OPERATIONAL PRINCIPLE.pdf

PART NO. TODCD-EN-00 PRINTED IN JAPAN (K) 2011, 04 ZX200-5G • 200LC-5G • 210H-5G • 210LCH-5G • 210K-5G • 210LCK-5G HY

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PART NO.

TODCD-EN-00

PRINTED IN JAPAN (K) 2011, 04

ZX200-5G • 200LC-5G • 210H-5G • 210LCH-5G • 210K-5G • 210LCK-5G HYDRAULIC EXCAVATOR TECHNICAL MANUAL OPERATIONAL PRINCIPLE

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

TODCD-EN-00

Technical Manual Operational Principle

ZX

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

Hydraulic Excavator Service Manual consists of the following separate Part No. Technical Manual (Operational Principle) : Vol. No.TODCD-EN Technical Manual (Troubleshooting) : 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 experienced technician to provide technical information needed to maintain and repair this machine.

 If you have any questions or comments, at if you 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 the form. Copy it for usage.):  Publications Marketing & Product Support Hitachi Construction Machinery Co. Ltd.  TEL: 81-29-832-7084  FAX: 81-29-831-1162  E-mail: [email protected]

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

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

This manual consists the Technical Manual, the Workshop Manual and the Engine Manual.  Information included in the Technical Manual: Technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.

 Information included in the Engine Manual: Technical information needed 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 Section Number Group Number Consecutive Page Number for Each Group

IN-01

Workshop Manual Section Number Group Number Sub Group Number Consecutive Page Number for Each 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.

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

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 attention to component/part weights. To avoid injury and damage, be sure to use 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

Torque

N·m

kgf·m

Pressure

MPa

kgf/cm

MPa

psi

145.0

kW

PS

1.360

kW

HP

1.341

Temperature

°C

°F

°C×1.8+32

Velocity

km/h

mph

0.6214

min

rpm

1.0

L/min

US gpm

0.2642

mL/rev

cc/rev

1.0

Volume

Power

Flow rate

-1

fNOTE:

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

IN-02

0.10197 2

10.197

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

GPS CAN

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

Name

Explanation

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

Technical manual (Operational Principle). Technical manual (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. 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 by ISO (International Organization for Standardization). 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 ABBREVIATION (Blank)

SY-2

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

SECTION 2 SYSTEM TECHNICAL MANUAL (Operational Principle)

Group 1 Controller 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 Group 4 Pilot Valve Group 5 Travel Device Group 6 Signal Control 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, Japan All rights reserved

TECHNICAL MANUAL (Troubleshooting)

WORKSHOP 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 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 Procedure 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

SECTION 1

GENERAL CONTENTS Group 1 Specifications

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

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 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 I: Undercarriage Width J: Sprocket Center to Idle Center K: Track Shoe Width Ground Pressure Swing Speed Travel 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 ISUZU CC-6BG1T 125 kW/2100 min-1 (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 Attachment

ZX210LCK-5G 2.91 m K Arm

-

Bucket Capacity (Heaped)

m

Operating Weight

kg

21100

Base Machine Weight

kg

16300

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

MDCD-12-001

PCSA 0.80 m3 (1.3 yd3), CECE 0.70 m3

3

21500 16800

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

-

-1

2860

mm

2990

mm

2950

mm

2890

D: Minimum Ground Clearance E: Counterweight Clearance

mm

*450

mm

*1030

F: Engine Cover Height G: Overall Width of Upperstructure H: Undercarriage Length I: Undercarriage Width

mm

*2270

mm

2710

J: Sprocket Center to Idle Center K: Track Shoe Width Ground Pressure Swing Speed Travel 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 (rpm)

13.5(13.5)

km/h

5.5/3.5

Degree (%)

35(70)

-1

*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 do not include height of the shoe lug (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 Item A: Maximum Digging Reach B: Maximum Digging Depth C: Maximum Cutting Height D: Maximum Dumping Height

Category (mm) (mm) (mm) (mm)

E: Overall Height

(mm)

F: Overall Length G: Minimum Swing Radius

(mm) (mm)

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

f NOTE: The dimensions do not include height of the shoe lug (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 14

18

1- 2- 3- 4- 5- 6-

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

7- 8- 9- 10- 11- 12-

17

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

13- 14- 15- 16- 17- 18-

T1-2-1

16

Intercooler Air Conditioner Condenser Radiator Battery Travel Device Oil Cooler

13 TDCD-01-02-001

15

19- 20- 21- 22- 23-

Air Cleaner Signal Control Valve Pilot Shut-Off Solenoid Valve Travel 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 6

13

7 12

8 11 10 TDCD-01-02-003

9

1- 2- 3- 4- 5-

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

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 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

5 Engine Oil Pressure Switch

1

4 TDCD-01-02-004

3 1-

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

2- 3-

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

7

8

9

10 11 12

17 16 15 14 13 1- 2- 3- 4-

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

fNOTE:

5- 6- 7- 8- 9- 10-

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

11- 12- 13- 14- 15- 16-

*: This component is different 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

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

1- 2- 3- 4-

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

5- 6- 7- 8- 9-

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

10- 11- 12- 13-

T1-2-5

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

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

a-

Machine Front

1-

ECF (Engine Controller)

2-

Air Cleaner

TDCD-01-02-007

3-

T1-2-6

Air Cleaner Restriction Switch

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

1

2

3

4

5

1- 2-

Ambient Temperature Sensor Starter Relay 2

3- 4-

Battery Relay Glow Plug Relay

TDCD-01-02-002

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

1- 2- 3- 4-

Pilot Pump Pump 2 Pump 1 Pump 1 Delivery Pressure Sensor

5- 6- 7-

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

TDCD-03-01-004

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

3

Signal Control Valve

a

4

5

T1V1-01-02-014 a-

Pilot Valve Side

1- 2-

Pressure Sensor (Arm Roll-In) Main Relief Valve

3- 4-

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

Cross Section A-A

1 5

2

6

3

7

4

T178-03-06-002

a-

Pilot Valve Side

1- 2-

Shockless Valve Bucket Flow Rate Control Valve Control Spool

3- 4-

Pump 2 Flow Rate Control Valve Flow Combiner Valve Control Spool

5- 6-

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 Travel Device

Swing Device

3

1

2

5

4

T1HD-01-02-001

T1V1-01-02-005

1- 2-

Swing Relief Valve Pressure Sensor (Front Attachment)

3- 4-

Counterbalance Valve Travel Motor Swash Angle Control Valve

3

5-

T1-2-11

Travel Relief Valve

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

1

2

3

TDCD-03-07-001

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 a-

Utility Space (Refer to T1-2-15.)

1-

Pilot Valve (Auxiliary)

b-

Boom Upper Side (Refer to 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 Accumulator (High Pressure) Accumulator (Low Pressure) Secondary Pilot Relief Pressure Valve Secondary Pilot Relief Pressure Control 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

4

Selector Valve 5

TDCD-01-02-012

1-

Pressure Sensor (Auxiliary)

2-

Auxiliary Flow Combiner Control Solenoid Valve

3-

T1-2-16

Auxiliary Flow Rate Control Solenoid Valve

4- 5-

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

2

Breaker 2 (NPK Breaker) Shared Machine 3

4

5

1-

Secondary Pilot Relief Pressure Valve

2-

Secondary Pilot Relief Pressure Control Valve

TDCD-01-02-014

3- 4-

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 Cyl. No.- Bore × Stroke Piston Displacement Rated Output Compression Ratio Dry Weight Firing Order Rotation Direction

ISUZU CC-6BG1TRA-12 Diesel, 4-Cycle, Water-cooled, Direct Injection Type, Exhaust Turbo 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 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 Clockwise (Viewed from fan side)

T1-3-1

SECTION 1 GENERAL Group 3 Component Specifications COOLING SYSTEM

Cooling Fan Fan Pulley Ratio Thermostat

LUBRICATION SYSTEM

Water Pump Lubrication Pump Type

Oil Filter Oil Cooler STARTING SYSTEM Motor Voltage / Output PREHEAT SYSTEM Preheating 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 at Atmospheric Pressure: 82 °C (180 °F) Full Open (Stroke: 10 mm or more) Temperature: 95 °C (203 °F) Centrifugal Type Gear 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 Plug (24V, QOS II Type) Fuel Shut-Off (Electronic Control) Regulator Integrated AC Type, Brushless 24 V / 50 A Exhaust-Turbocharger Type RHG6 Type with Lubrication, 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: This list shows design specifications, which are not servicing standards. PERFORMANCE

Fuel Consumption Ratio

240 g/kW/h (177 g/PS·h) at 125+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) Maximum Output Torque 637+55-65 N·m (65+5.6-6.6 kgf·m) at approx. 1800 min-1 Compression Pressure 3.04 MPa (31 kgf/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)

T1-3-3

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

kW

g/kW·h

min-1 (rpm)

kW: Output N·m: Torque

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

T1-3-4

TDCD-01-03-001

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

Parallel Type 59 kg (130 lb)

Radiator Air-Tight Test Pressure Cap Opening Pressure BATTERY

Oil Cooler

98 kPa (1.0 kgf/cm , 14 psi) 49 kPa (0.5 kgf/cm2, 7 psi) 2

Type Capacity Voltage Weight

Intercooler

1470 kPa (15 kgf/cm , 213 psi) 245 kPa (2.5 kgf/cm2, 36 psi) − − 2

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 106 cm3/rev (6.5 in3/rev)×2 Rated Pressure Type Type Model Theoretical Displacement Type Main Relief Set-Pressure 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: 34.3 MPa (350 kgf/cm2, 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 Gear Ratio SWING MOTOR Model Type Theoretical Displacement VALVE UNIT Type Relief Set-Pressure SWING PARKING Type BRAKE Release Pressure TRAVEL DEVICE Type Reduction Gear Ratio TRAVEL MOTOR Type Theoretical Displacement (Fast/Slow) TRAVEL BRAKE VALVE Type Relief Set Pressure TRAVEL PARKING Type BRAKE Release Starting Pressure

Two-Stage Reduction Planetary Gear 17.53 M5X130CHB-10A-29B/330 Swash-Plate Type, Fixed Displacement 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 Spring Set Hydraulic Released Multi-Disc Brake 1.9 to 2.8 MPa (20 to 28.6 kgf/cm2, 284 to 410 psi) Three-Stage Reduction Planetary Gear 58.702 Swash-Plate Type Variable Displacement Axial Plunger Motor 79/122.5 cm3/rev (4.8/7.5 in3/rev) Counterbalance Valve Type 34.8 MPa (355 kgf/cm2, 5050 psi) Wet-Type Spring Set Hydraulic Released Multi-Disc Brake 0.97±0.07 MPa (9.9±0.7 kgf/cm2, 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 Stroke TRAVEL PILOT VALVE Model Plunger Stroke 3-SPOOL SOLENOID Type VALVE UNIT Rated Voltage Coil Resistance AUXILIARY FLOW Rated Voltage COMBINER CONTROL Coil Resistance SOLENOID VALVE (Optional) Rated Voltage AUXILIARY FLOW RATE CONTROL Coil Resistance SOLENOID VALVE (Optional) SIGNAL CONTROL Model VALVE Rated Pressure PILOT SHUT-OFF Type SOLENOID VALVE Rated Voltage Coil Resistance OIL COOLER BYPASS Cracking Pressure CHECK VALVE FILTER Engine Oil Filter Full-Flow Filter (Filtration) Suction Filter (Filtration) Pilot Filter (Filtration)

HVP07A-040-101 Ports 1, 3: 6.5 mm (0.26 in), Ports 2, 4: 8.0 mm (0.32 in) HVP08A-040-101 Ports 1, 2, 3, 4: 4.6 mm (0.18 in) 3-Spool Proportional 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≥2.0 177 μm (80 mesh) β10≥1.4

T1-3-9

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

Parts No. Voltage / Current Parts No. Voltage Parts No. Voltage Operating Temperature

HYDRAULIC OIL TEMPERATURE 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 Adjusting System Refrigerant Quantity Compressor Oil Quantity

ISUZU 8943795431 24 V / 100 A ISUZU 1825530391 24 V ISUZU 8942580140 24 V -30 to 120 °C (-22 to 248 °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 cm3

T1-3-10

MEMO

MEMO

SECTION 2

SYSTEM CONTENTS Group 1 Controller

Outline..................................................................................... T2-1-1 CAN Circuit............................................................................. T2-1-2

Group 2 Control System

Outline..................................................................................... T2-2-1 Engine Control...................................................................... T2-2-4 Pump Control......................................................................T2-2-28 Valve Control.......................................................................T2-2-42 Other Control......................................................................T2-2-62

Group 3 Hydraulic System

Outline..................................................................................... T2-3-1 Pilot Circuit............................................................................. T2-3-2 Main Circuit..........................................................................T2-3-12

Group 4 Electrical System

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

DCDT-2-1

(Blank)

DCDT-2-2

SECTION 2 SYSTEM Group 1 Controller Outline The following controllers are 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 corresponding group for 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 (CAN bus (4)), CAN 0 (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

9

6

1

6

7

10

15

11 5 16

8

6

6 12

13

14

TDCD-02-01-002

1- 2- 3- 4-

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

5- 6- 7- 8-

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

9- 10- 11- 12-

T2-1-3

Communication Controller Monitor Controller MPDr. Wiper / Light Controller

13- 14- 15- 16-

Radio Controller 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 control dial, 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 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 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 (Travel) 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 HP Mode Control Auto-Idle Control Hydraulic Oil Temperature Auto-Warming Up Control Idle Speed-Up Control Engine Starting Idle Speed-Up Control * Attachment Operation Speed Limit Control

MC

Pump Control (Torque Control Solenoid Valve) Speed Sensing Control Hydraulic Oil Temperature Pump Torque Decrease Control Travel Torque-Up Control * Attachment Pump Torque Decrease Control * Pump 1 Flow Rate Limit Control * Pump 2 Flow Rate Limit Control

ECF CAN

MPDr. Work Mode

 Monitor  Controller

fNOTE: 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 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 (Travel) 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 Lift Control Travel Motor Displacement Angle Control Arm Regenerative Control Digging Regenerative Control * Breaker 1 Control * Breaker 2 Control * Pulverizer Control * Crusher Control

MC

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

ECF CAN

MPDr. Work Mode

 Monitor  Controller

fNOTE: 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 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 Engine Starting Idle Speed-Up Control * Attachment Operation Speed Limit Control

fNOTE:

*This control is for only the machine with 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

1- 2- 3- 4- 5- 6- 7-

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)

8- 9- 10- 11- 12- 13- 14- 15- 16- 17-

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- Travel Mode Switch

T2-2-5

24- 25- 26- 27- 28- 29- 30-

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

C A - Engine Speed B - Engine Control Dial Position C - Slow Idle Position

T2-2-6

D

B

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

1- 2- 3- 4- 5- 6- 7-

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)

8- 9- 10- 11- 12- 13- 14- 15- 16- 17-

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- Travel Mode Switch

T2-2-7

24- 25- 26- 27- 28- 29- 30-

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 ECO Control A

Purpose: The ECO control reduces the engine speed 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 exist 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 EC motor (15) to reduce the engine speed by 100 min-1 from fast idle speed. Engine speed reduced (100 min-1) condition:  Engine control dial (28): Set the engine speed in the fast idle speed.  Power mode switch (27): PWR

C A - Engine Speed B - Engine Control Dial Position C - Slow Idle Position

D

B

D - Fast Idle Position

fNOTE:

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

fNOTE:

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

T2-2-8

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-02-02-003

1- 2- 3- 4- 5- 6- 7-

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)

8- 9- 10- 11- 12- 13- 14- 15- 16- 17-

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- Travel Mode Switch

T2-2-9

24- 25- 26- 27- 28- 29- 30-

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 Power Mode Control Purpose: The power mode control shifts the power mode (ECO/ PWR mode) by operating power mode switch (27). Operation: 1. MC (8) receives the signal from power mode switch (27). 2. MC (8) shifts the power mode 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 EC motor (15) to control the engine speed according to CAN communication (12). 5. In addition, MC (8) sends the power mode control mode to monitor controller (10) by using CAN communication (12). 6. Monitor controller (10) displays the power 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

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-02-02-004

1- 2- 3- 4- 5- 6- 7-

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)

8- 9- 10- 11- 12- 13- 14- 15- 16- 17-

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- Travel Mode Switch

T2-2-11

24- 25- 26- 27- 28- 29- 30-

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 ECO Mode Control A

Purpose: The ECO mode control reduces the engine 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 engine speed by engine 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. 2. ECF (13) drives EC motor (15) to reduce the engine speed from the required engine speed by engine control dial (28).

C A - Engine Speed B - Engine Control Dial Position C - Slow Idle Position

3. The engine speed becomes the required engine speed by engine control dial (28) during travel operation. 4. Therefore, proper travelling power is obtained. Engine speed reduced condition:  Control lever operation ratio: minimum (Pump 1 control pressure, or pump 2 control pressure: low)  Deceleration ratio: Large  Average pump delivery pressure: high  Deceleration ratio: Large

T2-2-12

D

B

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-02-02-005

1- 2- 3- 4- 5- 6- 7-

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)

8- 9- 10- 11- 12- 13- 14- 15- 16- 17-

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- Travel Mode Switch

T2-2-13

24- 25- 26- 27- 28- 29- 30-

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 Travel HP Mode Control A

Purpose: The travel HP mode control increases the engine speed and travels faster during travel single operation. Operation: 1. When all following 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 EC motor (15) to increase the engine speed to the travel HP mode speed and travels faster. Condition:  Engine control dial (28): Set the engine speed in the fast idle speed position.  Travel mode switch (23): Fast Speed (25)  Travel Pressure Sensor (5): Signal  Delivery pressure of pumps 1 and 2: Delivery pressure of either pump is high. (Reference: 19 MPa)

C A - Engine Speed B - Engine Control Dial Position C - Slow Idle Position

T2-2-14

D

B

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-02-02-007

1- 2- 3- 4- 5- 6- 7-

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)

8- 9- 10- 11- 12- 13- 14- 15- 16- 17-

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- Travel Mode Switch

T2-2-15

24- 25- 26- 27- 28- 29- 30-

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

fNOTE:  If slightly faster digging speed is required, the HP mode can be added to the power mode. This mode, however, increases fuel consumption. Before performing this mode, fully explain the customer about disadvantage of this mode and obtain customer’s understanding.  When the HP mode is added, related items are added in the “Power Mode Selection” menu. Each time pushing the power mode switch, the power mode is switched as following table. Power Mode Selection

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

Power mode when key switch is OFF

ECO PWR ECO PWR HP HP mode: Fixed  When the HP mode is added to the power mode, the attachment operation speed increase control (optional) can be set. In order to increase the engine speed while operating the front attachment (breaker, pulverizer, crusher or vibrating hammer), set the speed to the “faster (+) attachment operating speed” by using MPDr..

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 ECO ECO ECO PWR ECO HP HP HP

T2-2-16

SECTION 2 SYSTEM Group 2 Control System (Blank)

T2-2-17

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

Purpose: The auto-idle control reduces the engine speed when all the control levers are in neutral. 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).

F

C

2. ECF (13) drives EC motor (15) to change the engine speed into the auto-idle speed. 3. As soon as either control 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).

A - B - C - D - E -

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

fNOTE:

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

T2-2-18

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

D F - Auto-Idle Speed

B

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-02-02-008

1- 2- 3- 4- 5- 6- 7-

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)

8- 9- 10- 11- 12- 13- 14- 15- 16- 17-

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- Travel Mode Switch

T2-2-19

24- 25- 26- 27- 28- 29- 30-

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 Hydraulic Oil Temperature Auto-Warming Up Control A

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

E

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

F

2. When key switch (29) is in the ON or 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 EC motor (15) to increase the engine speed to the auto-warming up speed. 4. In 12 minutes after the key switch is set to the ON or START position or when hydraulic oil temperature is 2 °C or more, MC (8) deactivates the hydraulic oil temperature auto-warming up control.

G

C A - B - C - D - E -

5. Therefore, ECF (13) returns the engine speed to the engine speed set by engine control dial (28).

fNOTE:

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

IMPORTANT: When adjusting the auto-idle speed, deactivate the auto-warming up control by using 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)

T2-2-20

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

D

B

F - Auto- Warming Up Speed G - Slow Idle Speed

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-02-02-009

1- 2- 3- 4- 5- 6- 7-

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)

8- 9- 10- 11- 12- 13- 14- 15- 16- 17-

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- Travel Mode Switch

T2-2-21

24- 25- 26- 27- 28- 29- 30-

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 Idle Speed-Up Control A

Purpose: The idle speed-up control prevents the engine from hunting when the engine runs at slow speed. Operation: 1. When the travel or front attachment 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 EC motor (15) to increase the engine speed to the idle speed-up speed.

E

C A - B - C - D - E -

T2-2-22

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

D

B

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-02-02-010

1- 2- 3- 4- 5- 6- 7-

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)

8- 9- 10- 11- 12- 13- 14- 15- 16- 17-

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- Travel Mode Switch

T2-2-23

24- 25- 26- 27- 28- 29- 30-

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 Starting Idle Speed-Up Control Purpose: The engine starting idle speed-up control increases the engine speed and increases the engine oil pressure when the engine starts. Operation: 1. If engine control dial (28) is set below 1150 min-1 when the engine starts, MC (8) sends the signals equivalent to the target engine speed to ECF (13) by using CAN communication (12). 2. ECF (13) drives EC motor (15) to increase the engine speed to the idle speed-up speed. 3. MC (8) deactivates the engine starting idle speedup control in 15 seconds after the engine starts. 4. Therefore, ECF (13) returns the engine speed to the engine speed set by engine control dial (28).

T2-2-24

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-02-02-011

1- 2- 3- 4- 5- 6- 7-

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)

8- 9- 10- 11- 12- 13- 14- 15- 16- 17-

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- Travel Mode Switch

T2-2-25

24- 25- 26- 27- 28- 29- 30-

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 Attachment Operation Speed Limit Control (Only Machine Equipped with Attachment Parts) A

Purpose: The attachment operation speed limit control reduces the maximum engine speed to the attachment (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 exist 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 (12). 2. ECF (13) drives EC motor (15) to reduces the maximum engine speed by the attachment operating speed set by MPDr. (9).

C A - Engine Speed B - Engine Control Dial Position C - Slow Idle Position

Condition:  MPDr. (9): Resets the maximum engine speed to a slower (-) attachment (breaker, pulverizer, crusher, or vibrating hammer) operating speed.  Work mode: Attachment mode Attachment selected by using monitor (11) is set slower (-) by MPDr. (9).

T2-2-26

D

B

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-02-02-013

1- 2- 3- 4- 5- 6- 7-

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)

8- 9- 10- 11- 12- 13- 14- 15- 16- 17-

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- Travel Mode Switch

T2-2-27

24- 25- 26- 27- 28- 29- 30-

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 Pump Control The pump control consists of the followings.  Speed Sensing Control  Hydraulic Oil Temperature Pump Torque Decrease Control  Travel Torque-Up Control  * Attachment Pump Torque Decrease Control  * Pump 1 Flow Rate Limit Control  * Pump 2 Flow Rate Limit Control

fNOTE: * This control is for only the 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 1- 2- 3- 4- 5- 6- 7-

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)

8- 9- 10- 11- 12- 13- 14- 15- 16-

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

17- Pump 1 Delivery Pressure Sensor 18- Pump 1 Control Pressure Sensor 19- Pump 2 Control Pressure Sensor 20- Torque Control Solenoid Valve 21- Maximum Pump 2 Flow Rate Limit Control Solenoid Valve

T2-2-29

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 the pump 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 by engine control dial (24). 2. ECF (13) receives the signal from N sensor (15). 3. ECF (13) calculates and send actual engine speed to MC (8) by using CAN communication (12). 4. MC (8) calculates the difference in speed between the target engine speed and the actual engine speed detected by CAN communication (12) from ECF (13). Then, MC (10) sends the signals to torque control solenoid valve (20).

P

5. Torque control solenoid valve (20) delivers the pilot pressure according to the signals to the regulator and controls the pump delivery flow rate.

P - Pressure

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

fNOTE:

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

T2-2-30

Q - Flow Rate

SECTION 2 SYSTEM Group 2 Control System 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 1- 2- 3- 4- 5- 6- 7-

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)

8- 9- 10- 11- 12- 13- 14- 15- 16-

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

17- Pump 1 Delivery Pressure Sensor 18- Pump 1 Control Pressure Sensor 19- Pump 2 Control Pressure Sensor 20- Torque Control Solenoid Valve 21- Maximum Pump 2 Flow Rate Limit Control Solenoid Valve

T2-2-31

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 Hydraulic Oil Temperature Pump Torque Decrease Control Purpose: The hydraulic oil temperature pump torque decrease control reduces the pump flow rate and pump driving torque when hydraulic oil temperature increases so that the engine overheating is prevented. Operation: 1. MC (8) activates torque control solenoid valve (20) when hydraulic oil temperature increases. 2. Torque control solenoid valve (20) delivers the pilot pressure according to the signals to the regulator and reduces the pump delivery flow rate. 3. Therefore, the engine overheating is prevented when hydraulic oil temperature increases.

T2-2-32

SECTION 2 SYSTEM Group 2 Control System 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-02-02-016 1- 2- 3- 4- 5- 6- 7-

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)

8- 9- 10- 11- 12- 13- 14- 15- 16-

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

17- Pump 1 Delivery Pressure Sensor 18- Pump 1 Control Pressure Sensor 19- Pump 2 Control Pressure Sensor 20- Torque Control Solenoid Valve 21- Maximum Pump 2 Flow Rate Limit Control Solenoid Valve

T2-2-33

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 Travel Torque-Up Control

Q B

Purpose: The travel torque-up control effectively 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, 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 is raised in order to improve travel function.

b

A

a

P P - Pressure a - Normal P-Q Curve

Operation: 1. When all following 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 (20) delivers the pilot pressure according to the signals to the regulator and increases the pump delivery flow rate. Condition:  Engine Control Dial (24): Slow idle speed  Pressure sensor (travel) (5): Signal  Pressure sensor (front attachment) (6): No signal

T2-2-34

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

SECTION 2 SYSTEM Group 2 Control System 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 1- 2- 3- 4- 5- 6- 7-

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)

8- 9- 10- 11- 12- 13- 14- 15- 16-

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

17- Pump 1 Delivery Pressure Sensor 18- Pump 1 Control Pressure Sensor 19- Pump 2 Control Pressure Sensor 20- Torque Control Solenoid Valve 21- Maximum Pump 2 Flow Rate Limit Control Solenoid Valve

T2-2-35

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 Attachment Pump Torque Decrease Control (Only Machine with Attachment Parts Equipped) Purpose: When average pump delivery pressure becomes high while operating the attachment (pulverizer or crusher), driving torque of pumps 1, 2 is reduced and pump delivery pressure is reduced in order to prevent hydraulic oil temperature from rising while operating the attachment. Operation: 1. When all following conditions exist, MC (8) activates torque control solenoid valve (20). 2. Torque control solenoid valve (20) delivers the pilot pressure according to the signals to the regulator and reduces the pump delivery flow rate. 3. This prevents hydraulic oil temperature from rising when operating the attachment. Condition:  Average Pump 1, 2 delivery pressure: High  Work mode: Select pulverizers 1 to 5 or crushers 1 to 5 at attachment mode.  Attachment pump torque control is effective by MPDr. (9).

T2-2-36

SECTION 2 SYSTEM Group 2 Control System 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-02-02-018 1- 2- 3- 4- 5- 6- 7-

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)

8- 9- 10- 11- 12- 13- 14- 15- 16-

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

17- Pump 1 Delivery Pressure Sensor 18- Pump 1 Control Pressure Sensor 19- Pump 2 Control Pressure Sensor 20- Torque Control Solenoid Valve 21- Maximum Pump 2 Flow Rate Limit Control Solenoid Valve

T2-2-37

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 Pump 1 Flow Rate Limit Control (Only Machine Equipped with Attachment) Purpose: The pump 1 flow rate limit control 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. (Refer to SYSTEM / Hydraulic System.)

Q

Operation: 1. When the attachment is used with the travel control lever in neutral, MC (8) receives the signals from pressure sensor (auxiliary 1) (7) (optional). 2. In response to attachment control 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 flow rate can be limited to 50 % at the maximum by MPDr. (9). (P1 Maximum Flow Rate Adjustment)

P

P - Pressure

T2-2-38

Q - Flow Rate

SECTION 2 SYSTEM Group 2 Control System 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 1- 2- 3- 4- 5- 6- 7-

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)

8- 9- 10- 11- 12- 13- 14- 15- 16-

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

17- Pump 1 Delivery Pressure Sensor 18- Pump 1 Control Pressure Sensor 19- Pump 2 Control Pressure Sensor 20- Torque Control Solenoid Valve 21- Maximum Pump 2 Flow Rate Limit Control Solenoid Valve

T2-2-39

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 Pump 2 Flow Rate Limit Control (Only Machine Equipped with Attachment) Purpose: The pump 2 flow rate limit control 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 control lever in neutral, MC (8) receives the signals from pressure sensor (auxiliary 1) (7) (optional). 2. In response to attachment control 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 flow rate can be limited to 50 % 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

Q - Flow Rate

TDAA-05-02-006EN

T2-2-40

SECTION 2 SYSTEM Group 2 Control System 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 1- 2- 3- 4- 5- 6- 7-

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)

8- 9- 10- 11- 12- 13- 14- 15- 16-

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

17- Pump 1 Delivery Pressure Sensor 18- Pump 1 Control Pressure Sensor 19- Pump 2 Control Pressure Sensor 20- Torque Control Solenoid Valve 21- Maximum Pump 2 Flow Rate Limit Control Solenoid Valve

T2-2-41

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 Valve Control The valve control consists of the followings.         

Power Digging Control Auto-Power Lift Control Travel Motor Displacement Angle Control Arm Regenerative Control Digging Regenerative Control * Breaker 1 Control * Breaker 2 Control * Pulverizer Control * Crusher Control

fNOTE:

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

T2-2-42

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 1- 2- 3- 4- 5- 6- 7-

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)

8- 9- 10- 11- 12- 13- 14- 15-

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

T2-2-43

TDCD-02-02-021

23- Arm 2 Flow Rate Control Valve 24- Arm Regenerative Valve 25- Travel Motor Displacement Angle Control Valve 26- Travel Mode 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 control increases digging force by temporarily increasing relief pressure. Operation: 1. For maximum eight 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 to main relief valve (20) and increases relief pressure. (Refer to Control Valve / COMPONENT OPERATION.)

T2-2-44

SECTION 2 SYSTEM Group 2 Control System

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 1- 2- 3- 4- 5- 6- 7-

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)

8- 9- 10- 11- 12- 13- 14- 15-

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

T2-2-45

TDCD-02-02-022

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

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

fNOTE:

This control system is activated during combined operations.

T2-2-46

SECTION 2 SYSTEM Group 2 Control System

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 1- 2- 3- 4- 5- 6- 7-

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)

8- 9- 10- 11- 12- 13- 14- 15-

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

T2-2-47

TDCD-02-02-023

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

SECTION 2 SYSTEM Group 2 Control System Travel Motor Displacement Angle Control Purpose: The travel motor displacement angle 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 exist, MC (8) shifts solenoid valve unit (19) (SG). 2. Solenoid valve unit (19) (SG) delivers pilot pressure to travel motor displacement angle control valve (25) and decreases the displacement angle to the minimum, so that the travel speed increases. Condition:  Travel mode switch (26): Fast Speed (28)  Pressure Sensor (Travel) (4): Signal  Pressure Sensor (Front Attachment) (5): OFF  Pump 1 and 2 delivery Pressure Sensors (16, 15): Delivery pressure of either pump is low. (Reference: 24 MPa or less)  Pump 1 and 2 Control Pressure Sensors (17, 18): Pump control pressure of either pump is high. (Reference: 2.2 MPa or more)

fNOTE:

When the track is raise off 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.

T2-2-48

SECTION 2 SYSTEM Group 2 Control System

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 1- 2- 3- 4- 5- 6- 7-

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)

8- 9- 10- 11- 12- 13- 14- 15-

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

T2-2-49

TDCD-02-02-024

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

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 solenoid valve unit (19) (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 shifts arm regenerative valve (24) and the return circuit from arm cylinder 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, pilot pressure from solenoid 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:  Pump 1 and 2 delivery Pressure Sensors (16, 15): Either pump 1 or 2 delivery pressure is low. (The arm does not need much power to operate.) (Reference: 16.5 MPa or less)  Pressure Sensor (Arm Roll-In) (2): High output. (The arm control lever stroke is large.) (Reference: 0.5 MPa or more)  Pressure Sensor (Swing) (3) or Pressure Sensor (Boom Raise) (1): Signal

T2-2-50

SECTION 2 SYSTEM Group 2 Control System

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 1- 2- 3- 4- 5- 6- 7-

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)

8- 9- 10- 11- 12- 13- 14- 15-

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

T2-2-51

TDCD-02-02-025

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

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

T2-2-52

SECTION 2 SYSTEM Group 2 Control System

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 1- 2- 3- 4- 5- 6- 7-

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)

8- 9- 10- 11- 12- 13- 14- 15-

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

T2-2-53

TDCD-02-02-026

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

SECTION 2 SYSTEM Group 2 Control System Breaker 1 Control (Optional) Purpose: Breaker 1 Control reduces the breaker circuit pressure to prevent breaker from being damaged. Operation: 1. When selecting breaker 1 in monitor (3), MC (4) drives the selector valve (5) control solenoid valve. 2. Pressure oil from the pilot pump (11) flows through the selector valve control solenoid valve (5), shifts the selector valve (8), and the return circuit in breaker (7) is connected to the hydraulic oil tank. 3. At the same time, MC (4) drives the secondary relief control solenoid valve (6). 4. Pressure oil from the pilot pump (11) flows the secondary pilot relief pressure control solenoid valve (6), shifts the secondary pilot relief pressure control valve (9), and reduces relief set pressure in breaker circuit. 5. Therefore, breaker circuit pressure is reduced and prevent the breaker from being damaged. 6. When the maximum pump 2 flow rate limit control solenoid valve (13) is driven in the monitor(3), pump 2 flow rate can be adjusted finely.

T2-2-54

SECTION 2 SYSTEM Group 2 Control System 1

7

3

2

4 5

6

9

8 10

12 11

13

14

15 TDCD-02-02-027 1- 2- 3- 4- 5-

MPDr. Monitor Controller Monitor MC Selector Valve Control Solenoid Valve

6- 7- 8- 9-

Secondary Pilot Relief Pressure Control Solenoid Valve Attachment Selector Valve Secondary Pilot Relief Pressure Control Valve

10- Secondary Pilot Pressure Relief Valve 11- Pilot Pump 12- Attachment Pilot Valve 13- Maximum Pump 2 Flow Rate Limit Control Solenoid Valve

T2-2-55

14- Pilot Pressure from Signal Control Valve 15- Pump 2

SECTION 2 SYSTEM Group 2 Control System Breaker 2 Control (Optional) Purpose: Breaker 2 Control reduces the breaker circuit pressure to prevent breaker from being damaged. In addition, the accumulator in the breaker circuit reduces shock of oil pressure and buffers vibration when breaker is used. Operation: 1. When selecting breaker 2 in monitor (3), MC (4) drives selector valve control solenoid valve (6). 2. Pressure oil from pilot pump (12) flows through selector valve control solenoid valve (6), shifts the selector valve (8), and connects the return circuit of breaker (7) to the hydraulic oil tank. 3. At the same time, MC (4) drives the accumulator control solenoid valve (5). 4. Pressure oil from pilot pump (12) flows to accumulator control solenoid valve (5) and shifts accumulator control valve (9). 5. Accumulators (10, 11) are connected to high pressure side and low pressure side in breaker (7). 6. This reduces shock of oil pressure and buffers vibration when breaker is used. 7. When the maximum pump 2 flow rate limit control solenoid valve (14) is driven in the monitor(3), pump 2 flow rate can be adjusted finely.

T2-2-56

SECTION 2 SYSTEM Group 2 Control System 1

7

9

10

3

2

11 4 5

6

8

13 12

14

15

16 TDCD-02-02-028 1- 2- 3- 4- 5-

MPDr. Monitor Controller Monitor MC Accumulator Control Solenoid Valve

6-

Selector Valve Control Solenoid Valve 7- Attachment 8- Selector Valve 9- Accumulator Control Valve 10- Accumulator (High Pressure)

11- 12- 13- 14-

T2-2-57

Accumulator (Low Pressure) Pilot Pump Attachment Pilot Valve Maximum Pump 2 Flow Rate Limit Control Solenoid Valve

15- Pilot Pressure from Signal Control Valve 16- Pump 2

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 1 in monitor (3), MC (4) drives auxiliary flow combiner control solenoid valve (16). 2. When operating pulverizer (10), pressure 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 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, operating speed of the pulverizer increases. 4. Flow rate of auxiliary flow rate control solenoid valve (17) can be adjusted finely in the monitor (3).

 During Combined Operation 1. When the following 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. 2. As pressure oil which flows to arm roll-out, 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. Condition:  Pressure Sensor (Auxiliary): Outputting signal Pressure Sensor (Arm Roll-Out): Outputting signal  Pressure Sensor (Auxiliary): Outputting signal Pressure Sensors (Arm Roll-Out and Boom Raise): Outputting Signal  Pressure Sensor (Auxiliary): Outputting signal Pressure Sensor (Swing): Outputting signal  Pressure Sensor (Auxiliary): Outputting signal Pressure Sensor (Travel): Outputting signal

T2-2-58

SECTION 2 SYSTEM Group 2 Control System 1

3

2

10

5 6 7 8 9

4

13

12

11

19

18 17

14 15 16

1- 2- 3- 4- 5- 6-

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

7- 8- 9- 10- 11-

TDCD-02-02-029

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

12- 13- 14- 15- 16-

T2-2-59

Auxiliary Flow Combiner Valve From Pump 1 Bypass Shut-Out Valve From 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 1 in monitor (3), MC (4) drives auxiliary flow combiner control solenoid valve (16). 2. When operating crusher (10), pressure 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 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, operating speed of the crusher increases. 4. Flow rate of auxiliary flow rate control solenoid valve (17) can be adjusted finely in monitor (3).

 During Combined Operation 1. When the following 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, 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): Outputting signal Pressure Sensor (Arm Roll-Out): Outputting signal  Pressure Sensor (Auxiliary): Outputting signal Pressure Sensors (Arm Roll-Out and Boom Raise): Outputting signal  Pressure Sensor (Auxiliary): Outputting signal Pressure Sensor (Swing): Outputting signal  Pressure Sensor (Auxiliary): Outputting signal Pressure Sensor (Travel): Outputting signal

T2-2-60

SECTION 2 SYSTEM Group 2 Control System 1

3

2

10

5 6 7 8 9

4

13

12

11

19

18 17

14 15 16

1- 2- 3- 4- 5- 6-

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

7- 8- 9- 10- 11-

TDCD-02-02-029

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

12- 13- 14- 15- 16-

T2-2-61

Auxiliary Flow Combiner Valve From Pump 1 Bypass Shut-Out Valve From 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.    

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

fNOTE:

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

T2-2-62

SECTION 2 SYSTEM Group 2 Control System Work Mode Control The work mode control consists of digging and attachment 1 to 11. The mode can be selected 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 T2-2-26), increasing or decreasing pump flow rate (refer to T2-2-38 to 41), and valve selection (refer to T2-2-54 to 61) are controlled. The engine speed and pump flow rate control settings are made by MPDr..

fNOTE:

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

T2-2-63

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

fNOTE:

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

1 4

3

6

2

5

7 TDAA-02-02-010

1-

Pressure Sensor (Auxiliary 1) (Optional)

2- 3-

MC CAN

4- 5-

T2-2-64

MPDr. Monitor Controller

6- 7-

Monitor Buzzer

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

1- 2-

Pressure Sensor (Travel) MC

3- 4-

Travel Alarm Device Buzzer Deactivation Switch

5-

T2-2-65

Buzzer

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

1- 2-

Pressure Sensor (Swing) MC

3- 4-

Swing Alarm Relay Buzzer Deactivation Switch

5- 6-

T2-2-66

Buzzer Beacon Light

SECTION 2 SYSTEM Group 3 Hydraulic System Outline The hydraulic system mainly consists of the pilot 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

Signal Control Valve

Travel Motor Displacement Angle Control Circuit 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 Motor Displacement Angle Control Circuit Swing Parking Brake Release Circuit

T2-3-2

SECTION 2 SYSTEM Group 3 Hydraulic System 5

6

2

1

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

1- 2- 3- 4- 5- 6-

Pilot Valve (Left) Travel Pilot Valve 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- Torque 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

20- 21- 22- 23- 24- 25- 26- 27- 28- 29- 30-

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 Motor 32- Travel Motor 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

SECTION 2 SYSTEM Group 3 Hydraulic System Operation Control Circuit 1. The pilot valve controls pressure oil from pilot pump (20) and moves the spool in control valve (19). 2. In addition, signal control valve (18) is 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

SECTION 2 SYSTEM Group 3 Hydraulic System 14

15

16

17 13 18

9 10 11 12

4 3

2

1

8

7 6 5 19

9

10

11

12

7

1

2

8

1

4 3 3 5

6

20 TDCD-02-04-002 1- 2- 3- 4- 5- 6-

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

7- 8- 9- 10- 11- 12-

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

13- 14- 15- 16- 17- 18-

T2-3-5

Pilot Shut-Off Solenoid Valve Travel Pilot 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 Rate Control Pressure Pi 1. The pilot pressure from control valve is selected by the shuttle valve in signal control valve (7) so that pump 1 flow control valve (9) or pump 2 flow control valve (8) in signal control valve (7) is shifted. 2. Pilot pressure from pilot pump (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 from pilot pump (11) is controlled 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

SECTION 2 SYSTEM Group 3 Hydraulic System 1

2

3

4

5

6

7

9 8

10

13 12 14

15 Pi

Ppc

11 1- 2- 3- 4- 5- 6-

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

7- 8-

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- Torque Control Solenoid Valve 14- Pump 2 15- Pump 1

T2-3-7

TDCD-02-04-003

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

T2-3-8

SECTION 2 SYSTEM Group 3 Hydraulic System 18

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

1- 2- 3- 4- 5- 6-

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

7- 8- 9- 10- 11- 12- 13- 14-

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- Travel (Right) 19- Arm Roll-In 20- Boom Lower 21- Auxiliary 22- Signal Control Valve

T2-3-9

TDCD-02-04-004

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 the 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 from solenoid valve unit (9) SG controls travel motor displacement angle control valve (11).

T2-3-10

SECTION 2 SYSTEM Group 3 Hydraulic System 1

2

3

4

5

SH

6

9

SG

8

7

10

11

1- 2- 3- 4-

Swing Arm Boom Bucket

5- 6- 7-

TDCD-02-04-005

Signal Control Valve Swing Parking Brake Release Spool Swing Motor

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

T2-3-11

11- Displacement Angel Control Valve

SECTION 2 SYSTEM Group 3 Hydraulic System Main Circuit Outline: 1. The main pump (pumps 1 and 2) draws 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 oil is supplied to the motor and cylinder according to operation of the spool in control valve (6). 3. Return oil from the motor or cylinder returns to hydraulic oil tank (21) through control valve (6) and oil cooler (22). 4. If oil temperature is low (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

19

18 22 20

21

TDCD-02-04-006 1- 2- 3- 4- 5- 6- 7-

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

8- 9- 10- 11- 12- 13- 14-

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

15- 16- 17- 18- 19- 20- 21-

T2-3-13

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

22- 23- 24- 25-

Oil Cooler Swing Motor Arm Cylinder Attachments

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

T2-3-14

SECTION 2 SYSTEM Group 3 Hydraulic System 4

21 2

1

3

20

5

19

6 7

18 17

8

16

9

15 14 10

13

12

11

TDCD-02-04-007 1- 2- 3- 4- 5- 6-

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

7- 8- 9- 10- 11- 12-

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

13- 14- 15- 16- 17- 18-

T2-3-15

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

19- Attachment 20- Travel (Left) Spool 21- Travel Motor (Left)

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

T2-3-16

SECTION 2 SYSTEM Group 3 Hydraulic System

1

2 9

3

8

4 7

6

5

TDCD-02-04-008 1- 2- 3-

Parallel Circuit (Pump 1) Boom 1 Spool Boom Cylinder

4- 5- 6-

Parallel Circuit (Pump 2) Pump 1 Pump 2

7- 8- 9-

T2-3-17

Swing Spool Swing Motor Boom 2 Spool

SECTION 2 SYSTEM Group 3 Hydraulic System  Travel and Arm Roll-In Operation 1. When the arm 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, pilot 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 from pump 1 (8) drives travel right motor (6) through travel right spool (4). 4. At the same time, pressure oil drives travel left motor (1) through flow combiner valve (3) and travel left spool (2). 5. Pressure oil from pump 2 (9) flows to arm cylinder (11) through arm 1 spool (10) and moves the arm. 6. Consequently, pressure oil 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 to arm 2 spool (7).

T2-3-18

SECTION 2 SYSTEM Group 3 Hydraulic System

1

6 2

3

4

5

11

10

7

9

8

TDCD-02-04-009 1- 2- 3- 4-

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

5- 6- 7-

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

8- 9- 10- 11-

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 such as a hydraulic breaker is operated, pilot pressure from attachment pilot valve (3) shifts auxiliary flow combiner valve (2) and bypass shut-out valve (6). 2. 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 of boom raise/lower, arm roll-in/out, bucket roll-in/out and right /left travel, pilot pressure from the signal control valve is supplied to port SN and auxiliary flow combiner valve (2) is not shifted. (Refer to SYSTEM/Control System.)

T2-3-20

SECTION 2 SYSTEM Group 3 Hydraulic System 3

2

4

1 SM

SN

10 5

9

6

8

7 TDCD-02-04-010

1- 2- 3-

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

4- 5- 6-

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

7- 8- 9- 10-

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: High Pressure (with the front attachment above the ground) 1. During combined operation of boom 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 control valve (switch valve) (2) is closed by boom lower pilot pressure. 3. Back pressure in boom flow rate 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 pump 1 (7) is cut by boom flow rate control valve (poppet valve) (1). 5. Pressure 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 oil from pumps 1 (7) and 2 (8) is used for actuators except the boom, the control speed increases.

T2-3-22

SECTION 2 SYSTEM Group 3 Hydraulic System

1

2

3

11 4

10

5

9 6

8

7

TDCD-02-04-011

1- 2-

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

3- 4- 5-

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

6- 7- 8- 9-

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: Low Pressure (JackUp) 1. During boom lower 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 is 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 from pump 1 (6) passes through 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 (8) is moved, combined operation of travel with the track raised is possible.

T2-3-24

SECTION 2 SYSTEM Group 3 Hydraulic System

2

1

3

8

4 5

7

6

TDCD-02-04-012 1- 2-

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

3- 4- 5-

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

6- 7- 8-

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 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.  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 circuit are as follows.  Electric Power Circuit: Supplies all electric power to all electrical systems on the machine. {Key switch, Battery, Fuses (Fuse box, Fusible link)}  CAN Circuit: Performs communication 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: Starts the engine. (Key switch, Starter, Starter relay 2)  Charging Circuit: Supplies electric power to the batteries and charges them. {Alternator, (Regulator)}  Surge Voltage Prevention Circuit: Prevents the occurrence of serge voltage developed when stopping the engine. (Load Dump Relay)  Pilot Shut-Off Circuit (Key switch: 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 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 grounded to the body. Current from the battery (1) plus terminal flows as shown below when key switch (5) is in the OFF position. Battery (1)

Fusible Link (2)

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

Terminal #10

Terminal #11 Terminal #19 Terminal #20

T2-4-4

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

SECTION 2 SYSTEM Group 4 Electrical System

5

3

1

4

2

11 8 19

13 7 8

9 10 20

6

9 10 11 12 14 15 16 17 18 19

TDCD-02-05-001 1- 2- 3- 4- 5- 6-

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

7- 8- 9- 10- 11- 12-

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 (Power) 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 (CAN bus (4)), CAN 0 (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

9

6

1

6

7

10

15

11 5 16

8

6

6 12

13

14

TDCD-02-01-002

1- 2- 3- 4-

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

5- 6- 7- 8-

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

9- 10- 11- 12-

T2-4-7

Communication Controller Monitor Controller MPDr. Wiper / Light Controller

13- 14- 15- 16-

Radio Controller 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, terminal B is connected to terminal ACC (3) in key switch (2). 2. Current from terminal 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 #14 Terminal #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 1- 2- 3-

Battery Key Switch Terminal ACC

4- 5- 6-

Fuse Box Monitor Controller Cigar Lighter

7- 8- 9-

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 position, key switch terminal B (5) is connected to terminal M (6) in key switch (5).

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

2. Current from M terminal (6) flows to terminal #1 of QOS controller through fuse #16. 3. When coolant switch (2) is set in the OFF position (coolant 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 function is operated, QOS controller (3) connects terminal #6 to #5 for 8 seconds. 6. Therefore, terminal #D5 of monitor controller (9) connects to the ground through QOS controller (9). 7. Monitor controller (9) 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

10

D5

7

9 8 TDCD-02-05-003

1- 2- 3-

Glow Plug Relay Coolant Switch QOS Controller

4- 5- 6-

Key Switch Terminal B Terminal M

7- 8- 9-

T2-4-11

Fuse Box Monitor Monitor Controller

10- Glow Plug

SECTION 2 SYSTEM Group 4 Electrical System Starting Circuit (Key Switch: START) 1. When key switch (7) is set to START position (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 (4). Current from battery (1) is routed to terminal B of starter (2) and terminal B of starter relay 2 (3) through battery relay (4). 3. In addition, 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, ECF (14) drives EC motor (15) to move the governor lever to the engine start position. 6. Current from terminal ST (9) flows to terminal S in starter relay 2 (3) through starter 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 terminal C in starter (2) from terminal B in starter relay 2 (3). 9. Consequently, the relay in starter (2) is turned ON so that the starter motor rotates.

T2-4-12

SECTION 2 SYSTEM Group 4 Electrical System 8

9

7

10

6

5 4 1

2

11

B

12

17 C C B S

3

13 14

TDCD-02-05-004

15 1- 2- 3- 4-

Battery Starter Starter Relay 2 Battery Relay

5- 6- 7- 8-

Starter Cut Relay START Position Key Switch Terminal M

9- 10- 11- 12-

T2-4-13

Terminal ST 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 position, terminal B is connected to terminal ST in key switch (4).

fNOTE:

Condenser (C1) as 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 to the base of transistor (Q2) through resistance (R4) in starter relay 2 (1). 3. Therefore, transistor (Q2) is turned ON and current flows to coil (L) in the relay. 4. Consequently, terminal B in starter (2) is connected to terminal C and starter (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 reaches 21 to 22V, Zener diode (Z) is turned ON. 7. Consequently, transistor (Q1) is turned ON and current flowing to the base of transistor (Q2) disappears so that transistor (Q2) is turned OFF. 8. At this moment, 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

1- 2-

Starter Relay 2 Starter

3- 4-

Battery Key Switch

5-

T2-4-14

From Alternator terminal L

SECTION 2 SYSTEM Group 4 Electrical System (Blank)

T2-4-15

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

T2-4-16

SECTION 2 SYSTEM Group 4 Electrical System 5

4

6

3

2

1

8

B L

9

7 1- 2- 3-

Battery Battery Relay ON Position

TDCD-02-05-006 4- 5- 6-

Key Switch Terminal ACC Terminal M

7- 8- 9-

T2-4-17

Alternator GSM Monitor Controller

SECTION 2 SYSTEM Group 4 Electrical System Alternator (5) Operation  Alternator (5) consists of field coil FC, stator coil SC, and diodes D.  Regulator (6) consists of transistors T1 and T2, Zener diode ZD, and resistances R1 and R2.  Terminal M (4) in the key switch is connected to base B of transistor T1 through R, RF, (R), and R1.  When battery relay (2) is in the ON 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, no current is flowing 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 through field coil FC, the rotor is further magnetized so that the generating voltage increases. Thereby, current through field coil FC increases. Therefore, generating voltage increases further and battery (1) start charging.

5

6

2

1

TDAA-02-05-004

1- 2-

Battery Battery Relay

3- 4-

To Key Switch Terminal B From Key Switch Terminal M

5- 6-

T2-4-18

Alternator Regulator

SECTION 2 SYSTEM Group 4 Electrical System Regulator (6) Operation  When generating voltage increases 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 through filed coil FC and generating voltage at stator coil SC decreases.

3

4

 When generating voltage 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 FC and generating voltage at stator coil SC increases. The above operation is repeated so that alternator (5) generating voltage is kept constant.

5

6

2

SC

1

TDAA-02-05-003

1- 2-

Battery Battery Relay

3- 4-

To Key Switch Terminal B From Key Switch Terminal M

5- 6-

T2-4-19

Alternator Regulator

SECTION 2 SYSTEM Group 4 Electrical System Surge Voltage Prevention Circuit 1. When the engine 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 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 (5) is generating 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 the exciting circuit in load dump relay (3) and load dump relay (3) is turned ON. 6. 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

SECTION 2 SYSTEM Group 4 Electrical System 4

3 2

1

D8 A15

6

L

TDCD-02-05-007

5 1- 2-

Battery Battery Relay

3- 4-

Load Dump Relay Key Switch

5- 6-

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 position, pilot shut-off switch (5) is turned ON. 2. Current from fuse #4 flows 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) is 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 (3) is turned ON and pressure oil from the pilot pump is supplied to the pilot valve.  Neutral Engine Start Circuit 1. When the pilot shut-off lever is set to the 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 position 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 shut-off lever is in the UNLOCK position, even if key switch (6) is set to the START position, the starter does not rotate and the engine does not start.

fNOTE:

When the pilot shut-off lever is set 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 position.

T2-4-22

SECTION 2 SYSTEM Group 4 Electrical System 7

6

2

3

4

5

1

8 4

S

10 9

C1

11

TDCD-02-05-008 1- 2- 3-

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

4- 5-

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

6- 7- 8-

T2-4-23

Key Switch Terminal 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, 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 that 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 starter rotates with engine stop switch (5) set in the ON position, the engine does not start.

T2-4-24

SECTION 2 SYSTEM Group 4 Electrical System 1

2

3

4 17

5

26

6

TDCD-02-05-009

7 1- 2-

Key Switch Terminal B

3- 4-

Terminal M Fuse Box

5- 6-

T2-4-25

Engine Stop Switch ECF

7-

EC Motor

SECTION 2 SYSTEM Group 4 Electrical System (Blank)

T2-4-26

SECTION 2 SYSTEM Group 4 Electrical System Monitor Circuit The major functions and circuits in the monitor circuit are as follows.  Security Circuit: Disconnects current for engine starting from the key switch according to the signals from the external alarm system or monitor 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. (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 (9), and starter cut relay (2) are excited. 3. When security horn relay (8) is excited, current from fuse #9 activates security horn (7). 4. When security relay (9) is excited, the ground circuit in pilot shut-off solenoid valve (1) is disconnected and pilot shut-off solenoid valve (1) is turned OFF. 5. Therefore, pressure oil which flows to the pilot valve from the pilot pump is blocked by pilot shut-off solenoid valve (1). 6. In addition, when starter cut relay (2) 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 if key switch (3) is set to the 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

1- 2- 3-

Pilot Shut-Off Solenoid Valve Starter Cut Relay Key Switch

4- 5- 6-

Terminal ST Fuse Box Monitor Controller

7- 8- 9-

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 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 (3) 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 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 (3) sends the signal to air conditioner controller (6) by using CAN communication and the air conditioner is operated.

T2-4-30

SECTION 2 SYSTEM Group 4 Electrical System

1

2

4 3 3

12

4

17 14

CAN1

6 5 1- 2-

Monitor Switch Panel

3- 4-

Monitor Controller Fuse Box

5- 6-

T2-4-31

Radio Controller Air Conditioner Controller

TDCD-02-05-011

SECTION 2 SYSTEM Group 4 Electrical System (Blank)

T2-4-32

SECTION 2 SYSTEM Group 4 Electrical System Accessory Circuit The major functions and circuits in the accessory circuit are as follows.  Work Light Circuit: Turns on the work light and boom 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 switch (4) is set to the 1 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 1 (8) is turned ON and current from fuse #1 turns on work light (9). 3. In addition, wiper/light controller (5) sends the signal to monitor controller (3) by using CAN communication. 4. Monitor controller (3) displays the operating condition of work light switch (4) on monitor (1).

MDAA-01-222

Boom Light (10) Circuit 1. When work light switch (4) is set to the 2 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 light relay 1 (8) and work light 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 controller (5) sends the signal to monitor controller (3) by using CAN communication. 4. Monitor controller (3) 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 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

SECTION 2 SYSTEM Group 4 Electrical System 1

2

3

6 1

17

CAN1

A6 A2

10

4

9 5 8

7

TDCD-02-05-012 1- 2- 3-

Monitor Switch Panel Monitor Controller

4- 5- 6-

Work Light Switch Wiper/Light Controller Fuse Box

7- 8- 9-

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. position, the signals according to the set intervals are sent to wiper/light controller (5). 2. Wiper/light controller (5) connects terminal #B9 to the ground inside according to the input intervals.

2 1

3. Therefore, wiper relay (6) is turned ON  OFF repeatedly. 4. When wiper relay (6) is ON, current from fuse #2 flows to wiper motor (9) and the wiper is operated. 5. In addition, wiper/light 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 controller (5) receives the signals from wiper/washer switch (4).

3

2. Wiper/light controller (5) connects terminal #A5 to the ground inside and washer relay (7) is excited. 3. Current from fuse #2 flows to washer motor (8) and washer liquid is jetted. 4. In addition, when pushing 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 are operated at the same time.

T2-4-36

MDAA-01-222

SECTION 2 SYSTEM Group 4 Electrical System

3

1

2

2

17

CAN1

B9 A5

5

8

6

7

TDCD-02-05-013

9 1- 2- 3-

Fuse Box Monitor Controller Monitor

4

4- 5- 6-

Wiper/Washer Switch Wiper/Light Controller Wiper Relay

7- 8- 9-

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 switch (7) is set to door interlocking position (6), current from fuse #9 flows to terminal #B10 of wiper/light controller (4). 2. When the 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 the cab door is closed and disconnects terminal #B10 from the ground. 4. When the 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 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 (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, cab light 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 and the 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 switch (7) is set to the ON position, current from fuse #9 flows to terminal #A7 of wiper/ light controller (4). 3. Consequently, cab light (8) is always on with cab light switch (7) set in the ON position.

SECTION 2 SYSTEM Group 4 Electrical System 1

2 9

5

B18 B10 A7

3

4 8

7

6

TDCD-02-05-014 1- 2-

Key Switch Fuse Box

3- 4-

Door Open/Close Switch Wiper/Light Controller

5- 6-

T2-4-39

ON Position Door Interlocking Position

7- 8-

Cab Light Switch Cab Light

SECTION 2 SYSTEM Group 4 Electrical System (Blank)

T2-4-40

MEMO

MEMO

SECTION 3

COMPONENT OPERATION CONTENTS Group 1 Pump Device

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

Group 2 Swing Device

Outline..................................................................................... T3-2-1 Swing Reduction Gear....................................................... 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 Flow Combiner Valve........................................................T3-3-28 Main Relief Valve................................................................T3-3-30 Overload Relief Valve (with Make-Up Function).....T3-3-34 Regenerative Valve............................................................T3-3-38 Anti-Drift Valve....................................................................T3-3-42 Flow Rate Control Valve...................................................T3-3-46 Digging Regenerative Valve...........................................T3-3-50 Boom Lower Meter-In Cut Valve...................................T3-3-52 Auxiliary Flow Combiner Valve and Bypass Shut-Out Valve...............................................................T3-3-54

Group 6 Signal Control Valve

Outline..................................................................................... T3-6-1 Pilot Port.................................................................................. T3-6-2 Shuttle Valve.......................................................................... T3-6-7 Shockless Valve...................................................................T3-6-10 Pump 1 and 2 Flow Rate Control Valve......................T3-6-14 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...........................T3-6-16

Group 7 Others (Upperstructure)

Pilot Shut-Off Solenoid Valve........................................... T3-7-1 Solenoid Valve....................................................................... T3-7-3 Pilot Relief Valve................................................................... T3-7-6 EC Motor................................................................................. T3-7-6 Hose Rupture Valve............................................................. T3-7-8

Group 8 Others (Undercarriage)

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

Group 4 Pilot Valve

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

Group 5 Travel Device

Outline..................................................................................... T3-5-1 Travel Reduction Gear........................................................ T3-5-2 Travel Motor........................................................................... T3-5-4 Parking Brake......................................................................... T3-5-6 Travel Brake Valve................................................................ T3-5-8 Overload Relief Valve........................................................T3-5-12 Travel Mode Control.........................................................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 (11), main pump (pump 1 (3), pump 2 (2)), and pilot pump (1). The engine output power is 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 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 control solenoid valve (7), and 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

5

1- 2- 3- 4-

Pilot Pump Pump 2 Pump 1 Pump 1 Delivery Pressure Sensor

5- 6- 7-

TDCD-03-01-001

4

Pump 2 Delivery Pressure Sensor Pump 1 Control Pressure Sensor Torque 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- Transmission 12- Coupling

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Main Pump The main pump supplies pressure 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

1- 2-

Regulator Housing

3- 4-

Shaft Plunger

5- 6-

T3-1-2

Valve Plate Cylinder Block

TDCD-03-01-002

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) surface. 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 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 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

5

4

TDCD-03-01-003

Minimum Displacement Angle (Operable Limit Angle)

α

T105-02-03-022

4- 5-

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 1, and pump 2 are equipped with regulator (16) for each.

14 13

The major parts of regulator (16) are spring (1), 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 delivery flow rate is controlled.

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

14- Maximum Pump 2 Flow Rate Limit Control Solenoid Valve

fNOTE:

Primary pilot pressure Pg is constantly routed to the small chamber side of servo piston (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 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

3

5

6 1

4

7 3

8 2

Dr

TDCD-03-01-005

9

4

Pi

15

Pd2 Pps

Dr

Pd1 Dr

5

7

8, 9

6

Pg

10

a

b

12

TDCD-03-01-006

Pd1- Pump 1 Delivery Pressure

Dr- Returning to Hydraulic Oil Tank

Pps- Torque Control Pressure

a-

Displacement Angle Increase

Pd2- Pump 2 Delivery Pressure

Pi- Pump Control Pressure

Pg- Primary Pilot Pressure (From Pilot Pump)

b-

Displacement Angle Decrease

1- 2- 3- 4-

5- 6- 7- 8-

9- 10- 12- 13-

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

Spring Sleeve A Spool A Piston

Load Piston Spool B Sleeve B Inner Spring

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 13

2

4

7

8 4

9

TDCD-03-01-007

14

3 1 Pi

15

Dr Pd2 Pps

Dr

Pd1

8, 9

Dr

5

7

6

10

Pg a

12 TDCD-03-01-008

b

Pd1- Pump 1 Delivery Pressure

Dr- Returning to Hydraulic Oil Tank

Pps- Torque Control Pressure

a-

Displacement Angle Increase

Pd2- Pump 2 Delivery Pressure

Pi- Pump Control Pressure

Pg- Primary Pilot Pressure (From Pilot Pump)

b-

Displacement Angle Decrease

1- 2- 3- 4-

5- 6- 7- 8-

9- 10- 12- 13-

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

Spring Sleeve A Spool A Piston

Load Piston Spool B Sleeve B Inner Spring

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 four control functions.

Q

 Control by Pump Control Pressure When a control lever is operated, the pump flow 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.

0

Pi

Q- Flow Rate

Pi- Pump Control Pressure

Q

 Control by Own and Partner Pump Delivery Pressure (Regulators for Pump 1 and Pump 2) The regulators for pump 1 and pump 2 receive own pump delivery pressure Pd1 or Pd2 and partner pump delivery pressure Pd2 or Pd1 as control signal pressures. If the two-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

P

Q- Flow Rate P- Pressure

c- d-

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 Pi- Pump Control Pressure Pps- Torque Control Pressure 15- Air Bleeding Circuit

T3-1-9

b

TDCD-03-01-008

Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement 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 control solenoid valve (13) 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

P

Q- Flow Rate

P-

Pressure

13

Pi

15

Dr Pd2 Pps

Dr

Pd1 Dr Pg a

b

TDCD-03-01-008

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

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

13- Torque Control Solenoid Valve

15- Air Bleeding Circuit

T3-1-10

SECTION 3 COMPONENT OPERATION Group 1 Pump Device  Control by Pilot Pressure from Maximum Pump 2 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 is limited. (Pump Flow Rate Limit Control) (Refer to SYSTEM / Control System.)

Q

0

Pi

Q- Flow Rate

Pi- Pump Control Pressure

c Q

d

0

P

Q- Flow Rate P- Pressure

c- d-

Maximum Flow Rate Upper Limit Flow Rate

14

Pi

15

Dr Pd2 Pps

Dr

Pd1 Dr

Pg a

b

TDCD-03-01-008

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

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

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 here.

 Flow Rate Increase 1. When a control lever is 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 of spool A (3), the circuit from the large chamber of servo piston (10) is opened to the hydraulic oil tank.

0 Q- Flow Rate

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

Pi- Pump Control Pressure

2

4

3 1

5. The movement of cylinder block is 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 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.

Pi

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

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

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

1- 2- 3- 4-

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

T3-1-12

Spring Sleeve A Spool A Piston

SECTION 3 COMPONENT OPERATION Group 1 Pump Device

fNOTE:

The illustration shows the pump2 regulator. 1

Dr

2

Pg

3

4 Pi

Pps

Pd2

12

Pd1

10

1

Dr

2

Pg

TDCD-03-01-009

3

4 Pi

Pps

Pd2

12

Pd1

a

10

TDCD-03-01-010

b

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

Dr- Returning to Hydraulic Oil Tank

Pi- Pump Control Pressure Pps- Torque Control Pressure

Pg- Primary Pliot Pressure (From Pilot Pump)

1- 2-

3- 4-

10- Servo Piston

12- Link

Spring Sleeve A

Spool A Piston

T3-1-13

SECTION 3 COMPONENT OPERATION Group 1 Pump Device  Flow Rate Decrease 1. When a control lever is returned, the flow rate control valve in the signal control valve is returned and pump control pressure Pi decreases.

Q

2. Piston (4) and spool A (3) are pushed by spring (1) so that spool A (3) is moved toward direction of the arrow. 3. Due to the movement of spool A (3), 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- Flow Rate

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

Pi- Pump Control Pressure

2

4

3

6. When sleeve A (2) is 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.

Pi

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

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

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

1- 2- 3- 4-

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

T3-1-14

Spring Sleeve A Spool A Piston

SECTION 3 COMPONENT OPERATION Group 1 Pump Device

fNOTE:

The illustration shows the pump2 regulator. 1

Dr

2

Pg

3

4 Pi

Pps

Pd2

12

Pd1

10

1

Dr

Pg

2

TDCD-03-01-011

3

4 Pi

Pps

Pd2

12

Pd1

a

10

TDCD-03-01-012

b

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

Dr- Returning to Hydraulic Oil Tank

Pi- Pump Control Pressure Pps- Torque Control Pressure

Pg- Primary Pilot Pressure (From Pilot Pump)

1- 2-

3- 4-

10- Servo 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

The pump 2 regulator is explained here.

 Flow Rate Decrease 1. When pump 2 (own pump) is loaded, pump 2 delivery pressure Pd2 (own pump pressure) increases. (During operation, pump control pressure Pi is kept increased.) 2. Load piston (5) pushes spool B (6), inner spring (8), and outer spring (9). Spool B (6) is moved toward direction of the arrow.

0

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

Q- Flow Rate

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.

Pressure

15

Dr Pd2 Pps

6. When sleeve B (7) is 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, servo piston (10) is stopped and the flow rate decreasing operation is completed.

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

P-

Pi

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

7. When pump 1 (partner pump) is also 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.

P

Dr

Pd1

8, 9

Dr

5

7 10

6

Pg a

b

12 TDCD-03-01-008

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

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

5- 6- 7- 8-

9- 10- 12- 15-

T3-1-16

Load Piston Spool B Sleeve B Inner Spring

Outer Spring Servo Piston Link Air Bleeding Circuit

SECTION 3 COMPONENT OPERATION Group 1 Pump Device

fNOTE:

The illustration shows the pump2 regulator. 5

Dr

6

Pg

7 Pi

Pps

8

Pd2

9

12

Pd1

10

5

Dr

TDCD-03-01-013

6

Pg

7 Pi

Pps

8

Pd2

9

12

Pd1

a

10

TDCD-03-01-014

b

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

Dr- Returning to Hydraulic Oil Tank

Pi- Pump Control Pressure Pps- Torque Control Pressure

Pg- Primary Pilot Pressure (From Pilot Pump)

5- 6-

7- 8-

9- Outer Spring 10- Servo Piston

12- Link

Load Piston Spool B

Sleeve B Inner Spring

T3-1-17

SECTION 3 COMPONENT OPERATION Group 1 Pump Device  Flow Rate Increase 1. When the load of pump 2 (own pump) is reduced, pump 2 delivery pressure Pd2 (own pump pressure) decreases. (During operation, pump control pressure Pi is kept increased.)

Q

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

0 Q- Flow Rate

P-

Pressure

2

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

3

6. When sleeve B (7) is 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

15

Dr Pd2 Pps

7. When the load of pump 1 (partner 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. 8. Consequently, as the movement of spool B (6) increases, the pump delivery flow rate increases further.

P

Dr

Pd1

8, 9

Dr

5

7 10

6

Pg a

b

12 TDCD-03-01-008

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

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

2- 3- 5- 6- 7-

8- 9- 10- 12- 15-

T3-1-18

Sleeve A Spool A Load Piston Spool B Sleeve B

Inner Spring Outer Spring Servo Piston Link Air Bleeding Circuit

SECTION 3 COMPONENT OPERATION Group 1 Pump Device

fNOTE:

The illustration shows the pump2 regulator. 5

Dr

2

Pg

3

6 Pi

Pps

8

Pd2

9

12

Pd1

10

5

6

Dr

Pg

2

TDCD-03-01-015

3

7 Pi

Pps

8

Pd2

12

Pd1

a

10

TDCD-03-01-016 b

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

Dr- Returning to Hydraulic Oil Tank

Pi- Pump Control Pressure Pps- Torque Control Pressure

2- 3- 5-

6- 7- 8-

9- Outer Spring 10- Servo Piston 12- Link

Sleeve A Spool A Load Piston

9

Spool B Sleeve B Inner Spring

T3-1-19

Pg- Primary Pilot Pressure (From Pilot Pump)

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

fNOTE:

Q

The pump 2 regulator is explained here.

 Flow Rate Decrease 1. Torque control solenoid valve (13) is 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) pushes spool B (6), inner spring (8), and outer spring (9). Spool B (6) is moved toward direction of the arrow.

P

Q- Flow Rate

P-

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

Pressure

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 inclination direction and the pump delivery flow rate decreases.

Pi

15

Dr

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

Pd2 Pps

Dr

Pd1

7. When sleeve B (7) is 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, servo piston (10) is stopped and the flow rate decreasing operation is completed.

8, 9

Dr

5

7 10

6

Pg a

b

12 TDCD-03-01-008

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

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

5- 6- 7- 8- 9-

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

SECTION 3 COMPONENT OPERATION Group 1 Pump Device

fNOTE:

The illustration shows the pump2 regulator. 5

Dr

6

Pg

7 Pi

Pps

8

Pd2

9

12

Pd1

10

5

Dr

TDCD-03-01-017

6

Pg

7 Pi

Pps

8

Pd2

9

12

Pd1

a

10

TDCD-03-01-018

b

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

Dr- Returning to Hydraulic Oil Tank

Pi- Pump Control Pressure Pps- Torque Control Pressure

Pg- Primary Pilot Pressure (From Pilot Pump)

5- 6-

7- 8-

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 Rate Control (only Pump 2) 1. Maximum pump 2 flow rate limit control 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 limit control solenoid valve (14) functions as a pressure reducing valve and pump control pressure Pi decreases.

0

Pi

Q- Flow Rate

Pi- Pump Control Pressure

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

a

Q

b

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

0

P

Q- Flow Rate P- Pressure

7. As primary pilot pressure Pg is constantly 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 the maximum inclination direction and the pump delivery flow rate increases.

a- b-

Maximum Flow Rate Upper Limit Flow Rate

4

2

14

3 1

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

Pi

15

Dr

9. When sleeve A (2) is 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 Dr

10. Therefore, servo piston (10) is stopped and the flow rate increasing operation is completed. 11. 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.

Pg

10

a

b

12 TDCD-03-01-008

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

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

1- 2- 3- 4-

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

T3-1-22

Spring Sleeve A Spool A Piston

SECTION 3 COMPONENT OPERATION Group 1 Pump Device

1

Dr

2

Pg

3

4 Pi

Pps

Pd2

12

Pd1

10

1

Dr

2

Pg

TDCD-03-01-019

3

4 Pi

Pps

Pd2

12

Pd1

a

10

TDCD-03-01-020

b

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

Dr- Returning to Hydraulic Oil Tank

Pi- 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)

1- 2-

3- 4-

10- Servo Piston

12- Link

Spring Sleeve A

Spool A Piston

T3-1-23

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Solenoid Valve

Operation

The torque control solenoid valve and the maximum pump 2 flow rate limit control solenoid valve are equipped for the pump 2 regulator. The torque control solenoid valve supplies 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 rate limit 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, port P (5) is connected to output port (4) through the notch on spool (3). 2. When current flows to solenoid (7) from MC (main controller), solenoid (7) is excited and pushes piston (6). 3. As piston (6) pushes spool (3), output 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 A as 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 at output port (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: Pressure Receiving Area on Spool (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

Operating state: 1

2

A

3

B

4

8

6 9

7

TDAA-03-01-002

1- 2- 3-

Spring 1 Spring 2 Spool

4- 5-

Output Port Port P

6- 7-

T3-1-25

Piston Solenoid

8- 9-

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

Pump Delivery Pressure Sensor

a-

Inlet Port

3

4

b-

Outlet Port

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.

3- 4-

Ground Output

5- 6-

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

5

6

T157-02-03-010

Pump Control Pressure Sensor This sensor detects the pump control 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.

7- 8-

Pressure Receiving Area (Diaphragm) Ground

9- Output 10- Power Source (5 V)

7

8

9

10

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 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

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 unit (1), swing 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 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 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 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 1- 2- 3-

Swing Motor Shaft (Swing Motor) First Stage Planetary Gear

4- 5- 6-

Ring Gear Second Stage Planetary Gear Shaft

7- 8- 9-

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 plate (9), rotor (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 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 of shaft (8) is transmitted to the swing reduction gear.

1 2

13

3 12

14

4 11

5

10

6

9

8

7 T1V1-03-02-008

1- 2- 3- 4-

Spring Brake Piston Plate Swing Parking Brake Selection Valve

5- 6- 7- 8- 9-

Friction Plate Plunger Retainer Shaft Swash Plate

10- 11- 12- 13- 14-

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 released multi-disc brake. When the brake release pressure is routed to brake piston chamber (6), the brake is released. The brake release 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 or front attachment control 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 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 to port SH (5) opens check valve (4) and acts on brake piston chamber (6).

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

3. Consequently, as brake piston (2) is pushed 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 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 4

10

8 5

6

7

TDAA-03-02-008 1- 2- 3-

Spring Brake Piston Orifice

4- 5-

Check Valve Port SH (Brake Release Pressure)

6- 7- 8-

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. 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 1- 2-

T3-2-6

Relief Valve Make-Up Valve

3- 4-

Port M Control Valve

SECTION 3 COMPONENT OPERATION Group 2 Swing Device

4

5

6 2

2

3

1 1- 2-

Relief Valve Make-Up Valve

3- 4-

Port M Control Valve

TDCD-03-02-001 5- 6-

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

 High-Pressure Relief Operation (Overload Prevention): 1. After piston (6) reaches the stroke end, spring (3) is compressed and the circuit pressure becomes the normal relief set pressure.

2. Pressure 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).

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 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, 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. 5. When piston (6) reaches the stroke 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

HP - Port HP (Swing Circuit)

LP - Port LP (Return Circuit)

1- 2- 3-

4- 5- 6-

Poppet Orifice Spring

Passage A Passage B Piston

7- 8- 9-

T3-2-8

Oil Chamber B Oil Chamber A Oil Chamber C

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Outline The control valve controls the oil pressure, flow rate, and flow direction in the hydraulic circuit. The major parts are the main relief valve, 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 a-

Machine Upper Side

b-

Machine Front Side

c-

4-Spool Section

d-

1- 2- 3-

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

4- 5- 6-

Boom 1 Arm 2 Swing

7- 8- 9-

Arm 1 Boom 2 Auxiliary

10- Travel (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

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

a- 1-

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 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 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 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 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

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

a- 1-

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

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)

23- Arm 2 Flow Rate Control Valve (Selector Valve) 24- Load Check Valve (Arm 2 Tandem 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 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 Circuit)

T3-3-5

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 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

T3-3-6

SECTION 3 COMPONENT OPERATION Group 3 Control Valve

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

a- 1-

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

B

c-

T1V1-03-03-026

T1V1-03-03-003

Machine Lower Side

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)

23- Arm 2 Flow Rate Control Valve (Selector Valve) 24- Load Check Valve (Arm 2 Tandem 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 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 Circuit)

T3-3-7

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 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

T3-3-8

SECTION 3 COMPONENT OPERATION Group 3 Control Valve

Section A-A

Section B-B

3

2 12 28

9

21

27 33 T1V1-03-03-001

a- 1-

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

c-

T1V1-03-03-002

Machine Lower Side

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)

23- Arm 2 Flow Rate Control Valve (Selector Valve) 24- Load Check Valve (Arm 2 Tandem 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 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 Circuit)

T3-3-9

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 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

T3-3-10

SECTION 3 COMPONENT OPERATION Group 3 Control Valve

Section D-D

Section E-E h

i

j

k

13 41 10 11

40

14

12 T1V1-03-03-004

a- e- 1-

Machine Upper Side Machine Lower 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

h- i-

Travel (Left) Travel (Right)

T1V1-03-03-005

J- k-

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)

Auxiliary Bucket

23- Arm 2 Flow Rate Control Valve (Selector Valve) 24- Load Check Valve (Arm 2 Tandem 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 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 Circuit)

T3-3-11

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 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

T3-3-12

SECTION 3 COMPONENT OPERATION Group 3 Control Valve

Section F-F

Section G-G l

m

22 37 19

39

16

17

15 38

20

21

26

28

T1V1-03-03-006 a- 1-

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

T1V1-03-03-007 l-

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)

Boom 2

23- Arm 2 Flow Rate Control Valve (Selector Valve) 24- Load Check Valve (Arm 2 Tandem 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 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 Circuit)

T3-3-13

m- Boom 1 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 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

T3-3-14

SECTION 3 COMPONENT OPERATION Group 3 Control Valve

Section H-H

Section I-I n

o

p

34 18

27 31

36 24 32

23 30

35

a- e- 1-

Machine Upper Side Machine Lower 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

n- o-

T1V1-03-03-008

Arm 1 Arm 2

T1V1-03-03-009

P-

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)

Swing

23- Arm 2 Flow Rate Control Valve (Selector Valve) 24- Load Check Valve (Arm 2 Tandem 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 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 Circuit)

T3-3-15

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 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

T3-3-16

SECTION 3 COMPONENT OPERATION Group 3 Control Valve

Section J-J 25

T1V1-03-03-010

a- 1-

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

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)

23- Arm 2 Flow Rate Control Valve (Selector Valve) 24- Load Check Valve (Arm 2 Tandem 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 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 Circuit)

T3-3-17

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 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

T3-3-18

SECTION 3 COMPONENT OPERATION Group 3 Control Valve

Section K-K

Section L-L 8

K

6

K

L

L

M

Section M-M

M

42

T1V1-03-03-027

TDCD-03-03-030 a- 1-

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

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)

23- Arm 2 Flow Rate Control Valve (Selector Valve) 24- Load Check Valve (Arm 2 Tandem 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 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 Circuit)

T3-3-19

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 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

T3-3-20

SECTION 3 COMPONENT OPERATION Group 3 Control Valve

Section N-N 1 N

N

TDCD-03-03-031

T1V1-03-03-028

a- 1-

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

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)

23- Arm 2 Flow Rate Control Valve (Selector Valve) 24- Load Check Valve (Arm 2 Tandem 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 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 Circuit)

T3-3-21

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 Circuit)

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 control valve. The parallel circuits (2), (10) are 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 (1) is provided in the 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 valves (5), (12) 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 1- 2- 3- 4-

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

5- 6- 7- 8-

Overload Relief Valve Boom Cylinder Flow Combiner Circuit Pump 1

9- 10- 11- 12-

T3-3-23

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

13- Arm Cylinder 14- Attachment 15- Travel Motor (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.  During arm roll-in (4) operation, pressure oil moves the arm spool and shifts the selector valve spool of the arm anti-drift valve (d).  During boom lower (2) operation, pressure oil moves the boom 1 spool and shifts the selector valve spool of the boom anti-drift valve (c).  In addition, during boom lower (2) operation, the 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 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.

T3-3-24

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

9 10 13

11

12

14 7

8

b

1 2

d

3

1

c

3

e

4 6

4

5

TDCD-03-03-027 a - Air Bleed Circuit

b - Boom Lower Meter-In Cut Valve

c - Boom Anti-Drift Valve d - Arm Anti-Drift Valve

e - Bypass Shut-out Valve

1- 2- 3- 4-

5- 6- 7- 8-

9- 10- 11- 12-

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

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

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

T3-3-25

Travel (Left Forward) Travel (Left Reverse) Travel (Right Forward) Travel (Right Reverse)

SECTION 3 COMPONENT OPERATION Group 3 Control Valve External Pilot Pressure Circuit  Pressure in main relief valve (1) is increased by pilot pressure (b) from solenoid valve unit (SG).  Arm 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 valve (4) is 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 valve (2) is shifted by pilot pressure (c) from the flow combiner valve control spool in the signal control valve.  Bucket flow rate control valve (3) is shifted by pilot pressure (d) from the bucket flow rate control valve control spool in the signal control valve.  Auxiliary flow rate control valve (9) is shifted by pilot pressure (h) from the auxiliary flow rate control solenoid valve (optional).

fNOTE:

In 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

10

1

2 3

c

9 d

h

4 5

e

6

g

f

8 7 TDCD-03-03-028 a - Pilot Pressure from Auxiliary Only machines equipped with Optional b - Pilot Pressure from Solenoid Valve Unit (SG)

c - Pilot Pressure from Flow Combiner Valve Control Spool in Signal Control Valve d - Pilot Pressure from Bucket Flow Rate Control Valve Control Spool in Signal Control Valve

e - Pilot Pressure from Solenoid Valve Unit (SF) f - Pilot Pressure from Solenoid Valve Unit (SC) g - Pilot Pressure from Arm 1 Flow Rate Control Valve Control Spool in Signal Control Valve

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

1- 2- 3-

4- 5- 6-

7- 8-

9-

Main Relief Valves Flow Combiner Valve Bucket Flow Rate Control Valve

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

T3-3-27

Arm Regenerative Valve Arm 1 Flow Rate Control Valve

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 pump 1 (8) is equally supplied to both left 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, the travel (right) pilot pressure shifts the flow combiner valve control spool in the signal control valve. 3. Pressure oil from the 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 the spring (2) force, spool (1) compresses spring (2) and moves to the left. 5. Pressure oil from pump 1 (8) flows to travel (right) spool (5). In addition, pressure oil from pump 1 (8) flows to travel (left) spool (4) through spool (1). 6. Pressure oil from pump 2 (9) flows to arm cylinder (11) through arm 1 spool (10) and moves the arm at this time.

Flow Combiner Valve

1

a

2

SL b

d

TDAA-03-03-057

c

a - Pressure Oil from Pump 1 (8)

b - Pilot Pressure from Flow Combiner Valve Control Spool

1-

2-

Spool (Flow Combiner Valve)

c - To Travel (Left) Spool (4)

Spring

T3-3-28

d - To Hydraulic Oil Tank

SECTION 3 COMPONENT OPERATION Group 3 Control Valve

3

4

2

1

5

6 b

SL

11

10

7

9

8 TDCD-03-03-029

b - Pilot Pressure from Flow Combiner Valve Control Spool 1- 2- 3-

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

4- 5- 6-

Travel (Left) Spool Travel (Right) Spool Travel Motor (Right)

7- 8- 9-

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 prevents the pressure in the main circuit from exceeding the set pressure when the actuator such as the motor or the cylinder is operated. Therefore, oil leak from hose and pipe joints and breakage of the actuator are prevented. Relief Operation 1. Pressure in port HP (main circuit) is 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, a pressure difference is caused between port HP and the spring chamber (10) due to orifice A (2). 4. When this pressure difference reaches the set pressure of spring A (9), main poppet (1) is opened and pressure oil from port HP flows to port LP. 5. Consequently, the main circuit pressure decreases. 6. When the main circuit pressure 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

During Relief Operation:

2

1

3

4

5

6

HP

LP

11

10

9

8

TDAB-03-03-021

HP - Main Circuit

LP - Hydraulic Oil Tank

SG - Pilot Pressure from Solenoid Valve Unit (SI)

1- 2- 3-

4- 5- 6-

7- 8- 9-

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 from solenoid valve unit (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, as pressure required in 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 - Main Circuit

LP - Hydraulic Oil Tank

SG - Pilot Pressure from Solenoid Valve Unit (SG)

6 - Spring B

7 - Piston

8 - Pilot Poppet

T3-3-33

T157-02-05-004

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Overload Relief Valve (with Make-Up Function) The overload relief valve is located in the 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 port HP (actuator circuit) is 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, a pressure difference occurs between port HP and spring chamber (9) due to orifice (11). 4. When this pressure 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, the actuator circuit pressure decreases. 6. When the actuator circuit pressure 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

During Relief Operation:

2

3

4

5

6

HP

LP

11

10

9

HP - Actuator Circuit

LP - Hydraulic Oil Tank

1- 2- 3-

4- 5- 6-

Make-Up Valve Main Poppet Sleeve

Spring A Passage A Spring B

8

7- 8- 9-

T3-3-35

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) decreases lower than pressure in port LP (hydraulic oil tank), sleeve (3) is moved to the right. 2. Hydraulic 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 - Actuator Circuit

LP - Hydraulic Oil Tank

3 - Sleeve

7 - Spring C

T3-3-37

T178-03-03-050

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

fNOTE:

Operational principle of the bottom regenerative valve is identical to that of the bucket regenerative valve. Therefore, the bucket 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, when pressure in the cylinder (1) bottom side is lower than the rod side, check valve (2) is opened. 3. Consequently, returning oil (b) from the cylinder (1) rod side flows to the bottom side and is combined with pressure oil from pump 1. The combined pressure oil is delivered to the cylinder (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 a - Pilot Pressure from Pump 1 1- 2-

T3-3-38

Bucket Cylinder Check Valve

3-

Bucket Spool

SECTION 3 COMPONENT OPERATION Group 3 Control Valve

b

4

3

c

2

TDCD-03-03-005 b - Returning Oil from Cylinder (1) Rod Side

c - Pressure Oil to Cylinder (1) Bottom Side

2 - Check Valve

3 - Bucket Spool

4 - Hole

T3-3-39

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Arm Regenerative Valve  During Normal Operation:

 During Regenerative Operation:

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

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

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

3. Therefore, as the 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 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, 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 speed is increased. 7. Pressure 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, 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

1- 2-

Chamber B Hole

3-

Spool (Arm Regenerative Valve)

4- 5-

Check Valve Arm 1 Spool

T3-3-40

TDCD-03-03-006

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

b - Pilot Pressure from Solenoid Valve Unit (SC) 3 - Spool (Arm Regenerative Valve) 4 - Check Valve

5 - Arm 1 Spool 6 - Boom Cylinder 7 - 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 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 are identical in structure.

Holding Operation 1. As pressure oil from the 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 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, as check valve (2) is pushed and the return circuit from cylinder (1) is blocked, the cylinder (1) drift is reduced.

1- 2-

T3-3-42

3

2

Boom Cylinder Anti-Drift Valve (Check Valve)

3-

TDCD-03-03-025 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 - Check Valve

3 - Selector Valve

4 - Spring

T3-3-43

TDCD-03-03-008

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Releasing Operation 1. Pressure oil from the 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 in the spring (4) chamber of check 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, 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

c - Pressure Oil from Pump 1 d - To Hydraulic Oil Tank

e - Pressure Oil from Pilot Valve

1- 2-

3-

T3-3-44

Boom Cylinder Anti-Drift Valve (Check Valve)

Anti-Drift Valve (Selector Valve)

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)

b - To Main Spool e - Pressure Oil from Pilot Valve

2 - Check Valve 3 - Selector Valve

4 - Spring

5 - Piston

T3-3-45

TDCD-03-03-009

6 - Orifice

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Flow Rate Control Valve The flow rate control valve is 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. Flow Rate Control Valve Boom Arm 1 Arm 2 Bucket Auxiliary

fNOTE: here.

Combined Operation Boom Lower (operation with the front attachment above ground (high pressure at bottom side)) Swing, Arm Roll-in Swing, Boom Raise, Arm Roll-In Boom Raise, Arm Roll-In Front Attachment; Auxiliary

The arm 1 flow rate control valve is explained

Normal Operation

1

1. Pressure oil from pump 2 (a) is routed to check 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 (3) is opened and pressure oil from pump 2 (a) flows to the arm 1 spool (b).

4

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

a TDCD-03-03-010 a - Pressure Oil from Pump 2 1- 2-

T3-3-46

Arm Cylinder Selector Valve

3- 4-

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 a - Pressure Oil from Pump 2

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 a - Pressure Oil from Pump 2

b - To Arm 1 Spool

2 - Selector Valve

3 - Poppet Valve

c - To Hydraulic Oil Tank

T3-3-47

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

1

1. Selector valve (2) of the arm 1 flow rate 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 (3) increases and the force to close poppet valve (3) appears.

3

3. Consequently, poppet valve (3) restricts flow 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

a - Pressure Oil from Pump 2

d - Pilot Pressure from Signal Control Valve

1- 2-

3- 6-

Arm Cylinder Selector Valve

Poppet Valve Arm 1 Spool

Boom Flow Control Valve e

d f

3

5

2

TDCD-03-03-012 d-

f-

Pressure Oil from Boom 2 Spool

e-

Pilot Pressure from Signal Control Valve Pressure Oil from Pump 1

2- 3-

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

a - Pressure Oil from Pump 2

b - To Arm 1 Spool

2 - Selector Valve

3 - Poppet Valve

c - To Hydraulic Oil Tank

T3-3-49

d - Pilot Pressure from Signal Control Valve

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

Operation 1. When solenoid 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 (b) from port SF is routed to the end of spool (4) through inner passage (2). 3. Spool (4) compresses spring (3) and moves downward. 4. Therefore, pressure oil 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 to arm cylinder (10) increases, speed of arm roll-in increases.

a

2

1

SF

4

b c

3

TDCD-03-03-016 a - To Arm 1 Spool (9)

b - Pilot Pressure from Solenoid Valve Unit (SF)

c - Returning Oil from Boom Cylinder (6) Rod Side

1- 2-

3-

4-

Check Valve Inner Passage

Spring

T3-3-50

Spool (Digging Regenerative Valve)

SECTION 3 COMPONENT OPERATION Group 3 Control Valve

4

5

11 6

10

b

9

1

8

7

TDCD-03-03-017

b - Pilot Pressure from Solenoid Valve Unit (SF) 1 - Check Valve 4 - Spool (Digging Regenerative Valve)

5 - Boom 1 Spool 6 - Boom Cylinder 7 - Pump 1

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

T3-3-51

11 - Boom 2 Spool

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Boom Lower Meter-In Cut Valve Boom lower meter-in cut valve (2) is provided in the 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 operation of boom lower and other actuator, the boom falls due to own weight by the regenerative circuit and uses pressure oil from the pump for other actuator so that speed of other actuator increases. (Refer to “Hydraulic System”/ SYSTEM.) Operation (Jack-Up)

Operation (Boom Lower with Front Attachment above Ground) 1. During boom 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 (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 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 from port PI7 (4) flows to selector valve (1) in boom flow rate control valve through the spool. 6. Selector valve (1) in boom flow rate control valve is shifted and pressure oil which flows to the boom 1 spool from pump 1 is reduced. (Refer to “Flow Control Valve”.) 7. Consequently, during combined operation of boom lower and other 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) chamber 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 from port PI7 (4) flows to 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 in 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 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

8

TDCD-03-03-018 a

2

12 e

13

c

PI7 d

PI9

a - Returning Oil from Boom Cylinder (6) Bottom Side

b - To Boom 2 Spool (11) c - To Switch Valve

d - Boom Lower Pilot Pressure e - To Hydraulic Oil Tank

1-

3- 4- 5- 6-

7- 8- 9- 10-

2-

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

Boom 1 Spool Port PI 7 Port PI 9 Boom Cylinder

TDCD-03-03-019

b

T3-3-53

Bypass Shut-Out Valve Pump 1 Pump 2 Arm Cylinder

11- Boom 2 Spool 12- Orifice 13- Spring

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Auxiliary Flow Combiner Valve and Bypass Shut-Out Valve

Auxiliary Flow Combiner Valve a

The auxiliary flow combiner 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.

2

1. When attachment (8) is single 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. 2. When spool (3) in the bypass shut-out valve is shifted, the neutral circuit in 4-spool section (e) is blocked.

1 SN

TDCD-03-03-020

d a - To Auxiliary Spool (7) b - Attachment Pilot Pressure

3. At this time, as spool (1) in the 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).

1-

Spool (Auxiliary Flow Combiner Valve)

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

c - Pressure Oil from Pump 1 (6) d - To Hydraulic Oil Tank 2-

Check Valve

Bypass Shut-Out Valve e

fNOTE:

The external shuttle valve is equipped for the machine equipped with auxiliary flow rate combiner valve. When attachment is operated, attachment pilot pressure (b) shifts the pump 1 flow rate control valve in signal control valve through the external shuttle valve. 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

b - Attachment Pilot Pressure d - To Hydraulic Oil Tank 3 - Spool (Bypass Shut-Out Valve)

T3-3-54

3

TDCD-03-03-021

e - Neutral Circuit in 4-Spool Section

SECTION 3 COMPONENT OPERATION Group 3 Control Valve

b

4

1 SM

SN

8

7 e

3 SJ

6

TDCD-03-03-022

5

fNOTE:

The illustration shows auxiliary (open) operation.

b - Attachment Pilot Pressure

e - Neutral Circuit in 4-Spool Section

1-

4-

3-

Spool (Auxiliary Flow Combiner Valve) Spool (Bypass Shut-Out Valve)

5-

Auxiliary Flow Combiner Control Solenoid Valve Pump 1

6- 7- 8-

T3-3-55

Pump 2 Auxiliary Spool Attachment

SECTION 3 COMPONENT OPERATION Group 3 Control Valve During Combined Operation

Auxiliary Flow Combiner Valve

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 pilot pressure (b) is routed to port SM in auxiliary flow combiner valve (1). 2. When the boom, arm, bucket or 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 from port SM is routed to spool (1) of the auxiliary flow combiner valve to the open direction, and pressure oil from port SN and the spring (9) force are routed to that to the close direction.

2

9

4. As the force to the close direction is larger, spool (1) is kept closed. 5. 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

a - To Auxiliary Spool (7) b - Attachment Pilot Pressure c - Pressure Oil from Pump 1 (5)

f -

1 - Spool (Auxiliary Flow Combiner Valve) 2 - Check Valve

9 - Spring

T3-3-56

TDCD-03-03-023

Pilot Pressure from Signal Control Valve

SECTION 3 COMPONENT OPERATION Group 3 Control Valve

b f

4

1

SM

SN

10

8

7 11

3 SJ

6

5

TDCD-03-03-024

fNOTE:

The illustration shows during auxiliary (open) / bucket roll-out operation.

b - Attachment Pilot Pressure

f -

Pilot Pressure from Signal Control Valve

1 - Spool (Auxiliary Flow Combiner Valve) 3 - Spool (Bypass Shut-Out Valve)

4 - Auxiliary Flow Combiner Control Solenoid Valve 5 - Pump 1

6 - Pump 2 7 - Auxiliary Spool 8 - Attachment

T3-3-57

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 pilot pressure oil in order to move the spool in the control valve. The pilot valve outputs pressure according to the 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 / swing and for travel are standard. The 2-port pilot valve is for auxiliary (optional).  Front Attachment / Swing Pilot Valve

Right

Left

Port No. 1 2 3 4 1 2 3 4

ISO Control Pattern Bucket Roll-Out Boom Lower Bucket Roll-In Boom Raise Swing (Right) Arm Roll- Out Swing (Left) Arm Roll-In P

Hitachi Pattern     Arm Roll-In Swing (Right) Arm Roll- Out Swing (Left)

T

Hydraulic Symbol

1

3 2

P

4

4

TPPP-03-04-002

3

1

T

2 P-

T3-4-1

Port P (Pressure Oil from Pilot Pump)

T-

TPPP-03-04-001

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 1

2 3

4 TPPP-03-04-002

3

4

2

1 TPPP-03-04-004

 Auxiliary Pilot Valve Auxiliary

P-

Port No. 1 2 P

Port P (Pressure Oil from Pilot Pump)

T-

Port T (To Hydraulic Oil Tank)

Open Close

T

Hydraulic Symbol T

P 1

2 TDAA-03-04-007

1 P-

T3-4-2

Port P (Pressure Oil from Pilot Pump)

2 T-

TDAA-03-04-006

Port T (To Hydraulic Oil Tank)

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve Operation (Front Attachment / Swing and Travel Pilot Valves)

Front Attachment / Swing Pilot Valve 1

The spool (7) head comes in 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 attachment and swing controls are determined by stroke dimension (E) of pusher (2). Total lever stroke for travel control is determined by stroke dimension (E) of cam (1).

5 6 E

7 8

TPPP-03-04-005

Travel Pilot Valve 1

E

2 3 4 5 6

7 8

TPPP-03-04-010 1- 2-

Cam Pusher

3- 4-

Casing Spring Guide

5- 6-

T3-4-3

Balance Spring Return Spring

7- 8-

Spool Hole

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve Neutral (Output Curve: A to B): 1. When in 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 T. 3. When the control lever is slightly tilted, cam (1) is tilted and pusher (2) is pushed downward. Pusher (2) compresses return spring (6) along with spring guide (4) together.

C

4. At this time, as pressure in the output port is equal to that in port 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 a-

5. This status 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-03-04-006

Travel Pilot Valve 1

1

2

2

3

T

3

7

4

4

8

5

5

6

6

a

T

7

T

7 P

8

P

P

8

a

a TPPP-03-04-016

TPPP-03-04-011

P-

Port P

T-

Port T

a-

Output Port

1- 2-

Cam Pusher

3- 4-

Casing Spring Guide

5- 6-

Balance Spring Return Spring

T3-4-5

7- 8-

Spool Hole

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve During Metering or Decompressing (Output Curve: C to D) 1. When the 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 the output port is routed to the bottom surface of spool (7) so that spool (7) is pushed upward. C

3. When the force to move spool (7) 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, 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 a-

5. As spool (7) is moved 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 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-

Control Lever Stroke

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve Front Attachment / Swing Pilot Valve 1

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-03-04-008

Travel Pilot Valve 1

1

2

2 T

7

3

3 P

4

P

4

8

5

T

7

8

5

6

6 a

a

T

7

T

7

P

P

8

8 a

a TPPP-03-04-012

TPPP-03-04-013

P-

Port P

T-

Port T

a-

Output Port

1- 2-

Cam Pusher

3- 4-

Casing Spring Guide

5- 6-

Balance Spring Return Spring

T3-4-7

7- 8-

Spool Hole

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve Full Stroke (Output Curve: E to F) 1. When the 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, the bottom surface of pusher (2) directly pushes spool (7). Therefore, even if pressure in the output port increases further, hole (8) on spool (7) is kept open.

C

3. Consequently, pressure in the output port is equal to that in port P.

A

b

B

T523-02-05-001 a-

T3-4-8

Pilot Pressure

b-

Control Lever Stroke

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve Front Attachment / Swing Pilot Valve 1

2 3 4 5 6

7 T P

8

a TPPP-03-04-009

Travel Pilot Valve 1

2

3 4 5 6

T

7

P

8 a TPPP-03-04-014 P-

Port P

T-

Port T

a-

Output Port

1- 2-

Cam Pusher

3- 4-

Casing Spring Guide

5- 6-

Balance Spring Return Spring

T3-4-9

7- 8-

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 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 by stroke dimension (E) of cam (1). 2 3 4 5 6 7 8

TDAA-03-04-001

1- 2-

Cam Pusher

3- 4-

Plate Spring Guide

5- 6-

T3-4-11

Balance Spring Return Spring

7- 8-

Spool Hole

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve  Auxiliary Pilot Valve Neutral (Output Curve: A to B): 1. When the control pedal is in neutral, spool (7) completely blocks pressure oil from port 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 T.

C

3. When the 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.

A

b

B

T1F3-03-09-004

4. At this time, as pressure in the output port is equal to that in port 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-

5. This status continues until hole (8) on spool (7) is connected to port P.

fNOTE:

The 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

1 7

2

T

8

P

3 a

4

T

5 6 7

P

8 a

TDAA-03-04-002

P-

Port P

T-

Port T

a-

Output Port

1- 2-

Cam Pusher

3- 4-

Plate Spring Guide

5- 6-

Balance Spring Return Spring

T3-4-13

7- 8-

Spool Hole

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve During Metering or Decompressing (Output Curve: C to D) 1. When the 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 to move spool (7) 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, 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 a-

5. As spool (7) is moved 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 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 7

2

T

8 P

3 a

4

T

5 6 7

P

8 a

TDAA-03-04-004

1 7

2

T

8 P

3 a

4

T

5 6 7

P

8 a

TDAA-03-04-003

P-

Port P

T-

Port T

a-

Output Port

1- 2-

Cam Pusher

3- 4-

Plate Spring Guide

5- 6-

Balance Spring Return Spring

T3-4-15

7- 8-

Spool Hole

SECTION 3 COMPONENT OPERATION Group 4 Pilot Valve Shockless Function (Only for Travel Pilot Valve) The travel pilot valve has damper (1) enabling 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 control lever (4) and travel pedal (3) are secure to bracket (6). 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 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 gear 2 (8) inside damper (1) receive opposing force due to friction.

8 9

A

3. 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

Section A-A

2

5

1

7 1- 2- 3- 4- 5-

T3-4-16

Damper Spring Pin Travel Pedal Travel Control Lever Support

T1M7-03-04-003 6- 7- 8- 9-

Bracket Pin Gear 2 Gear 1

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Outline The travel device consists of travel motor (4), travel reduction gear (2), and travel brake valve (1). Travel motor (4) is a swash plate type variable displacement axial plunger motor and equipped with a parking brake (a wet-type spring set hydraulic released multi-disc brake). 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 reduction gear, converts the travel motor (4) rotation power to a slow-large torque, and rotates sprocket (3) and the track. Travel brake valve (1) protects the travel circuit from being overloaded and prevents the occurrence of cavitation.

1

2

3

4 1-

Travel Brake Valve

2-

Travel Reduction Gear

T1V1-03-05-001 3-

T3-5-1

Sprocket

4-

Travel Motor

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Travel Reduction Gear The travel reduction gear is a three-stage planetary reduction gear. The travel 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 1234-

Ring Gear Third Stage Carrier Third Stage 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 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 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

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 flows to port B in valve 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) rotates, when plungers (5) reach port A, pressure oil is returned to the hydraulic oil tank. 4. Whether forward travel or 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

A-

Port A (Pressure oil from main pump or returning oil to hydraulic 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 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 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 control lever is 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 control lever is returned to neutral, counterbalance valve spool (8) in the travel brake valve is returned to neutral.

2. This pressure oil shifts counterbalance 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 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, as brake 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 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:

When brake is released:

1

a

2

2 3

3

4

7

7 6

BV

a

5

5

1

AV b

4

8

TDAA-03-05-005 AV- Port AV (Pressure oil from main pump)

BV- Port BV (Pressure oil from main pump)

12-

34-

Housing Friction Plate

Plate Rotor

a-

Brake Piston Chamber

b-

To Brake Piston

56-

Brake Piston Orifice

78-

Disc Spring Counterbalance Valve Spool

T3-5-7

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Travel Brake Valve The travel brake valve is located on the 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 or BV) to the parking 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 Valve (5): Travel motor displacement angle control 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 / fast speed): Orifice (4) makes the travel mode control (displacement angle control) smooth.

T3-5-8

SECTION 3 COMPONENT OPERATION Group 5 Travel Device

A

1

2

3

1 Section A-A

T1V1-03-05-003

A

6 12-

Shuttle Valve Counterbalance Valve

34-

Check Valve Orifice

5 5-

T3-5-9

Travel Motor Displacement Angle Control Valve

4 6-

Overload Relief Valve

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Counterbalance Valve  While Traveling 1. When pressure oil from the 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, returning oil from the travel motor is routed to motor port AM (4). However, its passage is blocked by check valve AC (3) and spool (9). 3. When pressure in port BV (8) increases further, pressure oil is routed to chamber B (10) through orifice (f ) in spool (9) and moves spool (9) to the right. 4. Consequently, returning oil from the 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 control 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 descends a slope, the travel motors are forcibly rotated by the machine self weight like a pump. 2. If the travel motor draws oil, oil 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 is 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.

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

5

During travel operation:

10

8

9

2

1

h

6

f

4

7

3

TDAA-03-05-002

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 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 in the travel circuit is routed to poppet (5) through motor port BM (9) (or motor port AM (3)).

1. When the machine descends a slope, the travel motors are forcibly rotated by the machine self weight like a pump.

2. Pressure 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 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, 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, the pressure difference between the front and rear of poppet (5) disappears and poppet (5) is closed. 6. Under this condition, normal relief pressure is set. 7. When the pressure in the travel 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

10- Check Valve BC

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Travel Mode Control The displacement angle of swash plate (10) is changed by piston (11) movement in order to shift the travel mode.  Slow Speed 1. When the travel mode switch 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

SECTION 3 COMPONENT OPERATION Group 5 Travel Device

7 1, 2

4

3

5

6 a

8 9

10

11

TDAA-03-05-006 a-

To Drain

123-

Motor Port BM Motor Port AM Travel Motor 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 mode switch is set to the Fast position, MC (main controller) sends the signals to solenoid valve unit (SI) in response to travel loads. (Refer to SYSTEM / Control system / Travel Motor Displacement Angle Control.) 2. Pilot pressure is supplied from pilot port (4) of 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 (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

SECTION 3 COMPONENT OPERATION Group 5 Travel Device

7

b

1, 2

4

3

5

6

8

9

10

11

TDAA-03-05-007 b-

Pressure oil from motor port AM (2) or BM (1)

123-

Motor Port BM Motor Port AM Travel Motor 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 is provided in the 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 signal control 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

TDCD-03-06-001 a-

Pilot Valve Side

1- 2-

Shockless Valve Bucket Flow Rate Control Valve Control Spool

3- 4-

Pump 2 Flow Rate Control Valve Flow Combiner Valve Control Spool

5- 6-

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

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

T3-6-3

SECTION 3 COMPONENT OPERATION Group 6 Signal Control Valve

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 Port SP

Auxiliary Flow Combiner Solenoid Valve Auxiliary Flow Rate Combiner Control Valve Auxiliary Flow Combiner Solenoid Valve

T3-6-4

Auxiliary Flow Combiner Valve Control Pressure Auxiliary Flow Combiner Valve Control Pressure Pump 1 Control Pressure

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

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

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 to perform each operation and routes pilot pressure to the corresponding control valves and/or control spools. The spools corresponding to 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 (Right) Travel (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 control valve is operated by pressure from the auxiliary pilot valve.

T3-6-7

Flow Combiner Swing Parking Valve Brake Release Control Spool Spool          

Arm 1 Flow Rate Control Valve Control Spool  -

SECTION 3 COMPONENT OPERATION Group 6 Signal Control Valve

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 a- b- c- d- e-

Travel (Left) Travel (Right) Swing Arm Boom

f- g-

1- 2- 3- 4-

Travel (Left) Travel (Left, Right) Travel (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 Rate Control 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 k- l-

T1V1-03-06-001

Pump 2 Flow Rate Control Valve Pump 1 Flow Rate Control Valve

16- Swing, Auxiliary 17- Auxiliary

SECTION 3 COMPONENT OPERATION Group 6 Signal Control Valve

B

9

8

5

B

16

7

17

15

a

11

13

6

14

3

10 12

4

1

2

TDCD-03-06-001

a-

Pilot Valve Side

1- 2- 3- 4-

Travel (Left) Travel (Left, Right) Travel (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

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 Shockless Valve

1

2

3

The shockless valve is 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 to spool (1) through port A (2).

5

2. Immediately after operation is started, low 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

2

3

3. When pilot pressure 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, 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. 4

1- 2- 3- 4-

T3-6-10

Spool Port A Spring B Port 1

5- 6- 9-

T1V1-03-06-002

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

2

1

4

T183-03-06-004

7

Detail of Clearance C

1 T1V1-03-06-008

1- 2-

Spool Port A

3- 4-

Spring B Port 1

5- 6-

T3-6-11

Inner Passage 2 Spring A

7- 9-

Housing 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

2

1

3

1. During boom lower operation or when stopping boom raise operation, the returning oil from the boom raise spool in control valve is routed to port 1 (4). 2. As spool (1) blocks the oil 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 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 in spring B (3) flows from 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, clearance C between spool (1) and housing (7) is closed, so that pressure oil is blocked.

7. Consequeltly, the shockless valve reduces the shock during boom lower operation or when stopping boom raise operation.

1

2

3

8

5. When clearance C is closed, pressure in spring B (3) increases and spool (1) is moved to the left. Therefore, clearance C is opened again and pressure oil flows to the port A (2) side. 6. As the operations in step 4 to step 5 are repeated and pressure oil is gradually returned to the port A (2) side, the control valve spool is returned slowly.

T1V1-03-06-004

4

1- 2- 3- 4-

T3-6-12

Spool Port A Spring B Port 1

5- 6- 8- 9-

T1V1-03-06-002

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

2

1

C

5

4

3

9

T183-03-06-005

2

1

4

5

9

T183-03-06-004

7

Detail of Clearance C

1 T1V1-03-06-008

1- 2- 3-

Spool Port A Spring B

4- 5- 6-

Port 1 Inner Passage 2 Spring A

7- 8- 9-

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 The pump flow rate control valve delivers pump control pressure Pi to the pump regulator in response to pilot pressure from the pilot valve. 1. Pilot oil pressure (5) from the pilot 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 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), auxiliary (machine with the attachment (pulverizers 1 to 5, crushers 1 to 5) equipped), and travel (right) functions are 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

a- b-

To Port SA To Port SB

c-

To Hydraulic Oil Tank

d-

From Pilot Valve

1- 2-

Spring Spool

3- 4-

Chamber A Shuttle Valve

5- 6-

Pilot Pressure Primary Pilot Pressure

T3-6-15

T1V1-03-06-005

SECTION 3 COMPONENT OPERATION Group 6 Signal Control Valve 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

Bucket Flow Rate Control Valve Control Spool: 1

a

2

b

fNOTE:

The four spools are identical in operational principle. T178-03-06-014

 The bucket flow rate control valve control spool is shifted by arm roll-in pilot pressure and supplies boom raise pilot pressure to the bucket flow rate control valve in control valve.  The flow combiner valve 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.

c

d a- b- 1-

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 1

a

2

b

T178-03-06-014 e

f a- b-

To Hydraulic Oil Tank Primary Pilot Pressure

e- f-

To Flow Combiner Valve Travel (RIght) Pilot Pressure

1-

Spool

2-

Spring

Swing Parking Brake Release Spool: 1

a

2

b

T178-03-06-014 h

g

a- b-

To Hydraulic Oil Tank Primary Pilot Pressure

g- h-

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 rate control valve 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 Control Valve Control Spool 1

a

2

i

T178-03-06-014 d

j

a- d- i-

To Hydraulic Oil Tank Arm Roll-In Pilot Pressure Swing Pilot Pressure

j-

To Arm 1 Flow Rate 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 The pilot shut-off solenoid valve is a 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 Z

A1

P

T1

T2

A2

A3 Z T4

T3

A4

T1V1-03-07-011 P- A1- A2- A3-

Primary Pilot Pressure Travel/Auxiliary Pilot Pressure Boom, Bucket Pilot Pressure Arm, Swing Pilot Pressure

1-

Spool

A4- Pilot Pressure to Signal Control Valve (Port PI) T1- Returning Oil from Travel/ Auxiliary Pilot

T2- Returning Oil from Boom, Bucket, Pilot T3- Returning Oil from Arm, Swing Pilot

T3-7-1

T4- Returning Oil to Hydraulic Oil Tank

SECTION 3 COMPONENT OPERATION Group 7 Others (Upperstructure)  Pilot Shut-Off Lever: LOCK Position 1. When the pilot shut-off lever is set to the LOCK position, the pilot shut-off relay is turned OFF and the pilot shut-off solenoid valve is turned OFF. (Refer to SYSTEM / Electrical System.)

Pilot Shut-Off Lever: LOCK Position

T1 to T4

2. Pressure oil from the pilot pump is blocked by spool (1) in the pilot shut-off solenoid valve. 3. Pressure oil in pilot valves (A1 to A3) and signal control valve (A4) sides flow to the hydraulic oil tank.

P A1 to A4

4. Therefore, even if the control/travel control lever is operated, the pilot valve is not activated.  Pilot Shut-Off Lever: UNLOCK Position 1. When the pilot shut-off lever is set to the 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

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 from the pilot pump flows to the pilot valve and signal control valve.

T1 to T4

4. Consequently, when the control/travel control lever is operated, the pilot valve is activated.

P A1 to A4

1 T1J1-03-07-001

P- A1- A2- A3- A4-

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 Travel/ Auxiliary Pilot T2- Returning Oil from Boom, Bucket Pilot T3- Returning Oil from Arm, Swing Pilot T4- Returning Oil to Hydraulic Oil Tank

SECTION 3 COMPONENT OPERATION Group 7 Others (Upperstructure) Solenoid Valve The solenoid valve 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 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 unit consists of proportional solenoid valves (SC, SF and SG).

TDCD-03-07-001

SC : Controls the arm regenerative valve in control valve and controls the arm 2 flow rate control valve (switch valve) in control valve. SF : Controls the digging regenerative valve in control valve. SG : Increases pressure of the main relief 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 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, 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-03-10-002 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 Valve The proportional solenoid 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) to the right and output port S is connected to tank port T.

 When excited 1. Solenoid (3) pushes spool (1) to the left in proportion to the current value flowing through solenoid (3). 2. Pilot pressure oil from port P flows to output port S and pressure at output port S increases. 3. This pressure at output port S is 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 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, pressure at output port S stops increasing.

T

S

1

P

2

3

a

a TDAA-03-07-013

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 shifts the brake switch and each control switch in order to shift pilot pressure.  In Neutral Spool (1) is pushed to the right by spring (2). Output port S is connected to tank port 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

3

T

2 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 1- 2-

EC Motor

Port P Pilot Relief Valve

1

2

3-

Pilot Filter

3

The EC Motor is used to 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

1- 2- 3- 4-

Output Gear Output Shaft Worm Gear Motor

T3-7-6

5

T157-02-05-018 5- 6- 7-

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 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 rupture valve in boom cylinder is explained here.

 Control Lever: In Neutral 1. As pilot pressure Pi does not act on piston (3), spool (2) is pushed to the right by the spring (10) force.

5

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).

9

4

6

a

3. Holding pressure through passage C (9) is 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, as holding 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

a-

External Force

b-

To Spool in Control Valve (To Hose of Front Attachment)

2- 3- 4- 5-

Spool Piston Passage A Spring

6- 8- 9- 10-

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

1- 2- 3- 4-

Relief Valve Spool Piston Passage A

5- 6- 7- 8-

Spring Poppet Orifice Passage B

9- 10- 11- 12-

T3-7-9

Passage C Spring Port A Port B

13- Orifice

SECTION 3 COMPONENT OPERATION Group 7 Others (Upperstructure)  During Boom Lowering Operation (Control Lever Stroke: Less then Half-Stroke) 1. When the boom is lowered, pilot pressure Pi acts on piston (3).

5

9

4

7

2. When the boom lower control lever is less than halfstroke, piston (3) restricts spool (2) and pushes spool (2) to the position where orifice (13) is opened.

6

3. Pressure oil in the spring (5) chamber is blocked by spool (2) and poppet (6) is pushed downward.

c

4. Pressure 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 valve is reduced by orifice (13), the boom is lowered slowly.

11

10

8

2

b

T1V1-03-07-019

b-

To Spool in Control Valve

c-

Pressure Pi

2- 3- 4- 5- 6- 7-

Spool Piston Passage A Spring Poppet Orifice

8- 9- 10 - 11- 12-

Passage B Passage C Spring Port A Port B

T3-7-10

3

SECTION 3 COMPONENT OPERATION Group 7 Others (Upperstructure)

10

13

1

2

3

c

4 5

9

6 7

8

12

11

T1V1-03-07-015 c-

Pressure Pi

1- 2- 3- 4-

Relief Valve Spool Piston Passage A

5- 6- 7- 8-

Spring Poppet Orifice Passage B

9- 10- 11- 12-

T3-7-11

Passage C Spring Port A Port B

13- Orifice

SECTION 3 COMPONENT OPERATION Group 7 Others (Upperstructure)  During Boom Lowering Operation (Control Lever Stroke: More than Half-Stroke) 1. When the boom lower control lever is 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 passage C (9) flows to passage B (8) through orifice (13).

12

4. At this time, a pressure difference between port B (12) and the spring (5) chamber appears due to orifice (7) and poppet (6) moves upward.

11

5. Consequently, return oil from port B (12) flows to the spool in control valve through poppet (6) from port A (11) and lowers the boom.

10

8

2

b

6. As pressure oil in port B (12) flows to port A (11) directly, oil flow rate through the spool in control valve increases and boom lowering speed becomes fast.

T1V1-03-07-020

b-

To Spool in Control Valve

c-

Pressure Pi

2- 3- 4- 5- 6- 7-

Spool Piston Passage A Spring Poppet Orifice

8- 9- 10- 11- 12-

Passage B Passage C Spring Port A Port B

T3-7-12

3

SECTION 3 COMPONENT OPERATION Group 7 Others (Upperstructure)

10

13

1

2

3

c

4 5

9

6 7

8

12

11

T1V1-03-07-016 c-

Pressure Pi

1- 2- 3- 4-

Relief Valve Spool Piston Passage A

5- 6- 7- 8-

Spring Poppet Orifice Passage B

9- 10- 11- 12-

T3-7-13

Passage C Spring Port A Port B

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 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 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

1- 2-

Outer Race Seal

3- 4-

Inner Race Seal

5- 6-

T3-8-1

Support Ball

SECTION 3 COMPONENT OPERATION Group 8 Others (Undercarriage) Center Joint The center joint is a 360° 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

a b-

Travel (Left Reverse) Travel (Right Forward)

c- d-

Travel (Right Reverse) Travel (Left Forward)

e- f-

for Travel Mode Control Pilot Pressure Drain

1-

Spindle

2-

Body

3-

Seal

T3-8-2

g- h-

Forward Reverse

SECTION 3 COMPONENT OPERATION Group 8 Others (Undercarriage) Track Adjuster (Front Idler Integrated Type) The track adjuster 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 is supplied through grease fitting (5), grease fills chamber (a) in adjuster cylinder (1), pushes piston rod (2), and reduces track sag.

TDAA-03-08-002

1

a

4

1- 2-

Adjuster Cylinder Piston Rod

3- 4-

Spring Front Idler

5-

T3-8-3

Grease Fitting

2

3

A

TDAA-03-08-001

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: 81-29-982-7084 Fax: 81-29-831-1162 E-mail: [email protected]

Hitachi Ref. No.

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