08-14-2025, 09:03 PM
Introduction
Hitachi's EX-series excavators, such as the EX200-2, EX200-3, EX220-2, and EX220-3, were originally equipped with electronic control systems to manage hydraulic functions. However, some operators prefer the simplicity and reliability of hydraulic control systems. Converting from electric to hydraulic control can enhance performance and reduce maintenance complexities. This guide provides detailed insights into the conversion process, common challenges, and practical solutions.
Understanding the Conversion Kit
A hydraulic conversion kit replaces the electronic control components with mechanical hydraulic parts. Typically, these kits include:
An operator of a Hitachi EX200-2 experienced high hydraulic pressure after installing a hydraulic conversion kit. The engine would stall under load, indicating an issue with the hydraulic system. Upon inspection, it was found that the swash plate was not fully loaded, and the angle sensor required adjustment. After making the necessary adjustments, the hydraulic pressure normalized, and the excavator operated smoothly.
Conclusion
Converting a Hitachi excavator from electric to hydraulic control can enhance reliability and simplify maintenance. By understanding the components involved, following the installation process carefully, and addressing common challenges proactively, operators can ensure a successful conversion. Always refer to the specific conversion kit's manual and consult professionals if needed to achieve optimal performance.
Hitachi's EX-series excavators, such as the EX200-2, EX200-3, EX220-2, and EX220-3, were originally equipped with electronic control systems to manage hydraulic functions. However, some operators prefer the simplicity and reliability of hydraulic control systems. Converting from electric to hydraulic control can enhance performance and reduce maintenance complexities. This guide provides detailed insights into the conversion process, common challenges, and practical solutions.
Understanding the Conversion Kit
A hydraulic conversion kit replaces the electronic control components with mechanical hydraulic parts. Typically, these kits include:
- Hydraulic Control Valve: Manages the flow of hydraulic fluid to various functions.
- Pressure Relief Valve: Prevents system overpressure by diverting excess fluid.
- Flow Control Valve: Regulates the speed of hydraulic actuators.
- Mounting Brackets and Hardware: Facilitates the installation of new components.
- Hoses and Fittings: Connects the hydraulic components.
- Instruction Manual: Guides the installation process.
- Preparation: Ensure the excavator is on a stable surface and the engine is turned off.
- Remove Electrical Components: Disconnect and remove the electronic control units, wiring harnesses, and sensors associated with the electric system.
- Install Hydraulic Components: Mount the hydraulic control valve and other components as per the kit's instructions.
- Connect Hydraulic Lines: Attach hoses and fittings to the hydraulic components, ensuring all connections are secure.
- System Check: After installation, check for leaks and ensure all functions operate smoothly.
- High Hydraulic Pressure: After conversion, some operators report excessively high hydraulic pressure, leading to engine stalling. This issue may arise if the swash plate is not fully loaded or if the angle sensor requires adjustment. Consulting the conversion kit's manual and making necessary adjustments can resolve this problem.
- Inadequate Flow Control: If hydraulic functions operate too quickly or slowly, recalibrating the flow control valve can help achieve the desired performance.
- Compatibility Issues: Ensure that the conversion kit is compatible with the specific model of the excavator. Using a kit designed for the EX200-2 may not be suitable for the EX220-3.
An operator of a Hitachi EX200-2 experienced high hydraulic pressure after installing a hydraulic conversion kit. The engine would stall under load, indicating an issue with the hydraulic system. Upon inspection, it was found that the swash plate was not fully loaded, and the angle sensor required adjustment. After making the necessary adjustments, the hydraulic pressure normalized, and the excavator operated smoothly.
Conclusion
Converting a Hitachi excavator from electric to hydraulic control can enhance reliability and simplify maintenance. By understanding the components involved, following the installation process carefully, and addressing common challenges proactively, operators can ensure a successful conversion. Always refer to the specific conversion kit's manual and consult professionals if needed to achieve optimal performance.
