CAT 390D Excavator Hydraulic System.pdf

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KENR7742 November 2010

390D Excavator Hydraulic System - Attachment WAG1-UP BYP1-UP WAP1-UP WBT1-UP KCZ1-UP

Boom Float

© 2010 Caterpillar, All Rights Reserved

Printed in U.S.A.

COMPONENT LOCATION Description

Part Number

Machine Location

Schematic Location

Accumulator GP - Charged (Return Line)

335-0538

1

C-1

Accumulator GP - Hydraulic (Charged)

335-0547

2

D-4

Breather GP

212-5467

3

A-8

Cooler GP - Hydraulic Oil

210-8157

4

B-7

Cylinder GP - Boom

Note A

5

F-7

Cylinder GP - Bucket

Note A

6

F-8

Cylinder GP - Stick

Note A

7

F-8

242-6878

8

A-8

Filter GP - Oil (Hydraulic)(Return) 1 Filter GP - Oil (Hydraulic)(Return) 2

234-4531

9

A-8

Filter GP - Oil (Hydraulic)

185-0336

10

B-8

Filter GP - Oil (Hydraulic)(Case Drain, Motors)

6E-5534

11

A-7

Filter GP - Oil (Hydraulic)(Case Drain, Pumps)

6E-5534

12

A-7

Manifold and Valve GP - Load Sensing

310-0122

13

B-5

Motor GP - Fan

247-8978

14

A-6

Motor GP - Hydraulic Fan

225-4614

15

A-7

Motor GP - Swing (Front)

295-9447

16

F-4

Motor GP - Swing (Rear)

295-9446

17

F-3

Motor GP - Travel (Left)

209-5895

18

F-6

Motor GP - Travel (Right)

209-5895

19

F-5

Pump GP - Fan Motor

170-9918

20

A-5

Pump GP - Hydraulic (Swing)

295-9678

21

A-4

Pump GP - Hydraulic (Main)

334-9990

22

A-3

Pump GP - Pilot

155-9222

23

A-5

Sensor AS - Pressure (Load Sensing)

221-8859

24

B-6

Sensor AS - Pressure (Overload Warning)

221-8859

25

C-6

Sensor AS - Pressure (Main Pump)

260-2180

26

A-3

Sensor AS - Pressure (Swing Pump)

260-2180

27

A-5

Swivel GP

295-9595

28

E-5

Tank AS - Hydraulic Oil

227-0678

29

A-8

Valve GP - Check 1

173-3429

30

A-6

Valve GP - Check 2

201-9382

31

C-1

Valve GP - Check 3

201-9381

32

C-8

Valve GP - Control (Swing)

241-8929

33

Valve GP - Control (Main)

295-7767

34

E-3 C-4

Valve GP - Manifold and Reducing

140-0736

35

D-5

Valve GP - Solenoid (High Pressure Cutoff)

352-6819

36

B-5

Valve GP - Swing Cushion

116-3420

37

E-4

Valve GP - Travel Counterbalance (Left)

155-9200

38

E-6

Valve GP - Travel Counterbalance (Right)

155-9200

39

E-5

Attachment - Boom Float Accumulator GP - Hydraulic (Charged)

335-0547

50

D-4

Sensor AS - Pressure (Boom Lowering)

221-8859

51

E-7

Switch AS - Pressure (Boom Lower)

202-9002

52

F-7

Valve GP - Check

297-0370

53

F-8

Valve GP - Load Control (Boom)

274-9053

54

Valve GP - Main Control (Smartboom, Boom Load Control)

295-7767

55

F-7 C-3

Valve GP - Manual (Boom Lower)

270-5692

56

E-7

Valve GP - Solenoid

171-0028

57

F-8

Note A: Check Parts Manual For Proper Cylinder Part Number

TAP LOCATION Tap Number

Description

Schematic Location

A

Drive Pump Output Pressure

A-3

B

Idler Pump Output Pressure

A-3

LS2

Load Sense Pressure (Main Hydraulic Pump)

A-2

M1

Stroking Pressure (Swing Pump)

A-4

P

Pilot Pump Output Pressure

A-5

P1

Pilot Pressure to Swing Pump

A-5

PG

Pilot Accumulator Pressure

D-4

PS1

Power Shift Pressure (Main Hydraulic Pump)

A-3

FLUID POWER SYMBOLS BASIC COMPONENT SYMBOLS

MAIN AUX.

PUMP or MOTOR

SPRING (ADJUSTABLE)

VARIABILITY

CONTROL VALVES

SPRING

FLUID CONDITIONER

PRESSURE COMPENSATION

LINE RESTRICTION (VARIABLE)

TWO POSITION

2-SECTION PUMP

HYDRAULIC PNEUMATIC ENERGY TRIANGLES

ATTACHMENT

LINE RESTRICTION

VALVE PORTS

TWO-WAY

THREE POSITION

PUMP: VARIABLE and PRESSURE COMPENSATED

VARIABLE and PRESSURE COMPENSATED

VALVES

VALVE ENVELOPES

ONE POSITION

LINE RESTRICTION (FIXED)

RESTRICTION

FOUR-WAY

THREE-WAY

CONTROL VALVES

CHECK VALVES

AB

AB

P T NORMAL POSITION

P T SHIFTED POSITION

INFINITE POSITION

SHUTTLE

SPRING LOADED

BASIC SYMBOL

PILOT CONTROLLED

FLUID STORAGE RESERVOIRS

VENTED

RETURN ABOVE FLUID LEVEL

PRESSURIZED

RETURN BELOW FLUID LEVEL

MEASUREMENT

PRESSURE

TEMPERATURE

ROTATING SHAFTS

FLOW

UNIDIRECTIONAL

BIDIRECTIONAL

COMBINATION CONTROLS

SOLENOID

SOLENOID or MANUAL

SOLENOID and PILOT or MANUAL

SOLENOID and PILOT

SERVO

DETENT

THERMAL

MANUAL CONTROL SYMBOLS

MANUAL SHUTOFF

PUSH-PULL LEVER

RELEASED PRESSURE

EXTERNAL RETURN

SPRING LOADED

HYDRAULIC PUMPS VARIABLE DISPLACEMENT NON-COMPENSATED

PEDAL

LINES CROSSING

LINES JOINING

VARIABLE DISPLACEMENT NON-COMPENSATED

UNIDIRECTIONAL

UNIDIRECTIONAL

BIDIRECTIONAL

BIDIRECTIONAL

INTERNAL SUPPLY PRESSURE

COMPLETE

HYDRAULIC AND PNEUMATIC CYLINDERS

SINGLE ACTING

DOUBLE ACTING

INTERNAL PASSAGEWAYS

HYDRAULIC MOTORS FIXED DISPLACEMENT

SPRING

REMOTE SUPPLY PRESSURE

SIMPLIFIED

CROSSING AND JOINING LINES

GAS CHARGED

PUSH BUTTON

PILOT CONTROL SYMBOLS

INTERNAL RETURN

ACCUMULATORS

FIXED DISPLACEMENT

GENERAL MANUAL

INFINITE POSITIONING

FLOW IN ONE DIRECTION

THREE POSITION

PARALLEL FLOW

CROSS FLOW

TWO POSITION

FLOW ALLOWED IN EITHER DIRECTION

ELECTRICAL SYMBOLS Hydraulic Symbols (Electrical)

M

G Transducer (Fluid)

Transducer (Gas / Air)

Pressure Switch (Adjustable)

Pressure Switch

Generator

Electric Motor

Electrical Wire

Temperature Switch

Electrical Symbols (Electrical)

T

Pressure Symbol

Temperature Symbol

Level Symbol

Flow Symbol

Wire Number Identification Codes

Electrical Schematic Example

Hydraulic Schematic Example Current Standard

Current Standard Harness identification code This example indicates wire 135 in harness "AG".

Wire

Circuit Number Identification

Wire Color

325-AG135 PK-14 325-PK

Circuit Identification Number

Wire Color

Wire Gauge

Previous Standard Wire Color

Wire

325-PK-14 B Circuit Number Identification

A

Wire Gauge (EXAMPLE VALVE)

8

(7) CYLINDER GP STICK

(6) CYLINDER GP BUCKET

(52) SWITCH AS PRESSURE (BOOM LOWER) 202-9002

7

6

(5) CYLINDER GP BOOM

5

(18) MOTOR GP TRAVEL (LEFT) 209-5895

TRAVEL MOTOR (LEFT)

4

(19) MOTOR GP TRAVEL (RIGHT) 209-5895

TRAVEL MOTOR (RIGHT)

SWING MOTOR (FRONT)

DB

3

(16) MOTOR GP SWING (FRONT) 295-9447

PG1

2

HYDRAULIC CIRCUIT COLOR DESCRIPTIONS

PG2

DB

PP3 AL2

BL2

AR1

(54) VALVE GP LOAD CONTROL (BOOM) 274-9053

BR1

(57) VALVE GP SOLENOID (53) VALVE GP 171-0028 CHECK 297-0370

AL1 B

CYL

L

BR

PD

PG

T1

T1

CYL

T2

T2

L

BR

B

A

PA

A

(37) VALVE GP PA SWING CUSHION 116-3420

PB

M B

A

A1

PP3

BG

AG

M

B1

A1

AG

BG

B A1

B1

(33) VALVE GP CONTROL (SWING) 241-8929

DR CV Pi

DR

X

T

CV Pi

DR

X

A2

P

(L)

(51) SENSOR AS PRESSURE (BOOM LOWERING) 221-8859

T

E

A

B

B

(38) VALVE GP TRAVEL COUNTERBALANCE (LEFT) 155-9200 (56) VALVE GP MANUAL (BOOM LOWER) 270-5692

BL1

A A

(28) SWIVEL GP 295-9595

(REV) BR2

AR2

(REV)

(FWD)

BR3

AR3

Pi1

PSA2

PSA3

PSA4

Pi1

Pi2

Pi3

Pi4

Pi5

T

SDr2

P

E

MU

PS2

PSA1

PG PG

DR4

SDr1

(39) VALVE GP TRAVEL COUNTERBALANCE (RIGHT) 155-9200

Pi2

(35) VALVE GP MANIFOLD AND REDUCING 140-0736

SP B

PS3

(FWD)

(R)

(L)

(R)

PS4

PS4

F

PB

A T

PILOT PUMP OUTPUT DRIVE PUMP OUTPUT HIGH PRESSURE CUTOFF CIRCUIT DRIVE AND IDLER PUMPS COMBINED CIRCUIT FAN PUMP AND CIRCUIT SUPPLY LINE STICK CYLINDER & CONTROL CIRCUIT LEFT TRAVEL MOTOR & CONTROL CIRCUIT ATTACHMENT CONTROL CIRCUIT SWING MOTOR & CONTROL CIRCUIT DRAIN / RETURN LINE SWING BRAKES IDLER PUMP OUTPUT BUCKET CYLINDER & CONTROL CIRCUIT RIGHT TRAVEL MOTOR & CONTROL CIRCUIT BOOM CYLINDER & CONTROL CIRCUIT

(17) MOTOR GP SWING (REAR) 295-9446

SWING MOTOR (REAR)

PR

F

1

(50) ACCUMULATOR GP HYDRAULIC (CHARGED) 335-0547

DR5 Pi6

DR1

DR2

DR3

DR4

P-IN

DR6

T-OUT

DR5

PAC

(55) VALVE GP CONTROL (MAIN) (SMART BOOM, BOOM LOAD CONTROL) 295-7767

D DR4 DR3 (DOWN)

aR2

aR3

(OUT)

(FWD)

(FWD)

BOOM

ATCH

aR1

TRAVEL(R)

(OPEN)

DR1

TRAVEL(L)

aL1

BUCKET

(RET)

aL2

STICK

aL3

DR2

D

(34) VALVE GP CONTROL (MAIN) 295-7767

C

C

R1 MU

(CLOSE)

(EXT) bL3

(UP)

bL2

HPC-OFF

bL1

AL1

AL3 BL3 DR2

BL2

PS2

BL1

(24) SENSOR AS PRESSURE (LOAD SENSING) 221-8859

(10) FILTER GP OIL (HYDRAULIC) 185-0336

DR

(9) FILTER GP OIL (HYDRAULIC) (RETURN) 2 234-4531

Dr P T

C1

(36) VALVE GP Dr SOLENOID (HIGH PRESSURE CUTOFF) 352-6819 (13) MANIFOLD AND VALVE GP LOAD SENSING 310-0122

(8) FILTER GP OIL (HYDRAULIC) (RETURN) 1 242-6878

P1

(27) SENSOR AS PRESSURE (SWING PUMP) 260-2180

A

DR

BR2 BR1

AR1

Pi2

PS3

T1

T2

BR3

AR3

DR3

B

(26) SENSOR AS PRESSURE (MAIN PUMP) 260-2180

PF

A M2

AR2

R

B

PS1

G

A

PR

(21) PUMP GP HYDRAULIC (SWING) 295-9678

PS1

SA1

a1

P1

P2

a2

SA2

PS2

(22) PUMP GP HYDRAULIC (MAIN) 334-9990

Drain / Return Lines Component Group

L1

P.P.O

7

6

LS2

LS1

(23) PUMP GP PILOT 155-9222

LS2

(20) PUMP GP FAN MOTOR 170-9918

5

S

DR1

DR

S

M1

M1

CALLOUTS

(Machine Location from Component LocationsTable)

D1

S1

Taps (Pressure, Sampling, Sensor - by letter)

YY

Callout Number

L2

P.P.I

(30) VALVE GP CHECK 1 173-3429

(11) FILTER GP OIL (HYDRAULIC)(CASE DRAIN, MOTORS) 6E-5534

8

Pressure Line Pilot / Load Sensing Pressure

Qmax Qmin

(29) TANK AS HYDRAULIC OIL 227-0678

LINE PATTERNS

B

B

(12) FILTER GP OIL (HYDRAULIC)(CASE DRAIN, PUMPS) 6E-5534

(31) VALVE GP CHECK 2 201-9382

DR6

P A

bR3

C2

(14) MOTOR GP FAN 247-8978

A

bR2

R2

(1) ACCUMULATOR GP CHARGED (RETURN LINE) 335-0538

(4) COOLER GP HYDRAULIC OIL 210-8157 (15) MOTOR GP HYDRAULIC FAN 225-4614

(REV)

L1

G

L2

(3) BREATHER GP 212-5467

(REV)

PR (25) SENSOR AS PRESSURE (OVERLOAD WARNING) 221-8859

B

A

bR1

PF

(32) VALVE GP CHECK 3 201-9381

AL2

(IN)

HPC-ON

(52) VALVE GP - CONTROL 138-1234 Part Number

390D EXCAVATOR HYDRAULIC SYSTEM ATTACHMENT: BOOM FLOAT MEDIA NUMBER : KENR7742 PART NUMBER: 297-0424, CHANGE: 00, VERSION: HE

D2

Component Name

Components are shown installed on a fully operable machine with the key and engine off, transmission shifter in neutral and with parking brake set. Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations.

4

3

2

1

A

MACHINE COMPONENT LOCATIONS 14 3

30

4

15

34

VIEW ALL CALLOUTS

29 11 9 8

19 39

38

12 18

10 24

7

13

6

LS2

PS1

22 A B

26

5 M1

P P1

37 16 28

33

17

23

20

27

21

BOOM FLOAT

55

VIEW ALL CALLOUTS

57 56

52

51

54

53

50

MAIN CONTROL COMPONENT LOCATIONS VIEW ALL CALLOUTS

25 31 32 1 REAR VIEW

36

35

PG FRONT VIEW

2