Componentes Hidráulicos (SK210 Y SK330)

Kobelco Dynamic Acera

Kobelco Construction Machinery America LLC Hydraulic Components Kobelco Construction Machinery America LLC Dynamic Acera 01/04-MC

Page 5-1

HYDRAULIC COMPONENTS 4. COMPONENTS AND CIRCUIT DIAGRAM 4-1 Layout of Hydraulic components (SK210)

(Battery relay) Fuel tank

Hydraulic tank

(Battery)

Control valve Pump

Slewing motor Engine Swivel joint

Travel pilot valve

Air cleaner

A/C Compressor

Radiator & Oil cooler (Receiver tank) Sub tank Pilot valve (RH) (Boom, Bucket) Pilot valve (LH) (Arm, Swing)

Page 5-2

(A/C Unit)

(Sensor block)

Washer tank

(A/C Condenser)

(Solenoid proportional valve block)

Dynamic Acera 01/04-MC

HYDRAULIC TANK

Sight Gauge

Pilot Filter Manifold

Filter (Remove, Clean & Reinstall) O-ring (Replace & Lubricate)

Suction inlet port

Air Breather

Main Filter Compartment

Tank return to main Filters

Cap

Cover (Remove, Replace filter & Reinstall) Filter (Remove, Replace every 500 Hours) Base (with one way checks)

Typical of SK210 SK250 Dynamic Acera 01/04-MC

Page 5-3

MINOR CHANGE HYDRAULIC TANK

Sight Gauge

Pilot Filter Manifold

Filter (Remove, Clean & Reinstall) O-ring (Replace & Lubricate)

Suction inlet port

Air Breather

Main Filter Compartment

Tank return to main Filters

Cap

Cover (Remove, Replace filter & Reinstall) Filter (Remove, Replace every 500 Hours) Base (with one way checks)

Typical of SK210 SK250 Page 5-4


NOTE Always consult you operation manual for proper maintenance intervals.

Service Interval : 500 hrs - Normal Conditions Option/Breaker Filter : 250 hrs. Sucton Strainer

O-Ring Service Interval : 2000 hrs - Normal Conditions Typical of SK210 SK250


Page 5-5

HYDRAULIC TANK

Main Return Filter

Main Return Filter Bypass Check Valve

Service Interval : 500 hrs - Normal Conditions Option/Breaker Filter : 250 hrs. Note: Always consult you operation manual for proper maintenance intervals.

If the main return filter plugs due to excessive contamination then unfiltered oil will bypass the filter thru this check valve and continue to supply the main pump with lubrication oil

Page 5-6


HYDRAULIC TANK

Bypass Check Valve

Typical Location of SK210 SK250

Bypass Check Valve

Typical Location of SK290 SK330 Dynamic Acera 01/04-MC

Page 5-7

HYDRAULIC PUMP

Proportional Valve Non Adjustable Positive Control

Typical of SK160 Page 5-8


HYDRAULIC PUMP

Dozer Gear pump

Typical of ED190 Dynamic Acera 01/04-MC

Page 5-9

HYDRAULIC PUMP Back-up Auxarily Pump mount

Mode Spool

Pump Casing Fill & air bleeder Plug Port a3

Port a2

Port a1

Back-up

High Pressure

Mode Spool

Sensors

OLD Style Pump SK210 ~330 Page 5-10


MINOR CHANGE HYDRAULIC PUMP Back-up

Auxarily Pump mount

Mode Spool

Pump Casing Fill & air bleeder Plug

Port a3

Port a2

Port a1

Independant

High Pressure

Travel Bypass Block

Sensors

Minor Change Style Pump SK210 ~290 Dynamic Acera 01/04-MC

Page 5-11

HYDRAULIC PUMP Pilot Pump - Specified as P3 3) Gear pump (For pilot control)

Note: 1. After assembly of gear pump, check that the drive gear rotates smoothly at 0.1 N•m {1.0 kgf•m} or less. 2. After assembly of gear pump, apply sufficient oil in the gear section. 3. Bring the opposite side of caulking of the filter shown in the left figure into contact with the insert end face, paying attention to the installing direction. Code 307 308 309 310 311 312 351 353 354 355 361 433 434 435 466 467 700 710 725 728 732 850

Page 5-12

Nam e Poppet Seat S p rin g s e a t S p rin g A d ju s t sc re w Lock nut G e a r ca s e D rive g e a r D rive n g e a r F ilte r F ro n t c a se S o ck e t b o lt (M 8 x 4 0 ) S o ck e t b o lt (M 8 x 5 5 ) S o ck e t b o lt (M 8 x 2 0 ) P lu g (P F 1 /4 ) A d a p te r (P F 1 /2 – P F 3 /8 ) S q u a re rin g O -rin g (J IS B 2 4 0 1 -G 9 5 ) O -rin g (J IS B 2 4 0 1 -P 1 1 ) O -rin g (J IS B 2 4 0 1 -P 1 8 ) O -rin g (J IS B 2 4 0 1 -P 1 6 ) L o c k in g rin g (J IS B 2 8 0 4 -R R -1 8 )

Q ty. 1 1 1 1 1 1 1 1 1 1 1 2 2 4 1 1 1 1 1 1 1 1

Hydraulic circuit T igh te n in g to rqu e Code 312 433, 434 435 466

T h re a d size M 1 4 x 1 .5

T o rqu e N •m {kgf•m } 2 9 .4 {3 .0 }

M8

1 6 .7 {1 .7 }

P F 1 /4

1 5 .7 {1 .6 } Dynamic Acera 01/04-MC

HYDRAULIC PUMP

Negative Control Typical of SK210 ~330 ( Old Style Pump)

Negative Control Typical of SK210 ~330 ( Old Style Pump) Dynamic Acera 01/04-MC

Page 5-13

MINOR CHANGE HYDRAULIC PUMP

Positive Control Typical of SK210

Positive Control Typical of SK210 Page 5-14


HYDRAULIC PUMP Typical of SK210 ~330

Note: GPM given are Approximate GPM = RPM X C.C. X .00026 1 Ounce U.S. = 29.5 C.C.

PUMP FLOW: SK160/ED190: MAX GPM: 37.9 X 2 PUMPS SK 210: MAX GPM: 55.5 X 2 PUMPS SK250: MAX GPM: 63.4 X 2 PUMPS SK290:

MAX GPM: 63.4 X 2 PUMPS SK330:

MAX GPM: 66.8 X 2 Pumps SK480: MAX GPM: 97.7 X 2 Pumps


Page 5-15

HYDRAULIC PUMP 3. Structure 1) Main pump

Typical of SK210 ~330

Code 111 113 114 123 124 127 141 151 152 153 156 157 211 212 214 251 261 271 312

Name Shaft (Front) Shaft (Rear) Spline joint Roller bearing Needle bearing Bearing spacer Cylinder block Piston Shoe Retainer Spherical bushing Cylinder spring Shoe plate Swash plate Tilting bushing Support Seal cover Pump casing Valve block

Page 5-16

Qty. 1 1 1 2 2 4 2 18 18 2 2 18 2 2 2 2 1 2 1

Code 313 314 325 401 406 407 466 468 490 531 532 534 535 546 548 702 710 717 724

Name Valve plate (R) Valve plate (L) Cover Socket bolt (M20 x 210) Socket bolt (M8 x 20) Socket bolt (M6 x 30) VP plug (PF 1/4) VP plug (PF 3/4) Plug (Meck) Tilting pin Servo piston Stopper (L) Stopper (S) Spacer Feed back pin O-ring O-ring (JIS B2401-G95) O-ring (JIS B2401-G145) O-ring (JIS B2401-P8)

Qty. 1 1 1 8 4 3 2 4 20 2 2 2 2 2 2 2 1 4 16

Code 725 728 732 774 789 792 806 808 824 885 886 901 953 954 981 983

Name O-ring (JIS B2401-P11) O-ring (JIS B2401-P24) O-ring Oil seal Back-up ring (JIS B2407-P18) Back-up ring (JIS B2407-G35) Nut (M16) Nut (M20) Snap ring Pin (φ 8 x 12L) Spring pin Eye bolt (M10) Set screw Set screw Name plate Rivet

Qty. 7 4 2 1 2 2 2 2 2 2 4 2 2 2 1 2


HYDRAULIC PUMP REGULATOR

Minimum Angle

Minumn Stroke Angle

Maximum Angle

Maxumn Stroke Angle

Internal Pump Control: Internal pressure is applied on the small side of the Servo piston to maintain positon when the pump flow rate is increased this is accomplished by two things. 1. PSV pressure enters the requlator on the large side of the servo piston to position the pump swash plate angle to minumn. 2. The PSV pressure is reduced on the large side of the servo piston which allows pressure on the large piston side of the servo piston to be redirected to tank allowing the pump to come on stroke and increase the pump flow. This internal differential pressureization allow variable control and also a more smooth control on the pump flow output. Dynamic Acera 01/04-MC

Page 5-17


Page 5-18


HYDRAULIC PUMP REGULATOR (NEGATIVE CONTROL) 2) Regulator ➀ Structure of regulator

a1

P

PH

PSV

a3

P

PN

a2

B1 Dynamic Acera 01/04-MC

Page 5-19

MINOR CHANGE REGULATOR (POSITIVE CONTROL)

Pi1 P1'

P2' Pi2

T2 a2

a1 SE22 P

PSVP1

PH1

a1 A1 A2

a2

P SE23

PSVP2

PH2

PN1

~85 psi

~85 psi

PN2

a4

a5

Dr

M

a3 B3 D3

A3

B1

Page 5-20



Code 412 413 418 436 438 439 466 467 496 541 543 545 601 611 612 613 614 615 621 622 623 624 625 626 627 628 629 630 631 641 642 643 644 645 646 651 652 653 654 655 656 708 722 724 725 727 728

Name Socket bolt (M8 x 50) Socket bolt (M8 x 70) Socket bolt (M5 x 12) Socket bolt (M6 x 50) Socket bolt (M6 x 20) Socket bolt (M6 x 40) VP plug (PF 1/4) Plug (PF 3/8 x M8) Plug Seat Stopper 1 Ball Casing Feed back lever Lever (1) Lever (2) Fulcram plug Adjust plug Compensating piston Piston casing Compensating rod Spring seat (C) Outer spring Inner spring Plunger (C) Adjust screw (C) Cover (C) Lock nut Pf sleeve Pilot cover rod Pilot piston Spring seat (Q) Plunger (Q) Pilot spring sleeve spool spring seat Return spring Set spring Port plate O-ring (JIS B2401-G75) O-ring (JIS B2401-P6) O-ring (JIS B2401-P8) O-ring (JIS B2401-P10) O-ring (JIS B2401-P14) O-ring (JIS B2401-P18)


Qty. Code Name Qty. 2 730 O-ring (JIS B2401-P22) 1 2 732 O-ring (JIS B2401-P16) 2 2 733 O-ring (JIS B2401-P20) 2 5 734 O-ring (JIS B2401-G25) 1 4 753 O-ring (JIS B2401-P9) 1 4 755 O-ring (JIS B2401-P11) 6 3 756 O-ring (JIS B2401-P26) 2 1 763 O-ring (JIS B2401-G35) 1 18 801 Lock nut (M8) 3 2 814 Snap ring (JIS B2804 SR-15) 1 2 836 Snap ring 1 2 858 Locking ring (JIS B2804 RR-15) 2 1 1 874 Pin (φ 4 x 11.7L) Pin (φ 4 x 8L) 1 875 4 1 887 Pin 1 1 1 897 Pin (φ 4 x 19L) 1 898 Pin (φ 6.5 x 9L) 1 1 924 Set screw 1 1 925 Set screw (Q1) 1 1 1 079 Solenoid valve 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Tightening torque 1 1 Code Size 1 412, 413 M8 1 436, 438, 439 M6 PF 1/4 1 466 PF 3/8 1 467 PTF 1/ 2 496 30 X 1 12 630 1 801 M8 1 1

Torque 29.4 {3} 11.8 {1.2} 36.3 {3.7} 73.5 {7.5} 8.8 {0.9} 156.8 {16} 15.7 {1.6}

Page 5-21

HYDRAULIC MAIN CONTROL VALVE

Travel Straight

Travel Right Bucket

Travel Left

Boom P1 by-pass cut (Top) & Arm Conflux (bottom)

Swing

Boom Conflux

Arm

Circuit Relief ArmV/R (top) & P2 by-pass cut (bottom)

Swing Priority Negative Control Relief Front of Machine

Back Pressure Port

Typical of SK210 SK250 Page 5-22


HYDRAULIC MAIN CONTROL VALVE Front of Machine

Option Valve Activation Port

Arm AVR Arm Variable Regen (top)

P1 By-Pass Cut (Top)

Boom Holding Valve Boom Conflux

Boom Bucket

Travel Right

Main Relief Travel Straight Travel Left Swing Typical of SK210 SK250


Page 5-23

MINOR CHANGE MAIN CONTROL VALVE (Positive Control)

Travel Right

Travel Straight

Bucket Travel Left

Boom P1 by-pass cut (Top) & Arm Conflux (bottom)

Swing Boom Conflux

Auxiliary Valve Activation Port

Arm

Circuit Relief Low Flow Port ArmV/R (top) & P2 by-pass cut (bottom)

Auxiliary Port (STD. Blank) Front of Machine

Typical of MINOR CHANGE SK210 SK250 Page 5-24


MINOR CHANGE MAIN CONTROL VALVE (Positive Control) Front of Machine

AVR Arm Variable Regen (top)

Option Valve Activation Port

Arm P1 By-Pass Cut (Top) Boom Holding Valve

Boom Conflux

Boom

Bucket

Swing

Travel Right

Travel Left

Main Relief

Travel Straight Typical of MINOR CHANGE SK210 SK250 Dynamic Acera 01/04-MC

Page 5-25

HYDRAULIC MAIN CONTROL VALVE Front of Machine Arm Conflux

Arm

Boom Conflux

Boom Bucket

Option 1

Travel Right

Travel Straight Swing

Travel Left

Main Relief

Cover for option -2 block

Typical of SK480 Page 5-26


HYDRAULIC COMPONENTS 7-7 Pilot valve (for Attachment)

2. Before tightening adjusting nut of pilot valve, apply Locktite #277 on joint thread section. 3. Apply grease on rotating and sliding sections of joint, and give attention to the assembling direction. 4. Apply grease on push rod top end. 5. Thickness of washer 2 (shim) for regulating secondary pressure is t = 0.4. 6. Not allowed to use seal washer again.

Type Max. primary pressure Max. back pressure Rated flow rate Weight

PV48K1008 50 kgf/cm², ( 711 PSI ) 3 kgf/cm², ( 42 PSI ) 20 L/min 1.9 kg

1. The material of casing has changed from casting iron to aluminum alloy to make lighter weight . 2. Shuttle block on lower part is canceled, and low pressure sensor is used to send pilot secondary pressure signal to controller. Note: 1. P port inlet has a filter of 40 mesh or more to protect spool from foreign matter.


Page 5-27

HYDRAULIC COMPONENTS 3. Construction Cross sectional view

Code

Name

Qty.

101 111 121 122 125 126 131 151 201-1 201-2 211 212 213 214

Casing Port plate Seal washer O-ring Socket bolt (M8 x 35) Spring pin Bushing Plate Spool Spool Plug Push rod Seal O-ring (1B P20)

1 1 2 1 2 1 1 1 2 2 4 4 4 4

Page 5-28

Torque N•m {kgf•m}

20.6 {2.1}

Code 216-1 216-2 217 218-1 218-2 221-1 221-2 241-1 241-2 246 301 302 312 501

Name Spring seat 1 Spring seat 2 Washer 2 (shim) Spring seat 1 Spring seat 2 Spring Spring Spring Spring Spring Joing (M14) Plate Adjusting nut (M14) Boot

Qty. 2 2 4 2 2 2 2 2 2 4 1 1 1 1


47 {4.8} 69 {7}


HYDRAULIC COMPONENTS 7-8 Pilot valve (for traveling) 1. Appearance

Code

Port name

1 2 3 4 T 5 6 P

Left travel forward port Left travel reverse port Right travel forward port Right travel reverse port Tank port Travel pressure sensor port Travel pressure sensor port Pilot primary pressure port

Size


PF 3/8

73.5 ± 5 {7.5 ± 0.5}

PF 1/4

36.3 ± 2 {3.7 ± 0.2}

2. Specifications Model Primary pressure Secondary pressure Rated flow Weight

07291-0000 50kgf/cm², ( 711 PSI) 5.5 ~ 24 kgf/cm², ( 78 ~ 341 PSI ) 10 L/min Approx. 11 kg

4. Control curve

3. Hydraulic diagram


Page 5-29

HYDRAULIC COMPONENTS 5. Construction

Code

Name

1 Orifice (Shim) 2 Seat 3 Orifice (Shim) 4 Spool 5 Body 6 Stopper 7 Spring 8 Spring 9 Name plate 10 Shim (t = 0.2) 11 Shim (t = 0.1) 12 Cam 13 Boot 14 Pin 15 Cover 16 Piston 17 Guide 18 Sleeve 19 Holder 20 Ring 21 Orifice (Shim) Apply Locktite #262 to ✩

Page 5-30

Qty. 4 2 4 4 1 4 4 4 1 4 4 2 2 2 2 4 4 4 4 12 4

Travel pilot valve Torque Code Name N•m {kgf•m} 22 Spring 24 Plug (PF 1/8) ✩15 {1.5} 25 Plug (PF 1/4) 26 Socket bolt (M10 x 60) 27 Flange bolt 28 Setscrew (M8) 29 Washer 30 Washer 31 Rivet 32 Pin ( φ 5) 33 Ball 34 Ball 35 Ball 36 Ball 37 U-packing 38 O-ring (1A P5) 39 O-ring (1A P24) 40 O-ring (1A P26) 41 O-ring (1B P8) 42 O-ring (1B P11) 44 Piston Assy

Qty. 4 3 3 2 4 4 4 2 2 4 6 4 4 6 4 4 4 4 3 3 4

Torque N•m {kgf•m} 9.8 25 59 5 15

{1.0} {2.5} {60} {0.5} {1.5}


HYDRAULIC COMPONENTS 6. Operations The pilot valve is made up of the following sections in the functions. A. Damper section B. Reducing valve section C. Shuttle section A. Damper section ➀ The primary pressure is fed through the P port, and flows into the damper chamber through passages (D) and (E). ➁ In addition, the primary pressure is stored in the damper chamber through the orifice and check valve. ➂ Then, the air stored in the damper chamber is discharged to T port through passages (F) and (G) to prevent the damper performance from instability due to the entry of air. ➃ If the cam actuates while traveling because the oil in the damper chamber is prevented from reversing with the check valve, the oil flows to passage (E) through only the orifice section. ➄ The damping operation is performed by the resistance generated when the oil passes through the orifice. ➅ The upper and lower bores of piston are 12 and 11 respectively, causing the difference of area, therefore the upward moving force always acts on the piston. ➆ Consequently, the cam operation and the piston on the other side rise due to the pressure caused by the difference of area, resulting in the condition where it follows the cam operation. ➇ Therefore, the damper operation is constant even the cam is located on any position.


Page 5-31

HYDRAULIC COMPONENTS B. Reducing valve (1) At neutral position ➀ The primary pressure fed through P port is blocked by the sealing function on the outside of spool and the hole on the body. ➁ And, since the secondary pressure port is connected to the T port through vertical hole (H) at the center section and side hole (I), the pressure is zero. (2) In operation ➀ If the cam inclines in the operating direction, the piston lowers. ➁ Since the cutout (J) on the outside of spool is connected with the secondary pressure port, the primary pressure fed through P port flows to the secondary pressure port. ➂ Then, the side hole (I) goes in the hole on the body and is sealed, and the circuit from the secondary pressure port to the T port is blocked. ➃ When the pressure at the secondary pressure port rises higher than the force of spring for the secondary pressure, the spool is pushed up and the cutout (J) goes in the hole on the body and the passage between the primary pressure port and the secondary pressure port is blocked. ➄ And, side hole (I) is connected with the T port to release the pressure at the secondary pressure port to the T port. ➅ By repeating the above procedures, it is possible to obtain the pressure at the secondary pressure port which is wellbalanced against the load of spring for the secondary pressure corresponding to the cam operation. ➆ The return spring acts to maintain the proper operating reaction force and to securely return the pressure reducing valve to the neutral position. C. Shuttle section ➀ If the pressure is produced on the ports 1 and 3, the ball is pressed against the seat. ➁ And, the pressure flows from the port 1 to the port 5 or port 3 to port 6. ➂ Only a little pressure leaks from the ports

Page 5-32


HYDRAULIC COMPONENTS 7-10 Solenoid/Proportional valve block 1. Appearance

On/OFF

On/OFF

On/OFF

On/OFF

Proportional Solenoid Valves

Note : A1 ~ A8 are Non - Adjustable Port Code P1, P2, T A1 A2 ~ A8

Size PF 3/8 PF 1/4

Torque: N•m {kgf•m} 74 ± 5 { 7.5 ± 0.5} 36 ± 2 {3.7 ± 0.2}

2. Specifications Item Type Rated pressure (P port) Allowable back press. (T port) Max. flow rate Solenoid valve ON/OFF Proportional valve Variable


Rated voltage Range of allowable voltage Rated power consumption Duty Coil resistance Rated current Coil resistance Range of secondary press Dither in use

Specifications 8KWE5G–30 / G24WR–804 B 0 ~ 50 kgf/cm² {0~711 psi} 10 kgf/cm² {142 psi} or lower Sol. valve: 16 L/min, Propo. valve: 10 L/min (per one spool) DC24V 20.4 ~ 30V 17W or less (at 24V, 20°C) 29V continuous (with surge killer) 34 ~ 40 Ω 700mA 17.5 Ω (at 20°C) 0 ~ 2.9 MPa {0 ~ 30 kgf/cm²} 100 Hz/300mAP -P {at 300mA} Page 5-33

HYDRAULIC COMPONENTS 2. Structure

Code 101 151 153 171

Name Casing Plug BP–1/16 (Meck) Plug BP–1/8 (Meck) Socket bolt (M5 x 12)

Qty. Code Name Qty. 1 601 Propo. valve (KDRDE5K-31/30C40-101) 4 8 701 Sol. valve (KWE5K-31/G24D40) 3 1 702 Sol. valve (KWE5K-31/G24Y40) 1 16 901 Name plate 1

3. Hydraulic diagram A1 ~ A8 are Non - Adjustable

Page 5-34


HYDRAULIC COMPONENTS 7-9 Swivel joint 1. Appearance

2. Specifications

3. Construction

Code 1 2 3 4 5 6 7 8 9 10


Name Body Stem Thrust plate Cover Seal assy O-ring O-ring Socket bolt Socket bolt Blank plug

Qty. 1 1 1 1 5 2 1 2 4 1

Page 5-35

HYDRAULIC COMPONENTS 7-6 Cushioning Mechanism of Cylinder 1) Cushioned cylinder Cushion mechanism is provided so that earth and sand in the bucket does not fall down due to shock produced when extending and retracting piston rod strikes rod cover and cylinder tube without reducing the speed. ➀ Boom cylinder ➁ Arm cylinder ➂ Bucket cylinder

Rod side Rod and head side Rod side

• Operation of cushion mechanism on rod side. ➀ When reaching close to cylinder stroke end, oil in A chamber passes through passage B, and flows into tank port (T) at constant speed. ➁ In addition, after piston rod (4) is extended, cushion ring (13) gets into rod cover (14), oil in A chamber is restricted and passes through passage B and flows into tank port (T) resulting in reduction of piston speed. ➂ After piston rod (4) extends further, cushion ring (13) gets into rod cover (14) completely, piston speed is reduced when oil in a chamber passes through and piston (5) strikes rod cover (14) that is, stroke end. • Operation of cushion mechanism on head side. ➀ When reaching close to cylinder stroke end, oil in a chamber passes through passage B, and flows into tank port (T) at constant speed. ➁ In addition, after piston rod (4) is retracted, plunger (4a) gets into cylinder tube (1), oil in A chamber is restricted and passes through passage B and flows into tank port (T) resulting in reduction of speed. ➂ After piston rod (4) retracts further, plunger (4a) gets into cylinder tube (1) completely, piston speed is reduced when oil in A chamber passes through, then piston (5) strikes cylinder tube (1), that is, stroke end. Page 5-36


HYDRAULIC COMPONENTS 7-6 Cushioning Mechanism of Cylinder Cont.


Page 5-37

7-6 Cushioning Mechanism of Cylinder Cont.

Page 5-38


Componentes Hidráulicos (SK210 Y SK330)

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