Komatsu PW130ES-6K Service Manual

Page 1

UEBM001201

PW130ES-6K

MACHINE MODEL

PW130ES-6K PW130ES-6K

• This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice.

SERIAL NUMBER

K32001 and up K34001 and up

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Page 2

No. of page

10 STRUCTURE AND FUNCTION......................................................... 10-1

20 TESTING AND ADJUSTING ............................................................. 20-1

30 DISASSEMBLY AND ASSEMBLY .................................................... 30-1

40 MAINTENANCE STANDARD............................................................ 40-1

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No. of page

01 GENERAL.......................................................................................... 01-1

10 STRUCTURE AND FUNCTION.............................................. 10-1

20 TESTING AND ADJUSTING .................................................... 20-1

30 DISASSEMBL Y AND ASSEMBLY........................................ 30-1

40 MAINTENANCE STANDARD.................................................. 40-1

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The affected pages are indicated by the use of the following marks. It is requested that necessary actions be taken to these pages according to the table below.

kraMnoitacidnIderiuqernoitcA

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Page 7

SAFETY SAFETY NOTICE

SAFETY

SAFETY NOTICE

IMPORT ANT SAFETY NOTICE

Proper service and repairs extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both sepcially designed by Komatsu for the specific purpose.

To prevent injury to workers, the symbol is used to mark safety precautions in this manual. The cautions accompaning these symbols should always be followed carefully . If any dangerous situation arises or may possibly arise, first consider safety , and take the necessary actions to deal with the situation.

GENERAL PRECAUTIONS

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance carefully BEFORE operating the machine.

1. Before carrying out any greasing or re-

pairs, read all the precautions given on the decals which are fixed to the machine.

2. When carrying out any operation, always

wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.

• Always wear safety glasses when hitting parts with a hammer.

• Always wear safety glasses when grinding parts with a grinder, etc.

3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.

6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

PREP ARA TIONS FOR WORK.

7. Before adding the oil or making any repairs park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.

8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the wrok equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.

9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.

4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment.

5. Keep all tools in good condition and learn the correct way to use them.

10. Remove all mud and oil from the steps or other paces used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

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Page 8

SAFETY SAFETY NOTICE

PRECAUTIONS DURING WORK

11. When removing the oil filter cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.

12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits.

13. Before starting work, remove the leads from the battery . Always remove the lead from the negative (-) terminal first.

14. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity . Install the lifting equipment at he correct places. Use a hoist of crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.

20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed.

21. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards. or parts which vibrate violently or rotate at high speed, be particulary careful to check that they are installed correctly .

22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.

23. When messuring hydraulic pressure, check that the messuring tool is correctly assembled for taking any measurements.

24. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.

15. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.

16. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires.

17. When removing piping, stop the fuel or oil from spilling out. If any oil or fuel drops onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.

18. As a general rule, do not use gasoline to wash parts. In particular, only use the minimum of gasoline when washing electrical parts.

19. Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts.

• When installing hoses and wires, be sure

that the will not be damaged by contact with oter parts when the machine is being operated.

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Page 9

FOREWORD FOREWORD GENERAL

FOREWORD

GENERAL

This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters: these chapters are further divided into the each main group of components.

STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.

TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs , as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "problems" to "Causes" are also included in this section.

DISASSEMBL Y AND ASSEMBLY

This section explains the order to be followed when removing, installing, disassembling or assembling eachr component, as well as precautions to be taken for these operations.

MAINTENANCE ST ANDARD

This section gives the judgement standards when inspecting disassembled parts.

NOTICE

The specifiactions contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.

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Page 10

FOREWORD HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

VOLUMES

Shop manuals are issued as a guide to carrying out repairs. They are devided as follows:

Chassis volume: Issued for every machine model Engine model: Issued for each engine series

Electrical volume: Attachments volume:

These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model, it is necessary that chassis, engine , electrical and attachement volumes be available.

DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-todate information before you start any work.

FILING METHOD

1. See the page number on the bottom of the page. File the pages in correct order.

2. Following examples show how to read the page number Example 1 (Chassis volume:)

10 - 3

Example 2 (Engine Volume:)

1 2 - 5

3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 10-4 12-203 10-4-1 12-203-1 10-4-2 12-203-2 10-5 12-204

Added pages

Each issued as one volume to cover all

}

models

Item number (10. Structure and Function) Consecutive page number for each item

Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item

REVISED EDITION MARK

When a manual is revised, an edition mark (1,2,3,...) is recorded on the bottom of the pages.

REVISIONS

Revised pages are shown in the LIST OF REVISED P AGES next to the CONTENTS page.

SYMBOLS

So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.

lobmySmetIskrameR

snoituacerpytefaslaicepS

★

ytefaS

noituaC

thgieW

gninethgiT

euqrot

taoC

.cte

retaw,liO

.yticapac

niarD

nehwyrassecenera

.krowehtgnimrofrep

lacinhcetlaicepS

rehtorosnoituacerp

gnivreserprofsnoituacerp

yrassecenerasdradnats

.krowehtgnimrofrepnehw

.smetsysfostrapfothgieW

nehwyrassecennoituaC

ro,eriwgnitsiohgnitceles

sierutsopgnikrownehw

.tce,tnatropmi

laicepseriuqertahtsecalP

gninethgitehtrofnoitnetta

.ylbmessagnirudeuqrot

htiwdetaocebotsecalP

,stnacirbuldnasevisehda

roretaw,lioerehwsecalP

ehtdna,deddaebtsumleuf

retawrolioerehwsecalP

dna,deniardebtsum

.deniardebotytitnauq

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Page 11

FOREWORD HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS

HOISTING

Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEM- BLY AND ASSEMBLY section, every part weighing 25 kg op mroe is indicated with the symbol

• If a part cannot be smootlhy removed from the machine by hoisting, the following checks should be made:

1) Check for removal of all bolts fastening the

part to the relative parts.

2) Check for existence of another part caus-

ing interference with the part to be removed.

WIRE ROPES

1) Use adequate ropes depending on the

weight of parts to be hoisted, referring to the table below:

seporeriW

seportsiwt"S"ro"Z"dradnatS(

gnizinavlagtuohtiw

)mm(retemaidepoR)snot(daolelbawollA

010.1

2.114.1

5.216.1

412.2

618..2

816.3

Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have a maximum strength at the middle portion.

3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load.

Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.

4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the nahging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically , at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150°.

024.4

4.226.5

030.01

040.81

050.82

060.04

★ The allowable load value is estimated to be

one-sixth or one-seventh of the breaking strength of the rope used.

2) Sling wire ropes from the middle portion of the hook.

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Page 12

FOREWROD COA TING MA TERIALS

COA TING MA TERIALS

The recommended coating materials prescribed in Komatsu Shop Manuals are listed below.

ST ANDARD TIGHTENING TORQUE

ST ANDARD TIGHTENING TORQUES OF BOLTS AND NUTS

The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in section of

DISASSEMBL Y AND ASSEMBLY.

1 Kgm = 9.806 Nm

retemaiddaerhT

tlobfo

mmmmmgkmN

60153.1 ± 51.02.31 ± 4.1

8312.3 ± 3.04.13 ± 9.2

01717.6 ± 7.07.56 ± 8.6

21915.11 ± 0.1211 ± 8.9

41220.81 ± 0.2771 ± 91

61425.82 ± 3972 ± 92 817293 ± 4383 ± 93 020365 ± 6945 ± 85 222367 ± 8547 ± 87

42635.49 ± 01729 ± 89 7214531 ± 510231 ± 041 0364571 ± 020271 ± 091 3305522 ± 520122 ± 042 6355082 ± 030572 ± 092

htdiW

stalfssorca

9306533 ± 520823 ± 043

★ This torque table does not apply to the bolts with nylon packaging or other nonferrous metal wash-

ers are to be used, or which require tightening to otherwise specified torque.

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Page 14

FOREWORD ST ANDARD TIGHTENING TORQUE

TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Use these torques for split flange bolts.

retemiaddaerhT

tlobfo

mmmmmgkmN

01417.6 ± 7.07.56 ± 8.6

21715.11 ± 1211 ± 8.9

61225.82 ± 3972 ± 92

TIGHTENING TORQUE FOR FLRED NUTS

Use these torques for flared part of nut.

retemiaddaerhT

tlobfo

mmmmmgkmN

htdiW

stalfssorca

htdiW

stalfssorca

euqrotgninethgiT

41915.2 ± 5.05.42 ± 9.4 81425± 294 ± 6.91 22728± 25.87 ± 6.91 422341 ± 33.731 ± 4.92 036381 ± 35.671 ± 4.92 331402 ± 51.691 ± 94 636452 ± 52.542 ± 94 245503 ± 52.492 ± 94

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Page 15

FOREWORD ELECTRIC WIRE CODE

ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominale number 5 and white coating with black stripe.

CLASSIFICA TION BY THICKNESS

lanimoN

rebmun

forebmuN

sdnarts

fo.aiD

)mm(sdnarts

noitcesssorC

)2mm(

elbaC

)mm(.D.O

58.01123.088.04.221.ctelangis,gnithgil,gnitratS

26223.090.21.302.ctelangis,gnithgiL

55623.032.56.473langisdnagnigrah

514854.063.310.795)gulpwolG(gnitratS

045808.037.244.11531gnitratS

0672108.048.366.31871gnitratS

00171208.01.9016.71032gnitratS

CLASSIFICATION BY COLOR AND CODE

stiucriC

eriwreppoC

-roirP

yti

-salC noitacifis

-irP

yrail

edoCWBB R Y G L

yram

roloCetihWkcalBkcalBdeRwolleYneerGeulB

edoCRW-WBWRRYWGWL

roloCdeR&etihW- etihW&kcalBetihW&deRdeR&wolleYetihW&neerGetihW&eulB

edoCBW-YBBRBYRGRL

roloCkcalB&etihW- wolleY&kcalBkcalB&deRkcalB&wolleYdeR&neerGdeR&eulB

edoCLW-RBYRGYYGYL

-ixuA roloCeulB&etihW-deR&kcalBwolleY&deRneerG&wolleYwolleY&neerGwolleY&eulB

edoCGW-- GRLYBGBBL

roloCneerG&etihW-- neerG&deReulB&wolleYkcalB&neerGkcalB&eulB

edoC--- LRWYLG-

roloC--- eulB&deRetihW&wolleYeulB&neerG-

gnigrahCdnuorGgnitratSgnithgiLtnemurtsnIlangiSrehtO

tnerruC

)A(gnitar

tiucricelbacilppA

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Page 16

FOREWORD CONVERSION T ABLE

CONVERSION T ABLE

METHOD OF USING THE CONVERSION T ABLE

The Conversion T able in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below.

EXAMPLE

• Method of using the Conversion Table to convert from millimeters to inches

1. Convert 55 mm to inches (1) Locate the number 50 in the vertical column at the left side, take this as 훽, then draw a horizontal line

from 훽.

(2) Locate the number 5 in the row across the top, take this as 훾, then draw a perpendicular line down

from 훾.

(3) Take the point where the two lines cross as 훿. This pint 훿 gives the value when converting from

millimeters to inches. Therefore, 55mm = 2.165 inches.

2. Convert 550 mm into inches. (1) The nuber 550 does not appear in the table, so divide by 10 (move the decimal point one place to the

left) to convert it to 55 mm. (2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point

one place to the right) to return to the orginal value. This gives 550 mm = 21.65 inches.

훾

Millimeters to inches 1 mm = 0.03937 in

0123456789

00 930.0970.0811.0751.0791.0632.0672.0513.0453.0

01493.0334.0274.0215.0155.0195.0036.0966.0907.0847.0

02787.0728.0668.0609.0549.0489.0420.1360.1201.1241.1

03181.1022.1062.1992.1933.1873.1714.1754.1694.1635.1

04575.1416.1456.1396.1237.1277.1118.1058.1098.1929.1

훿

훽

05969.1800.2740.2780.2621.2561.2502.2442.2382.2323.2

06263.2204.2144.2084.2025.2955.2895.2836.2776.2717.2

07657.2597.2583.2478.2319.2359.2299.2230.3170.3011.3

08051.3981.3822.3862.3703.3643.3683.3524.3564.3405.3

09345.3385.3226.3166.3107.3047.3087.3918.3858.3898.3

00-12

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Page 17

FORWORD CONVERSION T ABLE

Millimeters to Inches

1 mm = 0.03937 in

0123456789

00930.0970.0811.0751.0791.0632.0672.0513.0453.0

01493.0334.0274.0215.0155.0195.0036.0966.0907.0847.0

02787.0728.0668.0609.0549.0489.0420.1360.1201.1241.1

03181.1022.1062.1992.1933.1873.1714.1754.1694.1635.1

04575.1416.1456.1396.1237.1277.1118.1058.1098.1929.1

05969.1800.2740.2780.2621.2561.2502.2442.2382.2323.2

06263.2204.2144.2084.2025.2955.2895.2836.2776.2217.2

07657.2597.2538.2478.2319.2359.2299.2230.3170.3011.3

08051.3981.3822.3862.370.33643.3683.3524.3564.3405.3

09345.3385.3226.3166.3107.3047.3087.3918.3858.3898.3

Kilogram to Pound

0123456789

0002.214.416.628.820.1132.3134.5146.7148.91

0150.2252.4264.6266.8268.0370.3372.5384.7386.9398.14

0290.4403.6405.8417.0519.1521.5523.7535.9537.1639.36

0341.6643.8655.0757.2769.4761.7773.9775.1887.3889.58

0481.8893.0995.2908.4900.7912.9914.10126.30128.50130.801

0532.01144.21146.41158.61150.91152.12164.32166.53178.72170.031

0682.23184.43196.63198.83101.14103.34115.54117.74119.94121.251

1kg = 2.2046 lb

0723.45135.65137.85149.06141.36153.56155.76167.96169.17171.471

0873.67175.87187.08189.28191.58193.78106.98108.19110.49112.691

0924.89126.00230.20230.50242.70244.90246.11258.31250.61262.812

00-13

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Page 18

FORWORD CONVERSION T ABLE

Litre to U.S. Gallon

1l = 0.2642 U.S. Gal

0123456789

00462.0825.0397.0750.1123.1585.1948.1311.2873.2

01246.2609.2071.3434.3896.3369.3722.4194.4557.4910.5

02382.5845.5218.5670.60433.6406.6968.6331.7793.7166.7

03529.7981.8454.8817.8289.8642.9015.9477.9930.01303.01

04765.01138.01590.11953.11426.11888.11251.21614.21086.21449.21

05902.31374.31737.31100.41562.41925.41597.41850.51223.51685.51

06058.51511.61973.61346.61709.61171.71534.71007.71469.71822.81

07294.81657.81020.91582.91945.91318.91770.02143.02506.02078.02

08431.12893.12266.12629.12091.22554.22917.22389.22742.32115.32

09577.32040.42403.42865.42238.42690.52163.52526.52988.52351.62

Litre to U.K. Gallon

1l = 0.21997 U.K. Gal

0123456789

00022.0044.0066.0088.0001.1023.1045.1067.1089.1

01002.2024.2046.2068.2080.3003.302.53047.3059.3971.4

02993.4916.4938.4950.5972.5994.5917.5939.5951.69736

03995.6918.6930.7952.7974.7969.7919.7931.8953.8975.8

04997.8910.9932.9954.9976.9998.9911.01933.01955.01877.01

05899.01182.11834.11856.11878.11890.21813.21825.21857.21879.21

06891.31814.31836.31858.31870.41892.41815.41837.41859.41871.51

07893.51816.51838.51850.61872.61894.61817.61839.61851.71873.71

08895.71818.71730.81752.81774.81796.81719.81731.91753.91775.91

09797.91710.02732.02754.02776.02798.02711.12733.12755.12777.12

00-14

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Page 19

FORWORD CONVERSION T ABLE

kgm to ft. lb

1 kgm = 7.233 ft. lb

0123456789

002.75.417.129.822.634.346.059.751.56

013.276.978.680.493.1015.8017.5110.3212.0314.731

027.4419.1511.9514.6616.3718.0811.8813.5915.2028.902

030.7122.4225.1327.8329.5422.3524.0626.7629.4721.282

043.9826.6928.3030.1133.8135.5237.2330.0432.7434.453

057.1639.8631.6734.3836.0938.7931.5043.2145.9148.624

060.4342.1445.8447.5549.2642.0744.7746.4848.1941.994

073.6055.3158.0250.8252.5355.2457.9459.6552.4654.175

086.8759.5851.3953.0066.7068.4160.2263.9265.6367.346

090.1562.8564.5667.2769.9761.7864.4966.1078.8071.617

0013.3275.0378.7370.5472.2575.9577.6679.3772.1874.887

0116.5979.2081.0183.7186.4288.1380.9383.6485.3587.068

0210.8682.5784.2887.9889.6981.4094.1196.8198.5291.339

0313.0495.7498.4590.2692.9695.6797.3899.0992.8994.5001

0416.21019.91011.72013.43015.14018.84010.65012.36015.07017.7701

0519.48012.29014.99016.60119.31111.12113.82116.53118.24110.0511

0613.75115.46117.17110.97112.68114.39117.00219.70211.51214.2221

0716.92118.63211.44213.15215.85218.56210.37211.08215.78217.4921

0819.10312.90314.61316.32319.03311.83313.54216.25318.95310.7631

0913.47315.18317.88310.69312.30414.01417.71419.42411.23414.9341

00-15

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Page 20

FORWORD CONVERSION T ABLE

kg/cm

to lb/in

1 kg/cm2 = 14.2233 lb/in

0123456789

002.414.827.249.651.173.586.998.3110.821

012.2415.6517.0719.4811.9914.3126.7228.1420.6522.072

025.4827.8929.2131.7234.1436.5538.9630.4833.8935.214

037.6249.0441.5544.9646.3848.7940.2153.6255.0457.455

049.8652.3854.7956.1168.5261.0463.4565.8667.2869.696

052.1174.5276.9378.3571.8673.2875.6977.0180.5282.938

064.3586.7688.1881.6983.0195.4297.8390.3592.7694.189

076.599010142018301350176011801590190114211 088311251166111811591190213221732125216621 090821492190313231733115315631083149318041

0012241734115415641974139418051225163510551 0115651975139517061126163610561466187613961 0217071127153719471467187712971608112815381 0319481368177812981609102914391949136917791 0411991500202024302840226027702190250129112

0514312841226126712091250229122332274222622 0616722092240328132333274321632573298324042 0718142234264420642574298423052815223526452 0810652475298523062716113626462066247628862 0912072717213725472957237728872208261820382

0025482958237827882109261920392449285923792 0127892100351030303440385032703680310135113 0229213341385132713681300234123922334237523

00-16

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0321723682300334133823334337533174458339933 0424143824324436543074358439943315372532453

Page 21

FORWORD CONVERSION T ABLE

Temperature

Fahrenheit-Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.

1°C = 33.8°F

°C °F °C °F °C °F °C °F

4.04-04-0.04-7.11-118.158.7648.4112.72188.711

2.73-53-0.13-1.11-216.353.8746.6118.72286.971

4.43-03-0.22-6.01-314.559.8844.8113.82384.181

7.13-52-0.31-0.01-412.754.9942.0219.82482.381

9.82-02-0.4-4.9-510.950.01050.2214.92580.581

3.82-91-2.2-9.8-618.066.01158.3210.03688.681

8.72-81-4.0-3.8-716.261.11256.5216.03786.881

2.72-71-4.18.7-814.467.11354.7211.13884.091

7.62-61-2.32.7-912.662.21452.9217.13982.291

1.62-51-0.57.6-020.868.21550.1312.23090.491

6.52-41-8.61.6-128.963.31658.2318.23198.591

0.52-31-6.86.5-226.179.31756.4313.33296.791

4.42-21-4.010.5-324.374.41854.6319.33304.991

9.32-11-2.214.4-424.370.51952.8314.43492.102

3.32-01-0.419.3-522.576.51060.0410.53590.302

8.22-9-8.513.3-620.771.61168.1416.53698.402

2.22-8-6.718.2-728.877.61266.3411.63796.602

7.12-7-4.912.2-826.082.71364.5417.63894.802

1.12-6-2.127.1-924.288.71462.7412.73992.012

6.02-5-0.321.1-030.683.81560.9418.730010.212

0.02-4-8.426.0-138.789.81668.0516.045010.122

4.91-3-6.620236.984.91766.2513.340110.032

9.81-2-4.826.0334.190.02864.4511.645110.932

3.81-1-2.031.1432.396.02962.6519.840210.842

8.71-00.237.1530.591.12070.8517.155210.752

2.71-18.332.2638.697.12178.9514.450310.662

7.61-26.538.2736.892.22276.1612.755310.572

1.61-34.733.3834.0018.22374.3610.060410.482

6.51-42.939.3932.2013.32472.5617.265410.392

0.51-50.144.4040.4019.32570.7616.560510.203

4.41-68.240.5148.5014.42678.8613.865510.113

9.31-76.446.5246.7010.52776.0711.170610.023

3.31-84.641.6344.9016.52874.2719.375610.923

8.21-92.847.6442.1111.62972.4717.670710.833

2.21-010.052.7540.3117.62080.6714.975710.743

00-17

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Page 22

00-18

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Page 23

STRUCTURE AND FUNCTION

10 STRUCTURE AND FUNCTION

ENGINE RELATED PARTS ...................... 10-2

RADIATOR & OIL COOLER...................... 10-3

PTO........................................................... 10-4

POWER TRAIN......................................... 10-5

SWING CIRCLE........................................ 10-7

SWING MACHINERY ............................... 10-8

UNDERCARRIAGE................................... 10-9

TRANSMISSION....................................... 10-11

CLUTCH CONTROL ................................. 10-13

AXLE ......................................................... 10-15

SUSPENSION LOCK CYLINDER............. 10-19

BRAKING TRAIN ...................................... 10-21

BRAKE & STEERING CIRCUIT................ 10-22

BRAKE/STEERING PUMP ....................... 10-25

BRAKE PEDAL/BRAKE VALVE................ 10-26

PRIORITY VALVE ..................................... 10-27

ACCUMULATOR FOR BRAKE SYSTEM . 10-28

STEERING TRAIN .................................... 10-29

STEERING COLUMN ............................... 10-31

ORBITROL VALVE.................................... 10-32

HYDRAULIC CIRCUIT DIAGRAM ............ 10-33

FUEL/HYDRAULIC T ANK......................... 10-35

HYDRAULIC PUMP .................................. 10-36

LS VALVE/PC VALVE................................ 10-42

PPC PUMPLESS SYSTEM ...................... 10-56

CONTROL VALVE..................................... 10-58

CLSS......................................................... 10-68

SWING MOTOR........................................ 10-98

CENTER SWIVEL JOINT ......................... 10-103

TRAVEL MOTORS.................................... 10-104

WORK EQUIPMENT -

SWING PPC VALVE ................................. 10-110

TRAVEL PPC PEDAL ............................... 10-114

SERVICE PPC PEDAL ............................. 10-113

SAFETY LOCK SWITCH .......................... 10-117

PPC MANIFOLD BLOCK .......................... 10-118

PPC MANIFOLD BLOCK

PRESSURE SWITCHES .......................... 10-119

SOLENOID VALVE ................................... 10-120

TRAVEL SPEED - SWING BRAKE 2-STAGE RELIEF SUSPENSION

SOLENOID VALVE ................................... 10-121

BOOM SAFETY VALVE ............................ 10-122

HYDRAULIC CYLINDERS

(BOOM, ARM & BUCKET)........................ 10-125

OUTRIGGER CYLINDER ......................... 10-127

DOZER BLADE CYLINDER...................... 10-128

WORK EQUIPMENT................................. 10-129

ELECTRICAL WIRING DIAGRAM............ 10-130-1

ENGINE CONTROL SYSTEM .................. 10-131

MACHINE MONITOR SYSTEM................ 10-160

OVERLOAD WARNING DEVICE ............. 10-167

BREAKER MODE HYDRAULIC

PERFORMANCE ...................................... 10-168

10-1

Page 24

STRUCTURE AND FUNCTION

ENIGNE RELATED PARTS

ENGINE RELATED PARTS

1. Air cleaner

2. Intake hose

3. Muffler

4. Rear engine mount

5. Front engine mount

10-2

Page 25

STRUCTURE AND FUNCTION

RADIATOR AND OIL COOLER

SPECIFICATIONS

RADIATOR

- Core type: CWX-4

- Fin pitch: 3.5/2 mm

- Total radiation area: 40.37 m

- Pressure valve cracking pressure:

0.05 MPa (0.5 kg/cm2)

- Vacuum valve cracking pressure:

-0.005 MPa (-0.05 kg/cm2)

OIL COOLER

- Core Type: CF40-1

- Fin pitch: 4.5/2 mm

- Total radiation area 10.41 m

1. Radiator outlet hose

2. Radiator cap

3. Radiator

4. Radiator inlet hose

5. Fan guard

6. Fan

7. Drain valve

8. Shroud

9. Oil cooler

10. Reservoirtank

10-3

Page 26

STRUCTURE AND FUNCTION

PTO (COUPLING)

1. Shaft

2. Coupling

3. Breather

4. Cage

5. Hydraulic pump

6. Oil filler plug

7. Level plug

10-4

Page 27

STRUCTURE AND FUNCTION

POWER TRAIN - 20 Km/h TRAVEL SPEED SPEC.

POWER TRAIN

1. Front axle

2. Center swivel joint

3. Swing motor

4. Control valve

5. Swing brake solenoid valve

6. Travel speed solenoid valve

7. Travel motor

8. Propshaft

9. Hydraulic pump

10. Engine

11. Swing machinery

12. Swing circle

13. Transmission

14. Rear axle

10-5

Page 28

STRUCTURE AND FUNCTION

POWER TRAIN - 30 Km/h TRAVEL SPEED SPEC.

POWER TRAIN

1. Front axle

2. Center swivel joint

3. Swing motor

4. Control valve

5. Swing brake solenoid valve

6. Travel speed solenoid valve

7. Travel motor

8. Propshaft

9. Hydraulic pump

10-6

10. Engine

11. Swing machinery

12. Swing circle

13. Transmission

14. Rear axle

15. Gear pump

16. Priority valve

17. Power brake valve

18. Clutch

Page 29

STRUCTURE AND FUNCTION

SWING CIRCLE

1. Outer race

2. Ball

3. Inner race a. Inner race soft zone "S" position

b. Outer race soft zone "S" position

Specifications

Reduction ratio:

Amount of grease: 10 l (Grease: (G2-LI)

= 8.182

10-7

Page 30

STRUCTURE AND FUNCTION

SWING MACHINERY

1. Swing pinion (No. of teeth:11)

2. Case

3. No. 2 sun gear (No. of teeth: 17)

4. No. 2 planetary carrier (No. of teeth: 17)

5. Ring gear (No. of teeth:61)

6. No. 1 planetary carrier (No. of teeth: 17)

7. No. 1 sun gear (No. of teeth: 14)

8. Oil level gauge/oil filler port

9. Swing motor

10-8

10. No. 1 planetary gear (No. of teeth: 24)

11. No. 2 planetary gear (No. of teeth: 22)

12. Drain plug

13. Swing circle

Specification

Reduction ratio

14 + 61 x 17 +61

14 17

= 24.586

Page 31

UNDERCARRIAGE

UNDERCARRIAGESTRUCTURE AND FUNCTION

1. Undercarriage

2. Step

3. Wheel chock

4. Front oscillating steering axle

5. Rear axle

6. Propshaft

7. Travel motor

8. Transmission

9. Double wheel ass'y

10. Single wheel ass'y

10-9

Page 32

STRUCTURE AND FUNCTION

10-10

Page 33

STRUCTURE AND FUNCTION

TRANSMISSION - 20 Km/h TRAVEL SPEED SPEC.

TRANSMISSION

1. Screw-fork to shaft

2. Flange

3. Brake cylinder

4. Brake drum

5. Friction disk

6. Flange

7. Gear

8. Cover

9. Output shaft

10. Bearing

11. Gear

Specification

Reduction ratio: 2.265 : 1

10-11

Page 34

TRANSMISSIONSTRUCTURE AND FUNCTION

TRANSMISSION - 30 Km/h TRAVEL SPEED SPEC.

CLUTCH ASS'Y - 30 Km/h TRAVEL SPEED SPEC.

1. Screw-fork to shaft

2. Flange

3. Brake cylinder

4. Brake drum

5. Friction disk

6. Flange

7. Gear

8. Cover

9. Output shaft

10. Bearing

11. Gear

12. Clutch ass'y

Specification

Reduction ratio: 1.846 : 1

1. Casing

2. Drive shaft

3. Friction plates

4. Spring discs

5. Gear

6. Clutch control gear pump

7. Plug

8. Plug

10-12

Page 35

STRUCTURE AND FUNCTION

CLUTCH CONTROL CIRCUIT (30 Km/h SPEC. ONLY)

CLUTCH

STRUCTURE

1. Clutch control pump

2. Clutch control valve

10-13

Page 36

STRUCTURE AND FUNCTION

FUNCTION

The clutch is a device which automatically disengages the drive between the large diplacement (Rear) travel motor and the transmission. This occurs when the machine is accelerating and the disengagement occurs at 11 Kph. The transmission system becomes more efficient (by reducing losses caused by the unnecessary rotation of the rear travel motor) providing better acceleration and enabling a maximum speed of 30 Kph. When the machine decelerates from a high speed the clutch will re-engage automatically at 9 Kph and will remain engaged until the speed is increased above 11 Kpm again.

CLUTCH

10-14

Page 37

STRUCTURE AND FUNCTION

AXLE

OUTLINE

• Each axle consists of an axle housing supporting the chassis weight, a differential set in the axle housing, a final drive, and a brake provided at each end.

• A trunnion-type axle shaft with a king pin at the final drive end is used to enable the direction of travel of the machine to be changed.

FRONT AXLE

AXLE

10-15

Page 38

STRUCTURE AND FUNCTION

REAR AXLE

AXLE

10-16

Page 39

STRUCTURE AND FUNCTION

FRONT AXLE

AXLE

Axle reduction ratio = 17,73 : 1

1. Planetary carrier

2. Washer

3. Brake drum

4. Pin

5. Seal ring

6. Grease nipple

7. Seal ring

8. Seal ring

9. Bushing

10. Axle tube

11. Ring nut

12. Ball bearing

13. Ring nut

14. Ball bearing

15. Seal ring

16. Roller bearing

17. Roller bearing

18. Hexagon head screw

19. Shaft

20. Joint

21. Bushing

22. Grease nipple

23. Seal ring

24. Cylinder head screw

25. Roller bearing

26. Washer

27. Ring

28. Hexagon head screw

29. Sun gear

10-17

Page 40

STRUCTURE AND FUNCTION

REAR AXLE

AXLE

1. Planetary gear

2. Bolt

3. Planetary carrier

4. Stud

5. Wheel Hub

6. Bushing

7. Socket

8. Shaft

9. Axle tube

10. Ring nut

11. Roller bearing

12. Roller bearing

10-18

13. Shim

14. Bolt

15. Cover

16. Seal ring

17. Roller bearing

18. Roller bearing

19. Bevel gear

20. Cylinder head screw

21. Bearing

22. Ring gear plate

23. Sun gear

Page 41

STRUCTURE AND FUNCTION

SUSPENSION LOCK CYLINDER

1. Barrel

2. Plunger

Specifications

Piston: ø 85 mm Stoke: 160 mm Operating pressure: 40.0 MPa (408 kg/cm Pilot pressure: 3.0 MPa (30.6 kg/cm2) Max 5.0 MPa (51.0 kg/cm2)

)

10-19

Page 42

STRUCTURE AND FUNCTION

CIRCUIT

SUSPENSION LOCK CYLINDER

Purpose

The undercarriages of wheeled hydraulic excavators have one of the two driven axles oscillating mounted. This makes it possible to fully utilize the excavator's rimpull in rough terrain - all of the wheels being constantly in contact with the ground. An oscillation blocking ram is fitted on each side of the undercarriage to block the axle during digging or lifting work. Blocking the axle increases the excavator's stability .

1. Ram

2. Axle oscillation point

3. Oscillating axle

4. Oscillation lock solenoid valve

5. Pilot pressure reducing valve

6. Hydraulic tank

7. Swivel joint

8. Check valve

Function

The oscillating axle (3) is mounted in bearing (2) in the middle of the excavator. The two rams (1) which are full of hydraulic oil are connected through pipelines to the oscillation lock solenoid valve (4). When the excavator is being moved, the oscillation lock solenoid valve should be de-energized so that the hydraulic oil in the ram can be returned to tank as the axle is oscillating up and down. Before commencing excavating operations, the oscillation lock solenoid valve should be energized to pressurize the oil in the rams. This will lock the axle in the position it is in.

10-20

Page 43

STRUCTURE AND FUNCTION BRAKING TRAIN

1. Hydraulic oil filter

2. Hydraulic oil pump (shared with steering system)

3. Priority valve

4. Brake control valve

5. Accumulator - service brake

6. Accumulator - service brake

7. Accumulator - parking brake

8. Pressure switch - stop light

9. Pressure switch - accumulator

10. Pressure switch - parking brake

11. Pressure switch - service brake

12. Brake pedal

13. Swivel joint

14. Service brake cylinder

15. Service brake cylinder

16. Parking brake cylinder

Structure and function

The brake system is fully hydraulic. Oil is supplied at high pressure by a pump to a priority valve. The priority valve gives priority to the steering circuit. When braking, oil is sent to the brake valve which provides braking pressure to two separate braking circuits (service brakes). In the event of a failure of the power supply, the accumulators provide brake pressure to allow the machine to be safety stopped. A parking brake is provided which is operated by energizing a solenoid valve in the brake valve which sends pressure to the park brake in the transmission. Park brake on solenoid off.

10-21

Page 44

STRUCTURE AND FUNCTION BRAKE & STEERING CIRCUIT

BRAKE & STEERING CIRCUIT (ITALIAN SPECIFICATION)

10-22

Page 45

STRUCTURE AND FUNCTION

Function

The function of the steer/brake circuit (Italian specification) is identical to the standard circuit except for the tandem gear pump. The tandem pump consists of two gear pumps, one for each circuit. The priority value is maintened in the steering circuit to provide a load sensing output for emergency steering when required.

BRAKE AND STEERING CIRCUIT

10-23

Page 46

STRUCTURE AND FUNCTION BRAKE AND STEERING CIRCUIT

GEAR PUMP (ITALIAN SPECIFICATION)

10-24-1

Page 47

STRUCTURE AND FUNCTION BRAKING TRAIN

BRAKING TRAIN

10-24-2

Page 48

STRUCTURE AND FUNCTION

BRAKE/STEER PUMP

1. Delivery port

2. Suction port

Specifications

Rated peed: 2,400 RPM Displacement: 19 cc/REV Rated pressure: 250 bar Type: gear pump

10-25

Page 49

STRUCTURE AND FUNCTION

BRAKE PEDAL INCORPORATING BRAKE VALVE

BRAKE PEDAL

F = Accumulator pressure switch R = Accumulator (parking brake) R

= Accumulator (service brake)

= Service brake

= Service brake pressure switch

= Service brake

= Stop light pressure switch

X = Parking brake X

= Parking brake pressure switch

P = Delivery B = Return N = Tank

10-26

Specifications

Accumulator charge pressure (cut in) = 122 bar

(cut out) = 150 bar

-2 +8

-4

Page 50

STRUCTURE AND FUNCTION

PRIORITY V AL VE

P = Pressure port (from pump) EF = Output port to brake system CF = Output port to steering system LS = Load sensing port from steering valve

Specification

Control spring pressure: 7 bar

10-27

Page 51

STRUCTURE AND FUNCTION

ACCUMULATOR FOR BRAKE SYSTEM

Specifications

Volume: 0.75 l Max working pressure: 210 bar

10-28

Page 52

STRUCTURE AND FUNCTION

STEERING TRAIN

Structure and function

• The steering is fully hydraulic. The oil sent by the brake/steer pump (2) mounted on the PTO at the front of the engine (1) flows via the priority valve (3) to the steering valve (4). From here it is passed through swivel joint (7) to steering cylinder (5). The steering cylinder then extends or retracts to move the tie-rod and steer the machine.

• In the event of failure of the power supply the machine can be steered by emergency steering. The steering valve acts as a pump to send oil to the steering cylinder.

10-29

Page 53

STRUCTURE AND FUNCTION

STEERING TRAIN

ITEM

POSITIONS

1. ENGINE

2. HYDRAULIC OIL PUMP (SHARED WITH BRAKING CIRCUIT) .................................................... 19cc/rev

3. PRIORITY VALVE

CONTROL SPRING PRESSURE ........................................................................................................ 7 bar

4. STEERING VALVE.................................................................................................. OSPD 70/195 LS DYN.

5. STEERING CYLINDER ............................................................................... D=ø90, d=ø50, STROKE=170

STEERING CYLINDER VOLUME = (9 -5) x π x17 = 748 cmm

6. STEERING WHEEL .............................................................................................................................Ø352

7. SWIVEL JOINT

QUANTITIY OF STEERING TURNS

NORMAL

1 = CYL. VOL = 748 cm3= 3.8 TURNS

PUMP.VOL 195 cm

EMERGENCY

1 = CYL. VOL = 748 cm3= 10.7 TURNS

PUMP.VOL 70 cm

-1

10-30

Page 54

STRUCTURE AND FUNCTION BRAKING TRAIN

10-30-2

햲

Page 55

STRUCTURE AND FUNCTION

STEERING COLUMN

1. Steering wheel

2. Steering column

3. Gaiter

4. Pedal

5. Hose

6. Orbitroll valve

7. Mounting bracket

10-31

Page 56

STRUCTURE AND FUNCTION

ORBITROL V ALVE

ORBITROL V AL VE

P = Pressure port (from priority valve) T = Tank port L = Left turn port R = Right turn port LS = Load sensing port (to priority valve)

Specifications

Nominal displacement (normal operation):

195 cc/REV

Nominal displacement (emergency operation):

70cc/REV

Relief valve setting:

150 +5 bar

10-32

Page 57

STRUCTURE AND FUNCTION

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10-33

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Page 58

STRUCTURE AND FUNCTION

10-34

Page 59

STRUCTURE AND FUNCTION

FUEL / HYDRAULIC TANK

K32001 and up

FUEL / HYDRAULIC TANK

1. Suction strainer

2. Drain plug

3. Filter element

4. Bypass valve

5. Bypass strainer

6. Sight gauge

7. Vacuum valve

8. Pressure valve

Specifications

Fuel capacity: 246 l Oil capacity: 145 l Pressure valve cracking pressure:

38 ± 3.14.7 kPa (0.39 ± 0.15 kg/cm

Vacuum valve cracking pressure:

-4.5 - 0 Pa (-0.046 -0 kg/cm2)

Bypass valve cracking pressure

1.05 ± 0.2 kg/cm

10-35

햲

)

Page 60

STRUCTURE AND FUNCTION

FUEL / HYDRAULIC TANK

K34001 and up

HYDRAULIC T ANK

1. Suction strainer

2. Drain plug

3. Filter element

4. Bypass valve

5. Bypass strainer

6. Sight gauge

7. Vacuum valve

8. Pressure valve

10-35-1

10-36

햲

Specifications

Fuel capacity: 246 l Oil capacity: 145 l Pressure valve cracking pressure:

38 ± 3.14.7 kPa (0.39 ± 0.15 kg/cm2)

V acuum valve cracking pressure:

-4.5 - 0 Pa (-0.046 -0 kg/cm2)

Bypass valve cracking pressure

1.05 ± 0.2 kg/cm

Page 61

STRUCTURE AND FUNCTION

10-35-2

10-37

햲

Page 62

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

a. Port PS (suction) b. Port PA (delivery) c. Port PLS (load pressure input port) d. Port PEPC (EPC basis pressure port) e. Breather mounting port f. Port Pd3 (Air bleeder plug) g. Port Pd1 (case drain) h. Port im (PC mode selector current) j. Port isig (LS set selector current)

10-36

1. Main pump

2. LS valve

3. PC valve

4. Fixed throttle valve

5. PC-EPC valve (for PC mode selector)

6. LS-EPC valve (for LS set selector)

Page 63

STRUCTURE AND FUNCTION

MAIN PUMP

HPV 105

HYDRAULIC PUMP

a. Port Pd (drain) b. Port PA (discharge) c. Port PS (suction)

10-37

Page 64

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

1. Shaft

2. Cradle

3. Case

4. Rocker cam

5. Shoe

6. Piston

10-38

7. Cylinder block

8. Valve plate

9. End cap

10. Spring

11. Servo piston

12. Slider

Page 65

STRUCTURE AND FUNCTION

Function

• The engine rotation and torque transmitted to the pump shaft is converted into hydraulic energy, and pressurized oil is discharged according to the load.

• It is possible to change the delivery amount by changing the swash plate angle.

HYDRAULIC PUMP

Structure

• Cylinder block (7) is supported to shaft (1) by spline a, and shaft (1) is supported by the front and rear bearings.

• The tip of piston (6) is a concave ball, and shoe (5) is caulked to it to from one unit. Piston (6) and shoe (5) form a spherical bearing.

• Locker cam (4) has flat surface A, and shoe (5) is always pressed against this surface while sliding in a circular movement. Rocker cam (4) brings high pressure oil at cylindrical surface B with cradle (2), which is secured to the case,

and forms a static pressure bearing when it slides.

• Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7).

• Cylinder block (7) seals the pressure oil to valve plate (8) and carries out relative rotation. This surface is designed so that the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder block (7) is sucked in and discharged through valve plate (8).

10-39

Page 66

STRUCTURE AND FUNCTION

OPERATION

1. Operation of pump

1) Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat surface A. When this happens, rocker cam (4) moves along cylindrical surface B, so angle ( between center liner X of rocker cam (4) and the axial direction of cylinder block (7) changes. (Angle ( is called the swash plate angle.)

2) Center line X of rocker cam (4) maintains swash plate angle α in relation to the axial direction of cylinder block (7), and flat surface A moves as a cam in relation to shoe (5). In this way, piston (6) slides on the inside of cylinder block (7), so a difference between volume E and F is created inside cylinder block (7). The suction and discharge is carried out by this difference F - E. In other words, when cylinder block (7) rotates and the volume of chamber E becomes smaller , the oil is discharged during that stroke. On the other hand, the volume of chamber F becomes larger, so in that stroke, the oil is sucked in.

HYDRAULIC PUMP

3) If center line X of rocker cam (4) is in line with the axial direction of cylinder block (7) (swash plate angle = 0), the difference between volumes E and F inside cylinder block (7) becomes 0, so the pump does not carry out any suction or discharge of oil. (In actual fact, the swash plate angle never becomes 0.)

10-40

Page 67

STRUCTURE AND FUNCTION

2) Control of discharge amount

• If swash plate angle α becomes larger, the difference in volumes E and F becomes larger and discharge volume Q increases. Swash plate angle α is changed by servo piston (11).

• Servo piston (11) moves in a reciprocal movement () under the signal pressure of the PC and LS valves. This straight line movement is transmitted through rod (12) to rocker cam (4), and rocker cam (4), which is supported by the cylindrical surface to cradle (2), slides in a rotating movement in direction ().

• With servo piston (11), the area receiving the pressure is different on the left and right, so main pump discharge pressure (self pressure) PP is always brought to the pressure chamber on the small diameter piston side (front). Output pressure Pen of the LS valve is brought to the pressure chamber at the large diameter piston end (rear). The relationship in the size of pressure PP at the small diameter piston end and pressure Pen at the large diameter piston end, and the ratio between the area receiving the pressure of the small diameter piston and the large diameter piston controls the movement of servo piston (11).

HYDRAULIC PUMP

10-41

Page 68

STRUCTURE AND FUNCTION

LS V AL VE

HYDRAULIC PUMP

a. Port PLS (Control valve LS pressure inlet port) b. Port PA (Pump delivery pressure inlet port) c. Port PLP (LS valve signal pressure outlet port) d. Port PPL (PC valve signal pressure inlet port) e. Port Pa (Drain pressure outlet port) f. Port PSIG (LS control EPC valve pressure inlet port) g. Port PA (Pump delivery pressure inlet port)

PC V AL VE

1. Plug

2. Locknut

3. Sleeve

4. Spring

5. Seat

6. Spool

7. Piston

8. Sleeve

a. Port Pa (Drain pressure outlet port) b. Port PPL (PC valve signal pressure outlet port) c. Port PA (Pump delivery pressure inlet port) d. Port PA2 (Pump delivery pressure inlet port) e. Port PM (PC mode select pressure inlet port)

10-42

1. Piston

2. Spring

3. Seat

4. Spring

5. Seat

6. Spool

7. Piston

8. Sleeve

9. Locknut

10. Plug

11. Locknut

Page 69

STRUCTURE AND FUNCTION

FIXED THRO TTLE V AL VE

HYDRAULIC PUMP

a. Port Pa (drain pressure outlet port) b. Port Pout (control pressure outlet port) c. Port Pin (LS valve signal pressure inlet port)

1. Plug

2. Plug

10-43

Page 70

STRUCTURE AND FUNCTION

FUNCTION

1. LS VAL VE

The LS valve detects the load and controls the discharge amount. This valve controls main pump discharge amount Q according to differential pressure 왕PLS (=PP-PLS) (the difference between main pump pressure PP and control valve outlet port pressure PLS) [called the LS differential pressure]. Main pump pressure PP, pressure PLS [called the LS pressure] coming from the control valve output, and pressure PSIG [called the LS selec- tor pressure] from the LS-EPC valve enter this valve. The relationship between discharge amount Q and differential pressure 왕PLS, (the difference between main pump pressure PP and LS pressure PLS) (= PP-PLS) changes as shown in the diagram on the right according to LS selector current isig of the LS-EPC valve. When isig changes between 0 and 1A, the set pressure of the spring changes according to this, and the switching point for the pump discharge amount changes at the rated central value between 0.64  2.1 MPa {6.5  21.5 kg/cm2).

2. PC VAL VE

When the pump discharge pressure PP is high, the PC valve controls the pump so that no more oil than the constant flow (in accordance with the discharge pressure) flows even if the stroke of the control valve becomes larger. In this way, it carries out equal horsepower control so that the horsepower absorbed by the pump does not exceed the engine horsepower. In other words, if the load during the operation becomes larger and the pump discharge pressure rises, it reduces the discharge amount from the pump; and if the pump discharge pressure drops, it increases the discharge amount from the pump. The relationship between the pump discharge pressure PP and pump discharge amount Q is shown in the diagram on the right, with the current given to the PC-EPC valve solenoid shown as a parameter. However , in the heavy-duty operation mode, there are cases where it is given the function of sensing the actual speed of the engine, and if the speed drops because of an increase in the load, it reduces the pump discharge amount to allow the speed to recover. In other words, when the load increases and the engine speed drops below the set value, the command current to the PC-EPC valve solenoid from the controller increases according to the drop in the engine speed to reduce the pump swash plate angle.

HYDRAULIC PUMP

10-44

Page 71

STRUCTURE AND FUNCTION

OPERATION

HYDRAULIC PUMP

1. LS VAL VE

1) When control valve is at neutral

position

• The LS valve is a three-way selector valve.

with pressure PLS (LS pressure) from the inlet port of the control valve brought to spring chamber B, and main pump discharge pressure PP brought to port H of sleeve (8). The size of the force produced by this LS pressure PLS + force Z of spring (4) and the main pump pressure (self-pressure) PP determines the position of spool (6). However, the size of the output pressure PSIG (the LS selection pressure) of the EPC valve for the LS valve entering port G also changes the position of spool (6). (The set pressure of the spring changes.)

• Before the engine is started, servo piston

(11) is pushed to the right (large diameter end). (See the diagram on the right.)

• When the engine is started and the control

lever is at the neutral position, LS pressure PLS is 0 MPa {0 kg/cm nected with the drain circuit through the control valve spool.)

}. (It is intercon-

At this point, spool (6) is pushed to the left, and port C and port D are connected. Pump pressure PP enters the large diameter end of the piston from port K, and the same pump pressure PP also enters port J at the small diameter end of the piston, so the swash plate is moved to the minimum angle by the difference in area of piston (11).

10-45

Page 72

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

2) Operation in maximum direction for pump discharge amount

• When the difference between main pump pressure PP and LS pressure PLS, in other words, LS differential pressure 왕PLS becomes smaller (for example, when the area of opening of the control valve becomes larger and pump pressure PP drops), spool (6) is pushed to the right by the combined force of LS pressure PLS and the force of spring (4).

• When spool (6) moves, port D and port E are joined and connected to the PC valve. When this happens, the PC valve is connected to the drain port, so circuit D - K becomes drain pressure PT. (The operation of the PC valve is explained later.)

10-46

• For this reason, the pressure at the large diameter end of servo piston (11) becomes drain pressure PT, and pump pressure PP enters port J at the small diameter end, so servo piston (11) is pushed to the right. Therefore, the swash plate moves in the direction to make the discharge amount larger.

• If the output pressure of the EPC valve for the LS valve enters port G, this pressure creates a force to move piston (7) to the left. If piston (7) is pushed to the left, its acts to make the set pressure of spring (4) weaker, and the difference between hydraulic pressure PLS and PP changes when ports D and E of spool (6) are connected.

Page 73

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

3) Operation in minimum direction for pump discharge amount

• The following explains the situation if servo piston (1 1) moves to the left (the discharge amount becomes smaller). When LS differential pressure 왕PLS becomes larger (for example, when the area of opening of the control valve becomes smaller and pump pressure PP rises), the force produced by pump pressure PP pushes spool (6) to the left.

• When spool (6) moves, main pump pressure PP flows from port C to port D, and it enters the large diameter end of the piston from port K.

• Main pump pressure PP also enters port J at the small diameter end of the piston, but because of the difference in area between the large diameter end and the small diameter end of servo piston (1 1), servo piston (11) is pushed to the left. As a result, the swash plate moves in the direction to make angle smaller.

• If LS selection pressure PSIG enters port G, it acts to make the set pressure of spring (4) weaker.

10-47

Page 74

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

4) When servo piston is balanced

• Let us take the area receiving the pressure at the large diameter end of the piston as A1, the area receiving the pressure at the small diameter end as A0, and the pressure flowing into the large diameter end of the piston as Pen. If main pump pressure PP of the LS valve and the combined force of force Z of spring (4) and LS pressure PLS are balanced, and the relationship is A0 x PP = A1 x Pen, servo piston (11) will stop in that position, and the swash plate will be kept at an intermediate position. (It will stop at a position where the openings of the throttle from port D to port E and from port C to port D of spool (6) are approximately the same.)

10-48

• At this point, the relationship between the area receiving the pressure at both ends of piston (11) is A0 : A1 = 1 : 2, so the pressure applied to both ends of the piston when it is balanced becomes PP : Pen = 1.75 : 1.

• The position where spool (6) is balanced and stopped is the standard center, and the force of spring (4) is adjusted so that it is determined when PP-PLS = 2.1 MPa {21.5 kg/cm ever, if PSIG (the output pressure of 0  2.9 MPa {0  30 kg/cm2} of the EPC valve of the LS valve) is applied to port G, the balance stop position will change in proportion to pressure PSIG between PP-PLS = 2.1  0.64 MPa {21.5  6.5 kg/cm2}.

}. How-

Page 75

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

2. PC VAL VE

1) When pump controller is normal a. When the load on the actuator is small

and pump pressure PP is low

(1) Action of PC-EPC solenoid (1)

• The command current from the pump controller flows to PC-EPC solenoid (1). This command current acts on the PCEPC valve and outputs the signal pressure. When this signal pressure is received. the force pushing piston (2) is changed.

• On the opposite side to this force pushing piston (2) is the spring set pressures of springs (4) and (6) and pump pressure PP pushing spool (3). Spool (3) stops at a position where the combined force pushing spool (3) is balanced, and the pressure (pressure of port C) output from the PC valve changes according to this position.

• The size of command current X is determined by the nature of the operation (lever operation), the selection of the working mode, and the set value and actual value for the engine speed.

10-49

Page 76

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

(2) Action of spring

• The spring load of springs (4) and (6) in the PC valve is determined by the swash plate position.

• When servo piston (9) moves, piston (7), which is connected to slider (8), also moves to the right or left.

• If piston (7) moves to the left, spring (6) is compressed, and if it moves further to the left, spring (6) contacts seat (5) and is fixed in position. From this point, only spring (4) is actuated. In other words, the spring load is changed by piston (7) extending or compressing springs (4) and (6).

10-50

• If the command current input to PC-EPC valve solenoid (1) changes further, the force pushing piston (2) changes. The spring load of springs (4) and (6) also changes according to the value of the PC-EPC valve solenoid command current.

• Port C of the PC valve is connected to port E of the LS valve (see (1) LS valve). Self-pressure PP enters port B, the small diameter end of servo piston (9) and port A.

Page 77

STRUCTURE AND FUNCTION

• When pump pressure PP is small, spool (3) is on the left. At this point, port C and port D are connected, and the pressure entering the LS valve becomes drain pressure PT. If port E and port G of the LS valve are connected (see (1) LS valve), the pressure entering the large diameter end of the piston from port J becomes drain pressure PT, and servo piston (9) moves to the right. In this way, the pump discharge amount moves in the direction of increase.

• As servo piston (9) moves further, piston (7) is moved to the right by slider (8). Springs (4) and (6) expand and the spring force becomes weaker. When spring force becomes weaker, spool (3) moves to the right, so the connection between port C and port D is cut, and the pump discharge pressure ports B and C are connected. As a result, the pressure at port C rises, and the pressure at the large diameter end of the piston also rises, so the movement of piston (9) to the right is stopped. In other words, the stop position for piston (9) (=

pump discharge amount) is decided at the point where the force of springs (4) and (6) and the pushing force from the PC-EPC valve solenoid and the pushing force created by pressure PP acting on spool (3) are in balance.

HYDRAULIC PUMP

10-51

Page 78

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

b. When load on actuator is large and pump

discharge pressure is high

• When the load is large and pump discharge pressure PP is high, the force pushing spool (3) to the left becomes larger and spool (3) moves to the position shown in the diagram above. When this happens, as shown in the diagram above, part of the pressurized oil from port A passes through the LS valve, flows out from port C to port D, and the pressurized oil flowing from port C to the LS valve becomes approximately 3/5 of main pump pressure PP.

• When port E and port G of the LS valve are connected (see (1) LS valve), the pressure from port J enters the large diameter end of servo piston (9), and servo piston (9) stops.

10-52

• If main pump pressure PP increases further and spool (3) moves further to the left, main pump pressure PP flows to port C and acts to make the discharge amount the minimum. When piston (9) moves to the left, piston (7) is moved to the left. For this reason, springs (4) and (6) are compressed and push back spool (3). When spool (3) moves to the left, the opening of port C and port D becomes larger. As a result, the pressure at port C (= J) drops, and piston (9) stops moving to the left. The position in which piston (9) stops when this happens is further to the left than the position when pump pressure PP is low.

Page 79

STRUCTURE AND FUNCTION HYDRAULIC PUMP

• The relation of pump pressure PP and the position of servo piston (9) forms a bent line because of the double-spring effect of springs (6) and (4). The relationship between pump pressure PP and pump discharge amount Q is shown in the figure on the right.

• If command current X sent to solenoid (1) increases further, the relationship between pump pressure PP and pump discharge amount Q is proportional to the pushing force of the PCEPC valve of output pressure. In other words, if the pushing force of output pressure is added to the force pushing to the left because of the pump pressure applied to the piston (2), the relationship between PP and Q moves from  to  in accordance with the increase.

10-53

Page 80

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

2) When pump controller is abnormal and PC prolix switch in ON

a. When load on main pump is light

• If there is a failure in the pump controller, turn PC prolix switch ON to switch to the resistor side. In this case, the power source is taken directly from the battery . But if the current is used as it is, it is too large, so the resistor is used to control the current flowing to PC-EPC valve solenoid (1).

• When this is done, the current becomes constant, so the force pushing piston (2) is also constant.

10-54

• If main pump pressure PP is low , the combined force of the pump pressure and the force of PCEPC valve solenoid (1) is weaker than the spring set force, so spool (3) is balanced at a position to the left.

• At this point, port C is connected to the drain pressure of port D, and the large diameter end of the piston of servo piston (9) also becomes the drain pressure PT through the LS valve. When this happens, the pressure at the small diameter end of the piston is large, so servo piston (9) moves in the direction to make the discharge amount larger.

Page 81

STRUCTURE AND FUNCTION HYDRAULIC PUMP

b. When main pump load is heavy

• In the same way as in the previous item, when the PC prolix switch is ON, the command current sent to PC-EPC valve solenoid (1) becomes constant. For this reason, the force of piston (2) pushing spool (3) is constant.

• If main pump pressure PP increases, spool (3) moves further to the left than when the main pump load is light, and is balanced at the position in the diagram above.

• In this case, the pressure from port A flows to port C, so servo piston (9) moves to the left (to make the discharge amount smaller), by the same mechanism as explained in Item , and stops at a position to the left of the position when the load on the pump is light. In other words, even when the PC prolix switch is ON, the curve for the pump pressure PP and discharge amount Q is determined as shown in the

diagram for the value of the current sent to the PC-EPC valve solenoid through the resistor. The curve when the PC prolix switch is ON is curve , which is to the left of curve  for when the pump controller is normal.

10-55

Page 82

STRUCTURE AND FUNCTION

PPC PUMPLESS SYSTEM

1. Gear pump

2. Steering/braking priority valve

3. Power brake valve

4. Pressure reducing valve

FUNCTION

The PPC pumpless system discharged pressurized oil to operate the PPC circuit and solenoid valve assemblies.

10-56

Page 83

STRUCTURE AND FUNCTION

OPERATION

The PPC pumpless system utilizes the return line oil from the power brake valve. Oil is supplied to the steering/braking circuits from a gear pump driven by the engine. Oil flow is prioritized to the steering circuit via the priority valve with the remaining oil flow feeding the power brake valve. The return line from the brake valve passes through a pressure reducing valve where the oil pressure is maintained at 35 bar. This pressure is utilized to charge the PPC circuit.

-3

PPC PUMPLESS SYSTEM

10-57

Page 84

STRUCTURE AND FUNCTION

CONTROL V ALVE

OUTLINE

CONTROL V AL VE

The following control valve is standard:

• 8-spool valve (includes 2 service valves) The cross sections shown are for the 6-spool valve

(sub assembly) ★ The cross-sectional structure of the service

valve is the same as the structure for the bucket valve, so refer to the bucket valve for details.

General locations and names of ports (common for each external view diagram)

1. 6- spool valve sub assembly

2. Cover A (main relief valve)

3. Cover B (unload valve)

4. No. 1 service valve

5. No. 2 service valve a. Port PP (from main pump)

b. Port A1 (to swing motor MB) c. Port B1 (to swing motor MA) d. Port A2 (to stabilizer cylinder head) e. Port B2 (to stabilizer cylinder bottom) f. Port A3 (to travel motor A) g. Port B3 (to travel motor B) h. Port A4 (to boom lift cylinder bottom) i. Port B4 (to boom adjust cylinder head) j. Port A5 (to arm cylinder head) k. Port B5 (to arm cylinder bottom) l. Port A6 (to bucket cylinder head) m. Port B6 (to bucket cylinder bottom) n. Port A7 (to boom adjust cylinder bottom) o. Port B7 (to boom adjust cylinder head) p. Port A8 (to attachment) q. Port B8 (to attachment) t. Port Tsw (to swing motor) u. Port Tc (to oil cooler) v. Port Tb (to tank)

Pg. Port P7

(from boom lift cylinder RAISE PPC valve)

Ph. Port P8

(from boom lift cylinder LOWER PPC valve) Pi. Port P9 (from arm OUT PPC valve) Pj. Port P10 (from arm IN PPC valve) Pk. Port P11 (from bucket DUMP PPC valve) Pl. Port P12 (from bucket CURL PPC valve) Pm.Port P13

(from boom adjust EXTEND PPC valve) Pn. Port P14

(from boom adjust RETRACT PPC valve) Po. Port P15 (from service PPC valve) Pp. Port P16 (from service PPC valve)

aa. Port PLS1 (to pump LS valve) bb. Port PX1 (from 2-stage relief solenoid valve) dd. Port Bp (from PPC shuttle valve) ee. Pressure sensor port

(pressure sensor installed) vv. Port Ts (from sus lock solenoid valve) Pa. Port P1 (from swing LEFT PPC valve) Pb. Port P2 (from swing RIGHT PPC valve) Pc. Port P3 (from stabilizer EXTEND PPC valve) Pd. Port P4 (from stabilizer RETRACT PPC valve) Pe. Port P5 (from travel FORWARD PPC valve) Pf. Port P6 (from travel REVERSE PPC valve)

10-58

Page 85

STRUCTURE AND FUNCTION CONTROL VALVE

EXTERNAL VIEW

8-Spool valve (includes 2 service valves)

10-59

Page 86

STRUCTURE AND FUNCTION

Cross-sectional drawing

★ The cross section is given only for the 6-spool valve (STANDARD). The cross-sectional structure of the

service valves in an 8-spool valve are the same as the structure for the bucket valve, so refer to the bucket

valve for details.

CONTROL V AL VE

1. Pressure compensation valve (swing LEFT)

2. Pressure compensation valve

(stabilizer EXTEND)

3. Pressure compensation valve

(travel FORWARD)

4. Pressure compensation valve (boom RAISE)

5. Pressure compensation valve (arm OUT)

6. Pressure compensation valve (bucket DUMP)

Note: Pressure compensation valves are identi-

fied by marking on the valve assembly. (See disassembly and assembly section for details.)

10-60

7. Pressure compensation valve (bucket CURL)

8. Pressure compensation valve (arm IN)

9. Pressure compensation valve (boom LOWER)

10. Pressure compensation valve (travel REVERSE)

11. Pressure compensation valve (stabilizer RETRACT)

12. Pressure compensation valve (swing RIGHT)

Page 87

STRUCTURE AND FUNCTION

CONTROL V AL VE

1. Spool (swing)

2. Spool (stabilizer)

3. Spool (travel)

4. Spool (boom)

5. Spool (arm)

6. Spool (bucket)

7. LS bypass plug

8. Unload valve

9. Spool return spring

10. Main relief valve

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Page 88

STRUCTURE AND FUNCTION

CONTROL V AL VE

1. Suction valve (stabilizer head)

2. Suction valve (travel motor A)

3. Suction valve (boom lift cylinder bottom)

4. Safety-suction valve (arm head)

5. Safety-suction valve (bucket head)

10-62

6. Safety-suction valve (bucket bottom)

7. Safety-suction valve (arm bottom)

8. Safety-suction valve (boom lift cylinder head)

9. Suction valve (travel motor B)

10. Suction valve (stabilizer bottom)

Page 89

STRUCTURE AND FUNCTION

CONTROL V AL VE

1. LS shuttle valve (bucket)

2. LS shuttle valve (arm)

3. LS shuttle valve (boom)

4. LS shuttle valve (travel)

5. LS shuttle valve (stabilizer)

6. LS select valve Note: LS shuttle valves are identified by mark-

ings on the valve assembly. (See disassembly and assembly section for details.)

10-63

Page 90

STRUCTURE AND FUNCTION

CONTROL V AL VE

1. Cooler bypass valve

3. Main relief valve

4. Lift check valve

10-64

Swing valve

5. Pressure compensation valve (LEFT)

6. LS select valve

7. Pressure compensation valve (RIGHT)

8. Spool

Stabilizer valve

9. Pressure compensation valve (EXTEND)

10. LS shuttle valve

11. Pressure compensation valve (RETRACT)

12. Suction valve

13. Spool

14. Suction valve

Page 91

STRUCTURE AND FUNCTION

CONTROL V AL VE

Boom valve

1. Pressure compensation valve (RAISE)

2. LS shuttle valve

3. Pressure compensation valve (LOWER)

4. Safety-suction valve

5. Spool

6. Suction valve

Arm valve

7. Pressure compensation valve (OUT)

8. LS shuttle valve

9. Pressure compensation valve (IN)

10. Safety-suction valve

11. Spool

12. Safety-suction valve

Bucket valve (service valve)

13. Pressure compensation valve (DUMP)

14. LS shuttle valve

15. Pressure compensation valve (CURL)

16. Safety-suction valve

17. Spool

18. Safety-suction valve

10-65

Page 92

STRUCTURE AND FUNCTION

CONTROL V AL VE

1. LS bypass plug

2. Unload valve

10-66

Page 93

STRUCTURE AND FUNCTION

SAFETY-SUCTION VALVE FOR SERVICE VALVE

CONTROL V AL VE

1. Suction valve

2. Main valve

3. Piston

4. Piston spring

5. Poppet

6. Poppet spring

7. Suction valve

8. Sleeve

9. Adjustment screw

10. Locknut

Specifications

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20347-07-907mc/gk563(aPM97.53

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10-67

Page 94

STRUCTURE AND FUNCTION

CLSS

OUTLINE

Features

CLSS stands for Closed center Loads Sensing System, and has the following features.

1) Fine control not influenced by load

2) Control enabling digging even with fine control

3) Ease of compound operation ensured by flow divider function using area of opening of spool during compound operations

4) Energy saving using variable pump control

Structure

• The CLSS consists of a variable displacement single piston pump, control valve, and actuators.

• The pump body consists of the main pump, PC valve and LS valve.

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Page 95

STRUCTURE AND FUNCTION

BASIC PRINCIPLE

1. Control of pump swash plate angle

• The pump swash plate angle (pump discharge amount) is controlled so that LS differential pressure 왕PLS (the difference between pump pressure PP and control valve outlet port LS pressure PLS) (load pressure of actuator) is constant. (LS pressure 왕PLS = Pump discharge pressure PP - LS pressure PLS)

CLLS

• If LS differential pressure 왕PLS becomes lower than the set pressure of the LS valve (when the actuator load pressure is high), the pump swash plate moves towards the maximum position; if it becomes higher than the set pressure of the LS valve (when the actuator load pressure is low), the pump swash plate moves towards the minimum position.

10-69

Page 96

STRUCTURE AND FUNCTION

2) Pressure compensation control

• A valve (pressure compensation valve) is installed to the outlet port side of the control valve to balance the load. When there is compound operation of the actuators, this valve acts to make pressure difference 왕P constant for the upstream flow (inlet port) and downstream (outlet port) of the spool of each valve. In this way, the flow of oil from the pump is divided in proportion to area of opening S1 and S2 of each valve.

CLSS

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Page 97

STRUCTURE AND FUNCTION

3. Operation for each function and valve

Hydraulic circuit diagram and name of valves

CLSS

1. Unload valve (LS pressure + 2.45 MPa (25 kg/cm

2. Safety-suction valve

(35.8 MPa (365 kg/cm2)

Arm, Bucket & 2nd Boom

(33.3 MPa (340 kg/cm2)

3. Pressure compensation valve

4. LS shuttle valve

5. Suction valve

6. Main relief valve

(normal: 31.85 MPa (325 kg/cm2)),

when pressure rises: 34.79 Map (355 kg/cm2))

7. Lift check valve:

(cracking pressure: 0.2 MPa (2.0 kg/cm2))

8. Bypass check valve

9. LS select valve

)

10-71

Page 98

STRUCTURE AND FUNCTION

1) Unload valve

Function

1. When the control valve is at neutral, pump discharge amount Q discharged by the minimum swash plate angle is released to the tank circuit. When this happens, pump discharge pressure PP is set at 2.45 MPa (25 kg/cm valve. (LS pressure PLS: 0 MPa (0 kg/cm2))

) by spring (3) inside the

CLSS

Operation

When control valve is at neutral

• Pump discharge pressure Pp is acting on the left end of spool (4), and LS pressure PLS is acting on the right end.

• When the control valve is at neutral, LS pressure PLS is 0, so only pump discharge pressure PP has any effect, and Pp is set only by the load of spring (3).

• As pump discharge pressure Pp rises and reaches the load of spring (3) (2.45 MPa 25 kg/ cm2)), spool (4) is moved to the right in the direction of the arrow. Pump discharge pressure Pp then passes through the drill hole in sleeve (2) and is connected to tank circuit T.

• In this way, pump discharge pressure Pp is set to 2.45 MPa (25 kg/cm2)

10-72

1. Unload valve

2. Sleeve

3. Spring

4. Spool

Pp: Pump circuit (pressure) PLS:LS circuit (pressure) T: Tank circuit (pressure)

Page 99

STRUCTURE AND FUNCTION

CLSS

2. During fine control of the control valve, when the demand flow for the actuator is within the amount discharged by the minimum swash plate angle of the pump, pump discharge pressure Pp is set to LS pressure

LS + 2.45 MPa (25 kg/cm

). When the differential pressure between pump discharge pressure Pp and LS pressure PLS reaches the load of spring (3) (2.45 MPa (25 kg/cm2)), the unload valve opens, so LS differential pressure 왕PLS becomes 2.45 MPa (25 kg/cm2).

Operation

Fine control of control valve

• When fine control is carried out on the control valve, LS pressure PLS is generated and acts on the right end of spool (4). When this happens, the area of the opening of the control valve spool is small, so there is a big difference between LS pressure PLS and pump discharge pressure Pp.

• When the differential pressure between pump discharge pressure Pp and LS pressure PLS reaches the load of spring (3) (2.45 MPa (25 kg/ cm2)), spool (4) moves to the right in the direction of the arrow, and pump circuit Pp and tank circuit T are connected.

• In other words, pump discharge pressure Pp is set to a pressure equal to the spring force (2.45 MPa (25 kg/cm2)) + LS pressure PLS, and LS differential pressure 왕PLS becomes 2.45 MPa (25 kg/cm2).

1. Unload valve

2. Sleeve

3. Spring

4. Spool

Pp: Pump circuit (pressure) PLS:LS circuit (pressure) T: Tank circuit (pressure)

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Page 100

STRUCTURE AND FUNCTION

3. When the control valve is being operated and the demand flow for the actuator becomes greater than the pump discharge from the minimum swash plate angle, the flow of the oil out to tank circuit T is cut off, and all of pump discharge amount Q flows to the actuator circuit.

CLSS

Operation

Control valve operated

• When the control valve is operated to a bigger stroke, LS pressure P on the right end of spool (4). When this happens, the area of the opening of the control valve spool is large, so the difference between LS pressure PLS and pump discharge pressure Pp is small.

• For this reason, the differential pressure between pump discharge pressure Pp and LS pressure PLS does not reach the load of spring (3) (2.45 MPa (25 kg/cm2)), so spool (4) is pushed to the left by spring (3).

• As a result, pump circuit Pp and tank circuit T are shut off, and all the pump discharge amount

Q flows to the actuator circuit.

LS is generated and acts

10-74

1. Unload valve

2. Sleeve

3. Spring

4. Spool

Pp: Pump circuit (pressure) PLS:LS circuit (pressure) T: Tank circuit (pressure)

Komatsu PW130ES-6K Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

PW130ES-6K PW130ES-6K

CONTENTS

20 TESTING AND ADJUSTING ............................................................. 20-1

30 DISASSEMBLY AND ASSEMBLY .................................................... 30-1

CONTENTS

40 MAINTENANCE STANDARD.................................................. 40-1

SAFETY

SAFETY NOTICE

FOREWORD

GENERAL

HOW TO READ THE SHOP MANUAL

HOISTING INSTRUCTIONS

COA TING MA TERIALS

ST ANDARD TIGHTENING TORQUE

ELECTRIC WIRE CODE

CONVERSION T ABLE

ENIGNE RELATED PARTS

RADIATOR AND OIL COOLER

SPECIFICATIONS

PTO (COUPLING)

POWER TRAIN - 20 Km/h TRAVEL SPEED SPEC.

POWER TRAIN - 30 Km/h TRAVEL SPEED SPEC.

SWING CIRCLE

SWING MACHINERY

UNDERCARRIAGE

TRANSMISSION - 20 Km/h TRAVEL SPEED SPEC.

TRANSMISSION - 30 Km/h TRAVEL SPEED SPEC.

CLUTCH ASS'Y - 30 Km/h TRAVEL SPEED SPEC.

CLUTCH CONTROL CIRCUIT (30 Km/h SPEC. ONLY)

AXLE

SUSPENSION LOCK CYLINDER

CIRCUIT

BRAKE PEDAL INCORPORATING BRAKE VALVE

PRIORITY V AL VE

ACCUMULATOR FOR BRAKE SYSTEM

STEERING TRAIN

ITEM

POSITIONS

QUANTITIY OF STEERING TURNS

STEERING COLUMN

ORBITROL V ALVE

FUEL / HYDRAULIC TANK

FUEL / HYDRAULIC TANK

HYDRAULIC PUMP

MAIN PUMP

LS V AL VE

PC V AL VE

FIXED THRO TTLE V AL VE

PPC PUMPLESS SYSTEM

CONTROL V ALVE

EXTERNAL VIEW

CLSS