ZX200 5G Operational Principle TODCD en 01

PART NO.

TODCD-EN-01

Z X 2 0 0 5 G •

2 0 0 L C 5 G •

2 1 0 H 5 G

Technical Manual

•

2 1 0 L C H 5 G

Operational Principle

•

2 1 0 K 5 G •

2 1 0 L C K 5 G

H Y D R A U L I C E X C A V A T O R T E C H N I C A L M A N U A L O P E R A T I O N A L P R I N C I P L E

URL:http://www.hitachi-c-m.com

PRINTED IN

JAPAN (K) 2012, 01

T O D C D E N 0 1

ZX

200-5G 200LC-5G 210H-5G 210LCH-5G 210K -5G -5G 210LCK -5G -5G

Hydraulic Excavator Service Manual consists of the following separate Part No. Technical Tech nical Manual (Operational Principle) : Vol. No.TODCD-EN Technical Manual (Troubleshooti ng) : Vol. No.TTDCD -EN Workshop Manual : Vol. No.WDCD-EN Engine Manual : Vol. No.EDCD-EN

INTRODUCTION To The Reader This manual is written for an an experienced technician to provide technical information needed to maintain and repair this machine. 



Be sure to thoroughly thoroughly read this manual for correct product information and service ser vice procedures.

If you have any questions or comments, at at if you found found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form”” at the end of this manual. (Note: Do not tear off Form the form. Copy it for usage.): Product Support Hitachi  Publications Marketing & Product Construction Machinery Co. Ltd.  TEL: 81-29-832-7084  FA FAX: X: 81-2981-29-831-11 831-1162 62  E-mail: [email protected]

Additional References Please refer to the other materials (operator’s manual, parts catalog, engine technical material and Hitachi training material etc.) in addition to this manual.

Manual Composition This manual consists the Technical Manual, the Workshop Workshop Manual and the Engine Manual.

 Information included in the Workshop Manual: Technical information needed for Technical for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and assemble / disassemble procedures.

Information included in the Techni Technical cal Manual: Technical T echnical information needed for for redelivery and delivery, delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures. 

Information included included in the Engine Manual: Technical Techni cal information needed for for redelivery and delivery and maintenance and repair of the machine, operation and activation of all devices and systems, troubleshooting and assemble / 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:  Technical Manual: T 1-3-5 T 1 3 5



Workshop Manual: W 1-3-2-5

W 1 3 2 5

Technical Manual Technical Section Number Group Number Con onse secu cuti tiv ve Pa Page Num Numbe berr for for Eac ach h Gr Group

IN-01

Workshop Ma Manual Section Number Group Number Sub Group Number Cons nsec ecut utiv ive e Pa Page Nu Numb mber er fo forr Eac Each h Gr Group

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.

d CAUTION: Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death.

aler t symbol. When you see this d This is the safety alert

IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.

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 draw attention to component/part weights. To T o avoid injury and damage, damage, be sure to use appropriate appropriate lifting techniques and equipment when lifting heavy parts.

f NOTE: Indicates supplementary technical information or knowhow.

Units Used Example: 24.5 MPa (250 kgf/cm2, 3560 psi)

SI Units (International System of Units) are used in this manual. MKSA system units and English units are also indicated in parentheses just behind SI units.

A table for conversion from SI units to other system units is shown below for reference purposes.

Quantity

To Convert From

Into

Multiply By

Length

mm

in

0.03937

mm

ft

0.003281

L

US gal

0.2642

L

US qt

1.057

m3

yd3

1.308

Weight

kg

lb

2.205

Force

N

kgf

0.10197

N

lbf

0.2248

N·m

kgf·m

Volume

Torque To rque Pressure

0.10197 2

MPa

kgf/cm

10.197

MPa

psi

145.0

kW

PS

1.360

kW

HP

1.341

Temperature Tem perature

°C

°F

°C×1.8+32

Velocity

km/h

mph

0.6214

min-1

rpm

1.0

L/min

US gpm

0.2642

mL/rev

cc/rev

1.0

Power

Flow rate

fNOTE:

The numerical numerical value in this manual might be different from the above-mentioned table.

IN-02

SYMBOL AND ABBREVIA ABBREVIATION TION Symbol / Abbreviation TO TT T/M W, W/M MC ECF GSM

GPS CAN

A/C OP, OPT MPDr. A/I WU Li AT T HI, Hi LO, Lo

Name

Explanation

Technical manual (Operational (Operational principle) Technical manual (Troubleshooting) (Troubleshooting) Technical manual Workshop manual

Technical manual (Operational (Operational Principle). Technical manual (Troubleshooting). (Troubleshooting). Technical manual. Workshop manual (Removal and Installation, Disassembly and Assembly). Main Controller Main controller. MC controls the engine, pump, and valve according to the machine operating condition. Engine Controller Engine controller. ECF controls EC motor according to the machine operating condition. Global System for Mobile communications Communication controller. controller. GSM is a type of wireless controller communication system, is used in more than on 100 countries around Europe and Asia, and becomes the factual global standards of the mobile telephone. Global Positioning System Global positioning system. Controller Area Network CAN communication. CAN is a serial communications protocol internationally-standardized internationally-standardized by ISO (International Organization for Standardizatio Standardization). n). Air Conditioner Air conditioner. Option Optional component. Maintenance Pro Dr. MPDr. is software that troubleshooting, monitoring, and adjustment. Auto-Idle Auto-idle. Warming-Up Warming-up. Low (Slow) Idle Slow idle engine speed. Attachment Attachment. Attachment is optional parts such as breaker, crusher, and pulverizer in this manual. High Travel fast position. Low Travel slow position.

SY-1

SYMBOL AND ABBREVIA ABBREVIATION TION (Blank)

SY-2

SECTION AND GROUP SECTION 1 GENERAL Group 1 Specification CONTENTS Group 2 Component Layout Group 3 Component Specifications

SECTION 2 SYSTE SYSTEM M Group 1 Controller TECHNICAL MANUAL (Operational Principle)

Group 2 Control System Group 3 Hydraulic System Group 4 Electrical System

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Group 2 Swing Device Group 3 Control Valve Valve Group 4 Pilot Valve Valve Group 5 Travel Device Group 6 Signal Control Valve Valve Group 7 Others (Upperstructure) Group 8 Others (Undercarriage)

All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.

COPYRIGHT(C)2011 Hitachi Construction Machinery Co., Ltd. Tokyo T okyo,, Japan Japan All rights reserved

TECHNICAL MANUAL MANUAL (Troubleshooting)

WORKSHOP MANUAL MANUAL

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction Group 2 Standard Group 3 Engine Test Group 4 Excavator Test Group 5 Component Test Group 6 Adjustment SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Group 2 Monitor Group 3 e-Service Group 4 Component Layout Group 5 Troubleshooting A Group 6 Troubleshooting B Group 7 Air Conditioner

SECTION 1 GENERAL INFORMATION INFORMATION Group 1 Precautions for Disassembling and Assembling Group 2 Tightening Torque Group 3 Painting Group 4 Bleeding Air from Hydraulic Oil Tank Group 5 Hydraulic Circuit Pressure Release Procedur Procedure e Group 6 Preparation SECTION 2 MAINTENANCE STANDARD Group 1 Upperstructure Group 2 Undercarriage Group 3 Attachment SECTION 3 UPPERSTRUCTURE Group 1 Cab Group 2 Counterweight Group 3 Main Frame Group 4 Engine Group 5 Radiator Group 6 Hydraulic Oil Tank Group 7 Fuel Tank Group 8 Pump Device Group 9 Control Valve Group 10 Swing Device Group 11 Pilot Valve Group 12 Solenoid Valve Group 13 Signal Control Valve SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing Group 2 Travel Device Group 3 Center Joint Group 4 Track Adjuster Group 5 Upper and Lower Roller Group 6 Track SECTION 5 ATTACHMENT Group 1 Front Attachment Group 2 Cylinder Group 3 Hose Rupture Valve Valve

SECTION 1

GENERAL CONTENTS Group 1 Specifications Specifications ................... ...................................... ...................................... ................................. ..............T1-1-1 T1-1-1 Specifications ................... ...................................... ...................................... ................................. ..............T1-1-2 T1-1-2 Working Ranges (Grouser shoe) ............................ .................................... ........ T1-1-3 Working Ranges (Grouser shoe) ............................ .................................... ........ T1-1-4

Group 2 Component Layout Main Component ............................... .................................................. ................................. ..............T1-2-1 T1-2-1 Electrical System (Overview) ................. .................................... ........................ ..... T1-2-2 Engine ................. .................................... ...................................... ...................................... .............................. ........... T1-2-3 Electrical System (In Cab) .................. ..................................... .............................. ........... T1-2-3 Electrical System (Rear Tray)................. Tray).................................... ........................... ........ T1-2-4 Electrical System (Switch Panel) ............................ .................................... ........ T1-2-5 Electrical System (Around Air Cleaner) ....................... .......................T1-2-6 T1-2-6 Electrical System (Relays) .................................. ................................................. ...............T1-2-7 T1-2-7 Pump Device ................. .................................... ...................................... ....................................T1-2-8 .................T1-2-8 Control Valve.. Valve..................... ...................................... ...................................... ................................. ..............T1-2-9 T1-2-9 Signal Control Valve ............................................. ........................................................... ..............T1-2-9 T1-2-9 Swing Device ................. .................................... ...................................... ..................................T1-2-11 ...............T1-2-11 Travel Trav el Device.............................. Device................................................. ...................................... ......................T1-2-11 ...T1-2-11 3-Spool Solenoid Valve Unit .................... ....................................... ......................T1-2-12 ...T1-2-12 Layout of Attachment Spec. Parts...............................T1-2-14 Parts...............................T1-2-14

Group 3 Component Specifications Engine ................. .................................... ...................................... ...................................... .............................. ........... T1-3-1 Engine Accessories .................................. ..................................................... ........................... ........ T1-3-5 Hydraulic Component ............................ ............................................... ........................... ........ T1-3-6 Electrical Component....................................... ......................................................T1-3-10 ...............T1-3-10

DCDT-1-1

(Blank)

DCDT-1-2

SECTION 1 GENERAL Group 1 Specifications Specifications ZX200-5G, 200LC-5G, 210H-5G, 210LCH-5G A C

G

B F E D K

J I

Model Type of Front-End Front-End Attachment Bucket Capacity (Heaped) Operating Weight Base Machine Weight Engine A: Overall Width (Excluding back mirrors) B: Cab Height C: Rear End Swing Radius D: Minimum Ground Clearance E: Counterweight Clearance F: Engine Cover Height G: Overall Width of Upperstructure H: Undercarriage Length Undercarriage Width I: J: Sprocket Center to Idle Center Track Shoe Width Shoe Width K: Ground Pressure Swing Speed Travel Trav el Speed (fast/slow) Gradeability

H

m3 kg kg mm

MDCD-12-001

ZX200-5G ZX200LC-5G ZX210H-5G ZX210LCH-5G 2.91 m Arm 2.91 m H Arm PCSA 0.80 m3 (1.3 yd3), CECE 0.70 m3 19800 20400 21100 21500 15400 15900 16300 16800 -1 ISUZU CC-6BG1T 125 kW/2100 min (170 PS/2100 rpm) 2860

2990

mm mm

2950 2890

mm

*450

mm mm

*1030 *2270

mm

2710

2860

2990

mm mm

4170 2800

4460 2990

4170 2800

4460 2990

mm

3370

3660

3370

3660

mm kPa(kgf/cm2) min-1(rpm) km/h Degree (%)

600 (Grouser shoe) 44(0.45) 42(0.43)

600 (Reinforced grouser shoe) 47(0.48) 44(0.45)

13.5(13.5) 5.5/3.5 35(70) *The dimensions do not include the height of the shoe lug.

T1-1-1

SECTION 1 GENERAL Group 1 Specifications Specifications ZX210K-5G, 210LCK-5G A C

G

B F E D K

J I

H

ZX210K-5G

Model Type of Front-End Front-End Attachment

MDCD-12-001

ZX210LCK-5G

-

2.91 m K Arm

Bucket Capacity (Heaped)

m3

PCSA 0.80 m3 (1.3 yd3), CECE 0.70 m3

Operating Weight

kg

21100

21500

Base Machine Weight

kg

16300

16800

Engine A: Overall Overall Wid Width th (Exclud (Excluding ing back back mirrors) B: Cab Height C: Rear End Swing Radius

-

ISUZU CC-6BG1T 125 kW/2100 min-1 (170 PS/2100 rpm) 2860

mm

2990

mm

2950

mm

2890

D: Minimum Ground Clearance E: Counterweight Clearance

mm

*450

mm

*1030

F: Engine Cover Height G: Ove Overal ralll Wi Width dth of Upperstructure H: Undercarriage Length I: Undercarriage Width

mm

*2270

mm

2710

J: Sprocket Ce Center to to Id Idle Ce Center K: Track Shoe Shoe Width Width Ground Pressure Swing Speed Travel Trav el Speed (fast/slow) Gradeability

mm

4170

4460

mm

2800

2990

mm

3370

3660 600 (Reinforced grouser shoe)

mm kPa(kgf/cm 2)

47(0.48)

44(0.45)

min-1(rpm)

13.5(13.5)

km/h

5.5/3.5

Degree (%)

35(70) *The dimensions do not include the height of the shoe lug.

T1-1-2

SECTION 1 GENERAL Group 1 Specifications Working Ranges (Grouser shoe) ZX200-5G, 200LC-5G, 210H-5G, 210LCH-5G A G

C

D

E

B

F

MDCD-12-002

Backhoe

Model Category Item A: Maximum Digging Reach B: Maximum Digging Depth C: Maximum Cutting Height D: Maximum Dumping Height E: Overall Height F: Overall Length G: Minimum Swing Radius

fNOTE:

ZX200-5G, 200LC-5G 2.42 m Arm 2.91 m Arm Backhoe Backhoe

210H-5G, 210LCH-5G 2.91 m H Arm Backhoe

(mm)

9430

9920



(mm)

6180

6670



(mm)

9670

10040



(mm)

6830

7180



(mm) (mm)

3180 9745

3010 9660



(mm)

3280

3180



The dimensions dimensions do not not include height height of the shoe lug (except (except Item E).

T1-1-3



SECTION 1 GENERAL Group 1 Specifications Working Ranges (Grouser shoe) ZX210K-5G, 210LCK-5G A G

C

D

E

B

F

Backhoe

Model Category Item A: Maximum Digging Reach B: Maximum Digging Depth C: Maximum Cutting Height D: Maximum Dumping Height

(mm) (mm) (mm) (mm)

E: Overall Height

(mm)

F: Overall Length G: Minimum Swing Radius

(mm) (mm)

f NOTE:

ZX210K-5G, 210LCK-5G 2.91 m K Arm Backhoe 9920 6670 10040 7180 3010 (Standard) 3120 (High-Grade) 9660 3180

The dimensions do not not include height of the shoe lug (except (except Item E).

T1-1-4

MDCD-12-003

SECTION 1 GENERAL Group 2 Component Layout Main Component

2 3

1

23 4

5

6 7 8 9

22

10

21

11

20 12

19 13 14 18

123456-

Bucket Cylinder Boom Cylinder Arm Cylinder Center Joint Swing Bearing Swing Device

789101112-

17

Fuel Tank Hydraulic Oil Tank Control Valve Pilot Filter/ Pilot Relief Valve Pump Device Engine

131415161718-

T1-2-1

16

Intercooler Air Conditioner Condenser Radiator Battery Travel Tra vel Device Device Oil Cooler

TDCD-01-02-001 TDCD-01-0 2-001

15

1920212223-

Air Cleaner Signal Control Valve Pilot Shut-Off Solenoid Valve Valve Travel Trav el Pilot Valve Front Attachment / Swing Pilot Valve

SECTION 1 GENERAL Group 2 Component Layout Electrical System (Overview) 1

19

2

18

17 3

16

15

14 4 5 13

6

7 12

8 11 10 TDCD-01-02-003 TDCD-01-0 2-003

9

12345-

Rear View Camera Components Componen ts Related with Engine (Refer to T1-2-3.) Electrical System (Relays) (Refer to T1-2-7.) Battery *Communication Aerial (for Satellite Communica Communication) tion)

fNOTE:

6-

Electrical System (Around Air Cleaner) (Refer to T1-2-6.) 7- GPS Aerial 8- Components Related with Signal Control Valve (Refer to T1-2-9.) 9- Wiper Motor 10- Monitor

11- Horn 12- Work Light 13- Components Related with Swing Device (Refer to T1-211.) 14- Fuel Sensor 15- Hydraulic Oil Temperature Sensor

*: This component is different different by by an area.

T1-2-2

16- Components Related with Control Valve (Refer to T1-2-9.) 17- 3-Spool Solenoid Valve Unit 18- EC Motor/EC Sensor 19- Components Related with Pump Device (Refer to T1-2-8.)

SECTION 1 GENERAL Group 2 Component Layout Engine

7 5-

Overheat Switch

6-

6

Coolant Temperature Sensor

7-

Electrical System (In Cab)

TDCD-01-02-008 TDCD-01-0 2-008

5 Engine Oil Pressure Switch

1

4 TDCD-01-02-004 TDCD-01-0 2-004

3 1-

Components Related with Components Rear Tray (Refer to T1-2-4.)

23-

Engine Stop Knob Engine Stop Switch

4-

T1-2-3

2

Components Related with Switch Panel (Refer to T1-2-5.)

SECTION 1 GENERAL Group 2 Component Layout Electrical System (Rear Tray)

19 18

2 1

3 4 5 6

TDCD-05-04-001 TDCD-05-0 4-001

7

8

9

1 0 1 1 12

1 7 1 6 15 1234-

Monitor Controller *GSM (Mobile Communication Controller) MC (Main Controller) MPDr. Connector (Download Connector Using Combinedly Combinedly))

fNOTE:

5678910-

Fuse Box Fuse Box (for Attachment) Wiper/Light Controller Wiper Relay (R6) Work Light Relay 1 (R7) Work Light Relay 2 (R8)

1 4 13 111213141516-

*: This component is different different by by an area.

T1-2-4

Washer Relay (R9) Horn Relay (R10) Security Relay (R5) Starter Cut Relay (R4) Security Horn Relay (R3) Pilot Shut-Off Relay (R2)

TDCD-01-02-009 TDCD-01-0 2-009

17- Load Damp Relay (R1) 18- Engine Learning Switch 19- QOS Controller

SECTION 1 GENERAL Group 2 Component Layout Electrical System (Switch Panel)

1

2

3

16 4 15 5

6

13

7

14

8 9

12

11

10

TDAA-05-02-059 TDAA-0 5-02-059

1234-

Return to Previous Screen Switch Return to Basic Screen Switch Selector/Set Switch AM·FM Switch/Tuning Switch

56789-

Power Switch/Volume Control Switch Engine Control Dial Auto-Idle Switch Travel Tra vel Mode Switch Work Light Switch

10111213-

T1-2-5

Power Mode Switch Key Switch TEN-key Switch Switch Overhead Window Wiper/ Overhead Window Washer Switch (Optional)

14- Wiper/Washer Switch 15- AUTO/OFF Switch/Blower Switch 16- Tem Temperature perature Control Control Switch/ Switch/ MODE Switch

SECTION 1 GENERAL Group 2 Component Layout Electrical System (Around Air Cleaner)

A

a

View A

1

2

2 a

3

TDCD-01-02-006 TDCD-01-02 -006

a-

Machine Front

1-

ECF (Engine Controll Controller) er)

2-

Air Cleaner

TDCD-01-02-007 TDCD-01-0 2-007

3-

T1-2-6

Air Cleaner Restriction Switch

SECTION 1 GENERAL Group 2 Component Layout Electrical System (Relays)

1

2

3

4

5

12-

Ambient Temperature Sensor Starter Relay 2

34-

Battery Relay Glow Plug Relay

TDCD-01-02-002 TDCD-01-0 2-002

5-

T1-2-7

Fusible Link (Red: 45A, Black: 65A)

SECTION 1 GENERAL Group 2 Component Layout Pump Device

1

2

8

3

7 6 9

5

10

4 T1V1-01-02-032 T1V1-01-0 2-032

1234-

Pilot Pump Pump 2 Pump 1 Pump 1 Delivery Pressure Sensor

567-

Pump 2 Delivery Pressure Sensor Torque To rque Control Control Solenoid Valve Maximum Pump 2 Flow Rate Limit Control Solenoid Valve

TDCD-03-01-004 TDCD-03-0 1-004

8-

Pump 2 Control Pressure Sensor 9- Pump 1 Control Pressure Sensor 10- N Sensor

T1-2-8

SECTION 1 GENERAL Group 2 Component Layout Control Valve

1 2

T1V1-03-03-073 T1V1-03-0 3-073

3

Signal Control Valve Valve

a

4

5

T1V1-01-02-014 T1V1-01-0 2-014

a-

Pilot Valve Side

12-

Pressure Sensor (Arm Roll-In) Main Relief Valve

34-

Pressure Sensor (Boom Raise) Pressure Sensor (Swing)

5-

T1-2-9

Pressure Sensor (Travel)

SECTION 1 GENERAL Group 2 Component Layout

A

A

a

T178-03-06-016 T178-03 -06-016

Cross Section A-A

1

5

2

6

3

7

4

T178-03-06-002 T178-03 -06-002

a-

Pilot Valve Side

12-

Shockless Valve Bucket Flow Rate Control Valve Control Spool

34-

Pump 2 Flow Rate Control Valve Flow Combiner Valve Control Spool

56-

T1-2-10

Arm 1 Flow Rate Control Valve Control Spool Pump 1 Flow Rate Control Valve

7-

Swing Parking Brake Release Spool

SECTION 1 GENERAL Group 2 Component Layout Swing Device

Travel Device

3

1

2

5

4

T1HD-01-02-001 T1HD-01-02 -001

T1V1-01-02-005 T1V1-01-0 2-005

12-

Swing Relief Valve Pressure Sensor (Front Attachment)

34-

Counterbalance Valve Travel Tra vel Motor Swash Angle Control Valve

3

5-

T1-2-11

Travel Tra vel Relief Valve

SECTION 1 GENERAL Group 2 Component Layout 3-Spool Solenoid Valve Unit

1

2

3

TDCD-03-07-001 TDCD-03-0 7-001

1-

3-Spool Solenoid Valve Unit (SC)

2-

3-Spool Solenoid Valve Unit (SF)

3-

T1-2-12

3-Spool Solenoid Valve Unit (SG)

SECTION 1 GENERAL Group 2 Component Layout (Blank)

T1-2-13

SECTION 1 GENERAL Group 2 Component Layout Layout of Attachment Spec. Parts

b

c

1

a

TDCD-01-02-005 TDCD-01-0 2-005 a-

Utility Utili ty Spac Space e (Ref (Refer er to T1-2 T1-2-15. -15.))

1-

Pilot Valve (Auxiliary)

b-

Boom Uppe Upperr Side (Ref (Refer er to T1-2-15.) T1-2-15.)

c-

T1-2-14

Selector Valve (Refer to T1-215.)

SECTION 1 GENERAL Group 2 Component Layout a

Utility Space

b

Boom Upper Side

c

Selector Valve

Pressure Sensor (Auxiliary) Auxiliary Flow Combiner Control Solenoid Valve Auxiliary Flow Rate Control Solenoid Valve Pressure Reducing Valve Accumulator Control Valve Accumulatorr (High Pressure) Accumulato Accumulator (Low Pressure) Secondary Pilot Relief Pressure Valve Valve Secondary Pilot Relief Pressure Control Valve Valve –

T1-2-15

Refer to T1-2-16.

Refer to T1-2-17.

Refer to T1-2-16.

SECTION 1 GENERAL Group 2 Component Layout Utility Space

1

2

3

TDCD-01-02-011 TDCD-01-0 2-011

4

Selector Valv Valve e 5

TDCD-01-02-012 TDCD-01-0 2-012

1-

Pressure Sensor (Auxiliary)

2-

Auxiliar y Flow Combiner Auxiliary Control Solenoid Valve

3-

T1-2-16

Auxiliary Flow Rate Control Solenoid Valve

45-

Pressure Reducing Valve Selector Valve

SECTION 1 GENERAL Group 2 Component Layout Boom Upper Side

1

Breaker 1 (HSB Breaker) Shared Machine

TDCD-01-02-013 TDCD-01-0 2-013

2

Breaker 2 (NPK Breaker) Shared Machine 3

4

TDCD-01-02-014 TDCD-01-0 2-014

5

1-

Secondary Pilot Relief Pressure Valve

2-

Secondary Pilot Relief Pressure Control Valve

34-

T1-2-17

Accumulator Control Valve Accumulator (Low Pressure)

5-

Accumulator (High Pressure)

SECTION 1 GENERAL Group 2 Component Layout (Blank)

T1-2-18

SECTION 1 GENERAL Group 3 Component Specifications Engine Manufacturer Model Type

Compression Ratio Dry Weight Firing Order

ISUZU CC-6BG1TRA-12 Diesel, 4-Cycle, Water Water-cooled, -cooled, Direct Injection Type, Type, Exhaust Turbo Charged Charged Type 6-105 mm×125 mm (4.13 in×4.92 in) 6494 cm3 (396 in3) 118+8.6-1 kW/2000 min-1 (160.4+11.7-1.4 PS/2000 rpm) Travel Trav el HP Mode: 125+1.5-4.4 kW / 2100 min-1 (170+2-6 PS / 2100 rpm) 18 490 kg (1080 lb) 1-5-3-6-2-4

Rotation Direction

Clockwise ( Viewed from fan side)

Cyl. No.- Bore × Stroke Piston Displacement Rated Output

T1-3-1

SECTION 1 GENERAL Group 3 Component Specifications COOLING SYSTEM

Cooling Fan Fan Pulley Ratio Thermostat

LUBRICATION SYSTEM

Water Pump Lub ubri rica cati tion on Pum Pump p Ty Type

Oil Filter Oil Cooler STARTING SYSTEM Motor Voltage / Output PREHEAT SY SYSTEM Preheating Me Method ENGINE STOP SYSTEM Stop Method ALTERNATOR Type Voltage / Output SUPERCHARGING Type SYSTEM FUEL SYSTEM Type Governor Injection Nozzle

Dia. 650 mm (25.6 in), 7 Blades, HF Hybrid, with Fan Ring and Safety Net Belt Driven Rotation Ratio : 0.95 Cracking Temperature Temperature at Atmospheric Atmospheric Pressure: 82 82 °C (180 °F) Full Open (Stroke: 10 mm or more) Temperature: Temperature: 95 °C (203 °F) Centrifugal Type Gear Ge ar Pu Pump Full-Flow Paper Element Type with Bypass Water Cooled Integral 5-Stage Type Magnetic Pinion Shift Reduction Type 24 V / 4.5 kW Glow Pl Plug (2 (24V, QO QOS IIII Type) Fuel Shut-Off (Electronic Control) Regulator Integrated AC Type, Brushless 24 V / 50 A Exhaust-Turbocharger Exhaust-T urbocharger Type Type RHG6 Type Type with Lubrication, Oil-Cooled Oil-Cooled Type BOSCH Type (ADs Concave Cam) Centrifugal All Speed Control RSV Type Multi-Hole Type

T1-3-2

SECTION 1 GENERAL Group 3 Component Specifications IMPORTANT: IMPORT ANT: This list shows design specifications, specifications, which are not servicing servicing standards. PERF RFO ORM RMA ANC NCE E

240 g/k 240 /kW/ W/h h (17 177 7 g/P /PS· S·h) h) at 12 125 5+1.5-4.4 kW / (at Full Load: 2100 min -1) 230 g/kW/h (169 g/PS·h) at 118 +8.6-1 kW / (at Working Load: 2000 min-1) Maximu Max imum m Outp Output ut Torq orque ue 637+55-65 N·m (65+5.6-6.6 kgf·m) at approx. 1800 min -1 Comp Co mpre ress ssio ion n Pre ress ssur ure e 3.04 3. 04 MP MPa a (3 (31 1 kg kgf/ f/cm cm2) at 200 min-1 Valve Clearance (Inlet / 0.4 / 0.4 mm (when cool) Exhaust) No Load Speed Slow: (at Full Load: 950±20 min-1) Fast: (at Full Load: 2390+20-50 min-1) Fast: (at Working Load: 2300±50 min -1)

Fue uell Cons nsum umpt ptiion Ra Rati tio o

T1-3-3

SECTION 1 GENERAL Group 3 Component Specifications Engine Performance Curve (CC-6BG1TRA (CC-6BG1TRA-12) -12) Test Condition: Test 1. In conformity with JIS D1005 (Performance (Performance Test Test Method for Diesel Engine Used for Construction Machinery) under standard atmospheric pressure. 2. Equipped with the fan and alternator alternator.. N·m

kW

g/kW·h

min-1 (rpm)

kW: Output Torque que N·m: Tor

g/kW·h: Fuel Consumption Ratio min-1 (rpm): Engine Speed

T1-3-4

TDCD-01-03-001 TDCD-01-0 3-001

SECTION 1 GENERAL Group 3 Component Specifications Engine Accesso Accessories ries RADIATOR ASSEMBLY Type Weight

Parallel Type 59 kg (130 lb)

Radiator Air-Ti AirTigh ghtt Tes estt Pre Press ssur ure e Cap Ope peni ning ng Pres essu surre BAT TERY

Oil Cooler 2

98 kP kPa a (1. (1.0 0 kgf kgf/c /cm m , 14 14 psi) 49 kP kPa a (0. (0.5 5 kgf kgf/c /cm m2, 7 psi) Type Capacity Voltage Weight

Intercooler 2

1470 kP kPa (15 kg kgf/cm , 213 213 psi) psi) 245 kPa kPa (2. (2.5 5 kgf/c kgf/cm m2, 36 psi) − −

115E41L 88 Ah (5-Hour Rate) 12 V 27.5 kg (61 lb)×2

T1-3-5

SECTION 1 GENERAL Group 3 Component Specifications Hydraulic Component PUMP DEVICE MAIN PUMP

REGULATOR PILOT PUMP

CONTROL VALVE

Drive Gear Ratio Main Pump: 1, Pilot Pump: 1 Type Bent-Axis Type Variable Displacement Axial Plunger Pump Theoretical Displacement Displacement 106 cm3 /rev (6.5 in3 /rev)×2 Rated Pressure Type Type Model Theoretical Displacement Displacement Type Main Mai n Relief Relief Set Set-P -Pres ressur sure e Overload Relief SetPressure

34.3 MPa (350 kgf/cm2, 4980 psi) Hydraulic Pressure Operated Type FS 11/16.8 Fixed Displacement Type Gear Pump 16.8 cm3 /rev (1.0 in3 /rev)×2 Pilot Pressure Operated Type (4-Spools + 5-Spools) Normal Nor mal:: 34.3 34.3 MPa MPa (35 (350 0 kgf/c kgf/cm m2, 4980 psi) at 150 L/min (39.6 US gpm) Power Digging: 38.0 MPa (388 kgf/cm2) at 150 L/min (39.6 US gpm) 39.2 MPa (400 kgf/cm2, 5690 psi) at 50 L/min (13.2 US gpm) (Boom, Arm, Bucket)

T1-3-6

SECTION 1 GENERAL Group 3 Component Specifications SWING DEVICE

Type Reduction Ge Gear Ra Ratio SWING MOTOR Model Type Theoretical Displacement Displacement VALVE UNIT Type Relief Set-Pressure SWING PARKING Type BRAKE Release Pressure TRAVEL TRAV EL DEVICE Type Reduction Gear Ratio TRAVEL TRAV EL MOTOR MOTOR Type Theoretical Displacement Displacement (Fast/Slow) TRAVEL TRAV EL BRAKE VALV VALVE E Type Relief Set Pressure TRAVEL TRAV EL PARKING PARKING Type BRAKE Release Relea se Starting Starting Pre Pressure ssure

Two-Stage Reduction Planetary Gear 17.53 M5X130CHB-10A-29B/330 Swash-Plate Type, Fixed Fixed Displacement Axial Axial Plunger Motor 129.2 cm3 /rev (7.9 in3 /rev) Non Counterbalance Valve Type 32.4 MPa (330 kgf/cm2, 4710 psi) at 170 L/min Wet-Type WetType Spring Set Hydraulic Hydraulic Released Multi-Disc Brake Brake 2 1.9 to 2.8 MPa (20 to 28.6 kgf/cm , 284 to 410 psi) Three-Stage Reduction Planetary Gear 58.702 Swash-Plate Type Variable Displacement Displacement Axial Plunger Motor 3 79/122.5 cm /rev (4.8/7.5 in3 /rev) Counterbalance Valv Valve e Type Type 34.8 MPa (355 kgf/cm2, 5050 psi) Wet-Type WetType Spring Set Hydraulic Hydraulic Released Multi-Disc Brake Brake 2 0.97±0.07 0.97± 0.07 MPa (9.9 (9.9±0.7 ±0.7 kgf/c kgf/cm m , 141±10 psi)

T1-3-7

SECTION 1 GENERAL Group 3 Component Specifications CYLINDER

Boom Rod Diameter 85 mm (3.35’’) Cylinder Bore 120 mm (4.72’’) Stroke 1260 mm (4’2’’) Fully Retracted Length 1855 mm (6’1’’) Plating Thickness 30 μm (1.18 μm)

T1-3-8

Arm 95 mm (3.74’’) 135 mm (5.32’’) 1475 mm (4’10’’) 2007 mm (6’7’’) 30 μm (1.18 μm)

Bucket 80 mm (3.15’’) 115 mm (4.53’’) 1060 mm (3’6’’) 1590 mm (5’3’’) 30 μm (1.18 μm)

SECTION 1 GENERAL Group 3 Component Specifications FRONT ATTACHMENT Model PILOT VALVE Plunger St Stroke TRAVEL TRAV EL PILOT PILOT VAL VALVE VE Model Plunger Stroke 3-SPOOL SOLENOID Type VALVE VAL VE UNIT U NIT Rated Voltage Coil Resistance AUXILIARY FLOW Rated Voltage COMBINER CONTROL Coil Resistance SOLENOID VAL VALVE VE (Optional) AUXILIARY FLOW Rated Voltage RATE CONTROL Coil Resistance SOLENOID VAL VALVE VE (Optional) SIGNAL CONTROL Model VALVE Rated Pressure PILOT SHUT-OFF Type SOLENOID VAL VALVE VE Rated Voltage Coil Resistance OIL COOLER BYPASS Cracking Pressure CHECK VAL VALVE VE FILTER Engine Oil Filter Full-Fl Ful l-Flow ow Filt Filter er (Fi (Filtrat ltration) ion) Suctio Suc tion n Filt Filter er (F (Filt iltrat ration ion)) Pilot Fi Filter (F (Filtration)

HVP07A-040-101 Ports 1, 1, 3: 3: 6. 6.5 mm mm (0.26 in in), Po Ports 2, 2, 4: 4: 8. 8.0 mm mm (0 (0.32 in in) HVP08A-040-101 Ports 1, 2, 3, 4: 4.6 mm (0.18 in) 3-Spool Proportional Solenoid Solenoid valve DC 24 V 22 Ω DC 24 V 59.7 Ω

DC 24 V 23.2 Ω

KVSS-10-H 3.72 MPa (38 kgf/cm2, 540 psi) ON/OFF Solenoid Valve DC 24V 49 Ω 490 kPa (5 kgf/cm2) at 5 L/min ISUZU 8973243860 β10≥2.0 β10≥2 .0 177 μm (80 mes mesh) h) β10≥1.4

T1-3-9

SECTION 1 GENERAL Group 3 Component Specifications Electrical Component BAT TERY RELAY STARTER RELAY 2 GLOW PLUG RELAY

Parts No. Voltage / Current Parts No. Voltage Parts No. Voltage Oper Op erat atin ing g Tem Temper perat atur ure e

HYDRAULIC OIL TEMPERATURE TEMPERA TURE SENSOR AIR FILTER Operating Pressure RESTRICTION SWITCH HORN Voltage / Current Sound Pressure ILLUMINATION Working Light Cab Light AIR CONDITIONER Refrigerant Cooling Ability Cool Air Volume Heating Ability Warm Air Volume Temperature T emperature Adjusting Adjusting System Refrigerant Quantity Comp Co mpre ress ssor or Oi Oill Qua Quant ntit ityy

ISUZU 8943795431 24 V / 100 A ISUZU 1825530391 24 V ISUZU 8942580140 24 V -30 -3 0 to 120 120 °C °C (-22 (-22 to to 248 248 °F) °F)

6.2±0.6 kPa 24 V·2.5+0.5-1 A 113±5 dB (A) @2 m Halogen 24V, 70 W 24 V / 0.3 A 134 a 4.65 kW or More 550 m3 /h or More 5.49 kW or More 400 m3 /h or More Electronic Type 850±50 g 160 16 0 cm cm3

T1-3-10

MEMO

MEMO

SECTION 2

SYSTEM CONTENTS Group 1 Controller Outline ................... ...................................... ...................................... ...................................... ........................... ........ T2-1-1 CAN Circuit ........................................... .............................................................. ................................. ..............T2-1-2 T2-1-2

Group 2 Control System Outline ................... ...................................... ...................................... ...................................... ........................... ........ T2-2-1 Engine Control .......................................... ............................................................. ........................... ........ T2-2-4 Pump Control ................... ...................................... ...................................... ...............................T2-2-28 ............T2-2-28 Valve Control ................. .................................... ...................................... ..................................T2-2-38 ...............T2-2-38 Other Control ................... ...................................... ...................................... ...............................T2-2-54 ............T2-2-54

Group 3 Hydraulic System Outline ................... ...................................... ...................................... ...................................... ........................... ........ T2-3-1 Pilot Circuit................................................. .................................................................... ........................... ........ T2-3-2 Main Circuit................................................... ...................................................................... ......................T2-3-12 ...T2-3-12

Group 4 Electrical System Outline ................... ...................................... ...................................... ...................................... ........................... ........ T2-4-1 Main Circuit .......................................... ............................................................. ................................. ..............T2-4-2 T2-4-2 Electric Power Circuit (Key Switch: OFF) ..................... ..................... T2-4-4 CAN Circuit ........................................... .............................................................. ................................. ..............T2-4-6 T2-4-6 Accessory Circuit ......................................... ............................................................ ........................ ..... T2-4-8 Preheating Circuit (Key Switch: ON, START) ............T2-4-10 Starting Circuit (Key Switch: START) .................. ...........................T2-4-12 .........T2-4-12 Charging Circuit (Key Switch: ON) ..............................T2-4-16 ..............................T2-4-16 Surge Voltage Prevention Circuit ................................T2-4-20 ................................T2-4-20 Pilot Shut-Off Circuit (Key switch: ON) ......................T2-4-22 ......................T2-4-22 Engine Stop Circuit ......................... ............................................ ..................................T2-4-24 ...............T2-4-24 Monitor Circuit................................................ ...................................................................T2-4-27 ...................T2-4-27 Security Circuit.......................................... ............................................................. .........................T2-4-28 ......T2-4-28 Radio Circuit............ Circuit............................... ...................................... ...................................... ......................T2-4-30 ...T2-4-30 Air Conditioner Circuit .................. ..................................... ..................................T2-4-30 ...............T2-4-30 Accessory Circuit................................................... ...............................................................T2-4-33 ............T2-4-33 Work Light Circuit .......................................... .............................................................T2-4-34 ...................T2-4-34 Wiper/Washer Wiper/W asher Circuit................................................. .......................................................T2-4-36 ......T2-4-36 Cab Light Circuit .............................. ................................................. ..................................T2-4-38 ...............T2-4-38

DCDT-2-1

(Blank)

DCDT-2-2

SECTION 2 SYSTEM Group 1 Controller Outline The following controllers controllers are provided provided in this machine in order to control functions. Each controller excluding the communication controller communicates by using the CAN circuit and sends or receives the required signal. Controller

Control

MC ECF Monitor Controller Wiper / Light Controller Air Conditioner Controller Radio Controller Communication Controller

Controls the engine, pumps, and valves. Controls the actual engine speed. Displays the operating information and alarms on the monitor. Controls the wipers and work lights. Controls the air conditioner. Controls the radio. Sends the mails and operating information.

fNOTE:

Refer to the the corresponding corresponding group for details details of each controller control.

T2-1-1

Comment on Control T2-2 T2-2 T5-2 T2-4 T2-4, T5-7 T2-4 T5-4

SECTION 2 SYSTEM Group 1 Controller CAN Circuit CAN (Controller Area Network) is ISO Standards of the serial communication protocol. Two networks networks (CAN bus (4)), CAN 0 (1) (1) and CAN 1 (5) are equipped for this machine. CAN 0 (1) is used for the engine control. CAN 1 (5) is used for the accessories. CAN bus (4) consists of two harnesses, CAN-H (High) (2) and CAN-L (Low) (3). Each controller judges the CAN bus (4) level due to potential difference between CAN-H (High) (2) and CAN-L (Low) (3). Each controller arranges the CAN bus (4) level and sends the signal and data to other controllers. In addition, termination resistors (120 Ω) (6) are installed to both ends of CAN bus (4).

T2-1-2

SECTION 2 SYSTEM Group 1 Controller 2 1 3 4 2 5 3 TDAA-02-05-001 TDAA-02 -05-001

9

6

1

6

7

10

15

11 5 16

8

6

6 12

13

14

TDCD-02-01-002 TDCD-02-0 1-002

1234-

CAN 0 CAN-H (High) CAN-L (Low) CAN Bus

5678-

CAN 1 Termination Resistor (120 Termination (120 Ω) ECF (Engine Controller) MC (Main Controller)

9101112-

T2-1-3

Communication Controller Monitor Controller MPDr. Wiper / Light Controller

13141516-

Radio Controlle Controllerr Air Conditioner Controller Monitor Control Unit Information Control Unit

SECTION 2 SYSTEM Group 1 Controller (Blank)

T2-1-4

SECTION 2 SYSTEM Group 2 Control System Outline MC is used in order to control the machine operations. The signals from the engine engine control dial, various various sensors, and switches are sent to MC and processed in the logic circuit. MC sends the signals equivalent to the target engine speed to ECF (Engine Controller) by using CAN communication. ECF drives EC motor to control the engine according to the signal from MC. MC drives the solenoid valve unit and the torque control solenoid valve in order to control the pump and the th e valve.

T2-2-1

SECTION 2 SYSTEM Group 2 Control System Engine Control, Pump Control Input Signal

Output

EC Dial Power Mode Switch Auto-Idle Switch Travel Tra vel Mode Switch Key Switch Pilot Shut-Off Switch Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 1 Control Pressure Sensor Pump 2 Control Pressure Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Arm Roll-In) Pressure Sensor (Swing) Pressure Sensor ( Tra Travel) vel) Pressure Sensor (Front Attachment) Pressure Sensor (Auxiliary 1) (OP) Pressure Sensor (Arm Roll-Out) (OP) Hydraulic Oil Temperature Sensor N Sensor EC Sensor

 

Engine Control (ECF) Engine Control Dial Control ECO Control Power Mode Control ECO Mode Control Travel Trav el HP Mode Control Auto-Idle Control Hydraulic Oil Temperature Auto-Warming Up Control Idle Speed-Up Control * Attachment Operation Speed Increase Control * Attachment Operation Speed Limit Control Engine Learning Control

                 

MC

Pump Control (Torque Control Solenoid Valve) Speed Sensing Control Travel Torquee-U Up Control * Pump 1 Flow Rate Limit Control * Pump 2 Flow Rate Limit Control

ECF CAN

MPDr. Work Mode

fNOTE:

 

Monitor Controller

OP: Option

*: This control is for only the machine with the optional parts equipped.

T2-2-2

SECTION 2 SYSTEM Group 2 Control System Valve Control, Other Control Input Signal EC Dial Power Mode Switch Auto-Idle Switch Travel Tra vel Mode Switch Key Switch Pilot Shut-Off Switch Power Digging Switch Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 1 Control Pressure Sensor Pump 2 Control Pressure Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Arm Roll-In) Pressure Sensor (Swing) Pressure Sensor ( Tra Travel) vel) Pressure Sensor (Front Attachment) Pressure Sensor (Auxiliary 1) (OP) Pressure Sensor (Arm Roll-Out) (OP) Hydraulic Oil Temperature Sensor N Sensor EC Speed Sensor

 

Output Valve Control (Solenoid Valve Unit) Power Digging Control Auto-Power Auto-Pow er Lift Control Travel Tra vel Motor Displacement Displacement Angle Control Arm Regenerative Control Digging Regenerative Control * Pulverizer Control * Crusher Control

        

Other Control Work Mode Control * Breaker Alarm Control * Swing Alarm Control * Travel Alarm Control

     

MC

   

ECF CAN

MPDr. Work Mode

fNOTE:

 

Monitor Controller

OP: Option

*: This control is for only the machine with the optional parts equipped.

T2-2-3

SECTION 2 SYSTEM Group 2 Control System Engine Control The engine control consists consists of the followings.           

Engine Control Dial Control ECO Control Power Mode Control ECO Mode Control Travel HP Mode Control Auto-Idle Control Hydraulic Oil Temperature Auto-Warming Up Control Idle Speed-Up Control * Attachment Attachment Operation Speed Increase Control * Attachment Attachment Operation Speed Limit Limit Control Engine Learning Control

fNOTE:

*This control control is for only only the machine with the the optional parts equipped.

T2-2-4

SECTION 2 SYSTEM Group 2 Control System Engine Control System Layout 1

9 2 3 4 5 6 7

30

11 10

29 28

12

27 8 26

14 25

18

19

20

13 17

24

15

23

16

22

21

TDCD-02-02-001 TDCD-02-0 2-001

1234567-

Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Arm Roll-In) Pressure Sensor (Swing) Pressure Sensor (Travel) Pressure Sensor (Front Attachment) Pressure Sensor (Auxiliary 1) (OP)

891011121314151617-

MC MPDr. Monitor Controller Monitor CAN ECF EC Sensor EC Motor Governor Lever Engine

18- N Sensor 19- Pump 2 Delivery Pressure Sensor 20- Pump 1 Delivery Pressure Sensor 21- Pump 1 Control Pressure Sensor 22- Pump 2 Control Pressure Sensor 23- Tra Travel vel Mode Switch

T2-2-5

24252627282930-

Slow Speed Position Fast Speed Position Auto-Idle Switch Power Mode Switch EC Dial Key Switch Pilot Shut-Off Switch

SECTION 2 SYSTEM Group 2 Control System Engine Control Dial Control A

Purpose: The engine control dial dial control controls the engine engine speed according to the rotation angle of engine control dial (28).

Operation: 1. MC (8) sends the signals equivalent to the target engine speed to ECF (13) by using CAN communication (12) according to the rotation angle (required engine speed) of engine control dial (28). B

2. ECF (13) drives drives EC motor (15) to control control the engine speed according to CAN communication (12).

C AB-

T2-2-6

Engine Speed Engine Control Dial Position

D C - Slow Idle Position D - Fast Idle Position

SECTION 2 SYSTEM Group 2 Control System

1

9 2 3 4 5 6 7

30

11 10

29 28

12

27 8 26

14 25

18

19

20

13 17

24

15

23

16

22

21

TDCD-02-02-002 TDCD-02-0 2-002

1234567-


891011121314151617-



T2-2-7

24252627282930-


SECTION 2 SYSTEM Group 2 Control System ECO Control A

Purpose: The ECO control control reduces the engine speed by by 100 min-1 from fast idle speed in order to reduce fuel consumption and noise level when all the control levers are in neutral. Operation: 1. When all following conditions conditions exist and and all the control levers are set to the neutral position (pressure sensors (travel (5), front attachment (6)): OFF), MC (8) sends the signal to ECF (13) by using CAN communication (12) after one second. 2. ECF (13) drives drives EC motor (15) to reduce reduce the engine speed by 100 min-1 from fast idle speed.

B C AB-



Engine speed reduced (100 min-1) condition: (28):  Engine control dial (28): Set the engine speed in the fast idle speed. switch (27): PWR  Power mode switch

fNOTE:

The ECO ECO control is deactivated deactivated by MPDr. (9) temporarily or completely. The ECO control i s activated again when key switch (29) is turned OFF with the ECO control deactivated temporarily. temporarily. The ECO control is always deactivated with the ECO control deactivated completely.. (ECO-suspension) completely

fNOTE:

When the engine speed set set by engine control dial (28) has already been slower than the fast idle speed by 100 min -1 , the engine speed speed does not change. change. In addition, this control is done regardless of whether the auto-idle control is done or not. The fast i dle speed can be corrected by MPDr.(9).

T2-2-8


1

9 2 3 4 5 6 7

30

11 10

29 28

12

27 8 26

14 25

18

19

20

13 17

24

15

23

16

22

21

TDCD-02-02-003 TDCD-02-0 2-003

1234567-


891011121314151617-



T2-2-9

24252627282930-


SECTION 2 SYSTEM Group 2 Control System Power Mode Control Purpose: The power mode control control shifts the power mode (ECO/ (ECO/ PWR mode) by operating power mode switch (27). Operation: 1. MC (8) receives receives the signal from from power mode switch (27). 2. MC (8) shifts the power mode according according to the setting of Power Mode Selection and Power Mode Memory Selection by pushing power mode switch (27). (Refer to the table.) 3. MC (8) sends the signal equivalent to the target engine speed according to the power mode to ECF (13) by using CAN communication (12). 4. ECF (13) drives drives EC motor (15) to control control the engine speed according to CAN communication (12). 5. In addition, MC (8) sends the power mode control control mode to monitor controller (10) by using CAN communication (12). 6. Monitor controller controller (10) displays displays the power mode mode control mode on monitor (11). Power Mode Selection

Power mode when key switch is OFF

ECO, PWR mode: Selected (Default) ECO PWR ECO mode: Fixed PWR mode: Fixed -

T2-2-10

Power mode when key switch is ON next time Power Mode Memory Power Mode Memory Selection: OFF Selection: ON ECO ECO ECO PWR ECO ECO PWR PWR


1

9 2 3 4 5 6 7

30

11 10

29 28

12

27 8 26

14 25

18

19

20

13 17

24

15

23

16

22

21

TDCD-02-02-004 TDCD-02-0 2-004

1234567-


891011121314151617-



T2-2-11

24252627282930-


SECTION 2 SYSTEM Group 2 Control System ECO Mode Control A

Purpose: The ECO mode control control reduces the engine speed speed set by engine control dial (28) according to pump control pressure, pilot pressure, and average pump delivery pressure in order to reduce fuel consumption. Operation: 1. When the required required engine speed by engine control control dial (28) is faster than the engine speed set by ECO mode control and power mode switch (27) is in the ECO mode position, MC (8) sends the signals equivalent to the target engine speed to ECF (13) by using CAN communication (12) according to the following conditions.

B C AB-

2. ECF (13) drives drives EC motor (15) to reduce reduce the engine speed from the required engine speed by engine control dial (28). 3. The engine speed becomes becomes the required required engine speed by engine control dial (28) during travel operation. 4. Therefore, proper travelling travelling power power is obtained. obtained. Engine speed reduced condition:  Control lever lever operation ratio: ratio: minimum (Pump 1 control pressure, or pump 2 control pressure: low)  Deceleration ratio: Large Average e pump delivery pressure: pressure: high   Averag Deceleration ratio: Large

T2-2-12




1

9 2 3 4 5 6 7

30

11 10

29 28

12

27 8 26

14 25

18

19

20

13 17

24

15

23

16

22

21

TDCD-02-02-005 TDCD-02-0 2-005

1234567-


891011121314151617-



T2-2-13

24252627282930-


SECTION 2 SYSTEM Group 2 Control System Travel HP Mode Control A

Purpose: The travel HP mode mode control increases the engine engine speed and travels faster during travel single operation. Operation: 1. When all following conditions conditions exist, MC (8) sends the signals equivalent to the target engine speed to ECF (13) by using CAN communication (12). 2. ECF (13) drives drives EC motor (15) to increase the engine speed to the travel HP mode speed and travels faster. Condition:  Engine control control dial (28): Set Set the engine speed in the fast idle speed position. Travel mode switch (23): Fast Fast Speed (25)   Pressure Sensor (Travel) (5): Outputting signal pressure of pumps pumps 1 and and 2: Delivery Delivery  Delivery pressure pressure of either pump is high. (Reference: 19 MPa)

B C AB-

T2-2-14




1

9 2 3 4 5 6 7

30

11 10

29 28

12

27 8 26

14 25

18

19

20

13 17

24

15

23

16

22

21

TDCD-02-02-007 TDCD-02-0 2-007

1234567-


891011121314151617-



T2-2-15

24252627282930-


SECTION 2 SYSTEM Group 2 Control System Auto-Idle Control A

Purpose: The auto-idle control reduces reduces the engine speed when all the control levers are in neutral. Therefore, Therefore, fuel consumption and noise level can be reduced.

E

Operation: 1. Approx. 3.5 seconds after the control lever is set to the neutral position (pressure sensors (travel (5), front attachment (6)): OFF) with auto-idle switch (26) ON, MC (8) sends the signals equivalent to the auto-idle speed to ECF (13) by using CAN communication (12). 2. ECF (13) drives drives EC motor (15) to change the engine speed into the auto-idle speed. 3. As soon as either either control lever lever is moved (pressure sensors (travel (5), front attachment (6)): ON), MC (8) returns the signals sending to ECF (13) into those equivalent to the target engine speed set by engine control dial (28).

F

B C ABCD-

4. ECF (13) drives drives EC motor (15) to change the engine speed to the original engine speed. Auto-Idle Deactivation Condition:  Control lever: Operated Operated (pressure (pressure sensor (travel (5) or front attachment (6)): ON) Operated  Power mode switch (27): Operated control dial (28): Operated Operated  Engine control

fNOTE:

The auto-idle auto-idle speed can be adjusted adjusted by by MPDr. MPDr. (9). (AI Speed Adjustment)

T2-2-16

Engine Speed Engine Control Dial Position Slow Idle Position Fast Idle Position

D EF-

Fast Idle Speed Auto-Idle Speed


1

9 2 3 4 5 6 7

30

11 10

29 28

12

27 8 26

14 25

18

19

20

13 17

24

15

23

16

22

21

TDCD-02-02-008 TDCD-02-0 2-008

1234567-


891011121314151617-



T2-2-17

24252627282930-


SECTION 2 SYSTEM Group 2 Control System Hydraulic Oil Temperature Auto-Warming Up Control A

Purpose: The hydraulic oil temperature temperature auto-warming auto-warming up control automatically warms up the hydraulic system.

E

Operation: 1. MC (8) receives receives the signal from from hydraulic hydraulic oil temperature sensor (1).

F

2. When key switch (29) is in the ON ON or START START position and hydraulic oil temperature is 0 °C or less, MC (8) sends the signals equivalent to the target engine speed to ECF (13) by using CAN communication (12). 3. ECF (13) drives drives EC motor (15) to increase the engine speed to the auto-warming up speed.

G B C ABCD-

4. In 12 minutes after the key switch is set to the ON or START ST ART position or when hydraulic oil temperature is 2 °C or more, MC (8) deactivates the hydraulic oil temperature auto-warming up control. 5. Therefore, ECF (13) returns returns the engine speed to the engine speed set by engine control dial (28).

fNOTE:

The engine slow idle speed speed and auto-warming up speed can be adjusted by MPDr. (9). (Li Speed Adjustment, Warming Warming Up Speed Adjustment) Adjustment)

IMPORTANT: When adjusti adjusting ng the slow idle speed, deactivate the auto-warming up control by using MPDr.(9). MPDr .(9). Wait adjustment until 12 minutes after the engine starts.

fNOTE:

The auto-warming up control can be deactivated temporarily by MPDr. (9). Once key switch (29) is turned OFF, the auto-warming up control is effective again. (WU-suspension)

T2-2-18

Engine Speed Engine Control Dial Position Slow Idle Position Fast Idle Position

D EFG-

Fast Idle Speed Auto- Warming Up Speed Slow Idle Speed


1

9 2 3 4 5 6 7

30

11 10

29 28

12

27 8 26

14 25

18

19

20

13 17

24

15

23

16

22

21

TDCD-02-02-009 TDCD-02-0 2-009

1234567-


891011121314151617-



T2-2-19

24252627282930-


SECTION 2 SYSTEM Group 2 Control System Idle Speed-Up Control A

Purpose: The idle speed-up control control prevents the engine from from hunting when the engine runs at slow speed. Operation: 1. When the travel travel or front attachment attachment operation operation is performed while the engine is running at a speed between slow idle and idle speed-up speed, MC (8) sends the signals equivalent to the target engine speed to ECF (13) by using CAN communication (12). 2. ECF (13) drives drives EC motor (15) to increase the engine speed to the idle speed-up speed.

E

B C ABC-

T2-2-20

Engine Speed Engine Control Dial Position Slow Idle Position

D D - Fast Idle Position E - Idle Speed-Up Speed


1

9 2 3 4 5 6 7

30

11 10

29 28

12

27 8 26

14 25

18

19

20

13 17

24

15

23

16

22

21

TDCD-02-02-010 TDCD-02-0 2-010

1234567-


891011121314151617-



T2-2-21

24252627282930-


SECTION 2 SYSTEM Group 2 Control System Attachment Operation Speed Increase Control (Only Machine Equipped with Attachment Parts) A

Purpose: The attachment operation operation speed increase control increases the maximum engine speed to the attachment (hydraulic breaker, breaker, secondary crusher, primary crusher, or vibrating hammer) operating engine speed set by MPDr. (9) when the attachment is operated. Operation: 1. When all following conditions conditions exist and and the attachment is operated, MC (10) sends the signals equivalent to the target engine speed set by MPDr. (9) to ECF (13) by using CAN communication (12). 2. ECF (13) drives drives EC motor (15) to increase the maximum engine speed by the attachment operating engine speed set by MPDr. (9).

B C AB-

Condition: MPDr.. (9): Reset the maximum maximum engine speed to a  MPDr faster (+) attachment (hydraulic breaker, breaker, secondary crusher, primary crusher, or vibrating hammer) operating speed.  Engine control control dial (28): Set Set the engine speed in the fast idle speed position.  Power mode switch switch (27): PWR  Auxiliary: Operated Attachment mode  Work mode: Attachment Attachment selected by using monitor (11) is set (+) by MPDr. (9).

fNOTE:

The fast fast idle speed can can be adjusted by MPDr. (9). When the fast idle speed is preset to a slower speed, the maximum engine speed will not be increased when operating the attachment. (PWR Mode Speed)

fNOTE:

Even if the the attachment attachment is not operated, the increased engine speed can be kept for a specified time by MPDr. (9). (ATT Speed Deceleration Waiting Time)

T2-2-22




1

9 2 3 4 5 6 7

30

11 10

29 28

12

27 8 26

14 25

18

19

20

13 17

24

15

23

16

22

21

TDCD-02-02-030 TDCD-02-0 2-030

1234567-


891011121314151617-



T2-2-23

24252627282930-


SECTION 2 SYSTEM Group 2 Control System Attachment Operation Speed Limit Control (Only Machine Equipped with Attachment Parts) A

Purpose: The attachment operation operation speed limit control reduces reduces the maximum engine speed to the attachment (breaker, (breaker, pulverizer, crusher, or vibrating hammer) operating engine speed set by MPDr. (9) when the attachment mode is selected. Operation: 1. When all following conditions conditions exist and and the attachment mode is selected, MC (8) sends the signals equivalent to the target engine speed set by MPDr.. (9) to ECF (13) by using CAN communication MPDr (12).

B C AB-

2. ECF (13) drives drives EC motor (15) to reduce reduce the maximum engine speed by the attachment operating speed set by MPDr. (9). Condition: MPDr.. (9): Resets the maximum maximum engine speed to a  MPDr slower (-) attachment (breaker, pulverizer, crusher, or vibrating hammer) operating speed.  Work mode: Attachment Attachment mode Attachment selected by using monitor (11) is set slower (-) by MPDr. (9).

T2-2-24




1

9 2 3 4 5 6 7

30

11 10

29 28

12

27 8 26

14 25

18

19

20

13 17

24

15

23

16

22

21

TDCD-02-02-013 TDCD-02-0 2-013

1234567-


891011121314151617-



T2-2-25

24252627282930-


SECTION 2 SYSTEM Group 2 Control System Engine Learning Control Purpose: Inputs the governor lever stopper positions on both the STOP and FULL sides as the standard data to control the engine.

IMPORTANT: Be sure to perform the engine IMPORTANT: engine learning learning if the following repair work is done. (Refer to Troubleshooting Trou bleshooting Section) S ection) After performing the engine learning, check that the engine learning has been performed per formed correctly by using MPDr.(9).

Operation: 1. When learning switch (31) in the rear console is turned to the engine learning position, EC motor (15) is driven by the signals from the ECF (13). 2. EC motor (15) (15) moves the governor lever lever from the IDLE to FULL and to STOP positions in this order order.. 3. EC sensor (14) (14) detects the stopper positions positions of the governor lever on both the FULL and STOP sides.



After engine (17), the engine control cable, or EC motor (15) has been removed or replaced.



After ECF (13) has been replaced.

fNOTE:

4. EC sensor (14) sends each stopper position signal to ECF (13). 5. ECF (13) stores these signals in its memory. memory.

T2-2-26

The engine learning is not required when the batteries are replaced.


1

9 2 3 4 5 6 7

31 30

11 10 29 28 12 27

8 14

26

18

19

20

13 25 17 15 24 23 16

22

21

TDCD-02-02-031 TDCD-02-0 2-031

1234567-


891011121314151617-



T2-2-27

2425262728293031-

Slow Speed Position Fast Speed Position Auto-Idle Switch Power Mode Switch EC Dial Key Switch Pilot Shut-Off Switch Learning Switch

SECTION 2 SYSTEM Group 2 Control System Pump Control The pump control control consists of the followings.    

Speed Sensing Control Travel Torque-Up Control * Pump 1 Flow Rate Limit Control * Pump 2 Flow Rate Limit Control

fNOTE:

* This control is for only the machine machine with the optional parts equipped.

T2-2-28

SECTION 2 SYSTEM Group 2 Control System Pump Control System Layout 9

1

2 3 4 5 6 7

11 10

25

12

24

8 15

23

16

17

13

14

19

18

20 21 22 TDCD-02-02-014 TDCD-02-0 2-014

123456-

Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Arm Roll-In) Pressure Sensor (Swing) Pressure Sensor (Travel) Pressure Sensor (Front Attachment)

7891011121314-

Pressure Sensor (Auxiliary 1) (OP) MC MPDr. Monitor Controller Monitor CAN ECF Engine

15- N Sensor 16- Pump 2 Delivery Pressure Sensor 17- Pump 1 Delivery Pressure Sensor 18- Pump 1 Control Pressure Sensor 19- Pump 2 Control Pressure Sensor

T2-2-29

20- Torque Torque Control Control Solenoid Valve 21- Maximum Pump 2 Flow Rate Limit Control Solenoid Valve 22- Maximum Pump 1 Flow Rate Limit Control Solenoid Valve (OP) 23- Power Mode Switch 24- EC Dial 25- Key Switch

SECTION 2 SYSTEM Group 2 Control System Speed Sensing Control Purpose: The speed sensing control controls controls the pump delivery delivery flow rate in response to the engine speed changes due to variations in load so that the engine output power can be utilized more efficiently. Engine stall is prevented when the machine is operated under adverse conditions such as operating at high altitude.

Q

Operation: 1. The target engine speed can be set set by engine engine control dial (24). 2. ECF (13) receives receives the signal from N sensor (15). 3. ECF (13) calculates and send actual engine engine speed to MC (8) by using CAN communication (12). 4. MC (8) calculates calculates the difference difference in speed between the target engine speed and the actual engine speed detected by CAN communication (12) from ECF (13). Then, MC (8) sends the signals to torque control solenoid valve (20). 5. Torque control solenoid valve valve (20) delivers the pilot pressure according to the signals to the regulator and controls the pump delivery flow rate.

P

P-

6. If the engine load increases and the actual engine speed becomes slower than the target engine speed, the pump displacement angle is reduced so that pump flow rate will be reduced. Therefore, Therefore, the engine load is reduced and engine stall is prevented. 7. If the actual engine engine speed becomes faster than the target engine speed, the pump displacement angle is increased so that pump delivery flow rate will increase. Therefore, Therefore, the engine output power can be utilized more efficiently.

fNOTE:

When hydraulic hydraulic oil temperature temperature is low, low, the speed sensing control is deactivated deactivated..

T2-2-30

Pressure Pr

Q - Flow Rate


9

1

2 3 4 5 6 7

11 10

25

12

24

8 15

23

16

17

13

14

19

18

20 21 22 TDCD-02-02-015 TDCD-02-0 2-015

123456-


7891011121314-



T2-2-31


SECTION 2 SYSTEM Group 2 Control System Q

Travel Torque-Up Control

B

Purpose: The travel torque-up torque-up control effectively controls controls during single travel operation. When travel operation is performed with the engine running at slow speed, normally, the hydraulic pump delivers pressure oil at the flow rate corresponding to point A on the P-Q curve as illustrated. Therefore, Therefore, if any difference exists between pump 1 and pump 2 flow rate, the machine will mistrack. In order to prevent mistracking, when traveling the machine with the engine running at slow speed, the pump P-Q curve is raised and the pump delivers pressure oil at the flow rate corresponding to point B (maximum flow rate). When travel operation is made with the engine running at fast speed, the pump P-Q curve cur ve is raised in order to improve travel function.

b

A

a

P Pa-

Operation: 1. When all following conditions conditions exist, MC (8) calculates the data including the signals from pump 1 delivery pressure sensor (17) and pump 2 delivery pressure sensor (16) and sends the signals to torque control solenoid valve (20). 2. Torque control solenoid valve valve (20) delivers the pilot pressure according to the signals to the regulator and increases the pump delivery flow rate. Condition: control dial (24): Slow idle speed  Engine control  Pressure sensor (travel) (5): Outputting signal attachment) (6): No signal signal  Pressure sensor (front attachment)

T2-2-32

Pressure Normal P-Q Curve

Q - Flow Rate b - Increased Torque P-Q Curve


9

1

2 3 4 5 6 7

11 10

25

12

24

8 15

23

16

17

13

14

19

18

20 21 22 TDCD-02-02-017 TDCD-02-0 2-017

123456-


7891011121314-



T2-2-33


SECTION 2 SYSTEM Group 2 Control System Pump 1 Flow Rate Limit Control (Only Machine Equipped with Attachment) Purpose: The pump 1 flow rate rate limit control combines combines pressure oil from pump 1 with pressure oil from pump 2 in order to make up for pump flow rate for attachment operation when attachment (mainly a vibrating hammer) is used and pump 2 flow rate is lack. Then, the combined pressure oil is delivered to the actuator ac tuator.. (Refer to SYSTEM / Hydraulic System.)

Q

Operation: 1. When the attachment is used with the travel travel control control lever in neutral, MC (8) receives the signals f rom pressure sensor (auxiliary 1) (7) (optional). 2. In response to to attachment control operation, operation, MC (8) activates maximum pump 1 flow rate limit control solenoid valve (22) (optional) and controls maximum pump 1 flow rate.

fNOTE:

The pump 1 delivery delivery flow rate can be limited to 35 % at the maximum by MPDr. (9). (P1 Maximum Flow Rate Adjustment)

P

P-

T2-2-34

Pressure Pr

Q - Flow Rate


9

1

2 3 4 5 6 7

11 10

25

12

24

8 15

23

16

17

13

14

19

18

20 21 22 TDCD-02-02-019 TDCD-02-0 2-019

123456-


7891011121314-



T2-2-35


SECTION 2 SYSTEM Group 2 Control System Pump 2 Flow Rate Limit Control (Only Machine Equipped with Attachment) Purpose: The pump 2 flow rate rate limit control limits limits maximum pump 2 flow rate when a attachment (mainly a hydraulic breaker) is used. Q

Operation: 1. When the attachment is used with the travel travel control control lever in neutral, MC (8) receives the signals f rom pressure sensor (auxiliary 1) (7) (optional). 2. In response to to attachment control operation, operation, MC (8) activates maximum pump 2 flow rate limit control solenoid valve (21) and controls maximum pump 2 flow rate.

fNOTE:

The pump 2 delivery delivery flow rate can be limited to 35 % at the maximum by MPDr. (9). (P2 Maximum Flow Rate Adjustment) P

fNOTE:

When the auxiliary flow combiner solenoid valve stops, pump 2 flow rate can be adjusted finely by monitor (11).

P-

Pressure Pr

Q - Flow Rate

TDAA-05-02-006 TDAA-0 5-02-006EN EN

T2-2-36


9

1

2 3 4 5 6 7

11 10

25

12

24

8 15

23

16

17

13

14

19

18

20 21 22 TDCD-02-02-020 TDCD-02-0 2-020

123456-


7891011121314-



T2-2-37


SECTION 2 SYSTEM Group 2 Control System Valve Control The valve control control consists of the followings.       

Power Digging Control Auto-Power Auto-Pow er Lift Lift Control Control Travel Tra vel Motor Displacement Displacement Angle Control Control Arm Regenerative Control Digging Regenerative Control * Pulverizer Control * Crusher Control

fNOTE:

*This control control is for only only the machine with the the optional parts equipped.

T2-2-38

SECTION 2 SYSTEM Group 2 Control System Valve Control System Layout 10

1 2 3 4 5 6 7

9

12

11

15

16

13

14 29

18

17

8 28 27

19

20

21

22

26

23

25 24

1234567-

Pressure Sensor (Boom Raise) Pressure Sensor (Arm Roll-In) Pressure Sensor (Swing) Pressure Sensor (Travel) Pressure Sensor (Front Attachment) Pressure Sensor (Auxiliary 1) (OP) Pressure Sensor (Arm Roll-Out) (OP)

89101112131415-

MC CAN MPDr. Monitor Controller Monitor ECF Engine Pump 2 Delivery Pressure Sensor

16- Pump 1 Delivery Pressure Sensor 17- Pump 1 Control Pressure Sensor 18- Pump 2 Control Pressure Sensor 19- Solenoid Valve Unit 20- Main Relief Valve 21- Digging Regenerative Valve 22- Control Valve

T2-2-39

TDCD-02-02-021 TDCD-02-0 2-021

23- Arm 2 Flow Rate Control Valve 24- Arm Regenerative Valve 25- Trav Travel el Motor Displacement Displacement Angle Control Valve 26- Trav Travel el Mode Switch Switch 27- Slow Speed Position 28- Fast Speed Position 29- Power Digging Switch

SECTION 2 SYSTEM Group 2 Control System Power Digging Control Purpose: The power digging digging control increases digging digging force by by temporarily increasing relief pressure. Operation: 1. For maximum maximum eight seconds seconds after power digging switch (29) is turned ON, MC (8) continuously activates solenoid valve unit (19) (SG). 2. Solenoid valve unit (19) (SG) delivers pilot pressure pressure to main relief valve (20) and increases relief pressure. (Refer to Control Valve / COMPONENT OPERATION.)

T2-2-40


10

1 2 3 4 5 6 7

9

12

11

15

16

13

14 29

18

17

8 28 27

19

20

21

22

26

23

25 24

1234567-


89101112131415-



T2-2-41

TDCD-02-02-022 TDCD-02-0 2-022


SECTION 2 SYSTEM Group 2 Control System Auto-Power Lift Control Purpose: The auto-power lift control control increases pressure when raising the boom. Operation: 1. When all following conditions conditions exist, MC (8) activates activates solenoid valve unit (19) (SG). 2. Solenoid valve unit (19) (SG) delivers pilot pressure pressure to main relief valve (20) and increases relief pressure. (Refer to Control Valve / COMPONENT OPERATION.) Condition:  Pressure Sensor (Boom Raise) (1): (1): Outputting signals (The boom must be raised to a certain extent.) (Reference: 1.7 MPa) pressure sensor (16): High  Pump 1 delivery pressure (Reference: 31.5 MPa) Low  Pressure Sensor (Arm Roll-In) (2): Low

fNOTE:

This control control system is activated activated during combined operations.

T2-2-42


10

1 2 3 4 5 6 7

9

12

11

15

16

13

14 29

18

17

8 28 27

19

20

21

22

26

23

25 24

1234567-


89101112131415-



T2-2-43

TDCD-02-02-023 TDCD-02-0 2-023


SECTION 2 SYSTEM Group 2 Control System Travel Motor Displacement Angle Control Purpose: The travel motor motor displacement angle control control controls the travel mode. Operation:  Slow Speed 1. When travel mode switch (26) is in slow speed position (27), the travel motor displacement angle is kept in the maximum angle so that the travel speed is slow. Fast Speed 1. When all following conditions conditions exist, MC (8) shifts solenoid valve unit (19) (SG). 

2. Solenoid valve unit (19) (SG) delivers pilot pressure pressure to travel motor displacement angle control valve (25) and decreases the displacement angle to the minimum, so that the travel speed increases. Condition: Fast Speed (28)  Travel mode switch (26): Fast  Pressure sensor (travel) (4): Outputting signal  Pressure Sensor (Front Attachment) (5): (5): OFF  Pump 1 and 2 delivery Pressure Pressure Sensors (16, (16, 15): Delivery pressure of either pump is low. (Reference: 24 MPa or less) Control Pressure Sensors (17, 18):  Pump 1 and 2 Control Pump control pressure of either pump is high. (Reference: 2.2 MPa or more)

fNOTE:

When the track is raise off the the ground and is rotated, the one side pump control pressure increases, so that the raised track rotates at fast speed. When the machine is traveling at the fast speed and even if the front attachment is operated (pressure sensor (front attachment) (5): ON), the travel mode is kept at the fast speed.

T2-2-44


10

1 2 3 4 5 6 7

9

12

11

15

16

13

14 29

18

17

8 28 27

19

20

21

22

26

23

25 24

1234567-


89101112131415-



T2-2-45

TDCD-02-02-024 TDCD-02-0 2-024


SECTION 2 SYSTEM Group 2 Control System Arm Regenerative Control Purpose: Accelerates the arm roll-in speed in order to prevent arm hesitation during arm roll-in operation. Operation: 1. MC (11) activates activates solenoid valve unit unit (19) (SC) (SC) so that solenoid valve unit (19) (SC) delivers pilot pressure when the signals from pump 1 and 2 delivery pressure sensors (16, 15), pressure sensor (swing) (3), pressure sensor (arm roll-in) (2) and pressure sensor (boom raise) (1) meet the following conditions. 2. This pilot pressure pressure shifts arm regenerative regenerative valve valve (24) and the return circuit from arm c ylinder rod side to the hydraulic oil tank is closed. 3. Then, return oil from the arm cylinder rod side is combined with pressure oil from the pump and is routed to the cylinder bottom side so that arm roll-in speed increases and prevents arm hesitation. (Refer to Control Valve / COMPONENT OPERATION.) 4. At the same time, time, pilot pressure pressure from solenoid valve valve unit (19) (SC) shifts arm 2 flow rate control valve (23) in arm 2 parallel circuit. 5. Therefore, as pressure oil through arm 2 parallel circuit is controlled and delivered to boom 1, so that boom raise speed is kept. Condition: Pressure Sensors (16, (16, 15):  Pump 1 and 2 delivery Pressure Either pump 1 or 2 delivery pressure is low. (The arm does not need much power to operate.) (Reference: (Reference: 16.5 MPa or less)  Pressure Sensor (Arm Roll-In) (2): High High output. (The arm control lever stroke is large.) (Reference: 0.5 MPa or more)  Pressure Sensor (Swing) (3) or Pressure Pressure Sensor (Boom Raise) (1): Outputting signal

T2-2-46


10

1 2 3 4 5 6 7

9

12

11

15

16

13

14 29

18

17

8 28 27

19

20

21

22

26

23

25 24

1234567-


89101112131415-



T2-2-47

TDCD-02-02-025 TDCD-02-0 2-025


SECTION 2 SYSTEM Group 2 Control System Digging Regenerative Control Purpose: The digging regenerative regenerative control increases increases arm roll-in speed when operating digging (boom raise and arm rollin). Operation: 1. When all following conditions conditions exist, MC (8) activates activates solenoid valve unit (19) (SF). 2. Solenoid valve unit (19) (SF) delivers pilot pressure. pressure. This pilot pressure pressure shifts digging regenerative regenerative valve (21). 3. Pressure oil oil from boom boom cylinder rod side is combined with pressure oil from pump 2. The combined pressure oil flows to the arm 1 spool. 4. Pressure oil oil from the arm 1 spool is combined combined with pressure oil from the arm 2 spool. The combined pressure oil flows to the arm cylinder c ylinder bottom side. Therefore, arm roll-in speed increases. increases. Condition:  Work mode: Digging  Pump 1 and 2 delivery Pressure Pressure Sensors (16, (16, 15): High (Reference: 22 MPa or more)  Pressure Sensor (Arm Roll-In) (2): Specified pressure pressure or higher (Reference: 2.7 MPa or more) (1): Specified pressure pressure  Pressure Sensor (Boom Raise) (1): or lower (Reference: 2.0 MPa or less)

T2-2-48


10

1 2 3 4 5 6 7

9

12

11

15

16

13

14 29

18

17

8 28 27

19

20

21

22

26

23

25 24

1234567-


89101112131415-



T2-2-49

TDCD-02-02-026 TDCD-02-0 2-026


SECTION 2 SYSTEM Group 2 Control System Pulverizer Control (Optional) Purpose: Increases operating speed of the pulverizer. Reduces flow rate through the auxiliary spool and improve arm, boom, swing or travel operation during combined operation of arm roll-out, arm roll-out+ boom raise, swing or travel and pulverizer. Operation:  During Single Operation 1. When selecting pulverizer pulverizer 1 in monitor monitor (3), MC (4) (4) drives auxiliary flow combiner control solenoid valve (16).



2. When operating pulverizer (10), (10), pressure oil oil from attachment pilot valve (19) flows through auxiliary flow combiner solenoid valve (16) and shifts bypass shut-out valve (14) and auxiliary flow combiner valve (12). 3. As the neutral circuit circuit in 4-spool side is blocked by bypass shut-out valve (14), pressure oil from pump 1 (13) through auxiliary flow combiner valve (12) is combined with pressure oil from pump 2 (15) so that combined pressure oil is supplied to the auxiliary spool. Therefore, Therefore, operating speed of the pulverizer increases. 4. Flow rate of auxiliary flow rate rate control solenoid solenoid valve (17) can be adjusted finely in monitor (3).

During Combined Operation 1. When the following following conditions conditions exist, MC (4) drives auxiliary flow rate control solenoid valve (11) and controls restricted flow rate of the auxiliary flow rate control valve (17), and reduces pressure oil which flows to pulverizer (10) through the auxiliary spool from pump 2 (15). 2. As pressure oil which flows to arm roll-out, arm arm rollout+ boom raise, swing or travel from pump 2 (15) increases, arm roll-out, arm roll-out+ boom raise, swing or travel operation is improved improved..

Condition: (Auxiliary): Outputting signal  Pressure Sensor (Auxiliary): Pressure Sensor (Arm Roll-Out): Outputting signal  Pressure Sensor (Auxiliary): (Auxiliary): Outputting signal Pressure Sensors (Arm Roll-Out and Boom Raise): Outputting signal (Auxiliary): Outputting signal  Pressure Sensor (Auxiliary): Pressure Sensor (Swing): Outputting signal (Auxiliary): Outputting signal  Pressure Sensor (Auxiliary): Pressure Sensor (Trav ( Travel): el): Outputting signal

T2-2-50

SECTION 2 SYSTEM Group 2 Control System 10

1

5 6 7 8 9

3

2

4

13

12 11

19

18 17

14 15 16

123456-

MPDr. Monitor Controller Monitor MC Pressure Sensor (Travel) Pressure Sensor (Swing)

7891011-

TDCE-02-02-001 TDCE-02-0 2-001

Pressure Sensor (Boom Raise) Pressure Sensor (Arm Roll-Out) Pressure Sensor (Auxiliary) Attachment Auxiliary Flow Rate Control Solenoid Valve

1213141516-

T2-2-51

Auxiliary Flow Combiner Valve From Pump 1 Bypass Shut-Out Valve Pump 2 Auxiliary Flow Combiner Control Solenoid Valve

17- Auxiliary Flow Rate Control Valve 18- Pilot Pump 19- Attachment Pilot Valve

SECTION 2 SYSTEM Group 2 Control System Crusher Control (Optional) Purpose: Increases operating speed of the crusher. Reduces flow rate through the auxiliary spool and improve arm, boom, swing or travel operation during combined operation of arm roll-out, arm roll-out+ boom raise, swing or travel and crusher. Operation:  During Single Operation 1. When selecting crusher crusher 1 in monitor (3), (3), MC (4) drives auxiliary flow combiner control solenoid valve (16).



2. When operating operating crusher (10), (10), pressure pressure oil from from attachment pilot valve (19) flows through auxiliary flow combiner solenoid valve (16) and shifts bypass shut-out valve (14) and auxiliary flow combiner valve (12). 3. As the neutral circuit circuit in 4-spool side is blocked by bypass shut-out valve (14), pressure oil from pump 1 (13) through auxiliary flow combiner valve (12) is combined with pressure oil from pump 2 (15) so that combined pressure oil is supplied to the auxiliary spool. Therefore, Therefore, operating speed of the crusher increases. 4. Flow rate of auxiliary flow rate rate control solenoid solenoid valve (17) can be adjusted finely in monitor (3).

During Combined Operation 1. When the following following conditions conditions exist, MC (4) drives auxiliary flow rate control solenoid valve (11) and controls restricted flow rate of auxiliary flow rate control valve (17), and reduces pressure oil which flows to crusher (10) through the auxiliary spool from pump 2 (15). 2. As crusher (10) is heavier than the pulverizer pulverizer,, it increases the restricted flow rate of the auxiliary flow rate control valve and gives priority to arm rollout or arm roll-out+ boom raise during combined operation of arm roll-out or arm roll-out+ boom raise and crusher.

Condition:  Pressure Sensor (Auxiliary): (Auxiliary): Outputting signal Pressure Sensor (Arm Roll-Out): Outputting signal  Pressure Sensor (Auxiliary): (Auxiliary): Outputting signal Pressure Sensors (Arm Roll-Out and Boom Raise): Outputting signal (Auxiliary): Outputting signal  Pressure Sensor (Auxiliary): Pressure Sensor (Swing): Outputting signal (Auxiliary): Outputting signal  Pressure Sensor (Auxiliary): Pressure Sensor (Trav ( Travel): el): Outputting signal

T2-2-52

SECTION 2 SYSTEM Group 2 Control System 10

1

5 6 7 8 9

3

2

4

13

12 11

19

18 17

14 15 16

123456-

MPDr. Monitor Controller Monitor MC Pressure Sensor (Travel) Pressure Sensor (Swing)

7891011-

TDCE-02-02-001 TDCE-02-0 2-001

Pressure Sensor (Boom Raise) Pressure Sensor (Arm Roll-Out) Pressure Sensor (Auxiliary) Attachment Auxiliary Flow Rate Control Solenoid Valve

1213141516-

T2-2-53

Auxiliary Flow Combiner Valve From Pump 1 Bypass Shut-Out Valve Pump 2 Auxiliary Flow Combiner Control Solenoid Valve

17- Auxiliary Flow Rate Control Valve 18- Pilot Pump 19- Attachment Pilot Valve

SECTION 2 SYSTEM Group 2 Control System Other Control The other control consists of the followings. followings.    

Work Mode Control * Breaker Breaker Alarm Alarm Control Control * Swing Swing Alarm Alarm Control Control * Travel Alarm Control

fNOTE:

*: Depending on regional requirements, these controls will be equipped as standard.

T2-2-54

SECTION 2 SYSTEM Group 2 Control System Work Mode Control The work mode control control consists of digging and and attachment 1 to 11. The mode can be selected selec ted by using the monitor work mode. 



Digging Mode: Normal control is performed. Attachment Mode: This functions only when the attachment in the optional kit is operated. In response to attachment control operation, increasing or decreasing of engine speed (refer to T2-2-22 to 25), increasing or decreasing decreasing pump flow flow rate (refer to T2-2-34 to 37), and valve selection (refer to T2-2-50 to 53) are controlled. The engine speed and pump pump flow rate control control settings are made by MPDr MPDr....

fNOTE:

As the attachment mode, one to eleven attachment modes can be selected from breaker 1 to 5, pulverizer 1 to 5, 5, crusher 1 to 5, vibrating vibrating hammer 1 to to 5, grapple 1 to 5, and clamshell 1 to 5 by MPDr..

T2-2-55

SECTION 2 SYSTEM Group 2 Control System Breaker Alarm Control (Optional) Purpose: The breaker alarm control sounds the buzzer buzzer when the breaker is used in a fixed time continuously. Operation: 1. When the following following conditions exist in a fixed time time continuously,, MC (2) sends the signal to monitor continuously controller (5) by using CAN communication (3). 2. Monitor controller controller (5) sounds sounds buzzer (7). Condition:  Work mode: Breaker 1 to 5  Pressure Sensor (Auxiliary 1) (Optional): Outputting signal

fNOTE:

The breaker breaker alarm control control can be made made operable operable or inoperable by MPDr.(4).

1 4

3

6

2

5

7 TDAA-02-02-010 TDAA-0 2-02-010

1-

Pressure Sensor (Auxiliary 1) (Optional)

23-

MC CAN

45-

T2-2-56

MPDr. Monitor Controller

67-

Monitor Buzzer

SECTION 2 SYSTEM Group 2 Control System Travel Alarm Control (Only Machine with Optional Parts Equipped) Purpose: The travel alarm control control sounds the buzzer buzzer during travel operation. Operation: 1. MC (2) receives receives the signal from from pressure sensor (travel) (1) when the travel operation is carried out. 2. As long as MC (2) receives receives this signal, MC (2) sends the signals to travel alarm device (3) and sounds buzzer (5).

fNOTE:

After traveling continuously for more than 13 seconds, the alarm can be deactivated by buzzer deactivation switch (4).

1

2

3

4

5 TDAA-02-02-011 TDAA-0 2-02-011

12-

Pressure Sensor (Travel) MC

34-

Travel Alarm Device Travel Device Buzzer Deactivation Switch

5-

T2-2-57

Buzzer

SECTION 2 SYSTEM Group 2 Control System Swing Alarm Control (Only Machine with Optional Parts Equipped) Purpose: The swing alarm control control sounds the buzzer and turns on the beacon light during swing operation. Operation: 1. MC (2) receives receives the signal from from pressure sensor (swing) (1) when the swing operation is carried out. 2. As long as MC (2) receives receives this signal, MC (2) sends the signals to swing alarm relay (3), sounds buzzer (5), and turns on beacon light (6).

fNOTE:

The alarm can be deactivated by buzzer deactivation switch (4).

1

2

4

3

5

6 TDAA-02-02-012 TDAA-0 2-02-012

12-

Pressure Sensor (Swing) MC

34-

Swing Alarm Relay Buzzer Deactivation Switch

56-

T2-2-58

Buzzer Beacon Light

SECTION 2 SYSTEM Group 3 Hydraulic System Outline The hydraulic system system mainly consists of the pilot circuit, circuit, and main circuit. Pilot Circuit: Power Source Pilot Pump

Controller

Supplied to

Pilot Valve

Operation Control Circuit

Pump Regulator

Pump Control Circuit

Solenoid Valve Unit

Valve Control Circuit

Sig igna nall Con Contr tro ol Val alv ve

Travel Mo Moto torr Dis Disp pla laccem emen entt Ang Angle le Con ontr trol ol Ci Cirrcu cuit it Swing Parking Brake Release Circuit

Main Circuit: Power Source Main Pump

Controller Control Valve

Supplied to Motor Cylinder Attachment (Optional)

T2-3-1

SECTION 2 SYSTEM Group 3 Hydraulic System Pilot Circuit Outline: Pressure oil from the pilot pump is used in order to operate the following circuits.     

Operation Control Circuit Pump Control Circuit Valve Control Circuit Travel Tra vel Motor Displacement Displacement Angle Control Control Circuit Swing Parking Brake Release Circuit

T2-3-2

SECTION 2 SYSTEM Group 3 Hydraulic System 5

1

6

2

3

7

4

8 9

10

38 37

SB

ST

P2

P1

SA

36

11 35

13

14 15

12

16 17 34

24

18 19

33

20 SG

21

SF

22

SC

23

32

25

26

30 31

29

31

27

28 TDCD-02-04-001 TDCD-02-0 4-001

123456-

Pilot Valve (Left) Travel Pilot Valve Travel Pilot Valve (Right) Auxiliary Pilot Valve Operation Control Circuit Swing Parking Brake Release Circuit 7- Swing Motor 8- Pump Control Circuit 9- Pump 2 Maximum Flow Rate Limit Control Solenoid Valve 10- To Torque rque Control Control Solenoid Valve

11- Pump 1 Maximum Flow Rate Limit Control Solenoid Valve (OP) 12- Regulator 13- Flow Combiner Valve 14- Bucket Flow Rate Control Valve 15- Boom Anti-Drift Valve 16- Arm Anti-Drift Valve 17- Auxiliary Flow Combiner Valve 18- Bypass Shut-Out Valve 19- Auxiliary Flow Rate Control Valve

2021222324252627282930-

T2-3-3

Arm 1 Flow Rate Control Valve Main Relief Valve Digging Regenerative Valve Arm Regenerative Valve, Arm 2 Flow Rate Control Valve Control Valve Hydraulic Oil Tank Suction Filter Pilot Pump Pilot Filter Pilot Relief Valve Valve Control Circuit

31- Travel Travel Motor 32- Trav Travel el Motor Displacement Displacement Angle Control Circuit 33- Solenoid Valve Unit 34- Auxiliary Flow Rate Control Solenoid Valve (OP) 35- Auxiliary Flow Combiner Control Solenoid Valve (OP) 36- To Control Valve Spool 37- Signal Control Valve 38- Pilot Shut-Off Solenoid Valve Valve

SECTION 2 SYSTEM Group 3 Hydraulic System Operation Control Circuit 1. The pilot valve controls controls pressure oil oil from pilot pump pump (20) and moves the spool in control valve (19). 2. In addition, signal control valve valve (18) is provided provided between the pilot valve and control valve (19). Shockless valve (17) is provided in the boom raise circuit in signal control valve (18). 3. Shockless valve (17) reduces the returning oil from control valve (19) when stopping boom raise operation and dampens quick spool movement in control valve (19). (Refer to COMPONENT OPERATION / Signal Control Valve.)

T2-3-4


15

16

17 13 18

9 10 11 12 12

4 3

2

1

8

7

6 5 19

9

10

11

12

7

1

8

2 1 4

3 3 5

6

20 TDCD-02-04-002 TDCD-02-0 4-002

123456-

Boom Raise Boom Lower Arm Roll-Out Arm Roll-In Swing (Left) Swing (Right)

789101112-

Bucket Roll-In Bucket Roll-Out Travel Tra vel (Left Forward) Forward) Travel Tra vel (Left Reverse) Reverse) Travel Tra vel (Right Forward) Forward) Travel Tra vel (Right Reverse) Reverse)

131415161718-

T2-3-5

Pilot Shut-Off Solenoid Valve Travel Pilot Travel Pilot Valve Valve Pilot Valve (Left) Pilot Valve (Right) Shockless Valve Signal Control Valve

19- Control Valve 20- Pilot Pump

SECTION 2 SYSTEM Group 3 Hydraulic System Pump Control Circuit (Refer to COMPONENT OPERATION/Pump Device.) 

Pump Delivery Flow Rate Control by Flow Flow Rate Control Pressure Pi 1. The pilot pressure pressure from control valve valve is selected by the shuttle valve in signal control valve (7) so that pump 1 flow control valve (9) or pump 2 f low control valve (8) in signal control valve (7) is shifted. 2. Pilot pressure pressure from pilot pilot pump (11) (11) is supplied to the regulator in pump 1 (15) or pump 2 (14) as flow rate control pressure Pi by shifting pump 1 flow rate control valve (9) or pump 2 flow rate control valve (8).

fNOTE:

When operating boom (5) raise/ lower, arm (4) roll-out/in, bucket (6) roll-in/out and travel (right) (2), flow rate control pressure Pi is supplied to pump1 (15). When operating boom (5) raise/ lower, arm (4) roll- out/ in, swing (3) right/left, auxiliary and travel (left) (1), flow rate control pressure Pi is supplied to pump 2 (14).



Pump Control (Speed Sensing) by Torque Control Solenoid Valve  Pilot pressure pressure from pilot pump pump (11) is controlled by by torque control solenoid valve (13) and supplied to the regulator in pumps 1 (15) and 2 (14) as speed sensing pressure Ppc.

T2-3-6


2

3

4

5

6

7

9 8

10

13 12 14

15 Pi

Ppc

11 123456-

Travel (Left) Travel Travel Trav el (Right) Swing Arm Boom Bucket

78-

Signal Control Valve Pump 2 Flow Rate Control Valve 9- Pump 1 Flow Rate Control Valve 10- Control Valve

Ppc

Pi

11- Pilot Pump 12- Pump 2 Maximum Flow Rate Limit Control Solenoid Valve 13- T Torque orque Control Control Solenoid Valve 14- Pump 2 15- Pump 1

T2-3-7

TDCD-02-04-003 TDCD-02-0 4-003

SECTION 2 SYSTEM Group 3 Hydraulic System Valve Control Circuit (Refer to COMPONENT OPERATION/Control Valve.) 

Pilot pressure pressure from the pilot valve, valve, solenoid valve valve unit (27) (SC, SF, SG), flow combiner valve control spool (2) in signal control valve (22), bucket flow rate control valve control spool (3) and arm 1 flow rate control valve control spool (1) controls the valves below. 























Boom Lower Lower Pilot Pressure Pressure (24): Boom Anti-Drift Valve (8) Arm Roll-In Pilot Pressure Pressure (25): Arm Anti-Drift Anti-Drift Valve Valve (14) Auxiliary Pilot Pilot Pressure (21): Auxiliary Flow Flow Combiner Valve (17), Bypass Shut-Out Valve (10) (When the auxiliary spool is used.) Solenoid Valve Valve Unit (27) SC: Arm Regenerative Valve (12), Arm 2 Flow Control Valve (9) Solenoid Valve Valve Unit (27) SF: SF: Digging Regenerative Regenerative Valve (11) Solenoid Valve Valve Unit (27) SG: Main Relief Relief Valve Valve (16) (increasing the set-pressure) Auxiliary Flow Rate Control Control Solenoid Valve (28): (28): Auxiliary Flow Rate Control Valve Valve (15) (When the auxiliary spool is used.) Auxiliary Flow Combiner Combiner Control Solenoid Solenoid Valve Valve (23): Auxiliary Flow Combiner Valve (17), Bypass Shut-Out Valve (10) (When the auxiliary spool is used.) Flow Combiner Valve Control Spool (2): Flow Combiner Valve (4) Bucket Flow Rate Control Control Valve Valve Control Spool Spool (3): Bucket Flow Rate Control Valve (5) Arm 1 Flow Rate Control Valve Valve Control Spool (1): Arm 1 Flow Rate Control Valve Valve (13) Boom lower meter-in cut valve valve (7) controls boom flow rate control valve (6). (Refer to the Boom Lower Meter-In Cut.)

T2-3-8


19

20

21

22 1 2 25

24

23

17

16

3 4 28

15

5 6 7

27 14

24 8 SG

9 SF SC

26 25

123456-

Arm 1 Flow Rate Control Valve Control Spool Flow Combiner Valve Control Spool Bucket Flow Rate Control Valve Control Spool Flow Combiner Valve Bucket Flow Rate Control Valve Boom Flow Rate Control Valve

7891011121314-

13

12

11

Boom Lower Meter-In Cut Valve Boom Anti-Drift Valve Arm 2 Flow Rate Control Valve Bypass Shut-Out Valve Digging Regenerative Valve Arm Regenerative Valve Arm 1 Flow Rate Control Valve Arm Anti-Drift Valve

10

15- Auxiliary Flow Rate Control Valve 16- Main Relief Valve 17- Auxiliary Flow Combiner Valve 18- Tra Travel vel (Right) 19- Arm Roll-In 20- Boom Lower 21- Auxiliary 22- Signal Control Valve

T2-3-9

TDCD-02-04-004 TDCD-02-0 4-004

23- Auxiliary Flow Combiner Control Solenoid Valve 24- Boom Lower Pilot Pressure 25- Arm Roll-In Pilot Pressure 26- Pilot Pump 27- Solenoid Valve Unit 28- Auxiliary Flow Rate Control Solenoid Valve

SECTION 2 SYSTEM Group 3 Hydraulic System Swing Parking Brake Release Circuit (Refer to COMPONENT OPERATION/Swing Device.) 1. When operating operating the front front attachment or swing, pilot pressure is selected by the shuttle valve in signal control valve (5) and shifts swing parking brake release spool (6). 2. As a result, release signal pressure SH is supplied to swing motor (7) and the swing parking brake is released.

Travel Motor Displacement Angle Control Circuit (Refer to COMPONENT OPERATION/Travel Device.) 1. Pilot pressure pressure from solenoid solenoid valve unit (9) SG controls travel motor displacement angle control valve (11).

T2-3-10


2

3

4

5

SH

6

9

SG

8

7

10

11 TDCD-02-04-005 TDCD-02-0 4-005

1234-

Swing Arm Boom Bucket

567-

Signal Control Valve Swing Parking Brake Release Spool Swing Motor

8- Control Valve 9- Solenoid Valve Unit 10- Tra Travel vel Motor

T2-3-11

11- Displacement Angel Control Valve

SECTION 2 SYSTEM Group 3 Hydraulic System Main Circuit Outline: 1. The main pump pump (pumps 1 and 2) draws draws hydraulic hydraulic oil from hydraulic oil tank (21). Pump 1 (19) delivers pressure oil to 4-spool side (7) in control valve (6). Pump 2 (18) delivers pressure oil to 5-spool side (5) in control valve (6). 2. Delivered pressure pressure oil is supplied supplied to the motor and cylinder according to operation of the spool in control valve (6). 3. Return oil from from the motor motor or cylinder returns to hydraulic oil tank (21) through control valve (6) and oil cooler (22). 4. If oil temperature temperature is low (with (with high viscosity), and flow resistance is large in oil cooler (22), bypass check valve (17) opens and hydraulic oil directly returns to hydraulic oil tank (21).

T2-3-12

SECTION 2 SYSTEM Group 3 Hydraulic System

1

2 3

25

6

5

7

8

13

9

14

10

15

11

16

4

24

12

17

23

18

19

22 20

21

TDCD-02-04-006 TDCD-02-0 4-006

1234567-

Travel Motor (Left) Travel (Left) Travel Trav el Motor (Right) Bucket Cylinder Boom Cylinder 5-Spool Side Control Valve 4-Spool Side

891011121314-

Travel (Left) Spool Travel Auxiliary Spool Boom 2 Spool Arm 1 Spool Swing Spool Travel Tra vel (Right) Spool Spool Bucket Spool

15161718192021-

T2-3-13

Boom 1 Spool Arm 2 Spool Bypass Check Valve Pump 2 Pump 1 Suction Filter Hydraulic Oil Tank

22232425-

Oil Cooler Swing Motor Arm Cylinder Attachments

SECTION 2 SYSTEM Group 3 Hydraulic System Neutral Circuit 1. When the control control lever is in neutral, neutral, pressure pressure oil from pumps 1 (11) and 2 (12) returns to the hydraulic oil tank through control valve (2). Single Operation Circuit 1. Pressure oil oil from pump pump 1 (11) flows flows to each spool spool of travel right (5), bucket (6), boom 1 (8), and arm 2 (10) through 4-spool side (3) in control valve (2). 2. Pressure oil oil from pump pump 2 (12) flows flows to each spool spool of swing (13), arm 1 (15), boom 2 (17), auxiliary (18), and travel left (20) through 5-spool 5-spool side (1) control valve (2). 3. The boom and and arm are actuated by pressure pressure oil from two pumps and pressure oil from each pump is combined and supplied together.

T2-3-14


4 2

1

3

20 5 19

6 7

18 17

8

16

9

15 14 10

13

12

11

TDCD-02-04-007 TDCD-02-0 4-007

123456-

5-Spool Side Control Valve 4-Spool Side Travel Trav el Motor (Right) Travel Trav el (Right) Spool Bucket Spool

789101112-

Bucket Cylinder Boom 1 Spool Boom Cylinder Arm 2 Spool Pump 1 Pump 2

131415161718-

T2-3-15

Swing Spool Swing Motor Arm 1 Spool Arm Cylinder Boom 2 Spool Auxiliary Spool

19- Attachment 20- Trav Travel el (Left) Sp Spool ool 21- Trav Travel el Motor (Left) (Left)

SECTION 2 SYSTEM Group 3 Hydraulic System Combined Operation Circuit 

Swing and Boom Raise Operation Operation 1. When the boom boom is raised while swinging, pilot pressure shifts the spools of swing (7), booms 1 (2) and 2 (9). 2. Pressure oil oil from pump pump 1 (5) flows flows to boom cylinder (3) from boom 1 spool (2) through parallel circuit (1) and raises the boom. 3. Pressure oil oil from pump pump 2 (6) flows flows to swing motor motor (8) through swing spool (7) and swings. 4. At the same time, time, pressure pressure oil flows to boom cylinder (3) from boom 2 spool (9) through t hrough parallel circuit (4), combines with pressure oil from pump 1 (5) and raises the boom.

T2-3-16


1

2 9

3

8

4 7

6

5

TDCD-02-04-008 TDCD-02-0 4-008 123-

Parallel Circuit (Pump 1) Boom 1 Spool Boom Cylinder

456-

Parallel Circuit (Pump 2) Pump 1 Pump 2

789-

T2-3-17

Swing Spool Swing Motor Boom 2 Spool

SECTION 2 SYSTEM Group 3 Hydraulic System 

Travel and Arm Roll-In Operation Travel 1. When the arm is is rolled in while traveling, pilot pressure shifts the spools of travel right (4), travel left (2), arms 1 (10) and 2 (7). 2. At the same time, time, pilot pressure pressure shifts the flow combiner valve control spool in signal control valve. Pressure oil from the flow combiner valve control spool (5) flows to flow combiner valve (3) and shifts flow combiner valve (3). 3. Pressure oil oil from pump pump 1 (8) drives drives travel right right motor (6) through travel right spool (4). 4. At the same time, time, pressure pressure oil drives travel travel left motor (1) through flow combiner combiner valve (3) and and travel left spool (2). 5. Pressure oil oil from pump pump 2 (9) flows flows to arm cylinder (11) through arm 1 spool (10) and moves the arm. 6. Consequently, Consequently, pressure oil pump pump 2 (9) is used for the arm. Pressure oil from pump 1 (8) is equally supplied to both left and right travel motors and the machine can travel straight.

fNOTE:

As the travel right circuit is a tandem circuit, pressure oil from pump 1 (8) does not flow flow to arm 2 spool spool (7).

T2-3-18


1

6

2

3

4

5

11

10

7

9

8

TDCD-02-04-009 TDCD-02-0 4-009 1234-

Travel Motor (Left) Travel (Left) Travel Trav el (Left) Spool Spool Flow Combiner Valve Travel Trav el (Right) Spool

567-

From Flow Combiner Valve Control Spool Travel Tra vel Motor (Right) Arm 2 Spool

891011-

T2-3-19

Pump 1 Pump 2 Arm 1 Spool Arm Cylinder

SECTION 2 SYSTEM Group 3 Hydraulic System Auxiliary Circuit 1. When the attachment attachment such as as a hydraulic hydraulic breaker breaker is operated, pilot pressure from attachment pilot valve (3) shifts auxiliary flow combiner valve (2) and bypass shut-out valve (6). 2. Consequently, Consequently, neutral circuit (5) in 4-spool side is blocked by bypass shut-out valve (6). Pressure oil from pump 1 (7) through auxiliary flow combiner valve (2) is combined with pressure oil from pump 2 (8) so that combined pressure oil is supplied to auxiliary spool (9).

fNOTE:

During operation operation of boom raise/lower raise/lower,, arm arm roll-in/out, bucket roll-in/out and right /left travel, pilot pressure from the signal control valve valve is supplied to port SN and auxiliary flow combiner valve (2) is not shifted. (Refer to SYSTEM/Contr SYSTEM/Control ol System.)

T2-3-20


3

2

4 1

SM

SN

10 5

9

6

8

7

TDCD-02-04-010 TDCD-02-0 4-010 123-

Pilot Pressure from Signal Control Valve Auxiliary Flow Combiner Valve Attachment Pilot Pressure

456-

Auxiliary Flow Combiner Control Solenoid Valve Neutral Circuit (Pump 1) Bypass Shut-Out Valve

78910-

T2-3-21

Pump 1 Pump 2 Auxiliary 1 Spool Attachment

SECTION 2 SYSTEM Group 3 Hydraulic System Boom Lower Meter-In Cut Control Purpose: During boom lower operation with the front attachment above the ground, pressure oil which flows to boom cylinder (5) from the pump is cut. As the boom falls due to own weight due to the boom regenerative circuit and pressure oil from the pump is used for other actuators, other actuators are given priority to operate. In addition, in case meter-in cut control is deactivated with the track raised, the boom is given priority to operate and jack-up force increases.

fNOTE:

The operation during combined operation of boom lower and arm roll-in is explained here.



Boom Cylinder Bottom Pressure: Pressure: High Pressure Pressure (with the front attachment above the ground) 1. During combined combined operation of boom lower lower from boom raised position and other actuators, boom lower meter-in cut valve (3) is shifted by boom cylinder (5) bottom pressure. As boom lower pilot pressure does not act due to boom lower meter-in cut valve (3), boom 2 spool (11) does not move. 2. Boom flow rate rate control valve valve (switch valve) valve) (2) is closed by boom lower pilot pressure. 3. Back pressure in boom flow flow rate control control valve (poppet valve) (1) increases and boom flow rate control valve (poppet valve) (1) is closed. 4. Pressure oil to boom 1 spool (4) from from pump 1 (7) is cut by boom flow rate control valve (poppet valve) (1). 5. Pressure oil oil in boom cylinder (5) bottom side flows to boom cylinder (5) rod side through boom 1 spool (4) due to boom own weight. 6. As all pressure pressure oil from pumps 1 (7) and 2 (8) is used for actuators except the boom, the control speed increases.

T2-3-22


1

2

3

11 4

10

5

9 6

8

7

TDCD-02-04-011 TDCD-02-0 4-011

12-

Boom Flow Rate Control Valve (Poppet Valve) Boom Flow Rate Control Valve (Switch Valve)

345-

Boom Lower Meter-In Cut Valve Boom 1 Spool Boom Cylinder

6789-

T2-3-23

Arm 2 Spool Pump 1 Pump 2 Arm 1 Spool

10- Arm Cylinder 11- Boom 2 Spool

SECTION 2 SYSTEM Group 3 Hydraulic System 

Boom Cylinder Bottom Pressure: Pressure: Low Pressure Pressure (JackUp) 1. During boom lower operation operation while the bucket on the ground, boom cylinder (5) bottom pressure becomes low and boom lower meter-in cut valve (3) is shifted. 2. As boom lower pilot pressure pressure is released, released, the boom flow rate control valve (switch valve) (2) and boom flow rate control valve (poppet valve) (1) are opened. Boom lower pilot pressure moves boom 2 spool (8). 3. Pressure oil oil from pump pump 1 (6) passes passes through boom boom 1 spool (4). Pressure oil from pump 2 (7) through boom 2 spool (8) is combined with pressure oil from boom 1 spool (4) and combined pressure oil flows to boom cylinder (5) rod side.

fNOTE:

As boom 2 spool spool (8) is moved, moved, combined operation of travel with the track raised i s possible.

T2-3-24


2

1

3

8

4 5

7

6

TDCD-02-04-012 TDCD-02-0 4-012

12-

Boom Flow Rate Control Valve (Poppet Valve) Boom Flow Rate Control Valve (Switch Valve)

345-

Boom Lower Meter-In Cut Valve Boom 1 Spool Boom Cylinder

678-

T2-3-25

Pump 1 Pump 2 Boom 2 Spool

SECTION 2 SYSTEM Group 3 Hydraulic System (Blank)

T2-3-26

SECTION 2 SYSTEM Group 4 Electrical System Outline The electrical circuit is broadly broadly divided into the main circuit, monitor circuit, accessory circuit, and control circuit. 

Main Circuit: Operates the engine and the accessory related circuits.



Monitor Circuit: Displays the machine operating conditions. Consists of monitor controller, monitor, relays, and switches.



Accessory Circuit: Operates the accessory circuit. Consists of wiper/light controller,, relays, and switches. controller



Control Circuit: Controls the engine, pump, and valve. Consists of the actuators such as solenoid valves, MC, ECF, sensors, and switches. (Refer to SYSTEM / Control System.)

T2-4-1

SECTION 2 SYSTEM Group 4 Electrical System Main Circuit The major functions and circuits in the main main circuit are as follows. 

















Electric Power Power Circuit: Supplies Supplies all electric power power to all electrical systems on the machine. {Key switch, Battery, Fuses (Fuse box, Fusible link)} CAN Circuit: Performs communication communication between between each controller. Accessory Circuit: Is operated when the key switch is in the ACC position. Preheating Circuit: Assists the engine when starting in cold weather. (Key switch, QOS controller, Coolant switch, Glow plug relay, Glow plug) Starting Circuit: Circuit: Starts Starts the engine. (Key switch, Starter, Starter relay 2) Charging Circuit: Circuit: Supplies electric power to the batteries and charges them. {Alternator, (Regulator)} Surge Voltage Voltage Prevention Prevention Circuit: Prevents Prevents the occurrence of serge voltage developed when stopping the engine. (Load Dump Relay) Pilot Shut-Off Circuit (Key switch: switch: ON): ON): Supplies pressure oil from the pilot pump to the pilot valve by the pilot shut-off solenoid valve. (Pilot Shut-Off Solenoid Valve, Pilot Shut-Off Lever) Engine Stop Stop Circuit (Key Switch: OFF): Stops the engine by using ECF. (MC, ECF)

T2-4-2

SECTION 2 SYSTEM Group 4 Electrical System (Blank)

T2-4-3

SECTION 2 SYSTEM Group 4 Electrical System Electric Power Circuit (Key Switch: OFF) The battery (1) minus terminal is is grounded to the body. body. Current from the battery (1) plus terminal flows as shown below when key switch (5) is in the OFF position. Battery (1)

Fusible Li Link (2)

Glow Plug Relay (Power) (3) Key Switch (5) Terminal B Load Dump Relay (4) Fuse Box (6) Terminal #8 Terminal Term inal #9

Terminal Term inal #10

Terminal #11 Terminal Terminal Term inal #19 Terminal Term inal #20

T2-4-4

ECF (Power) (7) Monitor Controller (Backup (Backup Power) (14) Switch Panel (15) Cab Light (16) Radio (Backup Power) (17) Security Horn (Power) (18) Security Horn Relay (Power (Power)) (19) MC (Power) (10) GSM (Power) (11) Wiper/Light Controller (Power) (12) ECF (EC motor power)(13) power)(13) Horn Relay (Power) (Power) (8) Option (9)

SECTION 2 SYSTEM Group 4 Electrical System

5

3

1

4

2

11

13 7 8

8 19

9 10 20

6

9 10 11 12 14 15 16 17 18 19

TDCD-02-05-001 TDCD-02-0 5-001 123456-

Battery Fusible Link Glow Plug Relay (Power) Load Dump Relay Key Switch Fuse Box

789101112-

ECF (Power) Horn Relay (Power) Option MC (Power) GSM (Power) Wiper/Light Controller (Power)

13- ECF (EC motor power) 14- Monitor Controller (Backup power) 15- Switch Panel 16- Cab Light 17- Radio (Backup Power)

T2-4-5

18- Security Horn (Powe (Power) r) 19- Security Horn Relay (Power)

SECTION 2 SYSTEM Group 4 Electrical System CAN Circuit CAN (Controller Area Network) is ISO Standards of the serial communication protocol. Two networks networks (CAN bus (4)), CAN 0 (1) (1) and CAN 1 (5) are equipped for this machine. CAN 0 (1) is used for the engine control. CAN 1 (5) is used for the accessories. CAN bus (4) consists of two harnesses, CAN-H (High) (2) and CAN-L (Low) (3). Each controller judges the CAN bus (4) level due to potential difference between CAN-H (High) (2) and CAN-L (Low) (3). Each controller arranges the CAN bus (4) level and sends the signal and data to other controllers. In addition, termination resistors (120 Ω) (6) are installed to both ends of the CAN harness.

T2-4-6

SECTION 2 SYSTEM Group 4 Electrical System 2 1 3 4 2 5 3 TDAA-02-05-001 TDAA-02 -05-001

9

6

1

6

7

10

15

11 5 16

8

6

6 12

13

14

TDCD-02-01-002 TDCD-02-0 1-002

1234-

CAN 0 CAN-H (High) CAN-L (Low) CAN Bus

5678-

CAN 1 Termination Resistor (120 Termination (120 Ω) ECF (Engine Controller) MC (Main Controller)

9101112-

T2-4-7

Communication Controller Monitor Controller MPDr. Wiper / Light Controller

13141516-

Radio Controlle Controllerr Air Conditioner Controller Monitor Control Unit Information Control Unit

SECTION 2 SYSTEM Group 4 Electrical System Accessory Circuit 1. When key switch (2) is set to the ACC position, position, terminal B is connected to terminal ACC (3) in key switch (2). 2. Current from terminal ACC ACC (3) in key switch (2) flows as shown below and makes each accessory operable.

Key Switch Terminal ACC (3)

Fuse Box (4)

Terminal #12 Terminal #13 Terminal Terminal T erminal #14 Terminal T erminal #15

T2-4-8

Wiper/Light Controller (8) Radio (9) Cigar Lighter (6) Monitor Controller (5) Auxiliary (7)

SECTION 2 SYSTEM Group 4 Electrical System 3 2

1

13 15 12

6 7 8 9

14

4

5

TDCD-02-05-002 TDCD-02-0 5-002

123-

Battery Key Switch Terminal Te rminal ACC ACC

456-

Fuse Box Monitor Controller Cigar Lighter

789-

T2-4-9

Auxiliary Wiper/Light Controller Radio

SECTION 2 SYSTEM Group 4 Electrical System Preheating Circuit (Key Switch: ON, START)

fNOTE:

1. When key switch (4) is set to the ON or START START position, key switch terminal B (5) is connected to terminal M (6) in key switch (5).

When the preheating function is operated, operated, afterheating is operated for 30 seconds after engine starts.

2. Current from M terminal (6) flows to terminal terminal #1 of QOS controller through fuse #16. 3. When coolant switch switch (2) is set in in the OFF position (coolant temperature temperature is 10 °C or less) and key switch (4) is set in the ON or START position, QOS controller (3) connects terminal #4 to #5 (ground). 4. Therefore, glow plug relay (1) is turned ON and electric power is supplied to glow plug (10) to preheat. 5. When the preheating preheating function is operated, operated, QOS controller (3) connects terminal #6 to #5 for 8 seconds. 6. Therefore, terminal #D5 of of monitor controller controller (9) connects to the ground through QOS controller (9). 7. Monitor controller controller (9) recognizes recognizes that the preheating function is operated and displays the glow signal on monitor (8).

T2-4-10

SECTION 2 SYSTEM Group 4 Electrical System 5

6

4

2

3

1

16

7

10 D5

9

8 TDCD-02-05-003 TDCD-02-0 5-003

123-

Glow Plug Relay Coolant Switch QOS Controller

456-

Key Switch Terminal B Terminal Terminal Te rminal M

789-

T2-4-11

Fuse Box Monitor Monitor Controller

10- Glow Plug

SECTION 2 SYSTEM Group 4 Electrical System Starting Circuit (Key Switch: START) START) 1. When key switch (7) is set to ST START ART position (6), (6), terminal B is connected to terminals M (8) and ST (9) in key switch (7). 2. Current from terminal M (8) excites battery relay relay (4). Current from battery (1) is routed to terminal B of starter (2) and terminal B of starter star ter relay 2 (3) through battery relay (4). 3. In addition, current current from terminal M (8) in key switch flows to fuse #17. 4. Current from fuse #17 flows to GSM (10), monitor controller (12), ECF (14), and MC (13) as a signal indicating that key switch (7) is in ON or START position (6). 5. When ECF (14) receives this signal, signal, ECF (14) (14) drives EC motor (15) to move the governor lever to the engine start position. 6. Current from terminal ST (9) (9) flows to terminal S in starter relay 2 (3) through starter star ter cut relay (5). 7. Current flows to the coil in starter relay 2 (3) and starter relay 2 (3) is turned ON. 8. Therefore, current flows to to terminal C in starter (2) from terminal B in starter relay 2 (3). 9. Consequently, Consequently, the relay in starter (2) is turned ON ON so that the starter motor rotates.

T2-4-12


9

7

10

6 5 4 1

2

11

B

12

17 C C B S

3

13 14

TDCD-02-05-004 TDCD-02-0 5-004

15 1234-

Battery Starter Starter Relay 2 Battery Relay

5678-

Starter Cut Relay START Position Key Switch Terminal Te rminal M

9101112-

T2-4-13

Terminal ST Terminal GSM Fuse Box Monitor Controller

13- MC 14- ECF 15- EC Motor

SECTION 2 SYSTEM Group 4 Electrical System Operation of Starter Relay 2 1. When key switch (4) is set to the START START position, terminal B is connected to terminal ST in key switch (4).

fNOTE:

Condenser (C1) as illustrated illustrated is used to stabilize the operating voltage. Diode (D4) protects the circuit in case the battery terminals are reversely connected.

2. Current from battery (3) flows flows to the base of transistor (Q2) through resistance (R4) in starter relay 2 (1). 3. Therefore, transistor (Q2) (Q2) is turned ON and current flows to coil (L) in the relay relay.. 4. Consequently, Consequently, terminal B in starter (2) (2) is connected to terminal C and starter star ter (2) is operated. 5. After the engine starts, the alternator starts charging electricity and voltage at terminal R in starter relay 2 increases. 6. When the voltage voltage reaches 21 to 22V 22V,, Zener diode (Z) (Z) is turned ON. 7. Consequently, Consequently, transistor (Q1) is turned ON and and current flowing to the base of transistor (Q2) disappears so that transistor (Q2) is turned OFF. 8. At this moment, moment, terminal terminal B in the starter is disconnected from terminal C and the starter is turned OFF.

1

2

5

3

4 TDCD-02-05-005 TDCD-02-0 5-005

12-

Starter Relay 2 Starter

34-

Battery Key Switch

5-

T2-4-14

From Alternator terminal L


T2-4-15

SECTION 2 SYSTEM Group 4 Electrical System Charging Circuit (Key Switch: ON) 1. After the engine engine starts and key key switch (4) (4) is released, released, key switch (4) is returned to the ON position (3). 2. Terminal B is connected to terminals ACC ACC (5) and and M (6) in key switch (4) with key switch (4) set in the ON position (3). 3. Alternator (7) starts generating electricity electricity with the engine running. Current from alternator (7) terminal B flows to battery (1) through battery relay (2) and charges battery (1). 4. In addition, current current from alternator (7) terminal L flows to monitor controller (9) and GSM (8). 5. Monitor controller controller (9) detects detects the alternator (7) generating electricity according to current from alternator (7) and deletes the alternator alarm on monitor.

T2-4-16


4

6

3

2

1

8 B L

9

7 123-

Battery Battery Relay ON Position

TDCD-02-05-006 TDCD-02-0 5-006 456-

Key Switch Terminal ACC Terminal ACC Terminal Te rminal M

789-

T2-4-17

Alternator GSM Monitor Controller

SECTION 2 SYSTEM Group 4 Electrical System Alternator (5) Operation 







Alternator (5) consists of field coil coil FC, stator coil coil SC, and diodes D. Regulator (6) consists of of transistors T1 and and T2, Zener diode ZD, and resistances R1 and R2. Terminal M (4) in the key switch is is connected to base B of transistor T1 through R, RF, (R), and R1. When battery battery relay (2) is in the ON position, position, the battery (1) voltage is applied to base B of transistor T1 in regulator (6) so that collector C is connected to emitter E. Therefore, field coil FC is grounded through transistor T1.

3

4





At the beginning, beginning, no current is flowing through through field coil FC. When the rotor starts rotating, alternate current is generated in stator coil SC due to the rotor remain magnetism. When current flows flows through field coil FC, the rotor rotor is further magnetized so that the generating voltage increases. Thereby, Thereby, current through field coil FC increases. Therefore, Therefore, generating voltage increases further and battery (1) start charging.

5

6

2

1

TDAA-02-05-004 TDAA-0 2-05-004

12-

Battery Battery Relay

34-

To Key Switch Term Terminal inal B From Key Switch Terminal M

56-

T2-4-18

Alternator Regulator

SECTION 2 SYSTEM Group 4 Electrical System Regulator (6) Operation 





When generating generating voltage increases more more than the set voltage of Zener diode ZD, current flows to base B of transistor T2 and collector C is connected to emitter E. Current flowing to base B of transistor T1 disappears due to transistor T2 operation so that transistor T1 is turned OFF. No current flows flows through filed coil coil FC and generating generating voltage at stator coil SC decreases.

3

4





When generating voltage decreases decreases lower than the set voltage of Zener diode ZD, transistor T2 is turned OFF and transistor T1 is turned ON again. Current flows through field coil coil FC and generating generating voltage at stator coil SC increases. The above operation operation is repeated so that alternator (5) generating voltage is kept constant.

5

6

2

SC

1

TDAA-02-05-003 TDAA-0 2-05-003

12-


34-

To Key Switch Term Terminal inal B From Key Switch Terminal M

56-

T2-4-19

Alternator Regulator

SECTION 2 SYSTEM Group 4 Electrical System Surge Voltage Prevention Circuit 1. When the engine is is stopped (key switch (4): OFF), current from terminal M in key switch (4) disappears and battery relay (2) is turned OFF. 2. The engine continues to rotate due to inertia force just after key switch (4) is turned OFF so that alternator (5) continues to generate electricity. 3. As the generating generating current cannot flow to battery (1), surge voltage arises in the circuit and failures of the electronic components, such as the controller, possibly cause. In order to prevent the occurrence of surge voltage, the surge voltage prevention circuit is provided. 4. When alternator alternator (5) is generating electricity, electricity, the generating current from alternator (5) terminal L flows to terminal #A15 of monitor controller (6). Monitor controller (6) connects terminal #D8 to the ground. 5. Therefore, current flows to to the exciting circuit circuit in load dump relay (3) and load dump relay (3) is turned ON. 6. Consequently, Consequently, even if key switch (4) is turned OFF with the engine running, current from battery (1) continues to excite battery relay (2) through load dump relay (3). 7. In addition, when a fixed time has passed since alternator (5) stops generating electricity, monitor controller (6) disconnect terminal #D8 from the ground. Therefore, battery relay (2) is turned OFF.

T2-4-20


3 2

1

D8 A15

6

L

TDCD-02-05-007 TDCD-02-0 5-007

5 12-


34-

Load Dump Relay Key Switch

56-

T2-4-21

Alternator Monitor Controller

SECTION 2 SYSTEM Group 4 Electrical System Pilot Shut-Off Circuit (Key switch: ON) 1. When the pilot shut-off lever is set to the UNLOCK UNLOCK position, pilot shut-off switch (5) is turned ON. 2. Current from fuse #4 flows to to the ground through pilot shut-off relay (2) and pilot shut-off switch (5) so that pilot shut-off relay (2) is excited. 3. When pilot shut-off relay (2) (2) is excited, excited, the ground circuit in pilot shut-off solenoid valve (3) is connected to the ground through pilot shut-off relay (2) and security relay (10). 4. Therefore, pilot shut-off solenoid valve valve (3) is turned ON and pressure oil from the pilot pump is supplied to the pilot valve.



Neutral Engine Start Circuit Circuit 1. When the pilot shut-off lever is set to the UNLOCK UNLOCK position, the coil of starter cut relay (4) is connected to the ground circuit. 2. When key switch (6) is set to the START START position at at this time, starter cut relay (4) is excited. 3. When starter cut relay (4) is excited, the circuit between terminal ST (7) in key switch (6) and terminal S of starter relay 2 (9) is disconnected. 4. Therefore, when the pilot pilot shut-off lever is in the UNLOCK UNLOC K position, even if key switch (6) is set to the START ST ART position, the starter does not rotate and the engine does not start.

fNOTE:

When the the pilot shut-off lever lever is set to to the UNLOCK position, terminal #C1 of MC (11) is connected to the ground. Therefore, MC (11) recognizes that the pilot shut-off lever is in the UNLOCK UNLOCK position.

T2-4-22


6

2

3

4

5

1

8 4

S

10 9

C1

11

TDCD-02-05-008 TDCD-02-0 5-008

123-

Battery Pilot Shut-Off Relay Pilot Shut-Off Solenoid Valve Valve

45-

Starter Cut Relay Pilot Shut-Off Switch (Pilot Shut-Off Lever)

678-

T2-4-23

Key Switch Terminal T erminal ST Fuse Box

9- Starter Relay 2 10- Security Relay 11- MC

SECTION 2 SYSTEM Group 4 Electrical System Engine Stop Circuit Even if key switch (1) is set to the OFF position, the engine does not stop. When the engine does not stop due to some troubles that the machine is failed or damaged with key switch (1) OFF, OFF, set (lower) engine stop switch (5) to the ON position. Then, the engine stops. After that, return (raise) engine stop switch (5) to the OFF position. Do not use engine stop switch (5) dCAUTION: unless absolutely necessary. When the machine stops due to the machine failure, do not start the machine until repair is completed. 1. If the engine does not stop after key switch (1) is set to the OFF position, terminal B (2) continues to be connected to terminal M (3) in key switch (1). 2. When engine stop switch (5) is set to the ON position at this time, terminal #26 of ECF (6) connects to the ground. 3. ECF (6) recognizes recognizes that engine engine stop switch (5) is in the ON position. ECF (6) drives EC motor to stop position and stops the engine.

fNOTE:

Even if the the starter rotates with engine engine stop switch (5) set in the ON position, the engine does not start.

T2-4-24


3

1

4 17

5

26 6

TDCD-02-05-009 TDCD-02-0 5-009

7 12-

Key Switch Terminal B Terminal

34-

Terminal M Terminal Fuse Box

56-

T2-4-25

Engine Stop Switch ECF

7-

EC Motor


T2-4-26

SECTION 2 SYSTEM Group 4 Electrical System Monitor Circuit The major functions and circuits in the monitor monitor circuit are as follows. 





Security Circuit: Disconnects current for engine starting from the key switch according to the signals from the external ex ternal alarm system or monitor controller. controller. Turns the pilot shut-off solenoid valve OFF and disconnects the pilot circuit. Sounds the security horn at this time. (Monitor Controller, Security Relay, Security Horn Relay) Radio Circuit: Operates the radio. (Monitor Controller, Switch Panel, Radio) Air Conditioner Circuit: Operates the air conditioner conditioner.. (Monitor Controller, Switch Panel, Air Conditioner Controller)

T2-4-27

SECTION 2 SYSTEM Group 4 Electrical System Security Circuit 1. When monitor controller (6) receives the external alarm signal from e-Service or the numerical keypad password input error signal, monitor controller (6) connects terminals #D15 and #D16 to the ground inside. 2. Therefore, security horn relay (8), security relay relay (9), and starter cut relay (2) are excited. 3. When security horn relay relay (8) is excited, excited, current from fuse #9 activates security horn (7). 4. When security relay relay (9) is excited, excited, the ground ground circuit in pilot shut-off solenoid valve (1) is disconnected and pilot shut-off solenoid valve (1) is turned OFF. OFF. 5. Therefore, pressure oil which flows to the pilot valve valve from the pilot pump is blocked by pilot shut-off solenoid valve (1). 6. In addition, when starter cut relay (2) is is excited, the circuit between terminal ST (4) in key switch (3) and terminal S of starter relay 2 (10) is disconnected. 7. Therefore, even even if key switch (3) is set to the START START position, the engine does not start.

T2-4-28

SECTION 2 SYSTEM Group 4 Electrical System 4 3

1

2

5 4

6

9

D16 D15

S

7 10

9

8

TDCD-02-05-010 TDCD-02-0 5-010

123-

Pilot Shut-Off Solenoid Valve Valve Starter Cut Relay Key Switch

456-

Terminal ST Terminal Fuse Box Monitor Controller

789-

T2-4-29

Security Horn Security Horn Relay Security Relay

10- Starter Relay 2

SECTION 2 SYSTEM Group 4 Electrical System Radio Circuit 1. The operation on switch panel (2) is displayed displayed on monitor (1) through monitor controller (3). 2. When the setting for radio is adjusted on switch panel (2), the signal is sent to monitor controller (3). 3. Monitor controller controller (3) sends sends the signal to radio controller (5) by using CAN communication and the radio is operated.

Air Conditioner Circuit 1. The operation on switch panel (2) is displayed displayed on monitor (1) through monitor controller (3). 2. When the setting for air conditioner is adjusted on switch panel (2), the signal is sent to monitor controller (3). 3. Monitor controller controller (3) sends sends the signal to air conditioner controller (6) by using CAN communication and the air conditioner is operated.

T2-4-30


1

2

4 3 3

12

4

17 14

CAN1

6

TDCD-02-05-011 TDCD-02-0 5-011

5 12-

Monitor Switch Panel

34-

Monitor Controller Fuse Box

56-

T2-4-31

Radio Controller Air Conditioner Controller


T2-4-32

SECTION 2 SYSTEM Group 4 Electrical System Accessory Circuit The major functions and circuits in the accessory accessory circuit are as follows. 





Work Light Circuit: Turns on the work work light and boom light. light. (Wiper/Light Controller, Switch Panel, Work Light Relay) Wiper Circuit: Operates the intermittent operation of wiper and the washer. (Wiper/Light Controller, Switch Panel, Wiper Relay, Washer Relay) Cab Light Circuit: Turns on/off the cab light by shifting the switch or by opening/shutting the door.

T2-4-33

SECTION 2 SYSTEM Group 4 Electrical System Work Light Circuit Work Light (9) Circuit 1. When work light light switch (4) is set to the 1 position, position, current from fuse #17 flows to terminal #A6 of wiper/light controller (5) and switch panel (2), and connects to the ground in switch panel (2).

1

2. Therefore, work light relay relay 1 (8) is turned ON and current from fuse #1 turns on work light (9). 3. In addition, wiper/light wiper/light controller controller (5) sends the signal to monitor controller (3) by using CAN communication. 4. Monitor controller controller (3) displays displays the operating condition of work light switch (4) on monitor (1). MDAA-01-222

Boom Light (10) Circuit 1. When work light light switch (4) is set to the 2 position, position, current from fuse #17 flows to terminal #A2 of wiper/light controller (5) and switch panel (2), and connects to the ground in switch panel (2). 2. Therefore, work work light relay 1 (8) (8) and work light relay relay 2 (7) are turned ON and current from fuse #1 turns on work light (9) and boom light (10). 3. In addition, wiper/light wiper/light controller controller (5) sends the signal to monitor controller (3) by using CAN communication. 4. Monitor controller controller (3) displays displays the operating condition of work light switch (4) on monitor (1) and changes the monitor (1) screen to the nighttime mode screen.

fNOTE:

When the the monitor monitor (1) screen is the nighttime mode screen, push 0 on the numerical keypad switch for a few seconds so that the monitor (1) screen is changed to the daytime mode screen.

T2-4-34


2

3 6

1

17

CAN1

A6 A2

10

4

9 5

8

7

TDCD-02-05-012 TDCD-02-0 5-012

123-

Monitor Switch Panel Monitor Controller

456-

Work Light Switch Wiper/Light Controller Fuse Box

789-

T2-4-35

Work Light Relay 2 Work Light Relay 1 Work Light

10- Boom Light

SECTION 2 SYSTEM Group 4 Electrical System Wiper/Washer Circuit 3

Wiper Circuit 1. When wiper/washer switch (4) is set to the INT. INT. position, the signals according to the set inter vals are sent to wiper/light controller (5). 2. Wiper/light controller (5) connects terminal #B9 #B9 to the ground inside according to the input intervals.

2 1

3. Therefore, wiper relay relay (6) is turned ON  OFF repeatedly. 4. When wiper relay relay (6) is ON, current from fuse #2 flows to wiper motor (9) and the wiper is operated. 5. In addition, wiper/light wiper/light controller controller (5) sends the signal to monitor controller (2) by using CAN communication. 6. Monitor controller (2) displays the operating condition of wiper/washer switch (4) on monitor (3).

M178-01-016

No. 1 2 3

INT. Position Slow Speed Middle Fast Speed

Set Time 8 seconds 6 seconds 3 seconds

Washer Circuit 1. While pushing wiper/washer switch (4), wiper/light wiper/light controller (5) receives the signals from f rom wiper/washer switch (4).

3

2. Wiper/light controller (5) connects terminal #A5 #A5 to the ground inside and washer relay (7) is excited. 3. Current from fuse #2 flows to to washer motor (8) and washer liquid is jetted. 4. In addition, when pushing wiper/washer wiper/washer switch (4) for 1.4 seconds or more, wiper/light controller (5) turns washer relay (7) and wiper relay (6) ON. 5. Therefore, the washer and wiper wiper are operated operated at the same time.

T2-4-36

MDAA-01-222


3

1

2

2

17

CAN1

B9 A5

4 5

8

6

7

TDCD-02-05-013 TDCD-02-0 5-013

9 123-

Fuse Box Monitor Controller Monitor

456-

Wiper/Washer Switch Wiper/Light Controller Wiper Relay

789-

T2-4-37

Washer Relay Washer Motor Wiper Motor

SECTION 2 SYSTEM Group 4 Electrical System Cab Light Circuit Cab Light Switch (7): Door Interlocking Position (6) (Key Switch: ON) 1. When cab light light switch (7) is set to door interlocking interlocking position (6), current from fuse #9 flows to terminal #B10 of wiper/light controller (4). 2. When the cab cab door is shut, door open/close switch (3) is turned ON and terminal #B18 of wiper/light controller (4) is connected to the ground. 3. Wiper/light controller (4) recognizes that that the cab door is closed and disconnects terminal #B10 from the ground. 4. When the cab cab door is opened, door open/close switch (3) is turned OFF and terminal #B18 of wiper/ light controller (4) is disconnected from the ground. 5. Wiper/light controller (4) recognizes that that the cab door is open and connects terminal #B10 to the ground inside for thirty seconds. 6. Therefore, current from fuse #9 flows to terminal #B10 of wiper/light controller (4) and turns on cab light (8). 7. After cab light light (8) is turned on for thirty seconds or when the cab door is shut, wiper/light controller (4) disconnects terminal #B10 inside from the ground. 8. Therefore, cab light (8) is tuned off. 9. Consequently, Consequently, cab light switch switch (7) is in door interlocking position (6), cab light (8) is turned on/ off by opening/shutting the cab door.

fNOTE:

In case the cab door is open open and the key key switch is set to the ON position, cab light (8) is not turned on with cab light switch (7) set in door interlocking position (6). When shutting the cab door once and opening it again, cab light (8) can be turned on.

T2-4-38

Cab Light Switch (7): ON Position 1. Wiper/light controller (4) connects terminal #A7 to the ground inside. 2. When cab light light switch (7) is set to the ON position, position, current from fuse #9 flows to terminal #A7 of wiper/ light controller (4). 3. Consequently, cab light (8) is always on on with cab light switch (7) set in the ON position.


2 9

5

B18 B10 A7

3

4 8

7

6

TDCD-02-05-014 TDCD-02-0 5-014

12-

Key Switch Fuse Box

34-

Door Open/Close Switch Wiper/Light Controller

56-

T2-4-39

ON Position Door Interlocking Position

78-

Cab Light Switch Cab Light


T2-4-40

MEMO

MEMO

SECTION 3

COMPONENT OPERA OPERATION TION CONTENTS Group 1 Pump Device

Group 6 Signal Control Valve

Outline ................... ...................................... ...................................... ...................................... ........................... ........ T3-1-1 Main Pump ........................................... .............................................................. ................................. ..............T3-1-2 T3-1-2 Regulator ................. .................................... ...................................... ...................................... ........................ ..... T3-1-6 Solenoid Valve........................................... .............................................................. .........................T3-1-24 ......T3-1-24 Pilot Pump ................... ..................................... ..................................... ......................................T3-1-26 ...................T3-1-26 Pump Delivery Pressure Sensor ................................ ...................................T3-1-26 ...T3-1-26 Pump Control Pressure Sensor.....................................T3-1-26 Sensor.....................................T3-1-26 N Sensor (Engine Speed Sensor) ........................ .................................T3-1-27 .........T3-1-27

Group 2 Swing Device Outline ................... ...................................... ...................................... ...................................... ........................... ........ T3-2-1 Swing Reduction Gear ........................................ ...................................................... ..............T3-2-2 T3-2-2 Swing Motor .................................................... ....................................................................... ....................... T3-2-3 Swing Parking Brake .................................. ..................................................... ........................ ..... T3-2-4 Valve Unit................................................. .................................................................... .............................. ........... T3-2-6

Group 3 Control Valve Outline ................... ...................................... ...................................... ...................................... ........................... ........ T3-3-1 Hydraulic Circuit.................................................... ................................................................T3-3-22 ............T3-3-22 Flow Combiner Valve .............................. ................................................. .........................T3-3-28 ......T3-3-28 Main Relief Valve ...................................... ......................................................... .........................T3-3-30 ......T3-3-30 Overload Relief Valve (with Make-Up Make -Up Function) ....T3-3-34 Regenerative Valve.................................................. ...........................................................T3-3-38 .........T3-3-38 Anti-Drift Valv Valve e ................. .................................... ...................................... ...............................T3-3-42 ............T3-3-42 Flow Rate Control Valve .................................. ..................................................T3-3-46 ................T3-3-46 Digging Regenerative Valve .................... ....................................... ......................T3-3-50 ...T3-3-50 Boom Lower Meter-In Cut Valve .................. ..................................T3-3-52 ................T3-3-52 Auxiliary Flow Combiner Valve and Bypass Shut-Out Valve..................................... ........................................................ .........................T3-3-54 ......T3-3-54

Outline ................ ................................... ...................................... ...................................... .............................. ........... T3-6-1 Pilot Port....................................... ......................................................... ..................................... ........................ ..... T3-6-2 Shuttle Valv Valve e .................. ..................................... ...................................... ....................................T3-6-7 .................T3-6-7 Shockless Valve................................................ ..................................................................T3-6-10 ..................T3-6-10 Pump 1 and 2 Flow Rate R ate Control Valve .................. .....................T3-6-14 ...T3-6-14 Bucket Flow Rate R ate Control Valve Control Spool, Flow Combiner Valve Control Spool, Swing Parking Brake Release Spool, Arm 1 Flow Rate Control Valve Control Spool ..........................T3-6-16 ..........................T3-6-16

Group 7 Others (Upperstructure) Pilot Shut-Off Solenoid Valve.................. Valve..................................... ........................ ..... T3-7-1 Solenoid Valve.................................. ..................................................... ....................................T3-7-3 .................T3-7-3 Pilot Relief Valv Valve e ................. .................................... ...................................... .............................. ........... T3-7-6 EC Motor ................... ...................................... ..................................... ..................................... ........................ ..... T3-7-6 Hose Rupture Valve ........................................... ............................................................T3-7-8 .................T3-7-8

Group 8 Others (Undercarriage) Swing Bearing .............................................. ................................................................. ........................ ..... T3-8-1 Center Joint.......................................... ............................................................. ................................. ..............T3-8-2 T3-8-2 Track Adjuster Adjuster (Front (Front Idler Integrated Type)... Type).............. ........... T3-8-3

Group 4 Pilot Valve Outline ................... ...................................... ...................................... ...................................... ........................... ........ T3-4-1 Operation (Front Attachment / Swing and Travel Pilot Valv Valves) es)..................................................... ......................................................................T3-4-3 .................T3-4-3 Operation (Auxiliary Pilot Valve) ..................... ..................................T3-4-11 .............T3-4-11 Shockless Function (Only for Travel Travel Pilot Valve).....T3-4-16

Group 5 Travel Device Outline ................... ...................................... ...................................... ...................................... ........................... ........ T3-5-1 Travel Trav el Reduction Gear ................... ...................................... ....................................T3-5-2 .................T3-5-2 Travel Trav el Motor ................... ...................................... ...................................... ....................................T3-5-4 .................T3-5-4 Parking Brake.................................... ....................................................... ....................................T3-5-6 .................T3-5-6 Travel Trav el Brake Valve Valve ....................... .......................................... ...................................... ....................... T3-5-8 Overload Relief Valve ........................ ........................................... ...............................T3-5-12 ............T3-5-12 Travel Trav el Mode Control ...................... ......................................... ..................................T3-5-14 ...............T3-5-14

DCDT-3-1

(Blank)

DCDT-3-2

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Outline The pump device consists of transmission transmission (11), main pump (pump 1 (3), pump 2 (2)), and pilot pump (1). The engine output power is transmitted transmitted to transmission (11) via coupling (12). After being distributed by the gear, the engine output power drives pump 1 (3), pump 2 (2), and pilot pump (1).

The main pump is a bent-axis type variable variable displacement axial plunger pump. Pump 1 (3), and pump 2 (2) are integrated as two units in one housing. Pilot pump (1) is a gear pump. Torque To rque control solenoid valve valve (7), and maximum maximum pump 2 flow rate limit control solenoid valve (8) are installed in order to control the pump. Pump delivery pressure sensors (4, 5), pump control pressure sensors (6, 9), and N sensor (engine speed sensor) (10) are installed in order to control the engine, pump and valve. (Refer to SYSTEM / Control System.)

9 8 7 6

10 1

2

3

11

12

TDCD-03-01-001 TDCD-03-0 1-001

5

1234-

Pilot Pump Pump 2 Pump 1 Pump 1 Delivery Pressure Sensor

567-

4

Pump 2 Delivery Pressure Sensor Pump 1 Control Pressure Sensor Torque To rque Control Control Solenoid Valve

8-

Maximum Pump 2 Flow Rate Limit Control Solenoid Valve 9- Pump 2 Control Pressure Sensor 10- N Sensor

T3-1-1

11- Transmissio Transmission n 12- Coupling

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Main Pump The main pump supplies pressure oil oil to actuate the hydraulic components such as motors or cylinders. The main pump consists of pump 1, and pump 2. Shaft (3) is connected to each pump cylinder block (6) via seven plungers (4). When shaft (3) is rotated with cylinder block (6) together, plunger (4) oscillates in cylinder block (6) and hydraulic oil is drawn and delivered. Each pump is equipped with regulator (1) which controls the pump delivery flow rate.

1

2

3 6

5

4

12-

Regulator Housing

34-

Shaft Plunger

56-

T3-1-2

Valve Plate Cylinder Block

TDCD-03-01-002 TDCD-03-0 1-002

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Operational Principle Engine torque is transferred to shaft (3) and seven plungers (4), and causes cylinder block (6) to rotate while sliding along the valve plate (5) sur face. Plunger (4) reciprocates in the cylinder block (6) bore and alternately hydraulic oil is drawn and delivered.

4

5

3

6

T105-02-03-002 T105-02 -03-002 3-

Shaft

4-

Plunger

5-

T3-1-3

Valve Plate

6-

Cylinder Block

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Increasing and Decreasing Flow Rate Changing inclination of cylinder block (6) causes the plunger (4) stroke to increase or decrease depending on the slant angle in order to control the main pump delivery flow rate. Up-down movement of servo ser vo piston (8) changes inclination of cylinder block (6). Servo piston (8) is connected with valve plate (5) via pin (7). The one end of cylinder block (6) is kept in contact with the surface of valve plate (5) and slides along it.

Maximum Displacement Angle

4

6 α

7 6 8

T105-02-03-021 T105-02 -03-021

5

4

TDCD-03-01-003 TDCD-03-0 1-003

Minimum Displacement Angle (Operable Limit Angle)

α

T105-02-03-022 T105-02 -03-022

45-

Plunger Valve Plate

6-

Cylinder Block

7-

T3-1-4

Pin

8-

Servo Piston

SECTION 3 COMPONENT OPERATION Group 1 Pump Device (Blank)

T3-1-5

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Regulator Regulator (16) controls the main pump flow rate in response to the various command signal pressures so that the pump driving power does not exceed the engine output power. Pump Pump 1, and pump p ump 2 are equipped with regulator (16) for each.

14 13

The major parts of regulator regulator (16) are spring (1), sleeve sleeve A (2), sleeve B (7), spool A (3), spool B (6), piston (4), load piston (5), inner spring (8), outer spring (9), torque control solenoid valve (13), and maximum pump 2 flow rate limit control solenoid valve (14). According to the various command signal pressures, regulator (16) opens or closes the circuit to servo piston (10) and the inclination of cylinder block (11) is changed, so that the pump p ump delivery flow rate is controlled.

TDCD-03-01-004 TDCD-03-0 1-004 13- Torque Control Solenoid Valve

14- Maximum Pump 2 Flow Rate Limit Control Solenoid Valve

fNOTE:

Primary pilot pressure Pg is constantly constantly routed routed to to the small chamber side of servo pis ton (10).

As for each regulator (16), functions are different, but the operational principles are the same. The pump 2 regulator is explained here.

16 12

11 10

TDCD-03-01-003 TDCD-03-0 1-003 10- Servo Piston 11- Cylinder Block

T3-1-6

12- Link 16- Regulator

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Pump 1 Regulator

1

2

5

3

6 1

4

7 3

8 2

Dr

TDCD-03-01-005 TDCD-03-0 1-005

9

4

Pi

15

Pd2 Pps

Dr

Pd1 Dr

5

7

8, 9

6

Pg

10

a

b

12 TDCE-03-01-001 TDCE-03-0 1-001

Pd1Pd 1- Pu Pump mp 1 De Deli live very ry Pr Pres essu sure re

Dr-- Retu Dr Return rnin ing g to Hy Hydr drau auli licc Oi Oill Tank Ta nk

Pps ps-- Tor orqu que e Con ontr trol ol Pr Pres essu sure re

a-

Disp Di spla lace ceme ment nt An Angl gle e In Incr crea ease se

Pd2- Pump 2 Deliver y Pres su sure

Pi-

Pump Control Pressure

Pg- Primar y Pilot Pressure (From Pilot Pump)

b-

Displacementt Angle Decrease Displacemen

1234-

5678-

Load Piston Spool B Sleeve B Inner Spring

9101213-

14- Maximum Pump 2 Flow Rate Limit Control Solenoid Valve 15- Air Bleeding Circuit

Spring Sleeve A Spool A Piston

T3-1-7

Outer Spring Servo Piston Link Torque Control Solenoid Valve

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Pump 2 Regulator

1

2

5

3

6 2

4

7

8 4

13

9

TDCD-03-01-007 TDCD-03-0 1-007

14

3 1 Pi Dr

15

Pd2 Pps

Dr

Pd1

8, 9

Dr

5

7

12

6

10

Pg a

TDCD-03-01-008 TDCD-03-0 1-008

b

Pd1Pd 1- Pu Pump mp 1 De Deli live very ry Pr Pres essu sure re

Dr-- Retu Dr Return rnin ing g to Hy Hydr drau auli licc Oi Oill Tank Ta nk

Pps ps-- Tor orqu que e Con ontr trol ol Pr Pres essu sure re

a-

Disp Di spla lace ceme ment nt An Angl gle e In Incr crea ease se

Pd2- Pump 2 Deliver y Pres su sure

Pi-


Pg- Primar y Pilot Pressure (From Pilot Pump)

b-

Displacementt Angle Decrease Displacemen

1234-

5678-


9101213-

14- Maximum Pump 2 Flow Rate Limit Control Solenoid Valve 15- Air Bleeding Circuit


T3-1-8

Outer Spring Servo Piston Link Torque Control Solenoid Valve

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Regulator Control Function The regulator has the following following four control control functions. 

Control by Pump Pump Control Control Pressure Pressure When a control lever is operated, the pump flow f low rate control valve in the signal control valve regulates pump control pressure Pi in response to the control lever stroke. When the regulator receives pump control pressure Pi, the regulator controls the pump delivery flow rate in proportion to pump control pressure Pi. When the control lever is operated, pump control pressure Pi increases and the regulator increases the pump delivery flow rate. When the control lever is returned to neutral, pump control pressure Pi decreases and the regulator decreases the pump delivery flow rate.

Q

0

Q-

Pi

Flow Rate

Pi-


Q 

Control by Own and Partner Pump Pump Delivery Pressure Pressure (Regulators for Pump 1 and Pump 2) The regulators for for pump 1 and pump 2 receive receive own pump delivery pressure Pd1 or Pd2 and partner pump delivery pressure Pd2 or Pd1 as control signal pressures. If the two-pump t wo-pump average pressures increase over the set P-Q line, the regulator reduces both pump delivery flow rates and the total pump output is returned to the set P-Q line. Therefore, the engine is protected from being overloaded. In addition, as the P-Q line has been designated in order to jointly regulate both pump operations, both pump delivery flow rates are regulated almost equally to each other.

c d

0

QP-

P

Flow Rate Pressure

cd-

Pressure Increase Flow Rate Decrease

Pi

15 Dr Pd2 Pps

Dr

Pd1 Dr Pg a Pd1- Pump 1 Delivery Pressure Pd2- Pump 2 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Tan k Pi- Pump Control Pressure Pps- Torque Control Pressure 15- Air Bleeding Circuit

T3-1-9

b

TDCD-03-01-008 TDCD-03-0 1-008

Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacemen Displacementt Angle Increase b- Displacemen Displacementt Angle Decrease

SECTION 3 COMPONENT OPERATION Group 1 Pump Device 

Control by Pilot Pressure from Torque Control Solenoid Valve (13) MC (main controller) sends the signals to torque control solenoid valve (13) according to the engine speed and the signals from sensors. Torque T orque control solenoid solenoid valve (13) delivers delivers torque control pilot pressure Pps to the regulator in response to the signals from MC. When receiving torque control pilot pressure Pps, the regulator reduces the pump delivery flow rate. (Refer to SYSTEM / Control System.)

Q

0

Q-

P

Flow Rate

P-

Pressure Pr

13

Pi

15 Dr Pd2 Pps

Dr

Pd1 Dr Pg a

b

TDCD-03-01-008 TDCD-03-0 1-008

Pd1- Pump 1 Delivery Pressure Pd2- Pump 2 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Ta nk Pi- Pump Control Pressure Pps- Torque Control Pressure


13- Torque Control Solenoid Valve

15- Air Bleeding Circuit

T3-1-10


Control by Pilot Pilot Pressure from from Maximum Pump 2 Flow Flow Rate Limit Control Solenoid Valve (14) (only Pump 2) When the work mode is set to attachment, MC (main controller) sedns the signals to maximum pump 2 flow rate limit control solenoid valve (14) according to the settings. Maximum pump 2 flow rate limit control solenoid valve (14) reduces pump control pressure Pi in response to the signals from MC. Therefore,, the upper limit pump delivery flow rate Therefore rate is limited. (Pump Flow Rate Limit Control) (Refer to SYSTEM / Control System.)

Q

0 Q-

Pi

Flow Rate

Pi-


c Q

d

0 QP-

P

Flow Rate Pressure

cd-

Maximum Flow Rate Upper Limit Flow Rate

14

Pi

15

Dr Pd2 Pps

Dr

Pd1 Dr Pg a

b

TDCD-03-01-008 TDCD-03-0 1-008

Pd1- Pump 1 Delivery Pressure Pd2- Pump 2 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Tan k Pi- Pump Control Pressure Pps- Torque Control Pressure


14- Maximum Pump 2 Flow Rate Limit Control Solenoid Valve

15- Air Bleeding Circuit

T3-1-11

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Control by Pump Control Pressure

fNOTE: 

Q

The pump 2 regulator is explained explained here.

Flow Rate Increase 1. When a control control lever is operated, operated, the flow rate control valve in the signal control valve is shifted and pump control pressure Pi increases. 2. Piston (4) pushes spool A (3) and spring (1) so that spool A (3) is moved toward direction of the arrow. 3. Due to the movement movement of spool A (3), the circuit circuit from the large chamber of servo piston (10) is opened to the hydraulic oil tank.

0

Q-

4. As primary pilot pilot pressure Pg is constantly routed routed to the small chamber of servo piston (10), servo piston (10) is moved toward direction of arrow (a). Therefore, Therefore, the cylinder block is rotated in the maximum inclination direction and the pump delivery flow rate increases.

Pi

Flow Rate

Pi-


2

4

3 1

5. The movement movement of cylinder block is transmitted transmitted to sleeve A (2) via link (12). Sleeve A (2) is moved in the same direction as spool A (3).

Pi

15

Dr

6. When sleeve A (2) is moved moved by the same stroke as spool A (3), the open part between spool A (3) and sleeve A (2) is closed and the circuit from large chamber of servo piston (10) to the hydraulic oil tank is closed.

Pd2 Pps

Dr

Pd1

Therefore, servo piston (10) is stopped and the flow rate increasing operation is completed.

Dr Pg

10

a

b

12

TDCD-03-01-008 TDCD-03-0 1-008

Pd1- Pump 1 Delivery Pressure Pd2- Pump 2 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Tan k Pi- Pump Control Pressure

Pps- Torque Control Pressure Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacemen Displacementt Angle Increase b- Displacemen Displacementt Angle Decrease

1234-

10- Servo Piston 12- Link 15- Air Bleeding Circuit

T3-1-12


SECTION 3 COMPONENT OPERATION Group 1 Pump Device

fNOTE:

The illustration shows the pump2 regulator. 1

Pg

Dr

2

3

4 Pi

Pps

Pd2

12

Pd1

10

1

2

Pg

Dr

TDCD-03-01-009 TDCD-03-0 1-009

3

4 Pi

Pps

Pd2

12

Pd1

a

10

TDCD-03-01-010 TDCD-03-0 1-010

b

Pd1- Pump 1 Delivery Pressure Pd2- Pump 2 Delivery Pressure

Dr- Returning to Hydraulic Oil Tank Ta nk

Pi- Pump Control Pressure Pps- Torque Control Pressure

Pg- Primary Pliot Pressure (From Pilot Pump)

12-

34-

10- Ser vo Piston

12- Link

Spring Sleeve A

Spool A Piston

T3-1-13


Flow Rate Decrease 1. When a control control lever is returned, returned, the flow rate rate control valve in the signal control valve is returned and pump control pressure Pi decreases.

Q

2. Piston (4) and spool A (3) (3) are pushed by spring (1) so that spool A (3) is moved toward direction of the arrow. 3. Due to the movement movement of spool A (3), primary primary pilot pressure Pg is routed to the large chamber of servo piston (10). 4. Due to the difference in the pressure receiving areas between the large and small chambers, servo piston (10) is moved toward direction of arrow (b). The cylinder block is rotated in the minimum inclination direction and the pump delivery flow rate decreases.

0 Q-


Pi

Flow Rate

Pi-


2

4

3

6. When sleeve A (2) is moved moved by the same stroke as spool A (3), the open part between sleeve A (2) and spool A (3) is closed and primary pilot pressure Pg routed to servo piston (10) is blocked.

1 Pi

Therefore, servo piston (10) is stopped and the flow rate decreasing operation is completed.

15

Dr

Pd2 Pps

Dr

Pd1 Dr Pg

10

a

b

12

TDCD-03-01-008 TDCD-03-0 1-008



1234-

10- Servo Piston 12- Link 15- Air Bleeding Circuit

T3-1-14



fNOTE:


2

Pg

Dr

3

4 Pi

Pps

Pd2

12

Pd1

10

1

Dr

Pg

2

TDCD-03-01-011 TDCD-03-0 1-011

3

4 Pi

Pps

Pd2

12

Pd1

a

10

TDCD-03-01-012 TDCD-03-0 1-012

b




Pg- Primary Pilot Pressure (From Pilot Pump)

12-

34-

10- Ser vo Piston

12- Link

Spring Sleeve A

Spool A Piston

T3-1-15

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Control by Own and Partner Pump Delivery Pressure

fNOTE: 

Q


Flow Rate Decrease 1. When pump 2 (own pump) is loaded, loaded, pump 2 delivery pressure Pd2 (own pump pressure) increases. (During operation, pump control pressure Pi is kept increased.) 2. Load piston (5) (5) pushes spool B (6), (6), inner spring (8), (8), and outer spring (9). Spool B (6) is moved toward direction of the arrow. 3. Due to the movement movement of spool B (6), primary pilot pressure Pg is routed to the large chamber of servo piston (10).

0 Q-

P

Flow Rate

P-

Pressure Pr

4. Due to the difference in the pressure receiving areas between the large and small chambers, servo piston (10) is moved toward direction of arrow (b). The cylinder block is rotated in the minimum inclination direction and the pump delivery flow rate decreases.

Pi Dr

5. The movement movement of cylinder block is transmitted transmitted to sleeve B (8) via link (12). Sleeve B (7) is moved in the same direction as spool B (6).

Pd2 Pps

6. When sleeve B (7) is moved moved by the same stroke as spool B (6), the open part between sleeve B (7) and spool B (6) is closed and primary pilot pressure Pg routed to the large chamber of servo piston (10) is blocked. Therefore, Therefore, servo piston (10) is stopped and the flow rate decreasing operation is completed. 7. When pump 1 (partner pump) is also loaded loaded at this time, pump 1 delivery pressure (Pd1) and pump 2 delivery pressure (Pd2) is routed to load piston (5) and move spool B (6) further. fur ther. 8. Consequently, Consequently, as the movement movement of spool B (6) increases, the pump delivery flow rate decreases further.

15

Dr

Pd1

8, 9

Dr

5

7 10

12

6

Pg a

b

TDCD-03-01-008 TDCD-03-0 1-008



5678-

9101215-

T3-1-16


Outer Spring Servo Piston Link Air Bleeding Circuit


fNOTE:


Pg

Dr

6

7 Pi

Pps

8

Pd2

9

12

Pd1

10

5

6

Pg

Dr

TDCD-03-01-013 TDCD-03-0 1-013

7 Pi

Pps

8

Pd2

9

12

Pd1

10 a

TDCD-03-01-014 TDCD-03-0 1-014

b





56-

78-

9- Outer Spring 10- Servo Piston

12- Link

Load Piston Spool B

Sleeve B Inner Spring

T3-1-17


Flow Rate Increase 1. When the load of of pump 2 (own pump) is reduced, reduced, pump 2 delivery pressure Pd2 (own pump pressure) decreases. (During operation, pump control pressure Pi is kept increased.)

Q

2. Load piston (5), (5), and spool B (6) are pushed by inner spring (8) and outer spring (9). Spool B (6) is moved toward direction of the arrow arrow.. 3. Due to the movement movement of spool B (6), the circuit circuit from the large chamber of servo piston (10) is opened to the hydraulic oil tank. 4. As primary pilot pilot pressure Pg is constantly routed routed to the small chamber of servo piston (10), servo piston (10) is moved toward direction of arrow (a). Therefore, Therefore, the cylinder block is rotated in the maximum inclination direction and the pump delivery flow rate increases.

0 Q-

P

Flow Rate

P-

Pressure Pr

2


3

6. When sleeve B (7) is moved moved by the same stroke as spool B (6), the open part between spool B (6) and sleeve B (7) is closed and the circuit from large chamber of servo piston (10) to the hydraulic oil tank is closed. Therefore, servo piston (10) is stopped and the flow rate increasing operation is completed.

Pi Dr

15

Pd2 Pps

7. When the load load of pump pump 1 (partner pump) pump) is also reduced at this time, load piston (5), and spool B (6) are pushed by inner spring (8) and outer spring (9) further.

Dr

Pd1

8, 9

Dr

5

7

8. Consequently, Consequently, as the movement movement of spool B (6) increases, the pump delivery flow rate increases further.

10

12

6

Pg a

b

TDCD-03-01-008 TDCD-03-0 1-008

Pd1- Pump 1 Delivery Pressure Pd2- Pump 2 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Ta nk Pi- Pump Control Pressure


23567-

89101215-

T3-1-18

Sleeve A Spool A Load Piston Spool B Sleeve B

Inner Spring Outer Spring Servo Piston Link Air Bleeding Circuit


fNOTE:


Dr

2

Pg

3

6 Pi

Pps

8

Pd2

9

12

Pd1

10

5

6

Pg

Dr

2

TDCD-03-01-015 TDCD-03-0 1-015

3

7 Pi

Pps

8

Pd2

12

Pd1

TDCD-03-01-016 TDCD-03-0 1-016

10 a

b




235-

678-

9- Outer Spring 10- Servo Piston 12- Link

Sleeve A Spool A Load Piston

9

Spool B Sleeve B Inner Spring

T3-1-19


SECTION 3 COMPONENT OPERATION Group 1 Pump Device Control by Pilot Pressure from Torque Control Solenoid Valve

fNOTE: 

Q


Flow Rate Decrease 1. Torque control solenoid valve valve (13) is activated activated by the signals from MC (main controller) and torque control pressure Pps increases. 2. Torque control pressure Pps adding to pump delivery pressure is routed to load piston (5).

0

3. Load piston (5) (5) pushes spool B (6), (6), inner spring (8), (8), and outer spring (9). Spool B (6) is moved toward direction of the arrow.

Q-

P

Flow Rate

P-

4. Due to the movement movement of spool B (6), primary pilot pressure Pg is routed to the large chamber of servo piston (10).

Pressure Pr

13

5. Due to the difference in the pressure receiving areas between the large and small chambers, servo piston (10) is moved toward direction of the arrow.. The cylinder block is rotated in the minimum arrow inclination direction and the pump delivery flow rate decreases.

Pi Dr


15

Pd2 Pps

Dr

Pd1

7. When sleeve B (7) is moved moved by the same stroke as spool B (6), the open part between sleeve B (7) and spool B (6) is closed and primary pilot pressure Pg routed to the large chamber of servo piston (10) is blocked. Therefore, Therefore, servo piston (10) is stopped and the flow rate decreasing operation is completed.

8, 9

Dr

5

7 10

12

6

Pg a

b

TDCD-03-01-008 TDCD-03-0 1-008



56789-

10- Servo Piston 12- Link 13- Torque Control Solenoid Valve 15- Air Bleeding Circuit

T3-1-20

Load Piston Spool B Sleeve B Inner Spring Outer Spring


fNOTE:


6

Pg

Dr

7 Pi

Pps

8

Pd2

9

12

Pd1

10

5

Pg

Dr

TDCD-03-01-017 TDCD-03-0 1-017

6

7 Pi

Pps

8

Pd2

9

12

Pd1

a

10

TDCD-03-01-018 TDCD-03-0 1-018

b





56-

78-

9- Outer Spring 10- Servo Piston

12- Link

Load Piston Spool B

Sleeve B Inner Spring

T3-1-21

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Control by Pilot Pressure from Maximum Pump Flow Rate Limit Control Solenoid Valve (only Pump 2) 

Q

Upper Limit Flow Flow Rate Control Control (only Pump 2) 1. Maximum pump 2 flow rate rate limit control solenoid solenoid valve (14) in the pump control pressure Pi circuit is activated by the signals from MC (main controller). 2. Maximum pump 2 flow rate rate limit control solenoid solenoid valve (14) functions as a pressure reducing valve and pump control pressure Pi decreases.

0 Q-

Pi

Flow Rate

Pi-


3. Piston (4) is moved toward toward direction direction of the arrow by reduced pump control pressure Pi. a

4. Piston (4) pushes spool A (3) and spring (1), until the force acting on piston (4) by pump control pressure Pi becomes balanced with the spring (1) force, spool A (3) is moved toward direction of the arrow arrow..

Q

b

5. As pump control control pressure Pi Pi has been reduced, reduced, spool A (3) is moved in a shorter distance than usual. 6. Due to the movement movement of spool A (3), the circuit circuit from the large chamber of servo piston (10) is opened to the hydraulic oil tank.

0 QP-

7. As primary pilot pilot pressure Pg is constantly routed routed to the small chamber of servo piston (10), servo piston (10) is moved toward direction of the arrow.. Therefore, the cylinder block is rotated in arrow the maximum inclination direction and the pump delivery flow rate increases.

P

Flow Rate Pressure

ab-

Maximum Flow Rate Upper Limit Flow Rate

4

2

14

3 1


Pi Dr

9. When sleeve A (2) is moved moved by the same stroke as spool A (3), the open part between spool A (3) and sleeve A (2) is closed and the circuit from large chamber of servo piston (10) to the hydraulic oil tank is closed.

15

Pd2 Pps

Dr

Pd1 Dr

10. Therefore, servo piston (10) is stopped and the flow rate increasing operation is completed. 11. Accordingly Accordingly,, pump control pressure Pi increases according to the control lever stroke and the pump delivery flow rate increases. However, as pump control pressure Pi is regulated, the movement of spool A (3) and servo piston (10) are reduced so that the maximum flow rate becomes less than usual.

12 Pg

10

a

b

TDCD-03-01-008 TDCD-03-0 1-008


Pps- Torque Control Pressure Pg- Primary Pilot Pressure (From Pilot Pump) c- Displacemen Displacementt Angle Increase d- Displacement Angle Decrease

1234-

10- Servo Piston 12- Link 14- Maximum Pump 2 Flow Rate Limit Control Solenoid Valve 15- Air Bleeding Circuit

T3-1-22



1

Pg

Dr

2

3

4 Pi

Pps

Pd2

12

Pd1

10

1

2

Pg

Dr

TDCD-03-01-019 TDCD-03-0 1-019

3

4 Pi

Pps

Pd2

12

Pd1

10

a Pd1- Pump 1 Delivery Pressure Pd2- Pump 2 Delivery Pressure


Pi-

12-

34-

10- Ser vo Piston

Spring Sleeve A

Spool A Piston

T3-1-23

TDCD-03-01-020 TDCD-03-0 1-020

b

Pump Control Pressure Regulated by Maximum Pump 2 Flow Rate Limit Control Solenoid Valve

Pps- Torque Control Pressure Pg- Primary Pilot Pressure (From Pilot Pump)

12- Link

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Operation

Solenoid Valve The torque control control solenoid valve and the maximum maximum pump 2 flow rate limit control solenoid valve are equipped for the pump 2 regulator. The torque control control solenoid valve supplies torque torque control pressure Pps to both the pump 1 and pump 2 regulators and the pump delivery flow rate is reduced. The maximum pump 2 flow flow rate limit control control solenoid valve reduces pump control pressure Pi to the pump 2 regulator so that the upper limit of pump delivery flow rate is limited.

1. When in neutral, neutral, port P (5) is connected connected to output port (4) through the notch on spool (3). 2. When current flows flows to solenoid (7) (7) from MC (main (main controller), solenoid (7) is excited and pushes piston (6). 3. As piston (6) pushes spool (3), output port port (4) is connected to port T (8) through the notch on spool (3). 4. Therefore, pressure at output port (4) begins to decrease. 5. Diameter B is larger than diameter diameter A as for for the notch of spool (3). 6. Therefore, when pressure at output port (4) begins to decrease, spool (3) is move toward the right because of the force as Fsol (9)+P1×B+S1>P1×A+S2. 7. When pressure pressure at output port (4) (4) decreases and the following formula exists, Fsol (9)+P1×B+S1=P1×A+S2, spool (3) is stopped. P1:

Pressure at Output Port (4)

A and B: B: Pr Press essure ure Rece Receivi iving ng Area Area on Spoo Spooll (3)

T3-1-24

S1:

Spring 1 (1) Force (Force pushing spool (3) to the right)

S2:

Spring 2 (2) Force (Force returning spool (3) to the left)

Fsol:

Solenoid (7) Force

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Neutral state:

1

2

3

5

4

6 7

TDAA-03-01-001 TDAA-0 3-01-001

Operating state:

1

2

A

3

B

4

8

6 9

7

TDAA-03-01-002 TDAA-0 3-01-002

123-

Spring 1 Spring 2 Spool

45-

Output Port Port P

67-

T3-1-25

Piston Solenoid

89-

Port T Fsol

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Pilot Pump

2

1 a

Drive gear (1) is driven by the engine via the transmission, which rotates driven gear (2) as they are meshed together. 1-

Drive Gear

2-

Driven Gear

b T137-02-03-005 T137-02 -03-005

Pump Delivery Pressure Sensor

a-

Inlet Port

b-

O utlet Port Ou

This sensor detects the pump delivery pressures, which are used in order to control various operations. When oil pressure is applied to diaphragm (6), diaphragm (6) is deformed. The deformation of diaphragm (6) is detected as electrical signals.

34-

Ground Output

56-

Power Source (5V) Pressure Receiving Area (Diaphragm)

3

4

5

6

T157-02-03-010 T157-02 -03-010

Pump Control Pressure Sensor This sensor detects the pump control pressures, pressures, which are used in order to control various operations. When oil pressure is applied to diaphragm (7), diaphragm (7) is deformed. The deformation of diaphragm (7) is detected as electrical signals.

78-

Pressure Receiving Area (Diaphragm) Ground

9- Output 10- Power Source Source (5 V )

7

8

9

10

T176-03-01-023 T176-03 -01-023

T3-1-26

SECTION 3 COMPONENT OPERATION Group 1 Pump Device N Sensor (Engine Speed Sensor) The N sensor detects the engine speed, which is used to control various operations. The The N sensor is located close to the transmission teeth so that the sensor converts the number of teeth passing by the sensor into pulse signals, effectively sensing the engine speed. 11- Tooth 12- Output

12

13

11

13- Output

T178-03-01-020 T178-03 -01-020

T3-1-27

SECTION 3 COMPONENT OPERATION Group 1 Pump Device (Blank)

T3-1-28

SECTION 3 COMPONENT OPERATION Group 2 Swing Device Outline The swing device consists of valve valve unit (1), swing motor motor (2), and swing reduction gear (3). Valve unit (1) prevents the cavitation and the overload in the swing circuit. Swing motor (2) is a swash plate type axial plunger motor (with built-in swing parking brake), which is driven by pressure oil from the pump, and the t he rotation is transmitted to swing reduction gear (3). Swing reduction gear (3) converts swing motor (2) output into slow large torque to rotate the shaft. Thereby, the upperstructure is rotated.

1

2

3

T1V1-03-02-018 T1V1-03-0 2-018

1-

Valve Unit

2-

Swing Motor

3-

T3-2-1

Swing Reduction Gear

SECTION 3 COMPONENT OPERATION Group 2 Swing Device Swing Reduction Gear The swing reduction gear is a two-stage planetary planetary reduction gear. Ring gear (4) is attached to housing (7) and fixed to the upperstructure. Shaft (2) in swing motor (1) rotates first stage sun gear (11), whose rotating torque is transmitted to second stage sun gear (9) through first stage planetary gear (3) and first stage carrier (10). Second stage sun gear (9) rotates shaft (6) through second stage planetary gear (5) and second stage carrier (8).

Shaft (6) is engaged with the internal gear of the swing bearing fixed to the undercarriage in order to swing the upperstructure.

1 2 11 3

10

4

9

5

8

7

6

T1V1-03-02-018 T1V1-03-0 2-018

123-

Swing Motor Shaft (Swing Motor) First Stage Planetary Gear

456-

Ring Gear Second Stage Planetary Gear Shaft

789-

T3-2-2

Housing Second Stage Carrier Second Stage Sun Gear

10- First Stage Carrier 11- First Stage Sun Gear

SECTION 3 COMPONENT OPERATION Group 2 Swing Device Swing Motor The swing motor consists of swash swash plate (9), rotor (12), (12), plunger (6), valve plate (13), housing (11), and swing parking brake (14) (spring (1), brake piston (2), plates (3), friction plates (5), and swing parking brake selection valve (4)). Shaft (8) is connected to rotor (12) by a spline joint, and plunger (6) is inserted into rotor (12).

When pressure oil is supplied from f rom the pump, plunger (6) is pushed. As swash plate (9) is inclined, shoe (10) on the end of plunger (6) slides along swash plate (9) and rotor (12) rotates. The end of shaft (8) is connected to the first stage sun gear in the swing reduction gear by a spline joint. Therefore, the rotation rotation of shaft (8) is transmitted to the swing reduction gear.

1 2

13

3 14

12 4 11

5

10

6

9

8

7 T1V1-03-02-008 T1V1-03-0 2-008

1234-

Spring Brake Piston Plate Swing Parking Brake Selection Valve

56789-

Friction Plate Plunger Retainer Shaft Swash Plate

1011121314-

T3-2-3

Shoe Housing Rotor Valve Plate Swing Parking Brake

SECTION 3 COMPONENT OPERATION Group 2 Swing Device Swing Parking Brake The parking brake is a wet-type spring set hydraulic hydraulic released multi-disc brake. When the brake release pressure is routed to brake piston chamber (6), the brake is released. The brake release pressure pressure is supplied from the pilot pump only when either swing or front attachment is operated. In other cases (including engine stopping), the brake release pressure returns to the hydraulic oil tank, so that the brake is applied automatically by spring (1). When brake is released

When brake is applied

1. When the swing swing or front front attachment control lever lever is operated, the swing parking brake release spool in the signal control valve is shifted. Therefore, pilot pressure from the pilot pump is supplied to port SH (5).

1. When the swing or front attachment control control lever is returned to neutral, the swing parking brake release spool in the signal control valve is returned to neutral and pilot pressure to port SH (5) is not supplied.

2. Pilot pressure pressure to port SH (5) opens check valve valve (4) and acts on brake piston chamber (6).

2. Therefore, check valve (4) (4) is closed and the brake release pressure is released to the swing motor housing through orifice (3).

3. Consequently, Consequently, as brake piston piston (2) is pushed upward, upward, plate (8) and friction plate (7) are freed, so that the brake is released.

T3-2-4

3. Consequently, the spring (1) force acts on friction plates (7) engaging on the outer surface of rotor (9) and plates (8) engaging on the inner surface of the motor housing via brake piston (2), and the rotor (9) outer surface is secured by the friction force. When When the engine stops, the brake is applied automatically as pressure is not supplied to port SH (5).

SECTION 3 COMPONENT OPERATION Group 2 Swing Device

1 9 2 3 10 4 8 5

6

7

TDAA-03-02-008 TDAA-0 3-02-008 123-

Spring Brake Piston Orifice

45-

Check Valve Port SH (Brake Release Pressure)

678-

T3-2-5

Brake Piston Chamber Friction Plate Plate

9- Rotor 10- Swing Parking Brake Selection Valve

SECTION 3 COMPONENT OPERATION Group 2 Swing Device Valve Unit Valve unit (6) consists of make-up valve (2) and relief valve (1). Make-up valve (2) prevents cavitation in the circuit from occurring. Relief valve (1) prevents surge pressure in the circuit from occurring and protects the circuit from being overloaded.

1

2

Make-Up Valve During swing stopping operation, the swing motor is driven by inertial force of the upperstructure. The swing motor is turned forcibly in excess of oil flow rate from the pump, so that cavitation occurs in the motor motor.. In order to avoid this cavitation, when the swing circuit pressure becomes lower than pressure in the return circuit (port M (3)), poppet (5) opens, draws hydraulic oil, and compensates the lack of oil feed.

3

4 T107-02-04-013 T107-02 -04-013

12-

T3-2-6

Relief Valve Make-Up Valve

34-

Port M Control Valve

SECTION 3 COMPONENT OPERATION Group 2 Swing Device

4

5

6 2 2

3

1

12-

Relief Valve Make-Up Valve

34-

Port M Control Valve

TDCD-03-02-001 TDCD-03-0 2-001

56-

T3-2-7

Poppet Valve Unit

SECTION 3 COMPONENT OPERATION Group 2 Swing Device Relief Valve When starting or stopping swing operation, the swing circuit pressure becomes high. The relief valve prevents the circuit pressure from rising higher than the set pressure. 

Low-Pressure Low-Pressu re Relief Operation (Shockless (Shockless Function): Function): 1. Pressure at at port HP (swing circuit) circuit) is routed routed to oil chamber C (9) through orifice (2) in poppet (1).



2. Pressure oil oil in chamber C (9) flows to oil chamber A (8) through passage A (4), and to oil chamber B (7) through passage B (5).

High-Pressure Relief Operation (Overload Prevention): 1. After piston (6) reaches reaches the stroke end, spring (3) is compressed and the circuit pressure becomes the normal relief set pressure. 2. When pressure at port HP increases beyond the spring (3) set pressure, poppet (1) is opened and pressure oil flows to port LP.

3. As the pressure receiving area area in oil chamber B (7) is larger than that in oil chamber A (8), piston (6) moves to the left.

3. When pressure at port HP is reduced to the specified level, poppet (1) is closed by the spring (3) force.

4. As long as piston (6) keeps moving, moving, a pressure difference is developed between the front and rear of poppet (1) due to orifice (2). When this pressure difference is increased beyond the spring (3) force, poppet (1) is opened and pressure oil flows to port LP.. LP 5. When piston (6) reaches the stroke end, end, the pressure difference between the front and rear of poppet (1) disappears and poppet (1) is closed.

1

2

3

4

5

6

HP

LP

9

8

7 T178-03-02-005 T178-03 -02-005

HP - P or or t HP (Swing Circui t) t)

LP - Por t LP (Return Circuit)

123-

456-

Poppet Orifice Spring

Passage A Passage B Piston

789-

T3-2-8

Oil Chamber B Oil Chamber A Oil Chamber C

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Outline The control valve valve controls the oil pressure, pressure, flow rate, and flow direction in the hydraulic circuit. The major parts are the main relief relief valve, overload overload relief valve, flow combiner valve, anti-drift valve, flow rate control valve, regenerative valve, digging regenerative valve, boom lower meter-in cut valve, auxiliary flow combiner valve, bypass shut-out valve, and spools. The spools are operated by the pilot oil pressure.

As for the spools, in the 4-spool section, travel (right), bucket, boom 1, and arm 2 are arranged in that order as viewed from the machine front. In the 5-spool section, travel (left), auxiliary, boom 2, arm 1, and swing are arranged in that order as viewed from the machine front.

Control Valve 1

c

2 3

a

4 5

b

10 9 8 7 6

d T1V1-03-03-072 T1V1-03-0 3-072 a-

Machine Upper Side

b-

Machine Front Side

c-

4-Spool Section

d-

123-

Main Relief Valve (A Side) Travel (Right) Travel Bucket

456-

Boom 1 Arm 2 Swing

789-

Arm 1 Boom 2 Auxiliary

10- Trav Travel el (Left)

T3-3-1

5-Spool Section

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Layout of Control Valve

e

1

a

2

3

a

4

5

e

6

7

8

9

10

11

12

42

13 14

41 15

40

16 39 17 38

18 19

20

37 36 35

21

34

22 23

33 24

32

31

30

29

28

27

26

25

T1V1-03-03-021 T1V1-03-0 3-021

T3-3-2

SECTION 3 COMPONENT OPERATION Group 3 Control Valve 4-Spool Section

18

f

19, 22

13

10, 11

23

15, 17

16 7

g

20

14 T1V1-03-03-073 T1V1-03-0 3-073

a1-

Machine Upper Side

Load Check Valve (Travel (Left) Parallel Circuit) 2- Check Valve (Main Relief Circuit) 3- Main Relief Valves 4- Check Valve (Auxiliary Flow Combiner Circuit) 5- Auxiliary Flow Combiner Valve 6- Check Valve (Flow Combiner Circuit) 7- Flow Combiner Valve 8- Load Check Valve (Orifice) (Bucket) 9- Check Valve (Main Relief Circuit) 10- Bucket Flow Rate Control Valve (Poppet Valve) 11- Bucket Flow Rate Control Valve (Selector Valve) 12- Bucket Regenerative Valve

e-

Machine Lower Side

f-

13- Overload Relief Valve (Bucket: Rod Side) 14- Overload Relief Valve (Bucket: Bottom Side) 15- Boom Flow Rate Control Valve (Poppet Valve) 16- Boom Lower Meter-In Cut Valve 17- Boom Flow Rate Control Valve (Selector Valve) 18- Overload Relief Valve (Boom: Bottom Side) 19- Boom Anti-Drift Valve (Check Valve) 20- Overload Relief Valve (Boom: Rod Side) 21- Boom Regenerative Valve 22- Boom Anti-Drift Valve (Selector Valve)

Arm Roll-In Pressure Sensor

23- Arm 2 Flow Rate Control Valve (Selector Valve) 24- Load Check Valve (Arm 2 Tandem Ta ndem Circuit) 25- Bypass Shut-Out Valve 26- Arm 2 Flow Rate Control Valve (Poppet Valve) 27- Arm Regenerative Valve 28- Digging Regenerative Valve 29- Load Check Valve (Digging Regenerative Regenerativ e Circuit) 30- Arm 1 Flow Rate Control Valve (Poppet Valve) 31- Load Check Valve (Swing Circuit) 32- Arm 1 Flow Rate Control Valve (Selector Valve) 33- Load Check Valve (Arm Regenerative Regenerativ e Circuit)

T3-3-3

g-

Boom Raise Pressure Sensor

34- Arm Anti-Drift Valve (Selector Valve) 35- Overload Relief Valve (Arm: Bottom Side) 36- Arm Anti-Drift Valve (Check Valve) 37- Overload Relief Valve (Arm: Rod Side) 38- Check Valve (Digging Regenerative Circuit) 39- Load Check Valve (Boom 2 Parallel Circuit) 40- Auxiliary Flow Rate Control Valve (Poppet Valve) 41- Auxiliary Flow Rate Control Valve (Selector Valve) 42- Load Check Valve (Travel (Left) Tandem Tan dem Circuit)

SECTION 3 COMPONENT OPERATION Group 3 Control Valve

e

1

a

2

a

3

4

5 6

e

7

8

9

10

11

12

42

13 14

41 15

40

16 39 17 38

18 19

20

37 36 35

21

34

22 23

33 24

32

31

30

29

28

27

26

25

T1V1-03-03-021 T1V1-03-0 3-021

T3-3-4

SECTION 3 COMPONENT OPERATION Group 3 Control Valve 5-Spool Section

3

37

34, 36

1 30, 32

5

40, 41

28

35 T1V1-03-03-072 T1V1-03-0 3-072

a1-

Machine Upper Side


e-

Machine Lower Side



T3-3-5



e

1

a

2

a

3

4

5 6

e

7

8

9

10

11

12

42

13 14

41 15

40

16 39 17 38

18 19

20

37 36 35

21

34

22 23

33 24

32

31

30

29

28

27

26

25

T1V1-03-03-021 T1V1-03-0 3-021

T3-3-6


Section C-C A

B

3 C

C

D

D

E

E

F

F

G

G

H

H

I

I

J

J

4

5 7

A

a1-

Machine Upper Side


B

c-

T1V1-03-03-026 T1V1-03-0 3-026

T1V1-03-03-003 T1V1-03-0 3-003

Machine Lower Side



T3-3-7



e

1

a

2

a

3

4

5 6

e

7

8

9

10

11

12

42

13 14

41 15

40

16 39 17 38

18 19

20

37 36 35

21

34

22 23

33 24

32

31

30

29

28

27

26

25

T1V1-03-03-021 T1V1-03-0 3-021

T3-3-8


Section A-A

Section B-B

3

2 12 28

9

21

27 33 T1V1-03-03-001 T1V1-03-0 3-001

a1-

Machine Upper Side


c-

T1V1-03-03-002 T1V1-03-0 3-002

Machine Lower Side



T3-3-9



e

1

a

2

a

3

4

5 6

e

7

8

9

10

11

12

42

13 14

41 15

40

16 39 17 38

18 19

20

37 36 35

21

34

22 23

33 24

32

31

30

29

28

27

26

25

T1V1-03-03-021 T1V1-03-0 3-021

T3-3-10


Section D-D

Section E-E h

i

j

k

13

41 10 11

40

14

12 T1V1-03-03-004 T1V1-03-0 3-004

ae1-

Machine Upper Side Machine Lower Side


hi-

Travel (Left) Travel (Right (Right))

T1V1-03-03-005 T1V1-03-0 3-005

Jk-


Auxiliary Bucket


T3-3-11



e

1

a

2

a

3

4

5 6

e

7

8

9

10

11

12

42

13 14

41 15

40

16 39 17 38

18 19

20

37 36 35

21

34

22 23

33 24

32

31

30

29

28

27

26

25

T1V1-03-03-021 T1V1-03-0 3-021

T3-3-12


Section F-F

Section G-G l

m

22 37 19

39

16

17

15 38 20

21

26 28

T1V1-03-03-006 T1V1-03-0 3-006 a1-

Machine Upper Side


e-

Machine Lower Side

T1V1-03-03-007 T1V1-03-0 3-007 l-


Boom 2


T3-3-13

m-

Boom 1



e

1

a

2

a

3

4

5 6

e

7

8

9

10

11

12

42

13 14

41 15

40

16 39 17 38

18 19

20

37 36 35

21

34

22 23

33 24

32

31

30

29

28

27

26

25

T1V1-03-03-021 T1V1-03-0 3-021

T3-3-14


Section H-H

Section I-I n

o

p

34 18

27

36

31 24

32

23 30

35 T1V1-03-03-008 T1V1-03-0 3-008

ae1-

Machine Upper Side Machine Lower Side


no-

Arm 1 Arm 2

T1V1-03-03-009 T1V1-03 -03-009

P-


Swing


T3-3-15



e

1

a

2

a

3

4

5 6

e

7

8

9

10

11

12

42

13 14

41 15

40

16 39 17 38

18 19

20

37 36 35

21

34

22 23

33 24

32

31

30

29

28

27

26

25

T1V1-03-03-021 T1V1-03-0 3-021

T3-3-16


Section J-J 25

T1V1-03-03-010 T1V1-03-0 3-010

a1-

Machine Upper Side


e-

Machine Lower Side



T3-3-17



e

1

a

2

a

3

4

5 6

e

7

8

9

10

11

12

42

13 14

41 15

40

16 39 17 38

18 19

20

37 36 35

21

34

22 23

33 24

32

31

30

29

28

27

26

25

T1V1-03-03-021 T1V1-03-0 3-021

T3-3-18


Section K-K

Section L-L 8

K

6

K

L

L

Section M-M M

M

42

T1V1-03-03-027 T1V1-03-0 3-027

TDCD-03-03-030 TDCD-03-0 3-030

a1-

Machine Upper Side


e-

Machine Lower Side



T3-3-19



e

1

a

2

a

3

4

5 6

e

7

8

9

10

11

12

42

13 14

41 15

40

16 39 17 38

18 19

20

37 36 35

21

34

22 23

33 24

32

31

30

29

28

27

26

25

T1V1-03-03-021 T1V1-03-0 3-021

T3-3-20


Section N-N 1 N

N

TDCD-03-03-031 TDCD-03-0 3-031

T1V1-03-03-028 T1V1-03-0 3-028

a1-

Machine Upper Side


e-

Machine Lower Side



T3-3-21


SECTION 3 COMPONENT OPERATION Group 3 Control Valve Hydraulic Circuit Main Circuit Pressure oil from pump 1 (8) flows to the 4-spool section control valve. Pressure oil from pump 2 (9) flows to the 5-spool section sec tion control valve. The parallel circuits (2), (2), (10) are provided provided in each main circuit of 4-spool section and 5-spool section, and make the combined operation possible. In addition, the flow combiner circuit (7) is provided in both boom and arm circuits so that pressure oil from pump 1 (8) and pump 2 (9) are combined during a single operation. The main relief valve valve (1) is provided in the main main circuit (between the pump and the actuator). The main relief valve (1) prevents the pressure in the main circuit from exceeding the set pressure when the spool is operated (or when the control lever is operated). The overload relief relief valves (5), (12) are are is provided in the actuator circuits (between the control valve and the actuator) of boom, arm, bucket. The overload relief valves (5), (12) prevent surge pressure caused by external force in the actuator circuit does not exceed the set pressure when the spool is in neutral (with the control lever set in neutral).

T3-3-22

SECTION 3 COMPONENT OPERATION Group 3 Control Valve 1

2

15

3

14 4

5 6 13

12

11

7 10

9

8

TDCD-03-03-001 TDCD-03-0 3-001 1234-

Main Relief Valve 4-Spool Section Parallel Circuit Travel Trav el Motor (Right) Bucket Cylinder

5678-

Overload Relief Valve Boom Cylinder Flow Combiner Circuit Pump 1

9101112-

T3-3-23

Pump 2 5-Spool Section Parallel Circuit Swing Motor Overload Relief Valve

13- Arm Cylinder 14- Attachment 15- Trav Travel el Motor (Left) (Left)

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Pilot Operation Control Circuit Pressure oil (indicated with numbers) from the pilot valve acts on the spool in the control valve in order to move the spool. In the following operations, pressure oil moves the spool and is routed to the following selector valves. roll-in (4) operation, operation, pressure oil moves  During arm roll-in the arm spool and shifts the selector valve spool of the arm anti-drift valve (d). lower (2) operation, operation, pressure oil oil moves  During boom lower the boom 1 spool and shifts the selector valve spool of the boom anti-drift valve (c). (2) operation, the  In addition, during boom lower (2) divided pressure oil shifts bypass-shutout valve (e) and the boom 2 spool through the boom lower meter-in cut valve (b).  During auxiliary open operation (13) or auxiliary auxiliary close operation (14), pressure oil moves the spool and shifts auxiliary flow combiner valve (f). (Only machines equipped with optional parts) In addition, the air bleed circuit (a) is located in the upper of control valve and bleeds air automatically automatically..

T3-3-24

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Pilot Operation Control Circuit a

9

11

12 10

13

14 7 8

b

1 2

d

3

1

c

3

e

4 6

4

5

TDCD-03-03-027 TDCD-03-0 3-027

a-

Air Bleed Circuit

b-

Boom Lower Meter-In Cut Valve

cd-

Boom Anti-Drif t Valve Arm Anti-Dri Anti-Drift ft Valve

e-

1234-

Boom Raise Boom Lower Arm Roll-Out Arm Roll-In

5678-

Left Swing Right Swing Bucket Roll-In Bucket Roll-Out

9101112-

Travel (Left Forward) Travel Forward) Travel Tra vel (Left Reverse) Reverse) Travel Tra vel (Right Forward) Forward) Travel Tra vel (Right Reverse) Reverse)

13- Auxiliary (Open) 14- Auxiliary (Close)

T3-3-25

Bypass Shut-out Valve Valve

SECTION 3 COMPONENT OPERATION Group 3 Control Valve External Pilot Pressure Circuit  

 







Pressure in main relief valve valve (1) is increased by pilot pilot pressure (b) from solenoid valve unit (SG). Arm regenerative regenerative valve (7) and the arm 2 flow rate control valve (5) are shifted by pilot pressure (f) from solenoid valve unit (SC). Digging regenerative regenerative valve valve (4) is shifted shifted by pilot pressure (e) from solenoid valve unit (SF). Arm 1 flow rate control valve (8) is shifted by pilot pressure (g) from the arm 1 flow rate control valve control spool in the signal control valve. Flow combiner combiner valve (2) is shifted by pilot pressure pressure (c) from the flow combiner valve control spool in the signal control valve. Bucket flow rate rate control valve valve (3) is shifted shifted by pilot pressure (d) from the bucket flow rate control valve control spool in the signal control valve. Auxiliary flow rate rate control valve valve (9) is shifted by pilot pressure (h) from the auxiliary flow rate control solenoid valve (optional). (Only machines equipped with optional parts)

fNOTE:

In general, general, auxiliary flow combiner valve (10) and auxiliary flow rate control valve (9) are routed to the drain circuit. The auxiliary flow rate control solenoid valve is equipped for only the machine equipped with the optional parts.

T3-3-26

SECTION 3 COMPONENT OPERATION Group 3 Control Valve External Pilot Pressure Circuit a

b

1

10

2 3

c

9 d

h

4

5

e

g

6

f

8 7

TDCD-03-03-028 TDCD-03-0 3-028 abc-

123-

Pilot Pressure from Auxiliary (Optional) Pilot Pressure from Solenoid Valve Unit (SG) Pilot Pressure from Flow Combiner Valve Control Spool in Signal Control Valve

d-

Main Relief Valves Flow Combiner Valve Bucket Flow Rate Control Valve

456-

e-

Pilot Pressure from Bucket Flow Rate Control Valve Control Spool in Signal Control Valve Pilot Pressure from Solenoid Valve Unit (SF)

f-

h-

g-

Pilot Pressure from Solenoid Valve Unit (SC) Pilot Pressure from Arm 1 Flow Rate Control Valve Control Spool in Signal Control Valve

Digging Regenerative Valve Arm 2 Flow Rate Control Valve Bypass Shut-Out Valve

78-

Arm Regenerative Valve Arm 1 Flow Rate Control Valve

9-

T3-3-27

Pilot Pressure from Auxiliary Flow Rate Control Solenoid Valve (Optional)

Auxiliary Flow Rate Control Valve 10- Auxiliary Flow Combiner Valve

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Flow Combiner Valve

fNOTE:

The operation during combined operation of travel and arm roll-in is explained here.

7. Consequently, pressure oil from from pump 1 (8) is equally supplied to both left lef t and right travel motors and the machine can travel straight.

1. During combined operation arm roll-in and travel, pilot pressure shifts travel (right) spool (5), travel (left) spool (4), arm 1 spool (10), and arm 2 spool (7). 2. At the same time, time, the travel travel (right) pilot pressure shifts the flow combiner valve control spool in the signal control valve. 3. Pressure oil oil from the pilot pilot pump flows to port SL in the flow combiner valve through the flow combiner valve control spool and is routed to spool (1). 4. When pressure at port SL increases beyond beyond the spring (2) force, spool (1) compresses spring (2) and moves to the left. 5. Pressure oil oil from pump 1 (8) flows to to travel (right) (right) spool (5). In addition, pressure oil from pump 1 (8) flows to travel (left) spool (4) through spool (1). 6. Pressure oil oil from pump 2 (9) flows to to arm cylinder (11) through arm 1 spool (10) and moves the arm at this time.

a

1

2

Flow Combiner Valve

SL b

d

TDAA-03-03-057 TDAA-0 3-03-057

c

a-

Press Pr essur ure e Oil fro from m Pu Pump mp 1 (8)

b-

Pilot Pi lot Pr Press essur ure e fro from m Fl Flow ow Combiner Valve Control Spool

1-

Spool (Flow Combiner Valve)

2-

Spring

c-

T3-3-28

To Tra rav vel (L (Le eft ft)) Spo poo ol (4 (4))

d-

To Hy Hydr dra aul ulic ic Oi Oill Tank


3

4

2

1

5

6 b

SL

11

10

7

9

8 TDCD-03-03-029 TDCD-03-0 3-029

b-

Pilot Pressure from Flow Combiner Valve Control Spool

123-

Spool (Flow Combiner Valve) Spring Travel Trav el Motor (Left) (Left)

456-

Travel (Left) Spool Travel Spool Travel Tra vel (Right) Spool Travel Tra vel Motor (Right)

789-

T3-3-29

Arm 2 Spool Pump 1 Pump 2

10- Arm 1 Spool 11- Arm Cylinder

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Main Relief Valve The main relief valve valve prevents the pressure in the main main circuit from exceeding the set pressure when the actuator such as the motor or the cylinder is operated. Therefore, oil oil leak from hose and pipe joints joints and breakage of the actuator are prevented. Relief Operation 1. Pressure in in port HP (main circuit) circuit) is routed routed to pilot poppet (8) through orifice A (2) in main poppet (1) and orifice B (3) in seat (4). 2. When pressure in port HP reaches the set pressure of spring B (6), pilot poppet (8) is opened, pressure oil from passage A (5) flows along the external circumference of sleeve (11), and flows to port LP (hydraulic oil tank). 3. At this time, time, a pressure difference is caused between port HP and the spring chamber (10) due to orifice A (2). 4. When this pressure pressure difference difference reaches the set pressure of spring A (9), main poppet (1) is opened and pressure oil from port HP flows to port LP. LP. 5. Consequently Consequently,, the main circuit pressure pressure decreases. 6. When the main main circuit pressure decreases decreases to the specified level, main poppet (1) is closed by the force of spring A (9).

T3-3-30

SECTION 3 COMPONENT OPERATION Group 3 Control Valve During Normal Operation:

1

2

3

4

5

6

HP

LP

11

10

9

8

7

TDAB-03-03-020 TDAB-03 -03-020

During Relief Operation:

1

2

3

4

5

6

HP

LP

11

10

9

8

TDAB-03-03-021 TDAB-03 -03-021

HP - Ma Main Circuit

LP - Hydraulic Oil Tank

SG - P Piilot Pressure from Solenoid Valve Unit (SI)

123-

456-

789-

Main Poppet Orifice A Orifice B

Seat Passage A Spring B

T3-3-31

Piston Pilot Poppet Spring A

10- Spring Chamber 11- Sleeve

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Pressure Increasing Operation 1. When pilot pressure pressure from solenoid valve unit (SG) (SG) is routed to port SG, spring B (6) is compressed by piston (7). 2. Therefore, force of spring B (6) becomes strong. 3. Consequently, Consequently, as pressure required required in order order to open pilot poppet (8) is increased, the relief set pressure is increased.

T3-3-32

SECTION 3 COMPONENT OPERATION Group 3 Control Valve During Pressure Increasing Operation:

6

HP

SG

LP

8

7

HP - Ma Main Circuit


SG - P Piilot Pressure from Solenoid Valve Unit (SG)

6-

7-

8-

Spring B

Piston

T3-3-33

Pilot Poppet

T157-02-05-004 T157-02 -05-004

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Overload Relief Valve (with Make-Up Function) The overload relief relief valve is located in the boom, boom, arm, bucket, and auxiliary circuits. The overload relief valve prevents each actuator circuit pressure from rising excessively when the actuators are moved by external force. In addition, when the actuator circuit pressure decreases, the overload relief valve draws hydraulic oil from the hydraulic oil tank and prevents the occurrence of cavitation (make-up function). Relief Operation 1. Pressure in in port HP (actuator circuit) circuit) is routed routed to pilot poppet (8) through orifice (11) of piston (10). 2. When pressure in port HP reaches the set pressure of spring B (6), pilot poppet (8) is opened, pressure oil from passage A (5) flows along the external circumference of sleeve (3), and flows to port LP (hydraulic oil tank). 3. At this time, time, a pressure difference difference occurs between port HP and spring chamber (9) due to orifice (11). 4. When this pressure pressure difference difference reaches the set pressure of spring A (4), piston (10) and main poppet (2) are opened and pressure oil from port HP flows to port LP. 5. Consequently, Consequently, the actuator circuit circuit pressure decreases. 6. When the actuator actuator circuit pressure decreases decreases to the specified level, piston (10) and main poppet (2) are closed by the force of spring A (4).

T3-3-34

SECTION 3 COMPONENT OPERATION Group 3 Control Valve During Normal Operation:

1

2

3

4

5

6

HP

LP

11

10

9

8

7

T107-02-05-019 T107-02 -05-019

During Relief Operation:

2

3

4

5

6

HP

LP

11

10

9

HP - Ac Actuator Circuit


123-

456-

Make-Up Valve Main Poppet Sleeve

Spring A Passage A Spring B

8

789-

T3-3-35

T178-03-03-049 T178-03 -03-049

Spring C Pilot Poppet Spring Chamber

10- Piston 11- Orifice

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Make-Up Operation 1. When pressure in port HP (actuator circuit) circuit) decreases lower than pressure in port LP (hydraulic oil tank), sleeve (3) is moved to the right. 2. Hydraulic oil oil in port LP flows to port HP and cavitation is prevented. 3. When pressure in port HP increases to the specified pressure, sleeve (3) is closed by the force of spring C (7).

T3-3-36

SECTION 3 COMPONENT OPERATION Group 3 Control Valve During Make-Up Operation:

3

HP

LP

7

HP - Ac Actuator Circuit


3-

7-

Sleeve

Spring C

T3-3-37

T178-03-03-050 T178-03 -03-050

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Regenerative Valve The regenerative valves valves are provided provided in the boom lower, lower, arm roll-in, and bucket b ucket roll-in circuits. The regenerative valves increase cylinder speeds in order to prevent cylinder hesitation, and improve machine controllability. controllability. Boom Regenerative Valve, Bucket Regenerative Valve

fNOTE:

Operational principle of the boom regenerativ regenerativee valve is identical to that of the bucket regenerative valve. Therefore, the bucket generative generative valve is explained as an example.

a

Operation 1

1. Returning oil (b) from the bucket cylinder (1) rod side is routed to check valve (2) through hole (4) of bucket spool (3) during bucket roll-in operation. 2. At this time, time, when pressure in the cylinder (1) bottom side is lower than the rod side, check valve (2) is opened. 3. Consequently, Consequently, returning oil (b) (b) from the cylinder (1) rod side flows to the bottom b ottom side and is combined with pressure oil from pump 1. The combined pressure oil is delivered to the cylinder c ylinder (1) bottom side so that regenerative operation is done. This prevents cylinder hesitation and increases bucket roll-in operating speed during bucket roll-in operation.

3 2

TDCD-03-03-004 TDCD-03-0 3-004 a-

Pilot Pressure from Pump 1

12-

Bucket Cylinder Check Valve

T3-3-38

3-

Bucket Spool


b

4

3

c

2

TDCD-03-03-005 TDCD-03-0 3-005

b-

Returning Oil from Cylinder (1) Rod Side

c-

Pressure Oil to Cylinder (1) Bottom Side

2-

Check Valve

3-

Bucket Spool

4-

T3-3-39

Hole

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Arm Regenerative Valve 

During Normal Operation:



1. Returning oil (a) from the cylinder rod rod side flows to to chamber B (1) through notch (12) of arm 1 spool (5) during normal arm roll-in operation.

During Regenerative Operation: 1. When solenoid valve unit unit (SC) is activated by the signal from MC (main controller), spool (3) of the arm regenerative valve is shifted by pilot pressure. (Refer to SYSTEM / Control System.)

2. Pressure oil oil from chamber B (1) is divided divided into two directions. One flows to the hydraulic oil tank through notch (11) of arm 1 spool (5).

2. Pressure oil oil from chamber B (1) (cylinder rod rod side (a)) is blocked by spool (3) of the arm regenerative valve.

3. Therefore, as the pressure pressure at the cylinder (10) bottom side (c) is higher than the cylinder (10) rod side (a), check valve (4) is kept closed.

3. As only the circuit circuit through notch (11) of arm 1 spool (5) exists among the circuits which pressure oil from chamber B (1) flows to the hydraulic oil tank, pressure in chamber B (1) increases.

4. Consequently, Consequently, pressure oil from the cylinder (10) rod side (a) does not flow to the bottom side (c) so that regenerative operation is not done.

4. Therefore, the pressure at the cylinder (10) rod side (a) is higher than the cylinder (10) bottom side (c). 5. Consequently, pressure oil from the cylinder (10) rod side (a) opens check valve (4), is combined with pressure oil from pump 2 (8), and flows to the cylinder (10) bottom side (c). 6. Therefore, the cylinder operating operating speed is increased. 7. Pressure oil oil from pump 1 (7) flows to the boom raise spool of boom cylinder (6). Pressure oil from pump 2 (8) flows to the swing motor (9). Therefore, Therefore, boom raise speed and swing speed are kept.

During Regenerative Operation:

11 1 2

3

a

b

12

c

5

4

a-

Returning Oil from Arm Cylinder (10) Rod Side

b-

Pilot Pressure from Solenoid Valve Unit (SC)

c-

To Arm Cylinder (10) Bottom Side

12-

Chamber B Hole

3-

Spool (Arm Regenerative Valve)

45-

Check Valve Arm 1 Spool

T3-3-40

TDCD-03-03-006 TDCD-03-0 3-006

11- Notch 12- Notch

SECTION 3 COMPONENT OPERATION Group 3 Control Valve During Regeneration Operation:

6 10

5 9

b

4

3

8

7 TDCD-03-03-007 TDCD-03-0 3-007

b-

Pilot Pressure from Solenoid Valve Unit (SC)

3-

Spool (Arm Regenerati Regenerative ve Valve) Check Valve

4-

567-

Arm 1 Spool Boom Cylinder Pump 1

8 - Pump 2 9 - Swing Motor 10 - Arm Cylinder

T3-3-41

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Anti-Drift Valve The anti-drift valve is provided in in the circuits of the boom cylinder bottom side, arm cylinder rod side, and arm cylinder bottom side, and reduces the cylinder drift.

fNOTE:

Both boom and arm anti-drift valves valves are identical in structure.

Holding Operation 1. As pressure oil oil from the pilot pilot valve does not flow with the control lever set in neutral (the spool in neutral), selector valve (3) in anti-drift valve is not shifted.

1

2. Therefore, pressure in the boom cylinder (1) bottom bottom side (arm cylinder rod or bottom side) (a) is routed to check valve (2) (the spring (4) side) in the antidrift valve via selector valve (3). 3. Consequently, Consequently, as check valve valve (2) is pushed and and the return circuit from cylinder (1) is blocked, the cylinder (1) drift is reduced. 3

12-

T3-3-42

Boom Cylinder Anti-Drift Valve (Check Valve)

2

3-

TDCD-03-03-025 TDCD-03-0 3-025

Anti-Drift Valve (Selector Valve)

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Releasing Operation:

3

b

4

2 a

a-

Returning Oil from Cylinder (1) (Boom Cylinder: Bottom Side, Arm Cylinder: Rod or Bottom Side)

b-

To Main Spool

2-

C heck Valve Ch

3-

S elector Valve Se

4-

T3-3-43

S pring Sp

TDCD-03-03-008 TDCD-03-0 3-008

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Releasing Operation 1. Pressure oil oil from the pilot pilot valve (e) pushes piston (5) of the anti-drift valve and shifts selector valve (3) during arm roll-in, arm roll-out, or boom lower operation.

d

c

2. Pressure oil oil in the spring (4) chamber of check valve valve (2) is returned to the hydraulic oil tank through the passage of selector valve (3).

e

3. When pressure in the spring (4) chamber decreases and its pressure and the spring (4) force are lower than pressure in the cylinder (1) bottom side (a), check valve (2) moves upward (to the right in the circuit diagram). 4. Consequently, Consequently, returning oil from the boom cylinder (1) bottom side (arm cylinder rod side or bottom side) (a) flows to the spool (b). In addition, orifice (6) of selector valve (3) decreases pressure in the spring (4) chamber slowly so that check valve (2) is prevented from moving quickly and shock during arm roll-in or boom lower operation is reduced.

1

3

2

TDCD-03-03-026 TDCD-03-0 3-026

cd-

Pressure Oil from Pump 1 To Hydraulic Oil Tank

e-

Pressure Oil from Pilot Valve

12-

Boom Cylinder Anti-Drift Valve (Check Valve)

3-

Anti-Drift Valve (Selector Valve)

T3-3-44

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Releasing Operation:

5

e

3

6

b

4

2

a

a-

Returning Oil from Cylinder (1) (Boom Cylinder: Bottom Side, Arm Cylinder: Rod or Bottom Side)

be-

To Main Spool Pressure Oil from Pilot Valve

23-

Check Valve Selector Valve

4-

Spring

5-

T3-3-45

Piston

TDCD-03-03-009 TDCD-03-0 3-009

6-

Orifice

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Flow Rate Control Valve The flow rate control control valve is provided provided in the boom, arm bucket, and auxiliary circuits, restricts oil flow rate in the circuit during combined operation, and gives priority to other actuators. Each flow rate control valve is operated during combined operation as shown below. b elow. Flow Rate Control Valve Boom Arm 1 Arm 2 Bucket Aux uxil ilia iary ry

fNOTE:

Combined Operation Boom Lower (operation with the front attachment above ground (high pressure at bottom side)) Swing, Arm Roll-in Swing, Bo Boo om Ra Raiise, Arm Roll-In Boom Raise, Arm Roll-In Fro ront nt At Atta tach chme ment nt;; Au Auxi xili liar aryy

The arm 1 flow rate control valve valve is explained

here.

Normal Operation

1

1. Pressure oil oil from pump 2 (a) is routed routed to check valve valve (4) of poppet valve (3).

2

2. Normally, selector valve (2) is kept open so that pressure oil from pump 2 (a) opens check valve (4) and flows to the arm 1 spool (b) through selector valve (2).

3

3. When load in the actuator side is high, poppet valve valve (3) is opened and pressure oil from pump 2 (a) flows to the arm 1 spool (b).

4

4. Therefore, pressure oil flow flow rate flowing flowing to the arm 1 spool (b) increases and arm operating speed becomes fast.

a TDCD-03-03-010 TDCD-03-0 3-010 a-

Pressure Oil from Pump 2

12-

Arm Cylinder Selector Valve

T3-3-46

34-

Poppet Valve Check Valve

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Normal Operation (During Low Load) 4

3 b

c a

2 c

b TDCD-03-03-013 TDCD-03-0 3-013

a-


b-

To Arm 1 Spool

c-

To Hydraulic Oil Tank

2-

Selector Valve

3-

Poppet Valve

4-

Check Valve

Normal Operation (During High Load)

3

b

c a

2 c

b TDCD-03-03-014 TDCD-03-0 3-014 a-


b-

To Arm 1 Spool

2-

Selector Valve

3-

Poppet Valve

c-

T3-3-47


SECTION 3 COMPONENT OPERATION Group 3 Control Valve Flow Rate Control Operation

1

1. Selector valve (2) (2) of the arm 1 flow rate control control valve is shifted by pilot pressure from the arm 1 flow rate control valve control spool in the signal control valve.

6 2

2. Therefore, back pressure in poppet valve valve (3) increases and the force to close poppet valve (3) appears.

3

3. Consequently, Consequently, poppet valve (3) restricts flow rate rate to arm 1 spool (6) and pressure oil is supplied to the swing side which load pressure is higher.

d

a TDCD-03-03-011 TDCD-03-0 3-011

a-

Pres Pr essu sure re Oi Oill fr from om Pu Pump mp 2

d-

Pilott Pr Pilo Pres essu sure re fr from om Si Sign gnal al Control Valve

12-

Arm Cylinder Selector Valve

36-

Poppet Valve Arm 1 Spool

Boom Flow Control Valve e

d f

5

3

2

TDCD-03-03-012 TDCD-03-0 3-012 d-

f-

Pressure Oil from Boom 2 Spool

e-

Pilot Pressure from Signal Control Valve Pressure Oil from Pump 1

23-

Selector Valve Poppet Valve

5-

Boom Cylinder

T3-3-48

SECTION 3 COMPONENT OPERATION Group 3 Control Valve During Flow Rate Control Operation 3

b

d a

2 c

b TDCD-03-03-015 TDCD-03-0 3-015

a-


b-

To Arm 1 Spool

2-

Selector Valve

3-

Poppet Valve

c-

T3-3-49


d-

Pilot Pressure from Signal Control Valve

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Digging Regenerative Valve Valve The digging regenerative regenerative valve is provided provided in the return circuit of boom raise and functions func tions during combined operation of boom raise and arm roll-in. When the digging regenerative valve is shifted, pressure oil from the boom cylinder (6) rod side (return side) (c) flows through the digging regenerative valve. valve. This pressure oil is combined with pressure oil from pump 2 (8), and flows to arm 1 spool (9). Therefore, Therefore, speed of arm roll-in increases. (Refer to SYSTEM / Control System.)

Operation 1. When solenoid valve valve unit (SF) is activated by the signal from MC (main controller), pressure oil from the pilot pump flows to port SF through solenoid valve unit (SF). 2. Pressure oil oil (b) from port SF is routed to to the end of spool (4) through inner passage (2). 3. Spool (4) compresses spring (3) and moves downward. 4. Therefore, pressure oil from from the boom cylinder (6) rod side (return side) (c) opens check valve (1). This pressure oil is combined with pressure oil from pump 2 (8), and flows to arm 1 spool (9). 5. Consequently, as pressure oil flow rate flowing flowing to arm cylinder (10) increases, speed of arm roll-in increases.

a

2

1

SF

4 b c

3

TDCD-03-03-016 TDCD-03-0 3-016 a-

To Arm 1 Spool (9)

b-

Pilot Pressure from Solenoid Valve Unit (SF)

c-

Returning Oil from Boom Cylinder (6) Rod Side

12-

Check Valve Inner Passage

3-

Spring

4-

Spool (Digging Regenerative Valve)

T3-3-50


4

5

11 6

10

b

9

1

8

b-

Pilot Pressure from Solenoid Valve Unit (SF)

14-

Check Valve Spool (Digging Regenerative Valve)

567-

Boom 1 Spool Boom Cylinder Pump 1

7

8 - Pump 2 9 - Arm 1 Spool 10 - Arm Cylinder

T3-3-51

TDCD-03-03-017 TDCD-03-0 3-017

11 - Boom 2 Spool

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Boom Lower Meter-In Cut Valve Valve Boom lower meter-in cut valve (2) is provided in the th e boom lower circuit and functions with the boom flow control valve together. During boom lower operation with the front attachment above the ground, the boom flow rate control valve restricts pressure oil which flows to boom 1 spool (3) from pump 1 (8) and blocks pilot pressure to Boom 2 spool (11). Therefore, during during operation of boom lower lower and other actuator, the boom falls due to own weight by the t he regenerative circuit and uses pressure oil from the pump for other actuator so that speed of other actuator increases. (Refer to “Hydraulic “Hydraulic System”/ SYSTEM.) Operation (Jack-Up)

Operation (Boom Lower with Front Attachment above Ground) 1. During boom lower lower operation, pressure oil (d) from the pilot pump flows to boom 2 spool (11) from port PI9 (5) through port PI7 (4) and boom lower meter-in cut valve (2). 2. Pressure oil oil (return oil) from the boom cylinder (6) bottom side flows to the spring (13) chamber in boom lower meter-in cut valve (2) through orifice (12). 3. When pressure in the spring (13) chamber becomes larger than the spring (13) force, boom lower meterin cut valve (2) compresses spring (13) to move the left. 4. Therefore, as port PI9 (5) is connected connected to the hydraulic oil tank through boom lower meter-in cut valve (2), boom 2 spool (11) is returned to the neutral position. 5. Pressure oil oil from port PI7 (4) (4) flows to selector valve (1) in boom flow rate control valve through the spool of meter-in cut valve (2). 6. Selector valve (1) (1) in boom flow flow rate control control valve is shifted and pressure oil which flows to the boom 1 spool from pump 1 is reduced. (Refer to “Flow “Flow Control Valve”.) 7. Consequently, Consequently, during combined operation operation of boom lower and other actuator actuator,, more pressure oil is supplied to other actuator and speed of actuator increases.

T3-3-52

1. During jack-up operation, as pressure at the boom cylinder (6) bottom side decreases, therefore pressure in the spring (13) chamber decreases. 2. When pressure in spring (13) (13) chamber becomes becomes lower than the spring (13) force, boom lower meterin cut valve (2) moves to the right due to the spring (13) force. 3. Therefore, as pressure oil which acts to the selector valve (1) in boom flow rate control valve flows to the hydraulic oil tank through boom lower meter-in cut valve (2), selector valve (1) is returned to the original position. 4. Pressure oil oil from port PI7 (4) (4) flows to bypass bypass shutout valve (7) and boom 2 spool (11) from port PI9 (5) through boom lower meter-in cut valve (2). 5. Therefore, the neutral circuit circuit in 4-spool 4-spool section is blocked and pressure oil from pump 1 (8) flows to the bottom side of boom cylinder (6). 6. Therefore, during jack-up jack-up operation, the boom lower meter-in cut control is not operated. (Refer to “Hydraulic System”/ SYSTEM.)

SECTION 3 COMPONENT OPERATION Group 3 Control Valve During Boom Lower with Front Attachment above Ground

1 2 3

11

4 6 10

5

7

9

TDCD-03-03-018 TDCD-03-0 3-018

8 a

2

12 e

13

c

PI7

PI9

d

b

a-

Returning Oil from Boom Cylinder (6) Bottom Side

bc-

To Boom 2 Spool (11) To Switch Valve

de-

Boom Lower Pilot Pressure To Hydraulic Oil Tank

1-

Selector Valve (Boom Flow Rate Control Valve) Boom Lower Meter-In Cut Valve

3456-

Boom 1 Spool Port PI7 Port PI9 Boom Cylinder

78910-

Bypass Shut-Out Valve Pump 1 Pump 2 Arm Cylinder

2-

T3-3-53

TDCD-03-03-019 TDCD-03-0 3-019

11- Boom 2 Spool 12- Orifice 13- Spring

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Auxiliary Flow Combiner Valve

Auxiliary Flow Combiner Valve and Bypass Shut-Out Valve

a

The auxiliary flow combiner valve valve and the bypass shutout valve are provided in the 5-spool section circuit and the down the stream of 4-spool section circuit respectively. These valve functions differ depending on whether only the front attachment is single-operated or combinedoperated.

SM b

c

During Single Operation When attachment (8) is single operated, pressure oil from both pump 1 (5) and pump 2 (6) are combined. Therefore,, operating speed of attachment (8) increases. Therefore

2

1. When attachment (8) is single operated, operated, attachment pilot pressure (b) is routed to port SM and port SJ, and spools (1, 3) in the auxiliary flow combiner valve and bypass shut-out valve are shifted.

1

SN

2. When spool (3) in the bypass shut-out valve valve is shifted, the neutral circuit in 4-spool section (e) is blocked.

TDCD-03-03-020 TDCD-03-0 3-020

d

3. At this time, time, as spool (1) in the auxiliary auxiliary flow combiner valve is shifted, pressure oil (c) in pump 1 (5) flows to auxiliary spool (7) (a) through the auxiliary flow combiner valve (1).

ab-

To Auxiliar Auxiliaryy Spool (7) Attachment Pilot Pressure

cd-

Pressure Oil from Pump 1 (6) To Hydraulic Oil Tank

1-

Spool (Auxiliary Flow Combiner Valve)

2-

Check Valve

4. Consequently, Consequently, pressure oil in both pump 1 (5) and pump 2 (6) are combined so that operating speed of attachment (8) increases.

Bypass Shut-Out Valve e

fNOTE:

The external external shuttle valve is equipped for the the machine equipped with auxiliary flow rate combiner valve. When attachment is operated operated,, attachment pilot pressure (b) shifts the pump pump 1 flow rate rate control valve valve in signal control valve through the external shuttle valve. Therefore, Therefore, the displacement angle of pump 1 (5) increases and the pump delivery flow rate increases. (Refer to COMPONENT OPERATION / Pump Device, Signal Control Valve.)

SJ b

d

bd-

Attachment Pilot Pressure To Hydraulic Oil Tank

3-

Spool (Bypass Shut-Out Valve)

T3-3-54

3

e-

TDCD-03-03-021 TDCD-03-0 3-021

Neutral Circuit in 4-Spool Section


b

4

1 SM

SN

8

7 e

3 SJ

6

TDCD-03-03-022 TDCD-03-0 3-022

5

fNOTE:

The illustration shows auxiliary (open) operation.

b-

Attachment Pilot Pressure

e-

Neutral Circuit in 4-Spool Section

1-

Spool (Auxiliary Flow Combiner Valve) Spool (Bypass Shut-Out Valve Valve))

4-

Auxiliar y Flow Combiner Auxiliary Control Solenoid Valve Pump 1

3-

5-

678-

T3-3-55

Pump 2 Auxiliary Spool Attachment

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Auxiliary Flow Combiner Valve

During Combined Operation During combined operation of attachment (8) and boom, arm, bucket or travel (right), the auxiliary flow combiner valve should not be shifted. Therefore, boom, arm, bucket and the machine travel operating speed can be kept at the same speed during normal combined operation.

a

SM b

1. When attachment (8) is operated, attachment attachment pilot pressure (b) is routed to port SM in auxiliary flow combiner valve (1). 2. When the boom, arm, bucket or travel travel (right) are operated at the same time, pilot pressure (f) from the signal control valve is routed to port SN.

c

3. Pressure oil oil from port SM is acted on spool (1) of the auxiliary flow combiner valve to the open direction, and pressure oil from port SN and the spring (9) force are acted on that to the close direction.

2

9

4. As the force force to the close direction direction is larger, larger, spool (1) is kept closed. 5. Consequently, Consequently, pressure oil from pump 1 (5) is not combined with pressure oil from pump 2 (6) so that the machine travel operating speed can be kept at the same speed during normal combined operation.

1

SN f

TDCD-03-03-023 TDCD-03-0 3-023

abc-

To Auxiliar Auxiliaryy Spool (7) Attachment Pilot Pressure Pressure Oil from Pump 1 (5)

f-


1-

Spool (Auxiliary Flow Combiner Valve) Check Valve

9-

Spring

2-

T3-3-56


b f

4

1

SM

SN

10

8

7 11

3 SJ

6

TDCD-03-03-024 TDCD-03-0 3-024

5

fNOTE:

The illustration shows during auxiliary (open) (open) / bucket roll-out operation.

b-

Attachment Pilot Pressure

f-


1-

Spool (Auxiliar y Flow Combiner Valve) Spool (Bypass Shut-Out Valve Valve))

4-

Auxiliar y Flow Combiner Auxiliary Control Solenoid Valve Pump 1

3-

5-

678-

T3-3-57

Pump 2 Auxiliary Spool Attachment

10 - Bucket Cylinder 11 - Bucket Spool

SECTION 3 COMPONENT OPERATION Group 3 Control Valve (Blank)

T3-3-58

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve Outline The pilot valve controls controls pilot pressure oil in order order to move the spool in the control valve. The pilot valve outputs pressure pressure according to the control control lever stroke by PPC (Pressure Proportional Control Valve) function and moves the spool in the control valve. The 4-port pilot valves for front attachment attachment / swing and for travel are standard. The 2-port pilot valve is for auxiliary auxiliary (optional). 

Front Attachment / Swing Pilot Valve

Right

Left

Port No. 1 2 3 4 1 2 3 4

ISO IS O Co Cont ntro roll Pat atte tern rn Bucket Roll-Out Boom Lower Bucket Roll-In Boom Raise Swing (Right) Arm Roll- Out Swing (Left) Arm Roll-In P

Hita Hi tach chii Pat atte tern rn    

Arm Roll-In Swing (Right) Arm Roll- Out Swing (Left)

T

Hydraulic Symbol

1

3 2

P

4

4

TPPP-03-04-002 TPPP-03 -04-002

3

1

TPPP-03-04-001 TPPP-0 3-04-001

2 P-

T3-4-1

Port P T(Pressure Oil from Pilot Pump)

T Port T (To Hydraulic Oil Tank)

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve 

Travel Pilot Valve Port No. 1 2 3 4

Travel (Right Reverse) Travel (Right Forward) Travel (Left Forward) Travel (Left Reverse) P

T

T

P

Hydraulic Symbol

TPPP-03-04-003 TPPP-0 3-04-003 1

2 3

4 TPPP-03-04-002 TPPP-03 -04-002

3

4

2

1 TPPP-03-04-004 TPPP-0 3-04-004



Auxiliary Pilot Valve

Auxiliary

P-

Port No. 1 2 P


Port T (To Hydraulic Oil Tank)

Open Close

T

Hydraulic Symbol T

P 1

2 TDAA-03-04-007 TDAA-03 -04-007

1

P-

T3-4-2


2

TDAA-03-04-006 TDAA-0 3-04-006

Port T (To Hydraulic Oil Tank)

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve Front Attachment / Swing Pilot Valve

Operation (Front Attachment / Swing and Travel Pilot Valves)

1

The spool (7) head comes in contact contact with the upper surface of spring guide (4). Spring guide (4) is kept raised by return spring (6).

2

fNOTE:

3 4

Total lever strokes for front front attachment attachment and swing controls are determined by stroke dimension (E) of pusher (2). Tota Totall lever stroke for travel control is determined by stroke dimension (E) of cam (1).

5 6

E

7 8

TPPP-03-04-005 TPPP-0 3-04-005

Travel Tra vel Pilot Pilot Valv Valve e 1

E

2 3 4 5 6

7 8

TPPP-03-04-010 TPPP-0 3-04-010 12-

Cam Pusher

34-

Casing Spring Guide

56-

T3-4-3

Balance Spring Return Spring

78-

Spool Hole

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve Neutral (Output Curve: A to B): 1. When in neutral, neutral, spool (7) completely blocks pressure oil from port P (pilot pump). In addition, the output port is opened to port T (hydraulic oil tank) through the inner passage in spool (7).

E

a

F

D

2. Therefore, pressure in the output port is equal to that in port por t T. 3. When the control control lever is slightly slightly tilted, cam (1) is tilted and pusher (2) is pushed downward. Pusher (2) compresses return spring (6) along with sp ring guide (4) together.

C

4. At this time, as pressure in the output port is equal to that in port por t T, T, spool (7) moves downward due to the balance spring (5) force while keeping the lower surface of the spool (7) head in contact with spring guide (4).

A

b

B

T523-02-05-001 T523-02 -05-001 a-

5. This status continues continues until hole (8) on spool (7) is connected to port P.

T3-4-4

Pilot Pressure

b-

Control Lever Stroke

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve Front Attachment / Swing Pilot Valve 1

1

2

2

3

3

4

4

5

5

6

6

7 T

8 P a

7

T

7

T

8

P

8

P

a

a TPPP-03-04-015 TPPP-03 -04-015

TPPP-03-04-006 TPPP-0 3-04-006

Travel Tra vel Pilot Pilot Valve 1

1

2

2 T

3

3

7

4

4

8

5

5

6

6

P

a

T

T

7

7 P

8

P

8

a

a TPPP-03-04-016 TPPP-03 -04-016

TPPP-03-04-011 TPPP-0 3-04-011

P-

Port P

T-

Port T

a-

Output Port

12-

Cam Pusher

34-

Casing Spring Guide

56-


T3-4-5

78-

Spool Hole

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve During Metering or Decompressing (Output Curve: C to D) 1. When the control control lever is further tilted and pusher (2) is moved downward further, hole (8) on spool (7) is connected to port P and pressure oil in port P flows to the output port.

E

a

F

D

2. Pressure in in the output port is routed routed to the bottom surface of spool (7) so that spool (7) is pushed upward. C

3. When the force force to move move spool (7) upward upward is smaller than the balance spring (5) force, balance spring (5) is not compressed so that spool (7) is not raised and pressure in the output port increases. 4. As pressure in the output port increases further, further, the force to move spool (7) upward increases. When this force overcomes the balance spring (5) force, spool (7) compresses balance spring (5) and moves upward.

A

b

B

T523-02-05-001 T523-02 -05-001 a-

5. As spool (7) is moved upward, upward, hole (8) is closed so that pressure oil from port P stops flowing to the output port and pressure in the output port stops increasing. 6. As spool (7) is moved downward downward and and balance spring (5) is compressed, pressure routed to the bottom surface of spool (7) increases until pressure balances with the increasing spring force. This increasing pressure becomes pressure in the output port.

T3-4-6

Pilot Pressure

b-



1

2

2

7

3

7

3

T

T

4

4 8

5

8

5 6

6 P

P

7

7

T

T

P

8

P

8

a

a TPPP-03-04-007 TPPP-03 -04-007

TPPP-03-04-008 TPPP-0 3-04-008


1

2

2 T

T

7

3

3 P

4

P

4

8

5

7

8

5

6

6 a

a

T

7

T

7

P

P

8

8 a

a TPPP-03-04-012 TPPP-03 -04-012

TPPP-03-04-013 TPPP-0 3-04-013

P-

Port P

T-

Port T

a-

Output Port

12-

Cam Pusher

34-

Casing Spring Guide

56-


T3-4-7

78-

Spool Hole

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve Full Stroke (Output Curve: E to F) 1. When the control control lever is fully stroked, pusher (2) is moved downward until pusher (2) on the front attachment / swing pilot valve comes in contact with the casing (3) shoulder, or cam (1) on the travel pilot valve comes in contact with casing (3).

E

a

F

D

2. At this time, time, the bottom bottom surface of pusher (2) directly pushes spool (7). Therefore, Therefore, even if pressure in the output port increases further, hole (8) on spool (7) is kept open.

C

3. Consequently, Consequently, pressure in the output port is equal to that in port P.

A

b

B

T523-02-05-001 T523-02 -05-001 a-

T3-4-8

Pilot Pressure

b-



2 3 4 5 6

7 T

P

8

a TPPP-03-04-009 TPPP-03 -04-009


2

3 4 5 6

T

7 P

8 a TPPP-03-04-014 TPPP-03 -04-014 P-

Port P

T-

Port T

a-

Output Port

12-

Cam Pusher

34-

Casing Spring Guide

56-


T3-4-9

78-

Spool Hole

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve (Blank)

T3-4-10

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve Operation (Auxiliary Pilot Valve) The spool (7) head comes in contact contact with the upper surface of spring guide (4). Spring guide (4) is kept raised by return spring (6).

1

fNOTE:

E

Total lever stroke is determined determined by stroke stroke dimension (E) of cam (1). 2 3 4 5

6 7 8

TDAA-03-04-001 TDAA-0 3-04-001

12-

Cam Pusher

34-

Plate Spring Guide

56-

T3-4-11


78-

Spool Hole

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve 

Auxiliary Pilot Valve Neutral (Output Curve: A to B): 1. When the control control pedal is in neutral, neutral, spool (7) completely blocks pressure oil from port P. P. In addition, the output port is opened to port T (hydraulic oil tank) through the inner passage in spool (7).

a D

2. Therefore, pressure in the output port is equal to that in port por t T.

C

3. When the control control pedal is slightly depressed, cam (1) is moved and pusher (2) is pushed downward. Pusher (2) compress return spring (6) along with spring guide (4) together together.. 4. At this time, as pressure in the output port is equal to that in port por t T, T, spool (7) moves downward due to the balance spring (5) force while keeping the lower surface of the spool (7) head in contact with spring guide (4).

A

b

B

T1F3-03-09-004 T1F3-03 -09-004 a-

5. This status continues continues until hole (8) on spool (7) is connected to port P.

fNOTE:

The pedal pedal stroke while hole (8) on spool (7) is connected to port P is play.

T3-4-12

Pilot Pressure

b-

Pusher Stroke

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve

1

2

3 4 5

T

6 7

P

8

a

TDAA-03-04-001 TDAA-0 3-04-001

1 T

7

2

8 P

3

a

4 T

5

6 7

P

8 a

TDAA-03-04-002 TDAA-0 3-04-002

P-

Port P

T-

Port T

a-

Output Port

12-

Cam Pusher

34-

Plate Spring Guide

56-


T3-4-13

78-

Spool Hole

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve During Metering or Decompressing (Output Curve: C to D) 1. When the control control pedal is further depressed and pusher (2) is moved downward further, hole (8) on spool (7) is connected to port P and pressure oil in port P flows to the output port.

a D

2. Pressure in the output port acts on the bottom surface of spool (7) so that spool (7) is pushed upward. C

3. When the force force to move move spool (7) upward upward is smaller than the balance spring (5) force, balance spring (5) is not compressed so that spool (7) is not raised and pressure in the output port increases. 4. As pressure in the output port increases further, further, the force to move spool (7) upward increases. When this force overcomes the balance spring (5) force, balance spring (5) is compressed so that spool (7) is moved upward.

A

b

B

T1F3-03-09-004 T1F3-03 -09-004 a-

5. As spool (7) is moved upward, upward, hole (8) is closed so that pressure oil from port P stops flowing to the output port and pressure in the output port stops increasing. 6. As spool (7) is moved downward downward and and balance spring (5) is compressed, pressure acting on the bottom surface of spool (7) increases until pressure balances with the increasing spring force. This increasing pressure becomes pressure in the output port.

T3-4-14

Pilot Pressure

b-

Pedal Stroke

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve

1 T

7

2

8 P

3

a

4 T

5

6 7

P

8 a

TDAA-03-04-004 TDAA-0 3-04-004

1 T

7

2

8 P

3

a

4 T

5

6 7

P

8 a

TDAA-03-04-003 TDAA-0 3-04-003

P-

Port P

T-

Port T

a-

Output Port

12-

Cam Pusher

34-

Plate Spring Guide

56-


T3-4-15

78-

Spool Hole

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve Shockless Function (Only for Travel Travel Pilot Valve) The travel pilot valve valve has damper (1) enabling damping damping of the speed change shock by travel control lever (4). Damper (1) is composed of support (5), gear 1 (9) and gear 2 (8) and others. Gear 1 (9) is connected to support (5). Support (5) is secure to bracket (6) by spring pin (2). Travel Travel control lever (4) and travel pedal (3) are secure to bracket (6). Therefore, Therefore, support (5) rotates transversely around pin (7) according to movement of travel control lever (4).

1

3

2 A

4

Operation

5

1. If travel control control lever (4) is released white traveling, spring force of the return spring returns travel control lever (4) to the neutral position.

6 7

2. At this time, gear 1 (9) and and gear 2 (8) inside damper (1) receive opposing force due to friction.

8 9

A

3. Consequently, Consequently, as travel control lever (4) gradually returns to the neutral position, the extent of sudden stop at the time of abrupt release of travel control lever (4) is reduced.

T1M7-03-04-002 T1M7-03 -04-002

Section A-A

2

5 1

7

12345-

T3-4-16

Damper Spring Pin Travel Trav el Pedal Pedal Travel Trav el Control Lever Support

T1M7-03-04-003 T1M7-03 -04-003 6789-

Bracket Pin Gear 2 Gear 1

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Outline The travel device consists consists of travel motor motor (4), travel reduction gear (2), and travel brake valve (1). Travel Trav el motor (4) is a swash plate plate type variable displacement axial plunger motor and equipped with a parking brake (a wet-type spring set hydraulic released multi-disc brake). Travel Travel motor (4) is driven by pressure oil from the pump and transmits the rotation power to travel reduction gear (2).

Travel reduction gear (2) is a three-stage planetary Travel reduction gear, converts the travel motor (4) rotation power to a slow-large torque, and rotates sprocket (3) and the track. Travel Trav el brake valve (1) (1) protects the travel circuit circuit from being overloaded and prevents the occurrence of cavitation.

1

2

3

4 1-

Travel Trav el Brake Valve

2-

Travel Reductio Reduction n Gear

T1V1-03-05-001 T1V1-03-0 5-001 3-

T3-5-1

Sprocket

4-

Travel Motor

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Travel Tr avel Reduction Gear The travel reduction gear gear is a three-stage planetary reduction gear. The travel motor motor rotates propeller shaft (7). This rotation is transmitted to ring gear (1) through first stage planetary gear (8), first stage carrier (6), second stage sun gear (5), second stage planetary gear (9), second stage carrier (4), third stage sun gear (3), third stage planetary gear (10), and third stage carrier (2).

Housing (14) of the travel motor is secured to the track frame with bolts. In addition, housing (14) is secured to drum (13) via bearing (15) with bearing nut (11). Third stage carrier (2) is connected to housing (14) by a spline joint. Ring gear (1), drum (13), and sprocket (12) are secured with bolts respectively. Therefore, when ring gear (1) rotates, drum (13) and sprocket (12) also rotate.

15

1

2

3

4

5

6

7

14

13

11

10

9

8

12 T178-03-05-001 T178-03 -05-001 1234-

Ring Gear Third Stage Carrier Carrier Third Stage Sun Sun Gear Second Stage Carrier

5678-

Second Stage Sun Gear First Stage Carrier Propeller Shaft First Stage Planetary Gear

9101112-

T3-5-2

Second Stage Planetary Gear Third Stage Planetary Gear Bearing Nut Sprocket

13- Drum 14- Housing 15- Bearing

SECTION 3 COMPONENT OPERATION Group 5 Travel Device (Blank)

T3-5-3

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Travel Motor The travel motor motor is a swash plate type variable displacement axial plunger motor, and consists of valve plate (6), swash plate (4), rotor (2), plunger (5), and shaft (1). Shaft (1) is connected to rotor (2) by a spline joint into which plunger (5) is inserted.

When pressure oil is supplied from f rom the pump, plunger (5) is pushed. As swash plate (4) is inclined, shoe (3) on the end of plunger (5) slides along swash plate (4) and rotor (2) rotates.

1

2

6

3

4

5 T1V1-03-05-002 T1V1-03-0 5-002

12-

Shaft Rotor

34-

Shoe Swash Plate

5-

T3-5-4

Plunger

6-

Valve Plate

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Operation 1. Pressure oil oil flows to port port B in valve plate plate (6), enters one side in rotor (2), and pushes plunger (5). 2. This force and inclination of swash plate (4) make shoe (3) slide on swash plate (4) in order to rotate rotor (2) and output shaft (7). 3. As rotor (2) (2) rotates, when plungers (5) reach reach port A, pressure oil is returned to the hydraulic oil tank. 4. Whether forward travel travel or reverse reverse travel depends on whether pressure oil is supplied to port A or port B.

A

A

B

B

6 2 5

7

4

3

6 T183-03-05-009 T183-03 -05-009

A-

Port A (Pressure oil from main pump or returning oil to hydraul hydraulic ic oil tank)

B-

Port B (Pressure oil from main pump or returning oil to hydraulic oil tank)

23-

Rotor Shoe

45-

Swash Plate Plunger

6-

T3-5-5

Valve Plate

7-

Output Shaft

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Parking Brake The parking brake is a wet-type spring set hydraulic hydraulic released multi-disc brake. The brake is released when the brake release pressure oil is routed to brake piston chamber (a). The parking brake is automatically automatically applied unless the travel function is operated. Friction plates (2) and plates (3) are connected to housing (1) of the travel motor and rotor (4) by a spline joint respectively. When brake is released

When brake is applied

1. When the travel travel control lever lever is operated, operated, pressure oil from the main pump is routed to port AV or BV in the travel motor through the control valve.

1. When the travel travel control lever lever is returned to neutral, counterbalance valve spool (8) in the travel brake valve is returned to neutral.

2. This pressure oil shifts counterbalance counterbalance valve valve spool (8) in the travel brake valve and is routed to brake piston (5) through the notch on counterbalance valve spool (8).

2. As pressure oil oil routed to brake piston (5) is returned to the drain circuit through orifice (6) in brake piston (5), brake piston (5) is returned by disc spring (7).

3. Consequently, Consequently, as brake piston piston (5) is pushed, plates (3) and friction plates (2) become freed each other so that the brake is released.

3. Consequently, the spring force force acts on plate (3), which is engaged with the external circumference of rotor (4), and on friction plate (2), which is engaged with the inside of housing (1) of the travel motor through brake piston (5). Therefore, the external circumference of rotor (4) is secured with friction force.

T3-5-6

SECTION 3 COMPONENT OPERATION Group 5 Travel Device

When brake is applied:

a

When brake is released:

1

2

2 3

3

4

7

7 6

BV

a

5

5

1

AV b

4

8

TDAA-03-05-005 TDAA-0 3-05-005 AV- Port AV (Pressure oil from main pump)

BV- Port BV (Pressure oil from main pump)

a-

Brake Piston Chamber

b-

To Brake Piston

12-

34-

56-

Brake Piston Orifice

78-

Disc Spring Counterbalance Valve Spool

Housing Friction Plate

Plate Rotor

T3-5-7

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Travel Brake Valve The travel brake valve valve is located on the travel travel motor head and consists of the following valves. 

Counterbalance Valve (2): Counterbalance valve (2) ensures smooth start / stop travel operation and prevents the machine from running away when traveling on a down slope. In addition, counterbalance valve (2) routes the travel motor operating pressure oil in the high-pressure port (AV (A V or BV) BV ) to the parking park ing brake.



Check Valve (3): Check valve (3) assists the counterbalance valve (2) operation and prevents cavitation in the motor circuit.



Overload Relief Valve (6): Overload relief valve (6) prevents the occurrence of overload and surge pressure in the motor circuit and reduces shock loads developed when stopping travel operation.



Shuttle Valve (1): Shuttle valve (1) routes the travel motor operating pressure oil in high pressure port (AM or BM) to travel motor displacement angle control valve (5).



Travel Motor Displacement Angle Control Travel Control Valve Valve (5): Travel Tra vel motor displacement displacement angle control valve valve (5) delivers pressure oil routed by shuttle valve (1) for piston operation to the piston through orifice (4) (for slow / fast speed).



Orifice (4) (for slow slow / fast speed): Orifice (4) makes the travel mode control (displacement angle control) smooth.

T3-5-8


A

1

2

3

1 Section A-A

T1V1-03-05-003 T1V1-03-0 5-003

A

6 12-

Shuttle Valve Counterbalance Valve

34-

Check Valve Orifice

5 5-

T3-5-9

Travel Motor Displacemen Travel Displacementt Angle Control Valve

4 6-

Overload Relief Valve

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Counterbalance Valve 

While Traveling 1. When pressure oil oil from the control control valve enters port BV (8), pressure oil flows around the outer surface of spool (9), unseats check valve BC (7), and flows further to motor port BM (6). 2. On the other hand, hand, returning oil from from the travel travel motor is routed to motor port AM (4). However, However, its passage is blocked by check valve AC (3) and spool (9). 3. When pressure in port BV (8) (8) increases further, pressure oil is routed to chamber B (10) through orifice (f) (f ) in spool (9) and moves spool (9) to the right. 4. Consequently, Consequently, returning oil from from the travel travel motor flows to port AV (1) through notch (h) on spool (9). As pressure oil starts flowing at this stage, the travel motor starts rotating. 5. When the travel travel control lever lever is returned to neutral, spool (9) is returned to the original position by the spring force and blocks the oil passage so that the travel motor rotation is stopped.



While Descending a Slope 1. When the machine machine descends a slope, the travel motors are forcibly rotated by the machine self weight like a pump. 2. If the travel motor motor draws oil, oil pressure pressure in port BV (8) and chamber B (10) decrease. Spool (9) moves to the left so that returning oil from the travel motor is reduced. 3. Therefore, oil pressure in motor port AM (4) increases and functions the travel motor brake. 4. Once pressure oil oil is reduced, reduced, pressure in port BV (8) increases again and moves spool (9) to the right. By repeating this (hydraulic brake operation), the machine is prevented from running away away..

T3-5-10

SECTION 3 COMPONENT OPERATION Group 5 Travel Device When travel operation is neutral:

8

9

1

2

10

6

4

7

3

TDAA-03-05-003 TDAA-0 3-05-003

5

During travel operation:

10

8

9

1

2

h

6

4

f

7

3

TDAA-03-05-002 TDAA-0 3-05-002

5 123-

Port AV Chamber A Check Valve AC

456-

Motor Port AM Overload Relief Valve Motor Port BM

789-

T3-5-11

Check Valve BC Port BV Spool (Counterbalance Valve)

10- Chamber B

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Overload Relief Valve When the circuit pressure increases over the set pressure, the overload relief valve is opened and high pressure oil is relieved to the low-pressure side, so that the travel motor is protected from being b eing overloaded. In addition, overload relief valve relieves the shock loads developed due to inertia force when stopping the travel motor. When the travel motor draws pressure oil like a pump, check valve BC (10) is unseated (make-up operation) and prevents the cavitation. Operation (Relief Operation)

Operation (Make-Up Operation)

1. Pressure oil oil in the travel travel circuit is routed routed to poppet (5) through motor port BM (9) (or motor port AM (3)).

1. When the machine machine descends a slope, the travel travel motors are forcibly rotated by the machine self weight like a pump.

2. Pressure oil oil flows to the spring (7) chamber through orifice (4) in poppet (5).

2. When pressure in the port BV (1) (or port AV (2)) circuit becomes lower than pressure in the return circuit (motor port BM (9) or motor port AM (3)), check valve BC (10) is opened, draws hydraulic oil, and compensates the lack of oil feed.

3. Pressure oil oil flowing to the spring (7) chamber is routed to piston (6) through orifice (8) and moves piston (6) upward. 4. As long as piston (6) keeps moving, moving, a pressure difference is developed between the front and rear of poppet (5). When this pressure difference is increased beyond the spring (7) force, poppet (5) is opened and pressure oil flows to the hydraulic oil tank. (Shockless Function) 5. When piston (6) reaches the stroke end, end, the pressure difference between the front and rear of poppet (5) disappears and poppet (5) is closed. 6. Under this condition, condition, normal relief pressure pressure is set. 7. When the pressure pressure in the travel circuit circuit increases beyond the spring (7) force, poppet (5) is opened and pressure oil at the relief set pressure flows to the hydraulic oil tank. 8. As described above, relief operation in two-stages prevents the travel motor from being overloaded and reduces shocks developed in the circuit when stopping the travel motor.

T3-5-12

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Relief Operation (at Port BV Side):

1

2

10

9

3

4

4

5

5

6

6

7

7

8

123-

Port BV Port AV Motor Port AM

456-

Orifice Poppet Piston

8

789-

T3-5-13

Spring Orifice Motor Port BM

TDAA-03-05-004 TDAA-0 3-05-004

10- Check Valve BC

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Travel Mode Control The displacement angle of swash swash plate (10) is changed by piston (11) movement in order to shift the travel mode. 

Slow Speed 1. When the travel travel mode switch is is in the Slow position, MC (main controller) does not send the signals to solenoid valve unit (SI) so that pilot pressure is not routed to pilot port (4) of the travel motor displacement angle control valve (3). Spool (5) of the travel motor displacement angle control valve (3) is pushed upward by spring (6). 2. Therefore, as pressure oil in the high-pressure side motor port AM (2) or BM (1) is not routed to piston (11), the displacement angle is held to the maximum. Therefore, the stroke of plunger (9) is increased and the travel motor rotates at slow speed.

T3-5-14


7 1, 2

4

3

5

6 a

8 9

10

11

TDAA-03-05-006 TDAA-0 3-05-006 a-

To Drain

123-

Motor Port BM Motor Port AM Travel Trav el Motor Displacement Displacement Angle Control Valve

4567-

Pilot Port Spool Spring Piston Control Shuttle Valve

891011-

T3-5-15

Orifice (for slow / fast speed) Plunger Swash Plate Piston

SECTION 3 COMPONENT OPERATION Group 5 Travel Device 

Fast Speed 1. When the travel travel mode switch is is set to the Fast Fast position, MC (main controller) sends the signals to solenoid valve unit (SI) in response to travel loads. (Refer to SYSTEM / Control system / Travel Travel Motor Displacement Angle Control.) 2. Pilot pressure pressure is supplied from pilot port (4) of travel travel motor displacement angle control valve (3) and moves spool (5) downward. 3. Pressure oil in the high-pressure side motor port AM (2) or BM (1) flows through the inner passage of travel motor, shuttle valve (7), spool (5), and orifice (8). Pressure oil flowing through orifice (8) is gradually routed to piston (11). 4. Therefore, piston (11) pushes swash plate plate (10) so that the displacement angle of swash plate (10) is reduced. As the stroke of plunger (9) is reduced, the travel motor rotates at fast speed.

T3-5-16


7

b

1, 2

4

3

5

6

8

9

10

11

TDAA-03-05-007 TDAA-0 3-05-007 b-

Pressure oil from motor port AM (2) or BM (1)

123-

Motor Port BM Motor Port AM Travel Trav el Motor Displacement Displacement Angle Control Valve

4567-

Pilot Port Spool Spring Piston Control Shuttle Valve

891011-

T3-5-17

Orifice (for slow / fast speed) Plunger Swash Plate Piston

SECTION 3 COMPONENT OPERATION Group 5 Travel Device (Blank)

T3-5-18

SECTION 3 COMPONENT OPERATION Group 6 Signal Control Valve Outline The signal control valve valve is provided in the pilot pilot circuit between the pilot valve and the control valve, and controls various signal pressure used to regulate the pumps and valves. The major components of of signal control valve valve are the shuttle valve, shockless valve (1), pump 1 flow rate control valve (6), pump 2 flow rate control valve (3), bucket flow rate control valve control spool (2), flow combiner valve control spool (4), swing parking brake release spool (5), and arm 1 flow rate control valve control spool (7).

A

Section A-A A

1

a

7

2

6

3

5

4

T178-03-06-002 T178-03 -06-002

TDCD-03-06-001 TDCD-03-06 -001

a-

Pilot Valve Side

12-

Shockless Valve Bucket Flow Rate Control Valve Control Spool

34-

Pump 2 Flow Rate Control Valve Flow Combiner Valve Control Spool

56-

T3-6-1

Swing Parking Brake Release Spool Pump 1 Flow Rate Control Valve

7-

Arm 1 Flow Rate Control Valve Control Spool

SECTION 3 COMPONENT OPERATION Group 6 Signal Control Valve Pilot Port Pilot Valve Side Port Name Port A Port B Port C Port D Port E Port F Port G Port H Port I Port J Port K Port L Port M Port N Port SA Port SB Port PI Port PH Port SH Port DF

Connected to

Remarks Boom Raise Pilot Pressure Boom Lower Pilot Pressure Arm Roll-Out Pilot Pressure Arm Roll-In Pilot Pressure Swing (Left) Pilot Pressure Swing (Right) Pilot Pressure Bucket Roll-In Pilot Pressure Bucket Roll-Out Pilot Pressure Travel (Left Forward) Pilot Pressure Travel (Left Reverse) Pilot Pressure Travel (Right Forward) Pilot Pressure Travel (Right Reverse) Pilot Pressure Auxiliary Open Pilot Pressure Auxiliary Close Pilot Pressure Pump 1 Control Pressure Pump 2 Control Pressure Primary Pilot Pressure Plug Brake Release Pressure Returning to Hydraulic Oil Tank

Right Pilot Valve Right Pilot Valve Left Pilot Valve Left Pilot Valve Left Pilot Valve Left Pilot Valve Right Pilot Valve Right Pilot Valve Travel Pilot Valve Travel Pilot Valve Travel Pilot Valve Travel Pilot Valve Auxiliary Pilot Valve Auxiliary Pilot Valve Pump 1 Regulator Pump 2 Regulator Pilot Shut-Off Solenoid Valve Swing Parking Brake Hydraulic Oil Tank

T3-6-2

SECTION 3 COMPONENT OPERATION Group 6 Signal Control Valve

Pilot Valve Side C

PH A

E

M

D

B

H

SB G

F N PI I

K

J

SH DF

SA

L TDCD-03-06-002 TDCD-03-0 6-002

Control Valve Side 3

SM

5

1 13 2

4

SK

SE

S3

8

14

6

7 SN

9

10 11 SL TR

12

SP TDCD-03-06-003 TDCD-03-0 6-003

T3-6-3


Control Valve Side Port Name Port 1 Port 2 Port 3 Port 4 Port 5 Port 6 Port 7 Port 8 Port 9 Port 10 Port 11 Port 12 Port 13 Port 14 Port SE Port SM Port SN Port SP Port SL Port SK Port S3 Port TR

Connected to

Remarks Boom Raise Pilot Pressure Boom Lower Pilot Pressure Arm Roll-Out Pilot Pressure Arm Roll-In Pilot Pressure Swing (Left) Pilot Pressure Swing (Right) Pilot Pressure Bucket Roll-In Pilot Pressure Bucket Roll-Out Pilot Pressure Travel (Left Forward) Pilot Pressure Travel (Left Reverse) Pilot Pressure Travel (Right Forward) Pilot Pressure Travel (Right Reverse) Pilot Pressure Auxiliary Open Pilot Pressure Auxiliary Close Pilot Pressure Returning to Hydraulic Oil Tank Returning to Hydraulic Oil Tank Plug Returning to Hydraulic Oil Tank Flow Combiner Valve Control Pressure Bucket Flow Rate Control Valve Control Pressure -

Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve Hydraulic Oil Tank Hydraulic Oil Tank Hydraulic Oil Tank Control Valve Control Valve Pressure Sensor (Swing) Pressure Sensor ( Travel)

Machine with Attachment (Pulverizers 1 to 5 and Crushers 1 to 5) Equipped Port SM Port SN SN Port SP

Auxiliary Flow Combiner Solenoid Valve Auxiliary Fl Flow Ra Rate Co Combiner Co Control Valve Auxiliary Flow Combiner Solenoid Valve

T3-6-4

Auxiliary Flow Combiner Valve Control Pressure Auxiliary Flow Co Combiner Valve Co Control Pr Pressure Pump 1 Control Pressure


Pilot Valve Side C

PH A

E

M

D

B

H

SB G

F N PI I

K

J

SH DF

SA

L TDCD-03-06-002 TDCD-03-0 6-002

Control Valve Side 3

SM

5

1 13 2

4

SK

SE

S3

8

14

6

7 SN

9

10 11 SL TR

12

SP TDCD-03-06-003 TDCD-03-0 6-003

T3-6-5

SECTION 3 COMPONENT OPERATION Group 6 Signal Control Valve (Blank)

T3-6-6

SECTION 3 COMPONENT OPERATION Group 6 Signal Control Valve Shuttle Valve The shuttle valve selects pilot pressure used used to perform each operation and routes pilot pressure to the th e corresponding control valves and/or control spools. The spools corresponding to each each operation are as follows: Pump 1 Flow Rate Control Valve Boom Raise Boom Lower Arm Roll-Out Arm Roll-In Bucket Roll-In Bucket Roll-Out Swing (Right) Swing (Left) Travel Tra vel (Right) Travel Tra vel (Left) Auxiliary

Pump 2 Flow Rate Control Valve

Bucket Flow Rate Control Valve Control Spool -







-













-

-



-





-

-



*





fNOTE:

*: As for the matche with attachment (pulverizers 1 to 5 and crushers 1 to 5) equipped, the pump 1 flow rate rate control valve valve is operated by pressure from the auxiliary pilot pil ot valve.

T3-6-7

Flow Combiner Swing Parking Valve Brake Release Control Spool Spool          

Arm 1 Flow Rate Control Valve Control Spool 

-


5 a

4

6

7

b

8

c

9

d

e

10

f

11

3

12

2

13 14 15 16 1

17

g

l abcde-

Travel (Left) Travel (Right (Right)) Swing Arm Boom

fg-

1234-

Travel (Left) Travel Travel Trav el (Left, Right) Travel Trav el (Right) Boom, Arm, Bucket, Travel (Right) Arm

6-

5-

h-

k

Bucket Arm 1 Flow Rate Control Valve Control Spool Swing Parking Brake Release Spool

Boom, Arm, Bucket, Travel (Right) 7- Boom, Arm 8- Boom 9- Boom Raise, Arm 10- Boom Raise, Arm, Travel (Left), Swing

i j-

j

Flow Combiner Valve Control Spool Bucket Flow Flow Rate Control Control Valve Valve Control Spool

11- Boom, Arm, Bucket 12- Boom, Arm, Bucket, Swing, Auxiliary 13- Boom Raise, Arm, Swing, Auxiliary 14- Bucket 15- Swing

T3-6-8

i

h kl-

T1V1-03-06-001 T1V1-03-0 6-001

Pump 2 Flow Rate Control Valve Pump 1 Flow Rate Control Valve

16- Swing, Auxiliary 17- Auxiliary


B

9 8 5

B

16 7 17 15

a

11

13

6

14

3

10 12

4

1 2

TDCD-03-06-001 TDCD-03-06 -001

a-

Pilot Valve Side

1234-

Travel (Left) Travel Travel Trav el (Left, Right) Travel Trav el (Right) Boom, Arm, Bucket, Travel (Right) Arm

5-

6-

Boom, Arm, Bucket, Travel (Right) 7- Boom, Arm 8- Boom 9- Boom Raise, Arm 10- Boom Raise, Arm, Travel (Left), Swing

TDCD-03-06-004 TDCD-03-0 6-004

11- Boom, Arm, Bucket 12- Boom, Arm, Bucket, Swing, Auxiliary 13- Boom Raise, Arm, Swing, Auxiliary 14- Bucket 15- Swing

T3-6-9

16- Swing, Auxiliary 17- Auxiliary

SECTION 3 COMPONENT OPERATION Group 6 Signal Control Valve 1

Shockless Valve

2

3

The shockless valve is provided provided in the boom raise circuit and functions during boom lowering operation or when stopping boom raise operation. During boom raise operation 1. Boom raise pilot pressure is routed routed to spool (1) (1) through port A (2).

5

2. Immediately after operation is started, low pilot pilot pressure is routed to the spring B (3) chamber through clearance C between spool (1) and housing (7) and inner passage 3 (9). In addition, pilot pressure is also routed to port 1 (4) through inner passage 2 (5) at the same time.

4

6

1

9 T1V1-03-06-003 T1V1-03-0 6-003

2

3

4

T1V1-03-06-002 T1V1-03-0 6-002

3. When pilot pressure increases, increases, pressure in the spring B (3) chamber also increases. Spool (1) pushes spring A (6) and is moved to the left. 4. As spool (1) is moved, moved, port A (2) is connected to port 1 (4) and pressure in the port 1 (4) increases, so that the control valve spool is moved.

1234-

T3-6-10

Spool Port A Spring B Port 1

569-

Inner Passage 2 Spring A Inner Passage 3

SECTION 3 COMPONENT OPERATION Group 6 Signal Control Valve During boom raise operation: 6

1

2 C

5

3

9 4

T183-03-06-003 T183-03 -06-003

2

1

T183-03-06-004 T183-03 -06-004

4

Detail of Clearance C

7

1 T1V1-03-06-008 T1V1-03-0 6-008

12-

Spool Port A

34-

Spring B Port 1

56-

T3-6-11

Inner Passage 2 Spring A

79-

Housing Inner Passage 3

SECTION 3 COMPONENT OPERATION Group 6 Signal Control Valve 6

During boom lower operation or when stopping boom raise operation (shock reducing operation)

2

1

3

1. During boom lower operation operation or when stopping boom raise operation, the returning oil from the boom raise spool in control valve is routed to port p ort 1 (4). 2. As spool (1) blocks the oil passage passage between port 1 (4) and port A (2), the returning oil cannot flow directly to port A (2).

8 9 4

3. Port 1 (4) is is connected to the spring A (6) side in spool (1) through inner passage 1 (8) and to spring B chamber (3) through inner passage 3 (9). 6

4. Pressure oil oil in spring B (3) flows from clearance clearance C between spool (1) and housing (7) and pressure in spring B (3) decreases. Spool (1) is moved to the right by the pressure routed to the spring A (6) side. Therefore, Therefore, clearance C between bet ween spool (1) and housing (7) is closed, so that pressure oil is blocked.

7. Consequeltly, the shockless valve valve reduces the shock during boom lower operation or when stopping boom raise operation.

1

2

3

4

T1V1-03-06-002 T1V1-03-0 6-002

8

5. When clearance clearance C is closed, pressure pressure in spring B (3) increases and spool (1) is moved to the left. Therefore, clearance C is opened again and pressure pressure oil flows to the port A (2) side. 6. As the operations in step 4 to step step 5 are repeated repeated and pressure oil is gradually returned to the port A (2) side, the control valve spool is returned slowly.

T1V1-03-06-004 T1V1-03-0 6-004

1234-

T3-6-12

Spool Port A Spring B Port 1

5689-

Inner Passage 2 Spring A Inner Passage 1 Inner Passage 3

SECTION 3 COMPONENT OPERATION Group 6 Signal Control Valve During boom lower operation or when stopping boom raise operation (shock reducing operation) 6

8

1 2

3

C

5

9 T183-03-06-005 T183-03 -06-005

4 2

1

5

9 T183-03-06-004 T183-03 -06-004

4

Detail of Clearance C

7

1 T1V1-03-06-008 T1V1-03-0 6-008

123-

Spool Port A Spring B

456-

Port 1 Inner Passage 2 Spring A

789-

T3-6-13

Housing Inner Passage 1 Inner Passage 3

SECTION 3 COMPONENT OPERATION Group 6 Signal Control Valve Pump 1 and 2 Flow Rate Control Valve Valve The pump flow rate control control valve delivers delivers pump control pressure Pi to the pump regulator in response to pilot pressure from the pilot valve. 1. Pilot oil pressure pressure (5) from from the pilot valve valve is routed to the chamber A (3) side in either the pump 1 or pump 2 flow rate control valve after being selected by shuttle valve (4) in the signal control valve. 2. Spool (2) is moved to the left and primary pilot pressure (6) is routed to port SA or port SB. 3. Therefore, pressure in port SA (a) and port SB (b) increases. 4. In addition, pressure pressure oil in port SA (a) and port SB (b) is also routed to the spring (1) chamber. Therefore, spool (2) is moved back until the pressure force in port SA (a) and port SB (b) balances with the pilot pressure routed to the chamber A (3) side so that pressure in port SA (a) or port SB (b) stops increasing.

fNOTE:

The pump 1 flow rate control valve is operated when the boom (raise or lower), arm (roll-in or rollout), bucket (roll-in or roll-out), auxiliar y (machine with the attachment (pulverizers 1 to 5, crushers 1 to 5) equipped), and travel (right) functions are operated operated.. The pump 2 flow rate control valve is operated when the boom (raise), arm (roll-in or roll-out), travel (left), and auxiliary 1 functions are operated.

T3-6-14

SECTION 3 COMPONENT OPERATION Group 6 Signal Control Valve a, b

2

1

c

3

4 6

5

d

d

ab-

To Port SA To Port SB

c-


d-

From Pilot Valve

12-

Spring Spool

34-

Chamber A Shuttle Valve

56-

Pilot Pressure Primary Pilot Pressure

T3-6-15

T1V1-03-06-005 T1V1-03-0 6-005

SECTION 3 COMPONENT OPERATION Group 6 Signal Control Valve Bucket Flow Rate Control Valve Valve Control Spool:

Bucket Flow Rate Control Valve Control Spool, Flow Combiner Valve Control Spool, Swing Parking Brake Release Spool, Arm 1 Flow Rate Control Valve Control Spool

a

1

b

2

fNOTE:

The four spools are are identical identical in operational operational principle. T178-03-06-014 T178-03 -06-014







The bucket flow rate rate control valve control control spool is shifted by arm roll-in pilot pressure and supplies boom raise pilot pressure to the bucket b ucket flow rate control valve in control valve. The flow combiner combiner valve control control spool is shifted by travel (right) pilot pressure and supplies primary pilot pressure to the flow combiner valve in control valve. The swing parking brake release spool is shifted by the boom, arm, bucket, swing, auxiliary 1, or positioning/ auxiliary 2 pilot pressure and supplies primary pilot pressure to the swing motor.

d ab-

1-

c

To Hydraulic Oil Tank Boom Raise Pilot Pressure

c-

Spool

d-

To Bucket Flow Rate Control Valve Arm Roll-In Pilot Pressure

2-

Spring

Flow Combiner Valve Control Spool a

1

b

2

T178-03-06-014 T178-03 -06-014 f

e

ab-

To Hydraulic Oil Tank Primary Pilot Pressure

ef-

To Flow Combiner Valve Travel (RIght) Pilot Pressure

1-

Spool

2-

Spring

Swing Parking Brake Release Spool: a

1

b

2

T178-03-06-014 T178-03 -06-014 h

g

ab-

To Hydraulic Oil Tank Primary Pilot Pressure

gh-

To Swing Motor Boom, Arm, Bucket, Swing, Auxiliary

1-

Spool

2-

Spring

T3-6-16

SECTION 3 COMPONENT OPERATION Group 6 Signal Control Valve 

The arm 1 flow flow rate control control valve control control spool is shifted by arm roll-in pilot pressure and supplies swing pilot pressure to the arm 1 flow rate control valve in control valve.

Arm 1 Flow Rate R ate Control Valve Valve Control Spool a

1

i

2

T178-03-06-014 T178-03 -06-014 d

j

adi-

To Hydraulic Oil Tank Arm Roll-In Pilot Pressure Swing Pilot Pressure

j-

To Arm 1 Flow Flow Rate Control Control Valve

1-

Spool

2-

Spring

T3-6-17

SECTION 3 COMPONENT OPERATION Group 6 Signal Control Valve (Blank)

T3-6-18

SECTION 3 COMPONENT OPERATION Group 7 Others (Upperstructure) Pilot Shut-Off Solenoid Valve Valve The pilot shut-off solenoid valve is a solenoid solenoid valveoperated switch valve. Spool (1) in the pilot shut-off solenoid valve is shifted by the pilot shut-off lever and turns ON/OFF pilot pressure oil to the pilot valve and signal control valve.

Section Z-Z

T1 to T4

P A1 to A4

1 T1V1-03-07-012 T1V1-03-0 7-012 Z

A1

P

T1

T2

A2

A3 Z T4

T3

A4

T1V1-03-07-011 T1V1-03-0 7-011

PA1A2A3-

Primary Pilot Pressure Travel/Auxiliary Pilot Pressure Boom, Bucket Pilot Pressure Arm, Swing Pilot Pressure

1-

Spool

A4- Pilot Pressure to Signal Control T2- Returning Oil from Boom, T4- Returning Oil to Hydraulic Hydraulic Oil Valve (Port PI) Bucket, Pilot Tank Tank T1- Returning Oil from Trav Travel/ el/ T3- Returning Oil from Arm, Swing Auxiliary Pilot Pilot

T3-7-1

SECTION 3 COMPONENT OPERATION Group 7 Others (Upperstructure) 

Pilot Shut-Off Lever: LOCK Position

Pilot Shut-Off Lever: LOCK Position 1. When the pilot pilot shut-off lever is set to the LOCK LOCK position, the pilot shut-off relay is turned OFF and the pilot shut-off solenoid valve is turned OFF. OFF. (Refer to SYSTEM / Electrical System.)

T1 to T4

2. Pressure oil oil from the pilot pilot pump is blocked by spool (1) in the pilot shut-off solenoid valve. 3. Pressure oil oil in pilot valves valves (A1 to A3) and signal signal control valve (A4) sides flow to the hydraulic oil tank.

P A1 to A4

4. Therefore, even if the control/travel control/travel control control lever is operated, the pilot valve is not activated. 

Pilot Shut-Off Lever: UNLOCK Position 1. When the pilot pilot shut-off lever is set to the UNLOCK UNLOCK position, the pilot shut-off relay is turned ON and the pilot shut-off solenoid valve is excited. (Refer to SYSTEM / Electrical System.)

1 T1J1-03-07-011 T1J1-03 -07-011

2. Therefore, Spool (1) in the pilot shut-off solenoid valve is pushed down and the returning oil from the pilot valve and signal control valve are blocked by spool (1).

Pilot Shut-Off Lever: UNLOCK Position

3. Pressure oil oil from the pilot pilot pump flows to the pilot valve and signal control valve.

T1 to T4

4. Consequently, Consequently, when the control/travel control/travel control control lever is operated, the pilot valve is activated.

P A1 to A4

1 T1J1-03-07-001 T1J1-03 -07-001

PA1A2A3A4-

Primary Pilot Pressure Travel/Auxiliary Pilot Pressure Boom, Bucket Pilot Pressure Arm, Swing Pilot Pressure Pilot Pressure to Signal Control Valve (Port PI)

1-

Spool

T3-7-2

T1- Returning Oil from Trav Travel/ el/ Auxiliary Pilot T2- Returnin Returning g Oil from from Boom, Boom, Bucket Pilot T3- Returning Oil from Arm, Arm, Swing Pilot T4- Returning Oil to Hydraulic Hydraulic Oil Tank Tan k

SECTION 3 COMPONENT OPERATION Group 7 Others (Upperstructure) Solenoid Valve The solenoid valve consists consists of the 3-spool solenoid valve unit for pump and valve, and the 2-spool solenoid valve unit (optional).

SC

SF

SG

3-Spool Solenoid Valve Unit The 3-spool solenoid valve valve unit controls the control valve and the valve in travel motor according to the signal from MC (main controller). (Refer to SYSTEM / Control System.) The 3-spool solenoid valve valve unit consists of proportional solenoid valves (SC, SF and SG).

TDCD-03-07-001 TDCD-03-0 7-001

SC : Controls Controls the the arm rege regenera nerative tive valv valve e in contr control ol valve and controls the arm 2 flow f low rate control valve (switch valve) in control valve. SF : Controls Controls the the digging digging rege regenerat nerative ive valv valve e in contr control ol valve. SG : Increases Increases pressur pressure e of the the main main relief relief valve valve in control valve and controls the travel motor displacement angle control valve.

1

2-Spool Solenoid Valve Unit (Optional)

2

The 2-spool solenoid valve valve unit consists of auxiliary flow combiner control solenoid valve (1) and auxiliary flow rate control solenoid valve (2). Auxiliary flow combiner control solenoid valve (1) is an ON/OFF solenoid valve. When the attachment is selected by using the monitor monitor,, auxiliary flow combiner control solenoid valve (1) is turned ON and shifts the auxiliary flow combiner valve in control valve. (Refer to SYSTEM / Control System.) Auxiliary flow rate control solenoid valve (2) is a proportional solenoid valve. The auxiliary flow rate control valve (switch valve) in control valve is shifted by the signal from MC (main controller).

T1GL-03-10-00 T1GL -03-10-002 2 1-

T3-7-3

Auxiliary Flow Combiner Control Solenoid Valve

2-

Auxiliary Flow Rate Control Solenoid Valve

SECTION 3 COMPONENT OPERATION Group 7 Others (Upperstructure) Proportional Solenoid Valv Valve e The proportional solenoid valve valve is controlled by an electric current signal from MC (main controller) and outputs pressure in proportional to the electric current. 

When in neutral 1. Spring (2) pushes spool (1) (1) to the right and output output port S is connected to tank port por t T. T.



When excited 1. Solenoid (3) pushes spool (1) (1) to the left in proportion to the current value flowing through solenoid (3). 2. Pilot pressure pressure oil from port port P flows to output port S and pressure at output port S increases. 3. This pressure pressure at output port S is routed routed to stepped part a of spool (1). Spool (1) is pushed to the right due to difference in the pressure receiving area between stepped part a. 4. When pressure at output port port S increases and the force to push spool (1) to the right overcomes the force to push spool (1) to the left by solenoid (3), spool (1) is moved back to the right and the passage between output port S and port P is closed. Therefore, Therefore, pressure at output port S stops increasing.

T

S

1

P

2

3

a

a TDAA-03-07-013 TDAA-0 3-07-013

1-

Spool

2-

Spring

3-

T3-7-4

Solenoid

SECTION 3 COMPONENT OPERATION Group 7 Others (Upperstructure) ON/OFF Solenoid Valve The ON/OFF solenoid valve valve shifts the brake switch and each control switch in order to shift shif t pilot pressure. 

In Neutral Spool (1) is pushed to the right by spring (2). Output port S is connected to tank port p ort T.



In Operation As solenoid (3) is excited, spool (1) is pushed to the left. Pilot port P is connected to output port S and tank port T is blocked.

P

1

S

T

3

2 T105-02-11-010 T105-02 -11-010

1-

Spool

2-

Spring

3-

T3-7-5

Solenoid

SECTION 3 COMPONENT OPERATION Group 7 Others (Upperstructure) Pilot Relief Valve 2

Pilot relief valve (2) has pilot filter (3) incorporated. Pilot relief valve (2) functions to regulate pilot pump pressure routed to port P (1) to a constant pressure.

1

3

T178-03-07-001 T178-03 -07-001 12-

Port P Pilot Relief Valve

3-

Pilot Filter

EC Motor 1

2

3

The EC Motor is used to control control engine speed. A worm Gear (3) is incorporated into the EC motor to prevent a loss of synchronism from occurring. The EC sensor (6) is provided to calculate the governor lover position. (Refer to SYSTEM / Control System)

4

7

6

1234-

Output Gear Output Shaft Worm Gear Motor

T3-7-6

5

T157-02-05-018 T157-02 -05-018 567-

Worm Wheel EC Sensor Sensor Gear

SECTION 3 COMPONENT OPERATION Group 7 Others (Upperstructure) (Blank)

T3-7-7

SECTION 3 COMPONENT OPERATION Group 7 Others (Upperstructure) Hose Rupture Valve The hose rupture valve is is installed to boom cylinder (bottom side circuit), arm cylinder (rod side circuit). When the hose of front attachment is damaged, the hose rupture valve holds the front attachment and prevents the front attachment from falling.

fNOTE:

The hose hose rupture rupture valve valve in boom cylinder is explained here.



Control Lever: In Neutral Neutral 1. As pilot pressure pressure Pi does not act on piston (3), spool (2) is pushed to the right by the spring (10) force.

5

9

4

2. One holding pressure of cylinder at port B (12) acts on poppet (6) and the other acts on spool (2) through passage C (9).

6

a

3. Holding pressure pressure through passage C (9) is blocked blocked by spool (2). Although pressure oil in the spring (5) chamber also acts on spool (2) through passage A (4), pressure oil is blocked by spool (2) and does not flow to passage B (8).

12

4. Therefore, poppet (6) is pushed downward by force (pressure of the spring (5) chamber + spring (5)).

11

5. Consequently, Consequently, as holding pressure pressure at port B (12) is blocked completely, the front attachment is held and prevented from falling when the hose of front attachment is damaged.

10

8

2

b

3

T1V1-03-07-018 T1V1-0307-018

a-

External Force

b-

To Spool in Control Valve ( To Hose of Front Attachment)

2345-

Spool Piston Passage A Spring

68910-

Poppet Passage B Passage C Spring

T3-7-8

SECTION 3 COMPONENT OPERATION Group 7 Others (Upperstructure)

10

13

1

2

3

4 5

9

6 7

8

12

11

T1V1-03-07-017 T1V1-03-0 7-017

1234-

Relief Valve Spool Piston Passage A

5678-

Spring Poppet Orifice Passage B

9101112-

T3-7-9

Passage C Spring Port A Port B

13- Orifice


During Boom Lowering Operation (Control (Control Lever Lever Stroke: Less then Half-Stroke) 1. When the boom is lowered, pilot pressure Pi Pi acts on piston (3).

5

9

4

7

2. When the boom lower control lever is less than than halfstroke, piston (3) restricts spool (2) and pushes spool (2) to the position where orifice (13) is opened.

6

3. Pressure oil oil in the spring (5) chamber is blocked by by spool (2) and poppet (6) is pushed downward.

c

4. Pressure oil oil from port B (12) flows to the spool in control valve through passage C (9), orifice (13) and passage B (8) and lowers the boom.

12

5. As oil flow rate through the spool in control control valve is reduced by orifice (13), the boom is lowered slowly. slowly.

11

10

8

2

b

T1V1-03-07-019 T1V1-0307-019

b-

To Sp Spo ool in Con ontr trol ol Val alv ve

c-

Pre ress ssu ure Pi

234567-

Spool Piston Passage A Spring Poppet Orifice

8910 1112-

Passage B Passage C Spring Port A Port B

T3-7-10

3


10

13

1

2

3

c

4 5

9

6 7

8

12

11

T1V1-03-07-015 T1V1-03-0 7-015 c-

Pressure Pi

1234-


5678-


9101112-

T3-7-11


13- Orifice


During Boom Lowering Operation (Control (Control Lever Lever Stroke: More than Half-Stroke) 1. When the boom lower control lever is more more than half-stroke, piston (3) pushes spool (2) to the position where passage A (4) is connected to the hole on spool (2).

5

9

4

7

2. Therefore, pressure oil in the spring (5) chamber flows to passage B (8) through spool (2) from the hole on spool (2).

6

c

3. Pressure in in passage C (9) flows to passage passage B (8) through orifice (13).

12

4. At this time, time, a pressure difference difference between port B (12) and the spring (5) chamber appears due to orifice (7) and poppet (6) moves upward.

11

5. Consequently, Consequently, return oil from from port B (12) flows flows to the spool in control valve through poppet (6) from port A (11) and lowers the boom. 6. As pressure oil oil in port B (12) flows flows to port A (11) directly, oil flow rate through the spool in control valve increases and boom lowering speed becomes fast.

10

8

2

b

T1V1-03-07-020 T1V1-0307-020

b-

To Sp Spo ool in Con ontr trol ol Val alv ve

c-

Pre ress ssu ure Pi

234567-

Spool Piston Passage A Spring Poppet Orifice

89101112-

Passage B Passage C Spring Port A Port B

T3-7-12

3


10

13

1

2

3

c

4 5

9

6 7

8

12

11

T1V1-03-07-016 T1V1-03-0 7-016 c-

Pressure Pi

1234-


5678-


9101112-

T3-7-13


13- Orifice

SECTION 3 COMPONENT OPERATION Group 7 Others (Upperstructure) (Blank)

T3-7-14

SECTION 3 COMPONENT OPERATION Group 8 Others (Undercarriage) Swing Bearing The swing bearing supports the upperstructure on the undercarriage and allows the upperstructure to swing smoothly. This bearing is a single row row type ball bearing and consists of outer race (1), inner race (3), ball (6), support (5), and seals (2, 4). Outer race (1) is bolted to the upperstructure. Inner race (3) is bolted to the undercarriage. The The internal gear of inner race (3) meshes with the output shaft of the swing reduction gear.

1 2

5 3

4

6

T135-03-02-001 T135-03 -02-001

12-

Outer Race Seal

34-

Inner Race Seal

56-

T3-8-1

Support Ball

SECTION 3 COMPONENT OPERATION Group 8 Others (Undercarriage) Center Joint The center joint is a 360° rotating rotating joint. When the upper structure swings, the center joint eliminates twisting of the hoses and allows hydraulic oil to flow the travel motors. Spindle (1) and body (2) are secured to the upperstructure and to the swing center of the undercarriage respectively. Pressure oil flows to the right and left travel motors through spindle (1) and each oil port of body (2). Seals (3) prevent oil leaks between spindle (1) and body (2).

a

b

d

b

d

c

a

c

1 e

f

e

2

f

f

3 f :g :h :e

T157-03-02-004 T157-03 -02-004

a b-

1-

Travel (Left Reverse) Travel (Right Forward)

Spindle

cd-

2-

Travel (Right Reverse) Travel (Left Forward)

Body

ef-

for Travel Mode Control Pilot Pressure Drain

3-

Seal

T3-8-2

gh-

Forward Reverse

SECTION 3 COMPONENT OPERATION Group 8 Others (Undercarriage) Track Adjuster (Front Idler Integrated Type) The track adjuster located located on the side frame consists of front idler (4), spring (3), and adjuster cylinder (1). Spring (3) absorbs the loads applied to the front idler (4) part. Track sag is adjusted by adjuster cylinder (1). 

Detail A

5

When grease grease is supplied through grease grease fitting (5), (5), grease fills chamber (a) in adjuster cylinder (1), pushes piston rod (2), and reduces track sag.

TDAA-03-08-002 TDAA-0 3-08-002

1

a

4

12-

Adjuster Cylinder Piston Rod

34-

Spring Front Idler

5-

T3-8-3

Grease Fitting

2

3

A

TDAA-03-08-001 TDAA-0 3-08-001

SECTION 3 COMPONENT OPERATION Group 8 Others (Undercarriage) (Blank)

T3-8-4

MEMO

MEMO

Hitachi Construction Machinery Co. Ltd Attn: Publications, Marketing & Product Support Tel: T el: 81-29-982-7084 Fax: 81-29-831-1162 E-mail: [email protected]

Hitachi Ref. No.

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ZX200 5G Operational Principle TODCD en 01

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