Internal use only

PRODUCT
INFORMATION
Giant Hydraulic Excavator Series
EX1200-5 to EX5500-5

Introducing the
Introducing the Machine
Machine
Information Center
Information Center (MIC)
(MIC)
Mining
Mining

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Contents
Introduction
1. EXPLANATION OF THE MIC MINING
1.1 What’s the MIC Mining?
1.2 Applicable Models
2. USE OF THE MIC MINING
2.1 Example 1: Fault Diagnosis on the EX2500-5
2.2 Example 2: Preventive Maintenance on the EX5500-5
3. OPERATING DATA BY THE DLU − MIC MINING
3.1 Functions Using the PDA
3.2 Functions Using the PC
4. OVERALL CONFIGURAITON OF THE MIC MINING
5. OPTIONAL DEVICES
5.1 Satellite Communication System
5.2 Pump Monitor System (Except the EX1200-5 and EX1200-5C)
5.3 Connection to the MMS (Modular Mining System)
6. OPERATING PRECAUTIONS
6.1 What’s the MIC Mining?
6.2 Downloaded data from the DLU is required to be kept by the user or dealer.
6.3 If the user has any request or feels inconvenience like:
6.4 How to Contact
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 Introduction

This information introduces the Machine Information Center Mining, called

the MIC Mining, that is provided standard on the Hitachi Giant Hydraulic
Excavator Series, EX1200-5 to EX5500-5.

For details of system initialization, use and operation (such as system

requirements, software acquisition, data downloading / uploading, and data
reporting / analysis), refer to respective operating manuals.

We hope this information will help you make effective use of the MIC
Mining, and encourage sales of the Hitachi Giant Hydraulic Excavator
Series.

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1.
　　 EXPLANATION OF THE MIC MINING
1.1 What’s the MIC Mining?
On the global mining market, what customers need most is a 24-hour working giant
hydraulic excavator …
with minimized downtime and real-time production data acquisition.
To respond to the customers’ needs, Hitachi Contruction Machinery set up the goal:
to provide preventive maintenance for less downtime, and real-time daily
production reporting.

At the present phase (Phase 1), the MIC Mining is provided standard on the EX-5
series, and offers downloading tool (PDA), data acquisition system including
commercial release of data display software, and satellite communication system
(optional).
At the next phase (Phase 2, 3), the development of
new functions, such as data analysis and embodiment
of preventive maintenance, is scheduled.

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For better understanding, the features of the MIC Mining will be described using a
few application examples.

F e a t ur e s o f t he M I C M i n i n g a r e :
• Less fault diagnosis time
• Preventive maintenance using operating data showing a sign of malfunction

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1.2 Applicable Models
Models with MIC Mining (as Standard Equipment)
EX1200-5 / EX1200-5C
EX1900-5
EX2500-5
EX3600-5
EX5500-5

Models with MIC Mining (as Optional Equipment)

EX2500-1
EX3500-1 / EX3500-2 / EX3500-3
EX5500-1

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2.
　　 USE OF THE MIC MINING
2.1 Example 1: Fault Diagnosis on the EX2500-5
If fault is suspected, it is necessary to stop the machine to find its cause.
With the MIC Mining, fault can be identified using the accumulated operating data.
Let’s see how the MIC Mining works on the EX2500.

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We received a claim from a customer − the front attachment speed decreased several
times. Responding to this claim, we made an investigation immediately, but could not
find the cause.
Furthermore, we checked the data (Table 1) downloaded from the machine (a). There
were differences between alternator charging time and engine operating time. Then,
we inspected the N sensor, and lastly found iron particles deposited on it. This caused
the power-reducing system to work, retarding the front operation.
This is a typical example showing that the downloaded data helps make quick fault
diagnosis.

Table 1
Date Time Engine Operating Time (Minute)Alternator Charging Time (Minute)
Oct. 1 2002 12.00 30 30
12:30 28 30
13:00 0 30
13:30 0 30
Download a
18:00
Oct. 2 2002 8:00 30 30

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 2.2 Example 2: Preventing Maintenance on the EX5500-5
When malfunctioning occurs, a countermeasure must be taken. The periodically
downloaded data may include a sign of malfunctioning. If such a sign of
malfunctioning is found, serious trouble can be avoided by eliminating the cause in
advance.

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Here is a typical example of preventive maintenance on the EX5500.
Table 2 shows operating temperatures of the hydraulic oil in normal operation, with
sign of malfunctioning and at malfunctioning. On the middle graph, part of the
hydraulic oil reached 80° to 90°C which told a sign of malfunctioning. By finding this
sign and eliminating its cause, the occurrence of malfunctioning (the right graph)
could be avoided. This helped reduce downtime significantly.
Table 2

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3.
　　 OPERATING DATA BY THE DLU - MIC Mining
System Check Conditions
Engine
Communication
Engine, R Engine, L

MC (PVC) MCU Speed Fuel Rate Blowby Speed Fuel Rate Blowby

Model ON/OFF ON/OFF 1/min % X30 Pa 1/min % X30 Pa

EX2500-1 9 9 9 N/A N/A N/A N/A N/A

EX3500-1, 2, 3 N/A 9 N/A* N/A N/A N/A N/A N/A

EX5500-1 9 N/A 9 N/A N/A 9 N/A N/A

EX1200-5 9 N/A 9 9 N/A N/A N/A N/A

EX1900-5 9 N/A 9 9 N/A N/A N/A N/A

EX2500-5 9 N/A 9 9 9 N/A N/A N/A

EX3600-5 9 N/A 9 9 N/A N/A N/A N/A

EX5500-5 9 N/A 9 9 9 9 9 9
N/A: Not Available 9: Available
* Engine running status is shown. (Refer to the next table)
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 Other Output

Operation Travel Oil Temp. Engine

Model ON/OFF ON/OFF ON/OFF ON/OFF

EX2500-1 9 9 9 N/A

EX3500-1, 2, 3 9 9 9 9

EX5500-1 9 9 9 N/A

EX1200-5 9 9 9 N/A

EX1900-5 9 9 9 N/A

EX2500-5 9 9 9 N/A

EX3600-5 9 9 9 N/A

EX5500-5 9 9 9 N/A

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 System Check Alarms (1 and 2)

EX2500-1 EX3500-1,2,3 EX5500-1 EX1200-5 EX1900-5 EX2500-5 EX3600-5 EX5500-5

Alarm 1 Alternator Charging (Fault) 9 9 9 9 9 9 9 9
Coolant Level (Low), R* 9 N/A 9 9 9 9 9 9
Coolant Level (Low), L N/A N/A 9 N/A N/A N/A N/A 9
Coolant Temp. (Overheating), R* 9 9 9 9 9 9 9 9
Coolant Temp. (Overheating), L N/A N/A 9 N/A N/A N/A N/A 9
Hyd. Oil Level (Low) 9 9 9 9 9 9 9 9
Hyd. Oil Temp. (Overheating) 9 9 9 9 9 9 9 9
Engine Oil Pressure (Low), R* 9 9 9 9 9 9 9 9
Engine Oil Pressure (Low), L N/A 9 9 N/A N/A N/A N/A 9
Exhaust Temp. (High) N/A N/A N/A 9 9 N/A 9 N/A
Engine Stop Signal N/A N/A N/A 9 9 N/A 9 N/A
Engine Speed Reduction N/A N/A N/A 9 9 N/A 9 N/A
Engine Torque Reduction N/A N/A N/A 9 9 N/A 9 N/A
* For EX2500-1, “R” will not be shown.
Presence of alarm is displayed in two windows (Alarm 1 and Alarm 2).
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 EX2500-1 EX3500-1,2,3 EX5500-1 EX1200-5 EX1900-5 EX2500-5 EX3600-5 EX5500-5
Alarm2 Pump Transmission Oil Pressure 9 9 9 9 9 9 9 9
(Low), R*
Pump Transmission Oil Pressure N/A 9 9 N/A N/A N/A N/A N/A
(Low), L
Emergency Stop 9 9 9 N/A 9 9 9 9
Buzzer Stop 9 9 N/A 9 9 9 9 9
Fuel Level (Low) 9 9 9 9 9 9 9 9
Contamination Lamp 9 9 9 9 9 9 9 9
Air Cleaner Restriction 9 9 9 9 9 9 9 9
Auto Lubrication (Fault) 9 9 9 9 9 9 9 9
Engine Controller (Fault) 9 9 N/A N/A N/A N/A N/A N/A
Stop Lamp, R N/A N/A N/A N/A N/A 9 N/A 9
Stop Lamp, L N/A N/A N/A N/A N/A N/A N/A 9
Protection Lamp, R N/A N/A N/A N/A N/A 9 N/A 9
Protection Lamp, L N/A N/A N/A N/A N/A N/A N/A 9
* For EX2500-1, “R” will not be shown.

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 3.1 Functions Using the PDA

EX1900-5 to 5500-5 EX1200-5 EX1200-5C

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The following functions are available by connecting the PDA to the DLU downloading port
in the cab.

y Real-time Monitoring of DLU Data (System Check)

Operating Conditions (PDA)

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y Downloading Data

yDLU Initialization
(SAD : Settings Adjustment by Dealers)

DLU Time Setting

Hour Meter Setting
Serial Number Setting
DLU Memory Clearing

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3.2 Functions Using the PC

y Creating Graphs

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y Operating Record

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4.
　　 OVERALL CONFIGURATION
　 OF THE MIC MINING
The MIC Mining comprises the DLU on the machine, the PDA that retrieves data
from the DLU by downloading, and the PC that reads and analyzes the downloaded data.
Figure below shows schematic diagram of the MIC Mining.

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 The DLU collects alarm signals of the monitor panel in the cab, and stores alarm
occurrence time and operating hours. This stored data can be downloaded to the PDA,
and displayed on the PC
The figure below shows functional diagram of the MIC Mining.

MIC Mining

DLU Palm PC

Data Data Data Real-time Data Reporting

Collecting Storing Downloading Monitoring Management

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5.
　　 OPTIONAL DEVICES
5.1 Satellite Communication System

The satellite communication system enables daily monitoring of the hydraulic

excavator working at a distant jobsite. More specifically, types and frequency of alarms,
as well as cumulative operating hours of the engine can be read up to the previous day.
For details of available data, refer to the operation manual of each model. Notice that
applicable areas are limited, contact Product Support Division, Hitachi Construction
Machinery for more details.

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5.2 Pump Monitor System
(Except the EX1200-5 and EX1200-5C)
Each pump delivery flow can be monitored for easy pump condition analysis.

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5.3 Connection to the MMS (Modular Mining System)
The MIC Mining can be connected to the MMS mine management system in order
to transmit real-time operating conditions and alarm data in part.

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6.
　　 OPERATING PRECAUTIONS
6.1 IMPORTANT : Stored Data will be over-written from
older one.
Operating data is downloaded to the PDA from the DLU, and read and analyzed by
the PC. When data is stored up to the limit (80% of full storage capacity) of the DLU,
the download lamp goes on. At this time, it is required to download the data to the
PDA. Otherwise, the stored data will be deleted in sequence, starting with the older
one.

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 6.2 IMPORTANT : Downloaded data from the DLU is
required to be kept by the user or dealer.
The downloaded data is the user’s property, and it is prohibited to release it to a
third party without permission of the user.

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 6.3 IMPORTANT : If the user has any request or feels
inconvenience like:
• Request for downloading and analyzing other data for more effective use of the
MIC Mining.
• Improvements in devices and usage
please contact Product Support, Hitachi Construction Machinery. We will be
happy to assist in solving a problem.

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 6.4 How to Contact
When you need Hitachi’s analysis or support services, please mail the downloaded
data to Hitachi (e-mail address: hms-support@hitachi-kenki.co.jp).

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 END

PS-E206_CD 03.03 (KA)

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1. System Configuration
The Basic Monitoring system for EX3600-5 is a system that detects operational
statuses of the machine or warning events and then stores the data. DLU( Data
Logging Unit) , the system’s main unit, obtains through a serial communication the
sensor and switch signals which have been entered into the two main controllers,
MC(A) and MC(B), for control purpose and also warning lamp output signals the
two main controllers produce for the Panel Display Module.
The DLU is also connected to CSU( Contamination Sensing Unit ) and obtains
warning of contamination within the hydraulic oil for each pump and motors through
CAN communication*.
DLU internally has a clock function and controls the operational statuses by time or
day and stores the occurrence times of the warnings.
It is possible to download machine operational statuses or warnings stored in DLU
by connecting RS-232C(Service Port) to the personal computer.
The PC Download Warning Lamp lights up as prestored data superscription warning
when the data which has not yet been downloaded into the personal computer
exceeds 80% of the storage memory. The PC Download Warning Lamp blinks at a
frequecy of 1 second when there is any abnormality in DLU itself , sensor inputs, or
communication lines(See System status in 2.2 and Faults in 2.3 for more details).
By using CAN communication*,it is possible to link the Basic Monitor System to
optional equipment such as Pump Flow Monitor which fault-diagnoses pumps.
Furthermore, Pump Flow Monitor data can be read on the personal computer by
using RS232C(Service Port). By connecting the satellite communication unit
(optional equipment) to the additional RS232C Port, it is possible to transfer part of
the operational statuses or warnings to a personal computer in the office on daily
bases.
By connecting the Dispatch of Modular Minings System Inc. to RS422Port, it is
possible to transfer part of the operational statuses or warnings to the Dispatch.
*This system’s “CAN communication” is distinctive to Hitachi Construction
Machinery and it cannot be connected to a third party CAN.

2. Basic Monitoring Data

There are two types of data that are stored in DLU and that can be read by the
personal computer; data on operational statuses and data on events.

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 PC DOWN LOAD
WARNING LAMP

RS-232C PORT PANEL DISPLAY MODULES

RS-422 (SERVICE PORT)
Modular Minings System
Dispatch RS-232C PORT

Satellite
Comm.Radio

DLU

BASIC MONITORING MODULE ＭＣ(A)

ＭＣ(B)

C-MOS
CSU
(Contamination
Sensing Unit)
Sensors & Switches
C-MOS
Sensors & Switches

CAN CAN Option Unit

Pump Flow Monitor
Contamination Sensors
Fig.1 EX3600-5 Basic Monitor System

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 Table 2 Data
Data Name Definition
Operational status Life Chronology of total (operational) statuses from the time
DLU has been mounted
Hours Chronology of operational statuses checked at
thirty-minute intervals by using the internal clock (is able
to store up to 2000 hours of data)
Days Chronology of daily operational statuses checked by using
the internal clock.
Events Events Chronology of event occurrence / neutralization
Operational status "Life" is the data that chronicles the total operational statuses from
the time DLU has been mounted on the vehicle. "Hours" are the data that chronicle
the operational statuses at thirty-minute intervals through the internally mounted
clock. It can store up to 2000 hours of data. Just like "Hours", "Days" are the data
that chronicle the daily operational statuses by using the clock that has been mounted
internally .
"Events" that chronicle events are the data that reveal the occurrence/neutralization
of warning. In addition to showing the type of warning, it also shows the time of
warning occurrence/neutralization.

2.1 Operational status

Table 2.1 lists the data items that can be seen in Life, Hours and Days
Table 2.1 Life, Hours, Days
Operational status Life Hours Days
Starting Time Data commencement time －
Total Eng.Running Total engine operation time
Alternator Charge Charge time
Eng.Running Engine ON time
Operating Operation time
Traveling Traveling time
Hyd.Oil Temp.(Histogram) Hydraulic oil temperature frequency
distribution
Hyd.Oil Temp.(Maximum) Maximum hydraulic oil temperature value
Eng.Speed (Histogram) Engine rotation frequency distribution
Eng.Blow-by Pressure Average engine blow-by pressure － － －
Eng.Fuel Rate Average engine fuel consumption － －
EVENTS Occurrence frequency of each warning － －
There are two frequency distributions in hydraulic oil temperature frequency
distribution:80-90 degrees in Celsius and 90 degrees in Celsius or more.
There are two frequency distributions in engine rotation frequency distribution: 1200
/min. – 1450 /min. and 1450 /min. or more.

The average engine fuel consumption is the average ratio in a specific time interval
to the rated fuel consumption at full load which is 345 [L/hr] for EX3600-5. This

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 ratio is shown in percentage from 0% to 255%. In order to obtain the actual
average fuel consumption in a specific time interval, the ratio should be multiplied
by 345 and divided by 100.

2.2 Events
The detection-events detects the occurrence/neutralization of warning lamps.
Events also detects any status changes to the monitor system. Table 2.2 lists the
detection items.
Table 2.2 Events
Category Item
Warning Status Alternator Charge (Fault)
Coolant Level (Low)
Coolant Temp.(OverHeat)
Hyd.Oil Level (Low)
Hyd. Oil Temp.(OverHeat)
Eng.Oil Press.(Low)
Pump Trans. Oil Press.(Low)
Fuel Level (Low)
Contamination Lamp
Air Cleaner Restriction
Auto-Lubrication (Fault)
Exhaust Temp (High)
Engine Stop Sig.
Engine Speed Derate
Engine Torque Derate
Pump Contamination Status From Pump No.1 to No.6 ( ch.1-ch.8)
Front Left Swing Motor Drain (ch.17)
Rear Left Swing Motor Drain (ch.18)
Front Right Swing Motor Drain(ch.19)
Rear Right Swing Motor Drain(ch.20)
Travel Motor Drain (ch.21)
Operational Status Key Switch
Engine
Lamp Check Switch
Emergency Stop
Buzzer Stop Switch
System Status RTC Date Set Write
Option unit data Comm. (Fault)
Change Option Unit
System Error

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Warning Lamp Status
The warning lamps placed in the cab console serve as main detectors in a warning
event except for the Engine Speed Derate signal and Engine Torque Derate signal
which are both control signals to the engine control unit.
There is no Hyd. oil temp.(overheating) warning lamp in the cab console, but when
hydraulic oil temperature exceeds 95 degrees in Celsius or above, DLU is able to
detect an “overheat” of hydraulic oil. This event is neutralized when the
temperature drops below 80 degrees in Celsius.
Pump Contamination Status
Beside the event of Contamination Lamp, DLU is able to detect distinctively the
contamination of each pump and swing and travel motor drain ports. These event
signals are all sent by CSU( Contamination Sensing Unit ) to DLU through the CAN
communication.
Operational Status
“Key Switch” is an event which occurs at the time DLU is powered on.
Furthermore, “Engine” reveals that the engine has begun operating and engine
rotation has reached above 300 /min. The engine comes to a halt at 100 /min.
rotation.
The event of Lamp Check Switch occurs when the lamp check switch is pressed by
the operator. The events of Emergency Stop and Buzzer Stop Switch occur
likewise when each switch is pressed by the operator.
System Status
The system status RTC Date Set Write is an event that occurs when changes to the
DLU time( RTC, Real Time Clock) are made from an external instrument like a
personal computer.
In addition, Option Unit Data Comm. (Fault) is an event that occurs when
abnormality develops in the communication between DLU and MC(A). Change
Option Unit is an event that occurs when the Pump flow monitor or other options has
been connected to the system. System Error is an event that occurs when there is
DLU abnormality. When this event occurs, it is necessary to swiftly replace DLU.
The abnormality of DLU is notified as the PC Download Lamp blinks at a frequency
of 1 second.

2.3 Faults
The detection-faults detects the occurrence/neutralization of sensor abnormality.
The Faults also detects any abnormality in system’s communication other than the
communication line between DLU and MC(A) and option unit communication line.
The PC Download Warning Lamp blinks at a frequecy of 1 second when any one of
the faults listed below occur. Table 2.3 lists the items.

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 Table 2.3 Faults
Item
System Sensor Faults [Hyd. Oil Temp. Sensor]
System Sensor Faults [Front & Swing Press. Sensor]
System Sensor Faults [Travel Press. Sensor]
System Sensor Faults [Eng. Speed Sensor]
System Sensor Faults [Fast-Fill Press. Sensor]
System Sensor Faults [Intake Air Temp.Sensor1]
System Sensor Faults [Intake Air Temp.Sensor2]
System Sensor Faults [Governor Angle Sensor]
System Sensor Faults [Coolant Temp. Sensor]
System Sensor Faults [Exhaust Temp. Sensor1]
System Sensor Faults [Exhaust Temp. Sensor2]
System Comm. Faults [MCA-MCB]

System Sensor Faults

[Hyd. Oil Temp. Sensor]
The event of Hyd. Oil Temp.Sensor(Fault) occurs when the voltage input of tydraulic
oil temperature sensor to MC(A) becomes abnormal. The voltage which is detected
to be abnormal is lower than 0.25V or higher than 4.75V.
[Front & Swing Press. Sensor]
The pilot pressure sensor (Front / swing) is the sensor which measures the pilot
hydraulic oil pressure where pressure rises when any one of front operation and
swing operation is executed. The event of Front & Swing Press. Sensor (Fault)
occurs when the sensor voltage input to MC(B) becomes abnormal. The voltage
which is detected to be abnormal is lower than 0.25V or higher than 4.75V.
[Travel Press. Sensor]
Pilot Pressure Sensor (Travel) the sensor which measures the pilot hydraulic pressure
where pressure rises when travel operation is executed. The event of Travel Press.
Sensor (Fault) occurs when the sensor voltage input to MC(B) becomes abnormal.
The voltage which is detected to be abnormal is lower than 0.25V or higher than
4.75V.
[Eng. Speed Sensor]
The event of Eng. Speed Sensor (Fault) occurs when the engine rotation detection
becomes abnormal.
[Fast-Fill Press. Sensor]
The Pilot Pressure Sensor (Fast Filling) is the sensor which measures the pilot
hydraulic pressure that controls the Fast-Fill system. The event of Fast-Fill Press.
Sensor (Fault) occurs when the sensor voltage input to MC(A) becomes abnormal.
The voltage which is detected to be abnormal is lower than 0.25V or higher than
4.75V.

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 [Intake Air Temp.Sensor1]& [Intake Air Temp.Sensor2]
The events of Intake Air Temp.Sensor1 (Fault) & Intake Air Temp.Sensor2(Fault)
occur when the voltage input of intake Air temperature sensor1 or intake Air
temperature sensor2 to MC(A) becomes abnormal. The voltage which is detected
to be abnormal is lower than 0.25V or higher than 4.75V.
[Governor Angle Sensor]
The governor angle sensor is the sensor which measures the rack position of the
engine governor. The event of Governor Angle Sensor (Fault) occurs when the
sensor voltage input to MC(B) becomes abnormal. The voltage which is detected to
be abnormal is lower than 0.25V or higher than 4.75V.
[Coolant Temp. Sensor]
The event of Coolant Temp. Sensor (Fault) occurs when the voltage input of coolant
temperature sensor to MC(A) becomes abnormal. The voltage which is detected to
be abnormal is lower than 0.25V or higher than 4.75V.
[Exhaust Temp. Sensor1] & [Exhaust Temp. Sensor2]
The events of Exhaust Temp.Sensor1 (Fault) & Exhaust Temp.Sensor2(Fault) occur
when the voltage input of Exhaust Gas temperature sensor1 on Exhaust Gas
Temperature sensor2 to MC(A) becomes abnormal. The voltage which is detected
to be abnormal is lower than 0.25V.
System Comm. Faults [MCA-MCB]
The event of System Comm.Faults (MCAB) occur when there is a communication
abnormality between MC(A) and MC(B).

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3. Sensors , Switches & Control Units

P/N 9205330 MC(A)

MC(A) is one of the two main controllers in the system. MC(A) mainly controls
warning lamps on Panel Display Modules in the cab console, the auto-lubrication and
the radiator and oil cooler fun drive speed, etc. based on the sensor and switch inputs
to the controller . MC(A) communicates with MC(B) the other main controller.
Along with the sensor and switch inputs and warning lamp status of MC(B), MC(A)
sends its own sensor and switch inputs and warning lamp status to DLU(Data
Logging Unit). MC(A) also sends to DLU( Data Logging Unit) sensor fault
statuses produced both in MC(A) and MC(B)

P/N 9205330 MC(B)

MC(B) is one of the two main controllers in the system. Based on the sensor and
switch inputs, MC(B) mainly controls warning lamps on Panel Display Modules ,
controls pumps, executes engine protection and calculates fuel consumption rates,etc..
MC(B) communicates with MC(A) the other main controller in the system to send to
MC(A) such data as its warning lamp statuses, engine speed , and the calculated fuel
consumption rates.

P/N 9205329 DLU

DLU( Data Logging Unit) is connected to MC(A) by a serial communication.
DLU(Data Logging Unit) acquires the sensor and switch inputs of two main
controllers and warning lamp statuses to produce the basic monitoring data. DLU
(Data Logging Unit) also communicates with CSU ( Contamination Sensing Unit)
through CAN (Control Area Network) *to receive and record the status of each
contamination sensor mounted on pumps and motor drain ports.

P/N 4456394 CSU

CSU( Contamination Sensing Unit) communicates with DLU( Data Logging Unit)
through CAN (Control Area Network)* to send periodically ( once per second) to
DLU(Data Logging Unit) the status of each contamination sensor mounted on pumps
and motor drain ports. The status of each contamination sensor is recorded by DLU
as a data of EVENTS

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P/N 4436535 Pilot Pressure Sensor( Front/Swing)
The pilot pressure sensor (Front/Swing) detects the operation of front attachments
such as boom, arm and bucket and swing operation. DLU(Data Logging Unit)
produces the time of operation with the outputs of this sensor and the pilot pressure
sensor(Travel).
DLU(Data Logging Unit) also records as a data of FAULTS the abnormality of the
sensor output. ( System Sensor Faults [Front & Swing Press. Sensor] )

P/N 4436535 Pitot Pressure Sensor( Travel )

A pilot pressure sensor( Travel ) detects the operation of travel. DLU(Data Logging
Unit) produce the traveling time based on the output of this sensor.
DLU(Data Logging Unit) also records as a data of FAULTS the abnormality of
the sensor output. ( System Sensor Faults [Travel Press. Sensor ] )

P/N 4250260 Hydraulic Oil Temperature Sensor

A hydraulic oil temperature sensor measures the temperature inside the hydraulic oil
tank. The main controller ,MC(A), controls the oil cooler fun drive speed. In a 30
min. interval, DLU(Data Logging Unit) produces hydraulic oil temperature
histogram , detects the maximum hydraulic temperature, and records hydraulic oil
overheat as a EVENTS data based on the output of this sensor.
DLU (Data Logging Unit) also records as a data of FAULTS the abnormality of the
Sensor output ( System Sensor Faults [Hyd. Oil Temp. Sensor ] ).

P/N H04410-43400 Engine Speed Sensor

A engine speed sensor mounted on the housing of the flywheel measures the
revolutions of the engine shaft. The main controller, MC(B), controls pumps
whithe this sensor’s output. DLU( Data Logging Unit ) produces the engine
operation time and records ON/OFF status of engine as a EVENTS data based on
this measurement .

P/N 4377537 Pressure Switch (Front Attachment Lubrication Circuit) & Pressure
Switch (Swing Bearing Lubrication Circuit)
A pressure switch ( Front Attachment Lubrication Circuit) and a pressure switch
( Swing Bearing Lubrication Circuit ) detects the pressure of grease while
auto-lubrication is in action. When the pressure of grease won't rise at all ( the switch
stays OFF at all time) or stays high at all time( the switch stays ON at all time) , the
main controller, MC(A), lights up the auto-lubrication warning lamp in the cab console.
DLU(Data Logging Unit) records the auto-lubrication lamp status as a EVENTS data
"Auto-Lubrication(Fault)" when the status changes.

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P/N 4314752 Hydraulic Oil Level Switch (Level Warning Indicator)
A hydraulic oil level switch( Level Warning Indicator) becomes ON when the oil
level of a hydraulic oil tank is lower than it should be. The main controller
( MC(A)) lights up the hydraulic oil level warning lamp in the cab console when the
switch is on. DLU(Data Logging Unit) records the status of the warning lamp as a
EVENTS data "Hyd.Oil Level(Low)) when the status changes.

P/N 4296637 Fuel Level Switch( Indicator)

A fuel level switch( Indicator) becomes ON when the fuel level of a fuel tank is very
low. The main controller( MC(A)) lights up the fuel level warning lamp in the cab
console when the switch is on. DLU (Data Logging Unit) records the status of the
fuel level warning lamp as a EVENTS data" Fuel Level(Low)" when the status
changes.

P/N 4436535 Pilot Pressure Sensor ( Fast Filling)

A pilot pressure sensor (Fast Filling) measures the pilot pressure of a gate lock valve .
If the pressure rises ( This means the operator is intending to operate the machine)
while Fast Filling system is in action, the main controller, MC(B), beeps the buzzer
to notify the operator. DLU( Data Logging Unit) records the abnormality of this
sensor as a FAULTS data System Sensor Faults [Fast Fill Press. Sensor].

P/N H37892-00800 Intake Air Temperature Sensor１& 2

Intake air temperature sensor 1 and 2 measure the temperature of air going out from a
inter-cooler. The main controller, MC(A), uses these sensor's input for radiator fun
speed control. DLU( Data Logging Unit) records the abnormality of these sensors
as FAULTS data System Sensor Faults [Intake Air Temp.Sensor1] & System Sensor
Faults [Intake Air Temp.Sensor2].

P/N H37892-01100 Exhaust Gas Temperature Sensor 1& 2

Exhaust Gas Temperature Sensor 1 and 2 are mounted on exhaust manifolds of a
engine. These sensors measure temperature of exhaust gas. When the main
controller , MC(A), detects either one of the two sensors outputs higher than normal
highest temperature which is 700℃, it lights up the exhaust gas temperature
warning lamp in the cab console. DLU (Data Logging Unit) records the status of the
exhaust gas temperature warning lamp as a EVENTS data “Exhaust Temp( High) “.
DLU( Data Logging Unit) records the abnormality of these sensors as FAULTS data
“System Sensor Faults[Exhaust Temp. Sensor1] & System Sensor Faults [Exhaust
Temp.Sensor2]”.

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P/N H04442-27700 Engine Oil Pressure Switch ( Low Pressure)
A engine oil pressure switch( Low Pressure) detects the engine oil pressure. The
main controller, MC(B), lights up an engine oil warning lamp in the cab console
when engine oil pressure is below normal at the engine speed of below 1500 /min.
and the switch is ON. DLU( Data Logging Unit ) records the status of the engine
oil warning lamp as a EVENTS data ”Eng.Oil Press.(Low)”.

P/N H04442-28500 Engine Oil Pressure Switch ( High Pressure )

A engine oil pressure switch( High Pressure) detects the engine oil pressure. The
main controller, MC(B), lights up an engine oil warning lamp in the cab console
when engine oil pressure is below normal at the engine speed of 1500 /min. and
above and the switch is ON. DLU( Data Logging Unit ) records the status of the
engine oil warning lamp as a EVENTS data ”Eng.Oil Press.(Low)”.

P/N 4224238 Air Cleaner Restriction Switch(4 used)

Air cleaner restriction switches ( 4 used) detect state of air cleaners. The main
controller, MC(A), lights up an air restriction lamp in the cab console when at least
one of four air cleaners is restricted and the switch is ON. DLU( Data Logging
Unit) records the status of the air restriction lamp as a EVENTS data “Air Cleaner
Restriction”.

P/N 4259787 Coolant Level Switch(Level Warning Indicator)

A coolant level switch( Level Warning Indicator) detects the level of coolant water.
The main controller, MC(B), lights up a coolant level warning lamp in the cab
console as the coolant level becomes very low and the switch turns ON. DLU
(Data Logging Unit) records the status of coolant level warning lamp as a EVENTS
data ”Coolant Level (Low) “.

P/N 4250260 Coolant Temperature Sensor(Radiator Fun Motor Speed)

A coolant temperature sensor( Radiator Fun Motor Speed ) measures temperature of
coolant water going in to the radiator. The main controller, MC(A), controls the fun
speed of the radiator based on the output of this sensor. DLU( Data Logging Unit)
records abnormality of this sensor as a FAULTS data System Sensor Faults [Coolant
Temp. Sensor].

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P/N H37547-04100 Overheat Switch
An overheat switch detects overheat condition of engine coolant water. The main
controller, MC(B), lights up an overheat-lamp in the cab console when the coolant
water becomes overheat and the switch turns ON. DLU( Data Logging Unit )
records the status of the overheat lamp as a EVENTS data “Coolant
Temp.(OverHeat)”.

P/N 4335020 Pump Transmission Pressure Switch

A pump transmission pressure switch detects the oil pressure of pump transmission.
The main controller, MC(B), lights up a pump transmission warning lamp in the cab
console as the oil pressure becomes lower than normal and the switch tuns ON.
DLU(Data Logging Unit) records the status of the pump transmission warning lamp
as a EVENTS data ”Pump Trans. Oil Press.(Low)”.

P/N H04343-39010 Alternator

The main controller, MC(B), lights up a charge fault lamp in the cab console when
the alternator of the engine does not charge batteries properly or an alternator rely
does not work. DLU (Data Logging Unit) records the status of the charge fault
lamp as a EVENTS data “Alternator Charge Fault)”.
DLU also accumulates battery charge time based on the status of the charge fault
lamp. When the charge fault lamp is ON, DLU(Data Logging Unit) stops
accumulation of battery charge time and while the charge fault lamp is OFF,
DLU(Data Logging Unit) accumulates the battery charge time.

P/N H37863-10210 Governor

The angle measurement of a governor actuator reaches to the main controller through
ECM( Engine Control Module). The main controller, MC(B), calculates fuel
consumption rate with governor actuator angle and engine speed. DLU( Data
Logging Unit) records the fuel consumption rate as an average.
DLU ( Data Logging Unit ) also records abnormality of the governor actuator as a
FAULTS data System Sensor Faults [Governor Angle Sensor].

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P/N 4335020 Contamination Sensor( Main Pump,ch1～８)
Contamination Sensors ( Main Pump, ch.1 thru 8 ) are mounted on delivery ports of
main pumps in a way that the contamination sensor( Main Pump, ch1 ) is on the
delivery port of main pump #1, the contamination sensor( Main Pump, ch2) is on the
delivery port of main pump #2 and so on. These sensors detect metal worn outs
within hydraulic oil and if at least one of these sensors detects metal worn outs,
CSU( Contamination Sensing Unit) lights up a contamination warning lamp in the
cab console. On the other hand, the main controller, MC(A), detects the status of
the contamination warning lamp and sends it to DLU( Data Logging Unit). Then
DLU( Data Logging Unit) records the status of the contamination warning lamp as a
EVENTS data “Contamination Lamp (On)”.
Furthermore, CSU(Contamination Sensing Unit) sends periodically condition of the
eight sensors to DLU( Data Logging Unit). DLU(Data Logging Unit) records
statuses of all eight sensors respectively as a EVENTS data “Contamination Pump
[ch*] “.
* represents the number of a main pump.

P/N 4335020 Contamination Sensor(Left Side Front Swing Motor,ch17)

Contamination Sensor(Left Side Rear Swing Motor,ch18)
Contamination Sensor(Right Side Front Swing Motor,ch19)
Contamination Sensor( Right Side Rear Swing Motor, ch20)
Contamination Sensor( Travel Motor,ch21)
The channel 17 contamination sensor detects metal worn outs in the drain port of the
swing motor on the left in a front row. The channel 18 contamination sensor detects
metal worn outs in the drain port of the swing motor on the left rear side. The
channel 19 contamination sensor detects metal worn outs in the drain port of the
swing motor located on the right on a front row. The channel 20 contamination
sensor detects metal worn outs in the drain port of the swing motor on the rear right.
The channel 21 contamination sensor detects metal worn outs in the drain port of the
center joint to the travel motor.
When at least one of the five contamination sensor above detects worn outs ,
CSU(Contamination Sensing Unit) lights up a contamination warning lamp in the
cab console. On the other hand, the main controller, MC(A), detects the status of the
contamination warning lamp and sends it to DLU(Data Logging Unit). Then
DLU( Data Logging Unit) records the status of the lamp as a EVENTS data
“Contamination Lamp (On)”.

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 Furthermore, CSU( Contamination Sensing Unit) sends periodically condition of all
five sensors to DLU( Data Logging Unit) using CAN*. DLU( Data Logging Unit)
records each status of contamination sensors by channels as a EVENTS data ”
Contamination Motor [ch*]”. * represents the channel.

P/N 4449621 Emergency Switch

P/N 4449622 Emergency Switch
Three of the emergency switches ( Engine Stop Switch) are located in the engine
room and one located near the oil cooler fun. And one is found in the cab. At
least one of the switches is pressed, the engine stops running and the emergency
lamp( engine stop lamp) turns on. The main controller, MC(B), sends via MC(A)
to DLU(Data Logging Unit) the status of the switches. DLU ( Data Logging Unit)
records the status of the switches as EVENTS data ”Emergncy Stop”.

* This system's " CAN (Control Area Network)" is distinctive to Hitachi Construction Machinery and
it can not be connected to a third party CAN.

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 EX3600-5 System Configuration
Contamination Sensor
(Right Side Rear Swing
Contamination Sensor
Motor,ch20)
(Left Side Rear Swing Motor,ch18)
P/N4335020
P/N4335020 Emergency Switch
ViewA P/N4449621
Contamination Sensor Emergency Switch
(Travel Motor,ch21) Pressure Switch
P/N4449621
P/N4335020 (Front Attachment
Hydraulic Oil
Lubrication Circuit)
Level Switch
P/N4377537
(Level Warning
Hydraulic Oil Temperature
Indicator)
Sensor
P/N 4314752
P/N 4250260

ViewB
Emergency Switch
Contamination Sensor Contamination Sensor
P/N4449621
(Left Side Front Swing (Right Side Front Swing Emergency Switch Pressure Switch
Motor,ch17) Motor,ch19) P/N4449622 (Swing Bearing Lubrication Circuit)
P/N4335020 P/N4335020 P/N4377537
Exhaust･Gas
Temperature Sensor 2
A
P/N H37892-01100

B Governor
P/N H37863-10210

Contamination Sensor
(Main Pump,ch5)
P/N4335020 Coolant Level Switch
Contamination Sensor (Level Warning Indicator)
(Main Pump,ch6) P/N4259787
P/N4335020
Exhaust Gas Sensor
Fuel Level Switch CSU Tempereture 1
(Indicator) (contamination P/N H37892-01100
P/N4296637 sensing unit) Coolant
P/N4456394 Pilot Pressure Temperature
Sensor (Fast Filling) Sensor
P/N 4436535 (Radiator
Engine Oil Air Cleaner Fun Motor
Intake Air Presssure Switch Restriction Speed)
Sensor Temperature2 (Low Pressure) Switch(4 Used) P/N 4250260
P/N H37892-00800 P/N H04442-27700 P/N4224238
MC(A)
Overheat
P/N9205330 Contamination Sensor
Switch
Engine Oil Presssure Switch (Main Pump,ch3) P/N
MC(B) (High Pressure) P/N4335020 H37547-
P/N9205330 P/N H04442-28500 Contamination Sensor 04100
Pilot Pressure Engine Speed Sensor
Sensor (Main Pump,ch4) (MC(B))
(Travel) P/N4335020 P/N H04410-43400 Alternator
P/N4436535 DLU(Data P/NH04343-39010
Logging Unit) Pump Transmission Pressure Switch
P/N9205329 P/N4099039 Contamination Sensor
(Main Pump,ch7)
Pilot Pressure Sensor Contamination Sensor P/N4335020
(Front/Swing) (Main Pump,ch2)
P/N4436535 P/N4335020 Contamination Sensor Contamination Sensor
(Main Pump,ch1) (Main Pump,ch8)
P/N4335020 P/N4335020

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