction gear unit EX12.2, EX16-2, EX182 oo ort nat iF a shoe 2 ULI EVEN | sow WN: LI ‘swash Pate Plunger EX222, EX25.2, EX302, EX36.2 oo +4 shat Shoe. 3 2 Thee a rotor wasn Plate - i plunger EX40.2, ExA5.2 : Kemfexe) ivi] — | th all / LP eres 8, Soe TG i) id swash Pate = Plunger Shaft T3-2-2COMPONENT OPERATION / Swing Device PARKING BRAKE CHANGEOVER VALVE ‘The parking brake is a wet-negative-type multiple disc brake which is released only when the brake release pressure oil is routed into the brake piston chamber. Also, the parking brake is automatically applied when the engine stops. When Releasing the Brake When the swing or front attachment control lever is operated, the brake release signal pressure is guided to port SH from the control valve. Then, the brake re- lease signal pressure moves the spool downward. On the other hand, the pilot pressure is always fed to port PG while the engine is running. Therefore, when the spool is moved downward and the oil port to the brake piston chamber is connected to port PG, the pilot pressure is guided to the brake piston chamber. ‘Thereby, the brake piston is pushed upward, allowing the plate and the friction plate contact to free which releases the brake. When the Brake is Applied When the control lever is returned to the neutral posi- tion, the brake release signal pressure is not guided to port SH so that the spool is moved upward, At this time, the brake release pressure oil in brake piston chamber flows back via the orifice. Accordingly, the brake piston gradually moves down- ward, allowing the plates to slowly come in contact with the friction plates enabling the swing movement to stop smoothly, Port SH Spring Spring Friction Plate 13-2-3COMPONENT OPERATION / Swing Device VALVE UNIT ‘The valve unit consists of the make-up valves and re- lief valves. ‘The make-up valve prevents the occurrence of cavita- tion in the circuit, The relief valve also protects the cir- cuit from surge pressure and overloading Make-Up Valve When the upperstructure is swung downward on 2. slope, the upperstructure is accelerated by its own weight and moves quicker than the swing motor drive speed developed by the pump oil flow rate. Therefore, cavitation can occur in the circuit, To prevent cavitation, when the oil pressure in the cir- cuit is lower than the pressure at port M (hydraulic oil tank pressure), the poppet opens drawing hydraulic, oil into the circuit so that the pump oil flow rate is re- plenished EX122, EX152, EX182, EX222, EX262, EX302, Ex35.2 Make-Up Valve Relief Valve Ex40-2, EX45.2 Relief Vatve a 3-2-4Relief Valve The relief valve functions to reduce shocks developed when starting or stopping swing movement {shockless) and to protect the circuit from overloading (relief. + EX122, EX15-2, EX18-2, EX222, EX252, EX302, £X35.2 + Shockless Operation When the pressure in the circuit increases, the pressure oil enters in the piston chamber via ori- fice of poppet and housing, to move the piston The pressure in the spring chamber is kept low during the movement of piston. Therefore, when the pressure on port HP exceeds the spring set force a poppet opens to relieve the hydraulic oi When the piston moves to the stroke end, the pressure in the spring chamber becomes equal to the pressure on port HP. As a result, the relief set force becomes to the normal pressure, so the Poppet closes. Quick Retum of the Piston ‘To secure the response capability when operating the swing suddenly in the reverse direction, there is a function to return the piston to the original po- sition by leading the pressure to the opposite side (port LP, in this case) of the piston As a result, to secure the response capability of the shockless operation, the piston is moved back to the stroke end to the right Relief Operation When the pressure in the circuit exceeds the relief set pressure, the force which acting on poppet (Pressurized Area (S1-S2)«Pressure on Port HP) exceeds the spring force, so poppet opens to al- Jow the hydraulic ol to be relieved COMPONENT OPERATION / Swi ng Device COnfice Piston Chamber Poppet Piston | Oniice Spring = Si S2_ Housing Spring Chamber, Piston 13-2-5COMPONENT OPERATION / Swing Device ee X40.2, EX45-2 Shockless Function ‘When the pressure in the swing circuit increases, pressure cil through the orifice of the poppet, the spring chamber and the hole of the cartridge from the port HP, moves the piston to the right. As long as the shockless piston is moving, the pressure in the piston chamber is maintained at low pressure. Therefore, a pressure difference arises between the front and the rear of the pop- pet. When the pressure difference increases more than spring force, the poppet is unseated, relieving the pressure oil to the hydraulic cil tank. When the shockiess piston moves to position Y on the piston guide, the shockless piston stops Therefore, the pressure difference between the front and the rear of the poppet disappears, caus- ing the poppet to re-seat Spring Spring Chamber Cartage Hole Shockless Piston ‘Shockless Piston Swing Cireult 8 Y Piston Guide + Relief Function When the pressure in the circuit exceeds the relief set pressure, the force acting on poppet (Pressurized Area (S1-S2)+Pressure on Port HP) exceeds the spring force, so the poppet opens to allow the hydraulic ol to be relieved + Quick Return of Shockless Piston To secure the response capability when operating the swing suddenly in the reverse direction. When the swing lever is moved in reverse, high oil pres- sure (swing circuit B, in this case) acts on the chamber at the right end face corner of the piston guide. Then, the piston guide is moved to the left due to the pressure difference between both ends of the piston guide. Accordingly, pressure oil flows into the piston chamber from the clearance of the piston guide and the housing. Therefore the shockless piston is moved along with the piston guide to the left original position, by which shockless function is quickly resumed. Port M (Hydraulic ‘Ol! Tank) Piston Guide orice st 82 Piston Chamber Poppet Housing T3-2-6COMPONENT OPERATION / Swing Device SWING REDUCTION GEAR © EX12.2, EX15.2, EX18-2 The swing reduction gear is a one-stage planetary- gear reduction type. The swing motor rotation force is transmitted to the first stage sun gear via the shaft The rotation of first stage sun gear is reduced by the first stage planetary gear and the first stage carrier This in turn rotates the shaft EX12.2, EX152 EX182 ‘ol | fl iE [ret J First Stage Sun Gear —_{ | _— First Stage Planetary Gear First Stage Carrier 13-2-7COMPONENT OPERATION / Swing Device © EX22.2, EX25-2, EX30.2, EX35-2, EX40-2, EX45.2 ‘The swing reduction gear is a two-stage planetary- gear reduction type. The swing motor rotation force is transmitted to the first stage sun gear via shaft The rotation of first stage sun gear is reduced by the first stage planetary gear and the first stage carrier. This in turn rotates the second stage sun gear. The rotation of the second stage sun gear is re- duced by second stage planetary gear and second stage carrier. This in turn rotates the shaft, EX22-2, EX26-2, EX30.2, EX35.2 Exa0-2, EX45.2 First Stage Sun Gear First Stage | PPianetary Gear TE First Stage First Stage Planetary Gear First Stage Sun I First Stage Carrier jecond Stage ‘Sun Gear Second Stage lanetary Gear i econd Stage Carrier Ring Gear i Carrier Second Stage ‘Sun Gear 7 Pe Ring Gear Secone Stage = Planetary Gear jecond Stage 73-2-8COMPONENT OPERATION / Control Valve OUTLINE *EX122, EX15.2, EX182 The control valve controls oll pressure, flow rate and flow direction of the hydraulic circuit The main components are: main relief valve, over- load relief valve, make-up valve, flow combiner valve and spool ‘Spools in the sections for travel, blade, boom swing and auxiliary are operated mechanically. Spools in the sections for the boom, arm, bucket and swing are operated by pilot oil pressure system. EX12.2, EX15.2, EX18-2 Travel (en) Boom Bucket Swing Boom — Aux eas =e HOGA COO Overload Reliet Vane \ Valve @ NOTE: The illustration shows the EX12-2 (Serial number 02059 and up) and EX16-2 (Serial number 01542 and up). Boom section and bucket section are re- placed with EX12-2 (Serial number 02001 to 02058) and EX15-2 (Serial number 01501 to 01541) Travel Swing Blage rr) OOOO itary re © COOCS Flow Combiner Overload Reliet Vale to OO} OO © OOK} AOKO O i Codd eee: O |_- Main Reliet_ Valve Main Relief Valve seine Make-Up Valve Overload Relief Vane Overitad Relief resent Valve 13-3-1COMPONENT OPERATION / Control Valve © EX22.2, EX25.2, EX30-2, EX35.2, EX40-2, EX452 The control valve controls oil pressure, flow rate and flow direction of the hydraulic circuit The main components are: main relief valve, over- load relief valve, make-up valve, flow combiner valve and spool ‘Spools in the sections for travel, blade, boom swing and auxiliary are operated mechanically. Spools in the sections for the boom, arm, bucket and swing are operated by the pilot oil pressure system, EX22.2, EX25.2, EX30-2, EX35.2 Travel Boom Travel (Left) Boom — Swing Bucket Auxiliary Arm (Right) Swing Blade ° = OOOO OD} 5} | QIQIQIe 6) 6) 3 {O) ©) slalelolo QOOM QCOOOE Overload Relief Overioad Relief Flow Combiner Valve Valve Valve ae — af Ad Ga ©) ©@O© © @ © 0)1 Q)|'@) QOO A O O © OC Flt Ze Overlodd Relief Make-Up Overidad Relief vane Valve Valve LI[Crorore) = T3-3-2COMPONENT OPERATION / Control Valve Exa0.2, EX45.2 Travel Boom Travel A" 7 Right) r Boom 2 Amt Swing Blade = OOOO O} || Ale © @ © COO©O ©) Overload Relief Flow Combiner Overload Relief Make-Up — ve vive vate Vane = @OWOM TONONONS ) (O) | fo 7TOOWO Main Ree Main Rett vam aie COverloSd Relief Make-Up Ovenboad Relief Overload Relief Tervenonone valve a 4 3-3-3COMPONENT OPERATION / Control Valve HYDRAULIC CIRCUIT The hydraulic circuit in the control valve is divided into 3 parts: main circuit, pilot operation circuit and pilot signal circuit. Main Circuit (EX12-2, EX15-2, EX18-2) Pressure oll from main pumps (P1 and P2) flows into the control valve, respectively. When the spool is in neutral (ie. control levers are in neutral), the pressure oil from main pump returns to the hydraulic oil tank via the neutral circuit When a spool is operated (ie. control lever is oper- ated), pressure oil from main pump flows into the ac- tuator via the spool The main circuit has a parallel circuit and a flow com- bining circuit. Combined operation is possible be- cause of these circuits ‘The pressure in main circuit (between pump and ac- tuator) is controlled by main relief valve, to prevent the pressure in main circuit from exceeding the set pressure when the spool (the contro! lever) is oper- ated The pressure in actuator circuit (between control valve and actuator is controlled by the overioad relief valve, to prevent surge pressure from exceeding the set pressure at the spool (the control lever) isin neu- tral 13-3-4@NOTE: The illustration shows the EX12-2 (Serial number 02059 and up) and EX15-2 (Serial number 0142 and up). Boom section and bucket section are re- placed with EX12-2 (Serial number 02001 to 02058) and EX15-2 (Serial number 01501 to 01541) _COMPONENT OPERATION / Control Valve Travel Travel Boom Arm Blade Motor (R) Motor (L) Boom Swing Bucket Cylinger Cylinger Cylinder Cylinder Cylinder ‘Swing Motor : = | th CJ Overload Overloas Relief Valve Relief Valve Main Relist Lt - Valve Main Rell Valve _Thi 2 I J ! as il S. q al tow Parallel Crcut — Greuit Flow Combining Circuit Ae oS Hydraulic Oi Tank P2 Pa Main Pump OOK) \ Flow Combining Circuit Parallel Ci (° T3-COMPONENT OPERATION / Control Valve Main Circuit (EX22-2, EX25-2, EX30-2, EX35-2) Pressure oil from main pumps (P1 and P2) flows into the control valve, respectively When the spool is in neutral (ie. control levers are in neutral), the pressure oil from main pump returns to the hydraulic oll tank via the neutral circuit ‘When a spool is operated (i.e. control ever is oper- ated), pressure oll fom main pump flows into the ac- tuator via the spool. The main circuit has a parallel circuit and a flow com- bining circuit. Combined operation is possible be- cause of these circuits The pressure in main circuit (between pump and ac- tuator) is controlled by main relief valve, to prevent the pressure in main circuit from exceeding the set Pressure when the spool (the control lever) is oper- ated. 13-3-6COMPONENT OPERATION / Control Valve ‘Travel Motor (R) Travel Motor (L) 8 Bucket Swing Boom Cylinder Cylinder Cylinder am Blade Cylinder Cylinder o o Cc ‘Swing Motor Overioas rloas Relief Valve Relief Valve o I) | wel TA Ty fe TALC [| n iP vaNe co o ol Para Hydraulic O11 Tank 13-3-7COMPONENT OPERATION / Control Valve Main Circuit (EX40-2, EX45-2) Pressure oil from main pumps (P1 and P2) flows into the control valve, respectively When the spool is in neutral (ie. control levers are in neutral), the pressure oil from main pump returns to the hydraulic ol tank via neutral circuit When a spool is operated (i. control lever is oper- ated), pressure oil from main pump flows into the ac- tuator via the spool. The main circuit has a parallel circuit and a flow com- bining circuit. Combined operation is possible be- cause of these circuits The pressure in main circuit (between pump and ac- tuator) is controlled by main relief valve, to prevent the pressure in main circuit from exceeding the set pressure when the spool (the control lever) is oper- ated. 73-3-8COMPONENT OPERATION / Control Valve Ear eg T {J dle a u (aia fi = i + i 4 | Ty Neutral | Parallel Circuit Cireut | 0 3-3-9Pilot Operation Circuit The spool operation is controlled by pressure oil from the pilot valve. Pilot Signal Circuit (EX12-2, EX15-2, EX18-2) The pilct signal circut flows inside each spool If an operation other than travel is operated, the pilot signal circuit is blocked by @ spool, to raise the pres- sure in the circuit (The circuit will not be blocked even if the travel spool is switched.) As a result, the flow combiner vaive switches, and the release pressure is delivered to the swing parking brake. Pilot Valve (ett EX12-2, EX15-2, EX18-2 Swing Motor Pilot Signal Circuit pe Pilot Pump OOH ? : law Combiner Valve i go ow Com COMPONENT OPERATION / Control Valve @ NOTE: The illustration shows the type B. Type A series machines are equipped with ‘a manual-operated pilot shut-off valve from which the pilot relief valve is separated Refer to INTRODUCTION (IN-01) for the corresponding serial numbers. Pitot Valve Right) Travel) T3-3-10COMPONENT OPERATION / Control Valve Pilot Signal Circuit (EX22-2, EX25-2, EX30-2, EX35-2) The pilt signal circuit flows inside each spool @ NOTE: The ilustration shows type 8. If an operation other than travel is operated, the pilot Type A series machine are equipped with a signal circuit is blocked by a spool, to raise the pres- manual-operated pilot shut-off valve. sure in the circut. Refer to INTRODUCTION (1N-04) for the (The circuit will not be blocked even ifthe travel spool corresponding serial numbers. is switched ) ‘As a result, the flow combiner valve switches. ‘Swing Motor ‘Travel Motor Pitot Valve (Right) i Controt Valve Teavel (®) © Qraveliv i t Pilot Valve (Lett) © © i (Rar: : aloo ao. oH! Pilot Signal Flow Combiner Valve i Gireut Pilot Pump Travel Speed Changeover Solenoid Valve 13-3-11COMPONENT OPERATION / Control Valve Pilot Signal Circuit (EX40-2, EX45-2) The flow combiner valve changeover circuit and main relief set pressure changeover circuit are provided in the pilot signal circuit The flow combiner valve changeover circuit flows in- side each spool. if an operation cther than travel is ‘operated, the flow combiner valve changeover circuit is blocked by a spool, raising the pressure in the cir- cuit.(The circuit will not be blocked even if the travel spool switches.) As a result, the combiner valve switches. ‘The main relief set pressure changeover circuit flows between left travel spool to right travel spool. If an ‘operation travel is operated, main relief set pressure changeover circuit is blocked by a spool, raising the pressure in the circuit (The circuit will not be blocked even if other spools are switched) As a result, the re- lief pressure of the main relief valve raises, ‘Travel Motor ‘Swing Motor Main Relief Valve Tiavel (R) a La Flow Combiner Valve Main Rel Set Presoure Changeover veut (TT ‘Changeover Gxeut Flow Combiner Valve @ NOTE: The illustration shows type B. Type A series machine are equipped with a manual-operated pilot shut-off valve. Refer to INTRODUCTION (IN-01) for the corresponding serial numbers. Pilot Valve Pit Valve Right) TI Pump T3-3-12COMPONENT OPERATION / Control Valve FLOW COMBINER VALVE When any operation, other than travel, is performed, — NOTE: The circuit for the blade, swing and boom the pilot signal passage is blocked, so the pressure in ‘swing is separated from circuit for travel. circuit increases, and the flow combiner valve spool Therefore, combined operation is possible. switches, When travel operation is performed at the same time, the pressure oil from main pump (P2) flows to travel (Fight) spool. It also flows to travel (left) spool through the flow combiner valve Therefore, traveling straight during combined opera- tions is secured. Flow Combiner Valve Neutral Position Flow Combiner Valve Operating Position Spool roter rant cra | Pil Signal cifeuk ge p form Main Pump Pi SS = Pressure Oi! From Main Pump P2 ft an T3-3-13COMPONENT OPERATION / Control Valve MAIN RELIEF VALVE Main relief valve prevents the pressure in main circuit from exceeding the set pressure. EX12-2, EX15-2, EX18-2 ‘The pressure on port HP acts on main poppet (1). When the pressure on port HP becomes larger than spring (3) force, main poppet (1) opens to relieve the pressure oil from port HP to port LP. X22-2, EX25-2, EX30-2, EX95-2, EX40-2, EX45-2 QNOTE: Ex40-2 and EX45-2 are equipped with two- stage pressure set relief valve. But, relief function is the same as EX22-2 to EX35-2 The pressure on port HP acts on pilot poppet (5) through orifice (2) n main poppet (1) and orifice (4) in seat (6) When the pressure on port HP reaches the set pres- sure, pilot poppet (5) opens to release a small quan- tity of pressure oil to port LP via passage (7) of seat ©. At this time, the pressure difference between port HP ‘and spring chamber (9) occurs, caused by orifice (2) By this pressure difference, main poppet (1) opens when it becomes larger than spring (3) force, to re~ lieve the pressure ol from port HP to port LP. Relief Set Pressure Changeover Circuit of EX40-2 and EX45-2 When the travel spool is shifted, the spool blocks the pilot signal circuit. Thereby, pilot signal circuit pres- sure increases. This increased pressure flows into the pressure rais- ing port of the relief valve, moving piston (10). Piston (10) pushes spring (8). Then, the relief set pressure is increased as much as spring (8) is compressed EX12.2, EX15-2, EX18-2 EX40-2, EX45-2 1+ Main Poppet 7 Passage 2- Ortice 8- Spring 3- Spring 9- Spring Chamber 4- Orifice 10- Piston 5~ Pilot Poppet 11- Spring Chamber 6 Seat T3-3-14COMPONENT OPERATION / Control Valve OVERLOAD RELIEF VALVE ‘The overload relief valve has two operations; one is the relief operation which prevents the pressure in the ac- tuator circuit from exceeding the set pressure, and the other is the make-up operation which prevents cavita- tion Overload relief valve is provided in boom, arm and bucket circuits. Relief Operation When the pressure in the actuator circuit rises, the pressure oil is relieved to the hydraulic oil tank. + EX12-2, EX15-2, EX18-2 ‘The pressure on port HP acts on pilot poppet (9) via ofifice (1) in piston (3). When the pressure on port HP reaches the set pressure, pilot poppet (6) opens to release a small quantity of pressure oil to port LP via passage (7). At this time, the pressure difference between port HP and spring chamber (4) occurs, caused by orifice (1), By this pressure difference, main poppet (2) opens when it becomes larger than spring (5) force, to relieve the pressure oil from port HP to port LP EX22-2, EX25-2, EX30-2, EX36-2, EXA0-2, EX45-2 ‘The pressure on port HP acts on pilot poppet (13) Via orifice (9) in main poppet (10) and orifice (16) in seat (17) When the pressure on port HP reaches the set Pressure, pilot poppet (13) opens to release a small ‘quantity of pressure oil to port LP via passage (14) in seat (17), At this time, the pressure difference between port HP and spring chamber (11) occurs, caused by ori- fice (9). By this pressure difference, main poppet (10) opens when it becomes larger than spring (12) force, to relieve the pressure oil from port HP to port p. X12.2, EX15-2, EX18-2 5/6 pT PB 1+ Orfice 5- Spring 2- Man Poppet 6- Pilot Poppet 3 Piston 7. Passage 44> Spring Chamber 8- Spring EX22-2, EX25-2, EX30-2, EX35-2, EX40-2, EX45-2 185 19510 9 p12 516 17/13/15 TY HP Lp) SC 4 14 9 Orifice 418- Spring 40- Main Poppet 16 Orifice 11 Spring Chamber 17- Seat 12- Spring 18- Spring 13- Pilot Poppet 19- Vane. 14- Passage T3-3-15COMPONENT OPERATION / Control Valve Make-Up Operation When the boom is suddenly lowered, for example, the delivery pressure oil from pump may not be suffi- cient for the actuator circuit. Accordingly, the oil is supplied to the actuator circuit from the hydraulic oil tank Also, the pressure on the opposite circuit decreases when the relief operation acts by the external force as described on the previous page. At this time, the hy- draulic oil is supplied to the actuator circuit from the hydraulic oll tank. When the pressure on port HP becomes lower than port LP, sleeve (2) [sleeve (14) for EX22-2, EX25-2, EX30-2, EX35-2, EX40-2, EX45-2] opens. Thereby, the hydraulic oil is replenished to port HP from port LP, so cavitation is prevented (make-up) X12-2, EX15-2, EX18-2 wp 1 Onfice 5~ Spring 2- Main Poppet 8- Pilot Poppet 3= Piston 7- Passage 42 Spring Chamber 8- Spring EX22-2, EX25-2, EX30-2, EX35-2, EX40-2, EX45-2 184 19510 9 12716 1771315 He 1 14 8- Orifice 15- Spring 10 Main Poppet 18 - Once 11 Spring Chamber 17 Seat 12- Spring 18: Spring 13+ Pilot Poppet 18- Valve 14- Passage T3-3-16COMPONENT OPERATION! Control Valve MAKE-UP VALVE ‘The make-up valve prevents cavitation in the main circuit It is provided in the bottom circuit of blade and boom swing, The pressure on port HP acts on spring chamber (4), through passage (1) of poppet (2). so the pressure on ort HP and spring chamber (4) becomes equal. ‘Accordingly, when the pressure on port HP is higher, the closing force [(Pressure in Spring Chamber (4) = Pressurized Area S2) + Spring (3) force] becomes larger than the opening force of poppet [Port HP Pressurized Area St], which closes poppet (2) When the pressure on port HP is lower than the pres sure on port LP (pressure on port HP is almost zero), the closing force of poppet (2) comes from spring (3) force. Therefore, when the opening force of poppet (2) {Pressure on Port LP x (Pressurized Area S2 - S1)] becomes larger than the closing force [Spring Force]. which opens poppet (2) to supply hydraulic oil to port HP Thereby, cavitation at the port HP side is pre~ vented EX12-2, EX15-2, EX18-2 ty 2 HP fo st 82 sercaaeens EX22-2, EX25-2, EX30-2, EX35-2, £X40-2, EX45.2 si 2 esazocoo 1 Passage 3- Spring 2 Poppet 4 Spring Chamber 13-3-17COMPONENT OPERATION / Control Valve (Blank) 13-3-18OUTLINE COMPONENT OPERATION / Pilot Valve The pilot valve regulates pilot oil pressure from which the control spools are operated. As standard, this type has four output pressure ports for operating front and swing functions, Front and Swing Pilot Valve PortNo | HITACHI | 1SO Standard Standard 7 ‘Boom Raise = ignt|_—2 | Bucket Rolout = 3 Boom Lower. © 4 Bucket Roll-in . 1 ‘Arm Roll-out | Swing Left Ler [2 ‘Swing Left [Arm Rollin 3 ‘Arm Rollin | Swing Right 4 ‘Swing Right _ [Arm Roi-out 13-4-1COMPONENT OPERATION / Pilot Valve OPERATION Control Lever-In Neutral (Pusher Stroke: A to B) When the control lever is in neutral, spool (6) blocks the pressure oil at port P completely. The output port is connected to port T, so the pressure at the output port becomes equal to the hydraulic tank pressure. When the control lever is moved slightly, pusher (2) and spring guide (3) move downward together, compressing retum spring (5) and balancing spring (4). At this time, as the pressure under spool (6) (output port) is equal to the hydraulic oil tank pressure, ‘spool (6) moves downwards by balance spring (4). the top of the spool is kept even with spring guide (3) This state is maintained until clearance A of spool (6) becomes zero, Control Lever-Operated (Pusher Stroke: C to D- Metering) When the control lever is moved further, the lower notch of spool (6) reaches port P. The pressure cil in port P flows into the output port via the passage in spool (6), so the pressure at the output port increases. ‘The pressure at the output port acts on the bottom of spool (6), to push spool (6) upwards. IF the acting force on spool (6) is smaller than the spring force of batance spring (4), balance spring (4) will not be pressed. As a result, spool (6) will not be pushed up, and the pressure at the output port increases continuously. If the pressure at the output port increases further, the force to push up spool (6) increases. When this force becomes larger than the spring force of balance spring (4), spool (6) pushes balance spring (4), and moves upwards. When spool (6) moves upwards, the lower notch closes, so the pressure oil does not flow into output port from port P. Thereby, the pressure at port P stops raising, Accordingly, the amount the balance spring (4) is compressed is equal to the amount the spool (6) is pressed down, so the balanced pressure between the Spring force and the force on spool (6) becomes the pressure on output port. Control Lever-Full Stroke (Pusher Stroke: E to F) ‘When the control lever is moved to full stroke, pusher (2) is moved down until spring guide (3) comes into contact with the shoulder of casing, Thereby, spool (6) is pressed directly by the bottom of, pusher (2). As a result, the lower notch of spool (6) does not close even if the pressure on output port rises As a result, the pressure at the output port side becomes equal to the pressure on port P. Delivery Port Pressure (Pilot Pressure) AB Pusher Stroke OUTPUT DEAGRAM T3-4-2COMPONENT OPERATION / Pilot Valve 1 2 Pusher Stroke: A to B Post T Port P Output Port Lower Noten Pusher Stroke: C to D 2 5 4 I! Pont [i 5 pone =Erh s ouput Pon respon cam 3+ Spring Gude 5 Pusher 42 Balonte Song (Clearance A: 0} Pusher Stroke: E to F Por T Return Spring 6 -Spoo! T3-4-3COMPONENT OPERATION / Pilot Valve (Blank) 134-4COMPONENT OPERATION / Travel Device OUTLINE The travel device consists of travel motor, travel The travel reduction gear is a two-stage planetary-gear reduction gear and travel brake valve reduction type, reducing travel motor speed, increasing The travel motor is a variable displacement axial travel motor torque, and allowing the sprocket and plunger swash plate type. This motor is operated by _ track to rotate pressure oil from the pump, and transmits the rotation The travel brake valve functions to protect the travel to the travel reduction gear circuit EX12-2, 15-2, 182 EX22-2, 26-2, 30-2, 35-2 Travel Brake Valve Travel Reduction Gear Travel Brake Valve Travel Reduction Gear C Vue ay C am te HOF f os Travel Wotor Travel Brake Valve ravel Reduction Gear EX40-2, 45-2 wa Travel Redvct Travel Motor ssscama0o 3-5-1COMPONENT OPERATION / Travel Device TRAVEL MOTOR ‘The travel motor consists of valve plate (3), rotor (2) plungers (1), swash plate (4), shaft (5) and control piston (8) [Not provided in EX12-2, EX15-2 and EX18-2}. Rotor (2) is connected to shaft (5) by a spline joint, and plungers (1) are inserted in rotor (2) When the pressure oil is supplied from the pump, plungers (1) are pushed. Swash plate (4) is installed at ‘an angle toward plungers (1), shoe (6) slides on swash plate (4), so rotor (2) rotates. This rotation is transmitted to the travel reduction gear via shaft (5). @ NOTE: Rotor (2) is pushed by spring (7) force and comes into contact with valve plate (3).When the pressure in rotor (2) the end (A) of rotor bore pushing rotor(2) to valve plate (3) 3-5-212-2, EX16-2, EX18-2 7 Exa0-2, EXA5-2 1. Plunger 2+ Rotor COMPONENT OPERATION / Travel Device 5 2,4 5 af/i4 6 31 me 274 5 7 6 8 3- Valve Plate 5. Shat 7 Spring 4- Swash Plate 6 Shoe 8- Control Piston 3-5-3COMPONENT OPERATION / Travel Device TRAVEL BRAKE VALVE The travel brake valve consists of counterbalance valve (1), relief valves (3) and travel speed changeover valve (2). Counterbalance valve (1) has two functions; one is to start and stop the travel smoothly, and the other is to prevent the machine from running away while descending slopes. Relief valve (3) prevents the pressure in travel circuit from exceeding the set pressure. Travel speed changeover (2) valve is switched by pressure oil from the travel speed changeover solenoid valve. It switches the travel speed by the control piston. EX12-2, EX18-2, EX18-2 @nore: €x12-2, EX15-2 and EX18-2 are not provided travel speed changeover valve (2) and relief valve (3) 1+ Counterbalance Valve «4 Brake Valve 13-5-4COMPONENT OPERATION / Travel Device (Gross Section XX Gross Section VY EX40-2, EXA5-2 1 2 } 4 Gross Section YY Teanoceaea 1+ Counterbalance Valve «2 ‘Travel Speed Changeover 3- Relief Vale 4 Brake Vave valve T3-5-5COMPONENT OPERATION / Travel Device Counterbalance Valve ‘* Travel Operation ‘When pressure cil from control valve is supplied to port P1, the pressure oil flows to motor port AM through the inside of spool (8) and opens check valve L. (9). On the other hand, the return oil from motor port BM is blocked by check valve R (6) and spool (8) Thereby, the pressure on port P1 side increases gradually, so the pressure on port P1 enters into spring chamber (13) from orifice L (2), and moves spool (8) to the right by the pressure at the end surface of spool (8) As a result, spool notch (7) opens so port BM and port P2 connect, so the travel motor rotates. ‘= Descending Operation ‘When the machine travels down a slope, the travel motors are forcibly driven by the machine weight so that the motor draws oil like a pump. ‘The pressure oil in port P1 is drawn into the travel motor, so the pressure on port P1 decreases, Thereby, spool (8) returns to the left, and returning oil from port BM to port P2 is restricted, so the oil pressure brake is activated ‘When the returning oil from port BM is restricted, the pressure on port P1 increases again, and moves spool (8) to the right, so the motor rotates. This repeat movernent of spool (8) (hydraulic brake action) prevents the machine from overrunning 13-5-6COMPONENT OPERATION / Travel Device @ NOTE: The illustration shows the EX22-2. bs pr ft P2 oy Vie | ; eet ft Slaw ee 2 oer 3-5-7COMPONENT OPERATION / Travel Device Travel Speed Changeover Valve (EX22-2, EX25-2, EX30-2, EX35-2, EX40-2, EX45-2) There are two surfaces on swash plate (7), surface (2) and surface (b). Surface (2) makes contact with the housing at slow speed, and surface (b) makes contact with the housing at fast speed ‘Two balls (4) are located off the center line on swash plate (7), so they can roll freely. ‘Slow Speed Operation When the fast speed travel pedal is in the slow speed position, spool (1) is pushed to plug (12) side by spring (2) force, connecting control piston (6) chamber to the tank port. Thus, there is no pressure applied to control piston (6), to push swash plate (7) to change its inclination For this reason, the angle of swash plate (7) is “a” and the travel motor rotates at slow speed. 13-5-8COMPONENT OPERATION / Travel Device EX22-2, EX25-2, EX30-2, EX35-2 Large Angie iB Small Angie High Pressure " EX40-2, EX45-2 a 2 1 1+ Spool 2- Spring 3- Plunger Low Pressure wt le a 12 1 4- Steel Bal 7+ Swash Plate 5+ Spring 8 Shoe 5 Control Piston 9 Rotor Surface a Low Pressure ‘eseczotone 34 vis 10 Spring 11- Valve Plate 12 Plug (Ex402, EXe52 Spacer) 3-5-9COMPONENT OPERATION / Travel Device + Fast Speed Operation When the fast speed travel pedal s in the fast speed position, the pressure oil from the travel speed changeover solenoid valve is supplied to spool (1) left side, moving spool (1) to spring (2) compressing side Motor driving pressure P1 (P2) is applied to control piston (6) chamber, through port M1 (M2) and port Pit (Pi2). Swash plate (7) is pushed by control piston (@), the angle of swash plate (7) is “B” and the travel motor rotates at fast speed When the engine stops, no pressure oil from the pilot pump, spool (1) is move to the plug (12) side by the spring (2) force. Accordingly, control piston (6) chamber is connected to the tank port. and swash plate (7) is pushed by 2 spring (10), the angle of swash plate (7) is “a” (large angle) As a result, the travel motor always rotates in slow speed whenever the engine is restarted T3-5-10__COMPONENT OPERATION / Travel Device EX22-2, EX25-2, EX30-2, EX35-2 Tsurtace Pt Surface ONO High Pressure Low Pressure High Pressure Low Pressure =H#0204008 10 EX40-2, EX45-2 om =o ~ofk way S ‘ OX] _ tion a Pressure = 12 10 2 1 Ts reaeansa00e 45 Spool 5+ Spring 7+ Swash Plate 12. Pog (Ex40-2. 45-2 Spacer) 2+ Spring 6- Control Pston 10- Spring T3-5-11COMPONENT OPERATION / Travel Device Relief Valve (EX22-2, EX25-2, EX30-2, EX35-2, EX40-2, EX45-2) The relief valve functions to reduce shocks developed when starting or stopping travel_ movement (shockless) and to protect the circuit from overloading (relief, Q@NOTE: The opening force (Pressurized Area S1xPressure on Port HP) and closing force (Pressure of spring chamberx Pressurized Area S2)+spring force) act on poppet (6) And, the pressurized area S2 of the poppet (6) is smaller than S1 + Shockless Operation When the pressure in the circuit increases, the pressure oil enters in the piston chamber via orifice (2) of poppet (6) and seat, to move the piston(5) to left side. ‘The pressure in the spring chamber is kept low during the movement of piston (5). Therefore, when the pressure on port HP exceeds the spring set force a poppet opens to relieve the hydraulic oil, Therefore, the closing force of poppet (6) becomes only by the spring (3) force. Accordingly, the force which acting on poppet (Pressurized Area S1xPressure on Port HP) exceeds the spring (3) force, so poppet (6) opens to allow the hydraulic oil to be relieved Relief Operation ‘When the piston (5) moves to the stroke end, the pressure in the spring chamber becomes equal to the pressure on port HP (The relief set force becomes to the normal pressure, so the poppet closes.) ‘The opening force (Pressurized Area S1xPressure on Port HP) and closing force ((Pressure of spring chamberx Pressurized Area S2)+spring force) act on poppet (6). Accordingly, when the opening force on poppet (6) (Pressurized Area S1*Pressure on Port HP) become larger than closing force ((Pressure of spring chamberx Pressurized Area S2)+spring force), so poppet (6) opens to allow the hydraulic oil to be relieved. €X22-2, EX25.2, 6X02, A352 7 382 EXA0-2, EX45-2 gy S20 pt 73 = 2 a se w/6 sia 1+ Relief Vave 5- Piston 2+ Orifice 6- Poppet 3 Spring 7 Onfice 4 Once T3-5-12COMPONENT OPERATION / Travel Device TRAVEL REDUCTION GEAR The travel motor rotates first stage sun gear (3), and As second stage carrier (7) and the travel motor the rotation is reduced by first stage planetary gear housing is united into one part, the rotation of second (2) and first stage carrier (1), and is transmitted to stage planetary gear (6) is transmitted to the sprocket second stage sun gear (4). The rotation of second via the ring gear. stage sun gear (4) is reduced by second stage planetary gear (5) and second stage carrier (7) EX12.2, EX15-2, EX18-2 [‘/ . EF EX22-2, EX25-2, EX30-2, EX35-2 1 t s— lels le 7 ssreoszent EX40-2, EX45-2 5 1,2 3 } 4 TE 1| Ere Vy 7 8 yesosszoes 1+ First Stage Carer 3- First Stage Sun Gear 5- Second Stage Planetary 7- Second Stage Carrier Gear (Motor Housing) 2- First Stage Planetary Gear 4- Second Stage Sun Gear 6 - Ring Gear 13-5-13COMPONENT OPERATION / Travel Device (Blank) 73-5-14COMPONENT OPERATION / Others (Upperstructure) PILOT SHUT-OFF VALVE The pilot shut-off valve is a manual-operated switch valve. The spool in the pilot shut-off valve is rotated by moving the pilot control shut-off lever to turn on or off the pilot cil flow to the pilot valves @ NOTE: Only Type A is provided in the pilot shut-off valve with al the models as weil Refer to INTRODUCTION (IN-01) for the corresponding serial numbers. ‘= When the pilot control shut-off lever is lock position The spool of the lock vaive becomes closing position, pressure oil from the pilot pump does not flow into the pilot valves. Thus, the front attachment and swing functions can not be operated From Pilot Pump ‘* When the pilot control shut-off lever is unlock posi- tion The spool of the lock valve becomes opening posi- tion, pressure oil from the pilot pump flow into the pilot valves, Thus, the front attachment and swing functions can be operated Pilot Shut-Off valve To Pilot Pump 13-6-1COMPONENT OPERATION / Others (Upperstructure) SOLENOID VALVE ‘There are two kinds of solenoid valves; one is the So- lenoid valve for shutting off the pilot pressure, the other is the solenoid valve for the travel speed changeover which switches the travel speed @ NOTE: The ilustration shows the EX45-2. Only Type B is provided in the pilot shut-off solenoid vaive with all the models as well Refer to INTRODUCTION {IN-01) for the corresponding serial numbers, Solenoid Valve for Pilot Shut-off The solenoid valve is switched ON/OFF by the posi- tion of the pilot control shut-off lever to control the pi- lot pressure to the pilot valve When the pilot control shut-off lever is in the LOCK position, the plot shut-off switch is OFF. By this action, solenoid valve is OFF, so that pilot pressure is blocked by the solenoid valve spool. As a conse- quence, the pressure oil is not delivered to the pilot valve. When the pilot control shut-off lever is in the UN- LOCK position, the pilot shut-off switch is ON. By this action, the solenoid valve is ON, so the pilot pressure is supplied to the pilot valve through the solencid valve spool Solenoid Valve for Travel Speed Change 2m over ‘The travel speed is controlled by the fast speed travel pedal. When the fast speed travel pedal is in the slow speed position (released position), the travel speed changeover switch is OFF. By this action, the sole- noid valve is OFF, so that pilot pressure is blocked by the solenoid valve spool. As a consequence, the travel speed changeover pressure is not delivered to the travel motor. ‘When the fast speed travel pedal is in the fast speed position (step-on position), the travel speed changeo- ver switch is ON. By this action, the solenoid valve is ON, so that pilot pressure is delivered to the travel motor as the travel speed changeover pressure through the solenoid vaive spool, Solenoid Valve for pilot Shut-off Solenoid Valve for Travel Speed Changeover Ks Pump ‘To Hy- raulic On Tank Pilot Controt ‘Shut-Off Lever Pilot Shut-Off Switen From Pilot Pump To Travel Motor To Hydraulic i Tanke Fast Speed Travel Pedal SX x T3-6-2COMPONENT OPERATION / Others (Undercarriage) SWING BEARING The swing bearing supports the upperstructure on the Outer race (1) is bolted to the upperstructure undercarriage and allows the upperstructure to rotate _ Inner race (2) is bolted to the undercarriage. smoothly. ‘The internal gear meshes with the pinion of the swing The swing bearing is a single-row ball-type. device The major parts of the swing bearing are outer race (1), inner race (2) with internal geer, ball (5), support (4) and seal (3) 4 5 1+ Outer Race 3. Seal 4- Support 5- Ball 2. Inner Race 13-741COMPONENT OPERATION / Others (Undercarriage) CENTER JOINT The center joint is a 360° rotating joint. It allows oil to flow to and from travel motors (12) and blade cylinder (13) without twisting hoses when the upperstructure is, rotated Spindle (10) is fastened to the undercarriage using four bolts and body (5) is fastened to the upperstructure using lock pins Body (5) rotates together with the upperstructure around spindle (10) during swing operation il flows into and through the passages in body (5) to spindle (10) and then out of spindle (10) to travel motor (12) and blade cylinder (13). Oil seal (11) prevents oil leaks from the clearance be- tween spindle (10) and body (5) @ NOTE: Port G (for Travel Speed Changeover) and port DR (Drain) are not provided on EX12-2, EX15-2 and EX18-2, l ot Hydraulic Cireuit 3-7-2COMPONENT OPERATION / Others (Undercarriage) Mounting face to the track frame Tose 1+ Port E Blade5RBR)/ Pressure Oil fom Por & Lower 2+ Port F Glade eee)? Pressure Oil rom Port F 3+ Port G (for Teavel Speed Changeover) / Pressure Oil ftom Por G 4 Port DR (Drain) / Pressure Oil fom Pot OR 5. 6 7 Body Port A (Travel Right Re verse) / Pressure Oi from Por A. Port C (Travel Left Re- verse) / Pressure Oil from Por C. 8. Port B (Travel Right For. 11 - Seal ward) / Pressure Oil fom Port 8 9 PortD (Travel Let For 12. Travel Motor ward) / Pressure Oil fom Port D 10- Spindie 13 Bade Cyinger 3-7-3COMPONENT OPERATION / Others (Undercarriage) TRACK ADJUSTER The track adjuster located on the side frame is com- posed of spring (4) and adjuster cylinder (5). Spring (4) absorbs loads applied to the front idler. Adjuster cylin- der (5) adjusts track sag. ‘© Grease is applied through the grease fitting into chamber (A) of adjuster cylinder (5) as illustrated be- low. The pressure of the grease pushes piston rod (6) out and decreases track sag. + To increase track sag, loosen valve (1) 1 to 1.5 turns counterclockwise to release grease from the track adjuster cylinder through the grease discharge out- let By cxti0N; 00 not loosen vaive (1 quickly oF loosen it too much as high-pressure grease in the adjusting cylinder may spout out. Loosen carefully, keeping body parts and face away from valve (1 Never loosen grease fitting. Grease Fitting Grease Discharge Outlet — | Track Adjuster (Rubber Crawier) [Lae Grease Discharge Grea Track Adjuster (Iron Crawler)

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