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INTRODUCTION

TO THE READER

• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form” at the end of this man-
• Be sure to thoroughly read this manual for cor- ual.
rect product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-29-832-7084
FAX: 81-29-831-1162
E-mail: dc@hitachi-kenki.com

ADDITIONAL REFERENCES

• Please refer to the other materials (operator’s


manual, parts catalog, engine technical material
and Hitachi training material etc.) in addition to this
manual.

MANUAL COMPOSITION

• This manual consists the Technical Manual and the • Information included in the Workshop Manual:
Workshop Manual. technical information needed for maintenance
and repair of the machine, tools and devices
• Information included in the Technical Manual: needed for maintenance and repair, maintenance
technical information needed for redelivery and standards, and removal/installation and assem-
delivery, operation and activation of all devices ble/disassemble procedures.
and systems, operational performance tests, and
troubleshooting 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 : T 1-3-5

Consecutive Page Number for Each Group


Group Number
Section Number
T: Technical Manual W: Workshop Manual

IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and • CAUTION:
signal words are used to alert the reader to the Indicated potentially hazardous situation which
potential for personal injury of machine damage. could, if not avoided, result in personal injury or
death.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury. • IMPORTANT:
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention
to component/part weights.
• NOTE:
To avoid injury and damage, be sure to use appropri-
Indicates supplementary technical information or
ate lifting techniques and equipment when lifting
know-how.
heavy parts.

UNITS USED

• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.

To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
Length mm in 0.03937 Pressure MPa kgf/cm2 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 0.10197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375

IN-02
SECTION 1 GENERAL
SECTION AND GROUP
CONTENTS Group 1 Specifications
Group 2 Component Specifications
Group 3 Component Layout
SECTION 2 SYSTEM
Group 1 Controller
Group 2 Control System
TECHNICAL MANUAL
Group 3 ELU System
(Operation Principle) Group 4 Hydraulic System
Group 5 Electrical System
SECTION 3 COMPONENT OPERATION
Group 1 Pump Device
Group 2 Swing Device
Group 3 Control Valve
Group 4 Control Equipment
Group 5 DQR Valve
Group 6 Travel Device
Group 7 Others (Upperstructure)
Group 8 Others (Undercarriage)

All information, illustrations and speci-


fications 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)
SECTION 4 OPERATIONAL PER- SECTION 5 TROUBLESHOOTING
FORMANCE TEST Group 1 General
Group 1 Introduction Group 2 Cross Reference Table
Group 2 Standard Group 3 Component Layout
Group 3 Engine Test Group 4 Troubleshooting A
Group 4 Excavator Test Group 5 Troubleshooting B
Group 5 Component Test Group 6 Troubleshooting C
Group 7 Electrical System Inspection
SECTION 1
GENERAL

CONTENTS
Group 1 Specifications Group 3 Component Layout
Specifications ........................................... T1-1-1 Main Component....................................... T1-3-1
Working Range......................................... T1-1-2 Left Frame ................................................ T1-3-2
Cab ........................................................... T1-3-3
Group 2 Component Specifications Relay Panel .............................................. T1-3-7
Engine ...................................................... T1-2-1 Control Box ............................................... T1-3-8
Engine Accessories .................................. T1-2-4 Relay Box ............................................... T1-3-10
Hydraulic Component ............................... T1-2-5 Pilot Piping (L) ........................................ T1-3-11
Electrical Component ..............................T1-2-11 Pump Room (L)....................................... T1-3-16
Filter ....................................................... T1-2-13 Engine Room (L)..................................... T1-3-20
Others .................................................... T1-2-14 Folding Stairway ..................................... T1-3-24
Center Frame.......................................... T1-3-27
Pilot Piping.............................................. T1-3-32
Control Valve .......................................... T1-3-34
Hydraulic Oil Tank ................................... T1-3-38
Fuel Tank ................................................ T1-3-40
Travel Alarm, Fast-Filling Device ............ T1-3-42
Right Frame ............................................ T1-3-44
Oil Cooler Room ..................................... T1-3-45
Pilot Piping (R)........................................ T1-3-47
Auto-Lubrication Device.......................... T1-3-49
Pump Room (R) ...................................... T1-3-50
Engine Room (R) .................................... T1-3-53
Engine Oil Reserve Tank (R)................... T1-3-56
Undercarriage ......................................... T1-3-57

KCAT-1-1
(Blank)

KCAT-1-2
GENERAL / Specifications
SPECIFICATIONS

A C
F

J I
H G
MKCA-12-001

Model EX5600-6
Front Attachment Type Loader Front Backhoe
Standard Bucket Capacity (Heaped) PCSA 29.0 m3 (38.0 yd3) PCSA 34.0 m3 (44.0 yd3)
Operating Weight 533000 kg (1175000 lb) 537000 kg (1184000 lb)
Engine CUMMINS Diesel QSKTA50-CE
1119 kW/1800 min-1 (1521 PS/1800 rpm)×2
A: Overall Width 10080 mm (33 ft 1 in)
B: Cab Height 8600 mm (28 ft 3 in)
C: Rear End Swing Radius 7950 mm (26 ft 1 in)
D: Ground Clearance 1100 mm (3 ft 7 in)
E: Counterweight Clearance 3000 mm (9 ft 10 in)
F: Overall Width of Upperstructure 9310 mm (30 ft 7 in)
G: Undercarriage Length 9350 mm (30 ft 8 in)
H: Undercarriage Width 7400 mm (24 ft 3 in)
I: Sprocket Center to Idler Center 7000 mm (23 ft 0 in)
J: Track Shoe Width 1400 mm (4 ft 7 in) (Grouser Shoe)
Ground Pressure 232 kPa (2.37 kgf/cm2, 33.6 psi)
Swing Speed 3.3 min-1 (rpm)
Travel Speed (Fast/Slow) 2.3/1.6 km/h (1.4/1.0 mph)
Gradeability 30° (tanθ = 0.58)
NOTE: Dimensions for B: Cab Height, D: Ground
Clearance, and E: Counterweight Clear-
ance do not include the shoe lug height.

T1-1-1
GENERAL / Specifications
WORKING RANGE
Loading Shovel

M18N-12-002

Working Range Dimension


A: Minimum Digging Distance 6150 mm (20 ft 2 in)
B: Minimum Level Crowding Distance 9800 mm (32 ft 2 in)
C: Level Crowding Distance 5550 mm (18 ft 3 in)
D: Maximum Digging Reach 16600 mm (54 ft 6 in)
E: Maximum Cutting Height 18900 mm (62 ft 0 in)
E’: Maximum Dumping Height 13100 mm (43 ft 0 in)
F: Maximum Digging Depth 4550 mm (14 ft 11 in)
G: Working Radius at Max. Dumping Height 8900 mm (29 ft 2 in)
H: Max. Bucket Opening Width 2700 mm (8 ft 10 in)

T1-1-2
GENERAL / Specifications
Backhoe

MKCA-12-002

Working Range Dimension


A: Maximum Digging Reach 20200 mm (66 ft 3 in)
A’: Maximum Digging Reach (on ground) 19400 mm (63 ft 8 in)
B: Maximum Digging Depth 8750 mm (28 ft 9 in)
B’: Maximum Digging Depth (8″Level) 8650 mm (28 ft 5 in)
C Maximum Cutting Height 19700 mm (64 ft 8 in)
D: Maximum Dumping Height 12200 mm (40 ft 0 in)
E: Maximum Vertical Wall 4250 mm (13 ft 11 in)
F: Minimum Swing Radius 9900 mm (32 ft 6 in)
G: Minimum Level Crowding Distance 7200 mm (23 ft 8 in)
H: Minimum Dumping Height 5200 mm (17 ft 1 in)

T1-1-3
GENERAL / Specifications
(Blank)

T1-1-4
GENERAL / Component Specifications
ENGINE
Manufacturer ........................................................ Cummins
Model.................................................................... QSKTA50-CE
Type...................................................................... Four-Cycle Diesel Engine, Water-Cooled, 60°V Type,
Direct-Injection, Turbochrged, With After-cooler
Cyl. No.- Bore×Stroke .......................................... 16-159×159 mm (16-6.3×6.3 in)
Total Displacement............................................... 50 L (13.2 US gal.)
Rated Output (Gross)........................................... 1119 kW/1800 min-1 (1520 PS/1800 rpm)
Compression Ratio............................................... 15.0: 1
Weight .................................................................. 5530 kg (12190 lb)
Firing Order .......................................................... 1R-1L-3R-3L-2R-2L-5R-4L-8R-8L-6R-6L-7R-7L-4R-5L
Rotation Direction................................................. Counterclockwise (Viewed from Flywheel End Side)
Dimensions Length×Width×Height ...................... 2803×1471×1785 mm (110×58×70 in)

COOLING SYSTEM
Water Pump ...................................................... Centrifugal Pump
Thermostat........................................................ Engine Circuit: Opening Temperature 82 °C (180 °F)
Fully Open Throttle Temperature 94 ° (201 °F)
After-cooled Circuit: Opening Temperature 46 °C (115 °F)
Fully Open Throttle Temperature 57 °C (135 °F)
Coolant Capacities............................................ 140 L (37.0 US gal.) (In Engine Circuit)
30 L (7.9 US gal.) (In After Cooler Circuit)
47.2 L (12.5 US gal.) (In Water Tank)

LUBRICATING SYSTEM
Lubrication Pump Type ..................................... Gear Type, Gear Drive
Oil Filter............................................................. Paper Element (Spin-On Type)
Engine Oil Capacity .......................................... 151 L (40 US gal.) (HIGH), 121 L (32 US gal.) (LOW)

STARTING SYSTEM
Manufacture ...................................................... DELCO-REMY
Model ................................................................ 50MT-400
Voltage/Output .................................................. DC24 Vx9 kW×2

T1-2-1
GENERAL / Component Specifications
STARTING ASSIST EQUIPMENT
Type .................................................................. Ether (Optional)

ENGINE STOP SYSTEM


Method .............................................................. Cummins Electronic Control

ALTERNATOR
Type .................................................................. AC Generator with Diode Rectifier
Voltage/Output .................................................. DC24 Vx140 A

SUPERCHARGING SYSTEM
Manufacture ...................................................... HOLSET
Type .................................................................. Exhaust Turbocharger Type

PERFORMANCE (NEW ENGINE)


Fuel Consumption Amount ............................... 211 g/kW·h (155 g/PS·h) at rated output
Injection Timing ................................................. Variable Type (MCRS Electronic Control)
Maximum Output Torque .................................. 6570 N·m (670 kgf·m, 4707 lbf·ft) at 1400 min-1
No Load Maximum Idle Speed.......................... 1950±30 min-1

T1-2-2
GENERAL / Component Specifications
Engine Performance Curve (QSKTA50-CE)

Test Conditions
SAE J1995 (Atmospheric pressure: 100 kPa [Similar altitude 91 m (300 ft)], inlet air temperature: 25°C (77°F),
cooling water pressure: 1 kPa, SAE No. 2 diesel oil, with fuel system, inlet resistance 4.5 kPa, inlet pipe inner
diameter: 148.1 mm (5.8 in), outlet resistance 6.8 kPa, outlet pipe inner diameter: 197.9 mm (7.8 in), no alternator,
no fan)

Torque Torque
(lbf·ft) (N·m)

-1
Engine Speed (min )

Output Output Power


Power (kW)
(hp)

-1
Engine Speed (min )

Fuel Consumption Fuel Consumption


Rate Rate
(lb/hp·h) (g/kW·h)

-1
Engine Speed (min )

TKCA-01-02-001

T1-2-3
GENERAL / Component Specifications
ENGINE ACCESSORIES
RADIATOR ASSEMBLY
Weight............................................................... 1100 kg (2425 lb)

Radiator LTA Radiator


Core Dimension (Height×Width×Thickness) .... (999×2)×(841×2)×126 mm (999×2)×(841×2)×91 mm
((39×2)×(33×2)×5 in) ((39×2)×(33×2)×3.6 in)
Core Row .......................................................... 7 Lines 5 Lines
Fin Pitch ............................................................ 2.8 mm (0.1 in) 3.6 mm (0.1 in)
Fin Shape.......................................................... Plate Plate
Capacity ............................................................ 117 L (30.9 US gal.) 75 L (19.8 US gal.)
Heat Dissipation Area ....................................... 227 m2 (2443 ft2) 197 m2 (2120 ft2)

FUEL COOLER
Weight............................................................... 1.0 kg (2.2 lb)
Core Dimension (Hight×Width×Thickness) ...... 205×200×32 mm (8.1×7.9×1.3 in)
Fin Pitch ............................................................ 4.0 mm (0.2 in)
Fin Type ............................................................ Louver Corrugated Fin
Capacity ............................................................ 0.4 L (0.1 US gal.)
Heat Dissipation Area ....................................... 1.17 m2 (12.6 ft2)

BATTERY
Model ................................................................ 245H 52
Capacity ............................................................ 176 Ah (5-Hour Rating)
Voltage .............................................................. 12 V
Discharge Current............................................. 500 A
Duration ............................................................ 7.8 Minutes
30-Second Voltage............................................ 9.9 V
Height×Width×Length ....................................... 266×276×518 mm (10.5×10.9×20.4 in)
Weight............................................................... 65.5 kg (144 lb)

T1-2-4
GENERAL / Component Specifications
HYDRAULIC COMPONENT

PUMP DEVICE
Drive Gear Ratio .......................................... Engine: Main Pump 1: 1.019
Engine: 4-Unit Pump 1: 1.081

MAIN PUMP (MP1 to 4, 7 to 10)


Type ............................................................. Swash Plate Type Variable Displacement Tandem Plunger Pump
Model ........................................................... K3V280DTH14ZL
3 3
Theoretical Displacement ............................ 208 cm /rev×2 (12.7 in /rev×2)
Maximum Flow Rate .................................... 375 L/min×2 (99 US gpm×2)
Weight.......................................................... 300 kg (660 lb)

MAIN PUMP (MP5, 6, 11, 12)


Type ............................................................. Swash Plate Type Variable Displacement Tandem Plunger Pump
Model ........................................................... K3V280DTH18ZL
Theoretical Displacement ............................ 236 cm3/rev×2 (14.4 in3/rev×2)
Maximum Flow Rate .................................... 425 L/min×2 (112 US gpm×2)
Weight.......................................................... 300 kg (660 lb)

4-UNIT PUMP (LEFT ENGINE)


Type ............................................................. K3V112S (Oil Cooler Fan Motor Drive Pump)
KFP4156 (Pilot Pump/Air Compressor Drive Pump+
Pump Transmission Oil Pump)
Weight.......................................................... 100 kg (220 lb)
OIL COOLER FAN MOTOR DRIVE PUMP
Type ............................................................. Swash Plate Type Variable Displacement Plunger Pump
3 3
Theoretical Displacement ............................ 112 cm /rev (6.8 in /rev)
Maximum Flow Rate .................................... 202 L/min (53 US gpm)
PILOT PUMP (TRANSMISSION SIDE)/AIR COMPRESSOR DRIVE PUMP (CENTER)
Type ............................................................. Tandem Gear Pump
Theoretical Displacement
(Transmission Side).................................. 56 cm3/rev (3.4 in3/rev)
(Center) .................................................... 45 cm3/rev (2.7 in3/rev)
PUMP TRANSMISSION OIL PUMP (PUMP END SIDE)
Type ............................................................. Gear Pump
Theoretical Displacement ............................ 13 cm3/rev (0.8 in3/rev)

T1-2-5
GENERAL / Component Specifications
4-UNIT PUMP (RIGHT ENGINE)
Type .................................................................. K3V112S (Oil Cooler Fan Motor Drive Pump)
KFP4156 (Pilot Pump/Auxiliary Pump+
Pump Transmission Oil Pump)
Weight............................................................... 100 kg (220 lb)
OIL COOLER FAN MOTOR DRIVE PUMP
Type .................................................................. Swash Plate Type Variable Displacement Plunger Pump
Theoretical Displacement ................................. 80 cm3/rev (4.9 in3/rev)
Maximum Flow Rate ......................................... 175 L/min (46 gpm)
PILOT PUMP (TRANSMISSION SIDE)/AUXILIARY PUMP (CENTER)
Type .................................................................. Tandem Gear Pump
Theoretical Displacement
(Transmission Side)....................................... 56 cm3/rev (3.4 in3/rev)
(Center) ......................................................... 45 cm3/rev (2.7 in3/rev)
PUMP TRANSMISSION OIL PUMP (PUMP END SIDE)
Type .................................................................. Gear Pump
Theoretical Displacement ................................. 13 cm3/rev (0.8 in3/rev)

OIL COOLER
Core Dimension (Height×Width×Thickness) .... 1500×780×160 mm (59×31×6.3 in)
Fin Shape.......................................................... Corrugated Fin (With Wave)
Capacity ............................................................ 38 L (10 US gal.)
Heat Dissipation Area ....................................... 114 m2 (1227 ft2)
Weight............................................................... 144 kg (317 lb)

PUMP TRANSMISSION COOLER


Core Dimension (Height×Width×Thickness) .... 284.4×312×40 mm (11.2×12.3×1.6 in)
Core Row .......................................................... 1
Fin Shape.......................................................... Corrugated Fin (With Wave)
Capacity ............................................................ 2 L (0.5 US gal.)
Heat Dissipation Area ....................................... 3.34 m2 (36 ft2)

CONTROL VALVE
Type .................................................................. Pilot Control Multi-Block 4-Spool
Model ................................................................ KVS-1000
Main Relief Set-Pressure.................................. 29.4 MPa (300 kgf/cm2, 4266 psi)
Overload Relief Set Pressure ........................... 31.4 MPa (320 kgf/cm2, 4550 psi)
15.7 MPa (160 kgf/cm2, 2275 psi) (Bucket Open/Close)
Weight............................................................... 425 kg (937 lb)

SWING DEVICE
Type .................................................................. 2-Stage Planetary Reduction Gear
Reduction Gear Ratio ....................................... 13: 358
Weight............................................................... 1990 kg (4387 lb)

T1-2-6
GENERAL / Component Specifications
SWING MOTOR
Type .................................................................. Swash Plate Type Fixed Displacement Axial Plunger Motor
Model ................................................................ MX750
Theoretical Displacement ................................. 737 cm3/rev (45 in3/rev)
Relief Set Pressure........................................... 24.5 MPa (250 kgf/cm2, 3555 psi)
Parking Brake Release Pressure...................... 2.7 MPa (27.5 kgf/cm2, 392 psi)
Weight............................................................... 226 kg (498 lb)

TRAVEL DEVICE
Type .................................................................. Three Stage Transmission
Reduction Gear Ratio ....................................... 151.692
Weight............................................................... 5650 kg (12456 lb)

TRAVEL MOTOR
Type .................................................................. Swash Plate Type Variable Displacement Axial Plunger Motor
Model ................................................................ M3B1000BC-1027/718-001C
Theoretical Displacement (Slow Speed)........... 1027 cm3/rev (63 in3/rev)
(Fast Speed)............ 718 cm3/rev (44 in3/rev)
Parking Brake Release Pressure...................... 1.90+0.2-0 MPa (19.4+2.2-0 kgf/cm2, 276+31-0 psi)
Weight............................................................... 280 kg (617 lb)

TRAVEL BRAKE VALVE


Model ................................................................ VBR-12ST
Maximum Flow Rate ......................................... 660 L/min (174 US gpm)
Weight............................................................... 60 kg (132 lb)

OIL COOLER FAN MOTOR


Model ................................................................ A2F180/6.1
Theoretical Displacement ................................. 180 cm3/rev (11 in3/rev)
Weight............................................................... 60 kg (132 lb)

AIR COMPRESSOR DRIVING MOTOR


Model ................................................................ MSF-46
Theoretical Displacement ................................. 46.1 cm3/rev (3 in3/rev)
Weight............................................................... 20 kg (44 lb)

BOOM CYLINDER
(Loading Shovel) (Backhoe)
Rod Diameter.................................................... 300 mm (12 in) 300 mm (12 in)
Cylinder Bore .................................................... 420 mm (17 in) 420 mm (17 in)
Stroke................................................................ 3200 mm (10 ft 6 in) 3500 mm (11 ft 6 in)
Fully Retracted Length...................................... 5070 mm (16 ft 8 in) 5240 mm (17 ft 3 in)
Plating Thickness.............................................. 30 µm (1.18 µin) 30 µm (1.18 µin)
Weight............................................................... 6600 kg (14550 lb) 7390 kg (16292 lb)

ARM CYLINDER
(Loading Shovel) (Backhoe)
Rod Diameter.................................................... 260 mm (10 in) 260 mm (10 in)
Cylinder Bore .................................................... 360 mm (14 in) 360 mm (14 in)
Stroke................................................................ 2500 mm (8 ft 2 in) 2715 mm (8 ft 11 in)
Fully Retracted Length...................................... 4020 mm (13 ft 2 in) 4235 mm (13 ft 11 in)
Plating Thickness.............................................. 30 µm (1.18 µin) 30 µm (1.18 µin)
Weight............................................................... 4320 kg (9524 lb) 4690 kg (10340 lb)

T1-2-7
GENERAL / Component Specifications
BUCKET CYLINDER
(Loading Shovel) (Backhoe)
Rod Diameter.................................................... 250 mm (10 in) 230 mm (9 in)
Cylinder Bore .................................................... 340 mm (13 in) 310 mm (12 in)
Stroke................................................................ 2350 mm (7 ft 9 in) 2700 mm (8 ft 10 in)
Fully Retracted Length...................................... 4390 mm (14 ft 5 in) 4000 mm (13 ft 2 in)
Plating Thickness.............................................. 30 µm (1.18 µin) 30 µm (1.18 µin)
Weight............................................................... 4060 kg (8950 lb) 3120 kg (6878 lb)

LEVEL CYLINDER
Rod Diameter.................................................... 300 mm (12 in)
Cylinder Bore .................................................... 420 mm (17 in)
Stroke................................................................ 970 mm (3 ft 2 in)
Fully Retracted Length...................................... 2710 mm (8 ft 11 in)
Plating Thickness.............................................. 30 µm (1.18 µin)
Weight............................................................... 3840 kg (8466 lb)

DUMP CYLINDER
Rod Diameter.................................................... 160 mm (6 in)
Cylinder Bore .................................................... 280 mm (11 in)
Stroke................................................................ 625 mm (2 ft 1 in)
Fully Retracted Length...................................... 1700 mm (5 ft 7 in)
Plating Thickness.............................................. 30 µm (1.18 µin)
Weight............................................................... 985 kg (2172 lb)

LIFT CYLINDER
(Fast-Filling System) (Folding Stairway Cylinder)
Rod Diameter.................................................... 40 mm (2 in) 40 mm (2 in)
Cylinder Bore .................................................... 70 mm (3 in) 65 mm (3 in)
Stroke................................................................ 240 mm (9.5 in) 880 mm (2 ft 11 in)
Fully Retracted Length...................................... 512 mm (1 ft 8 in) 1160 mm (3 ft 10 in)
Plating Thickness.............................................. 30 µm (1.18 µin) 30 µm (1.18 µin)
Weight............................................................... 17 kg (37 lb) 28 kg (62 lb)

T1-2-8
GENERAL / Component Specifications
EHC VALVE
For Electric Lever Control (Pilot Panel (L) (Upper Side))
Application ........... SA: Right Swing Control SB: Left Swing Control
SC: Bucket Close Control (LD) SD: Right Travel Reverse Control
Auxiliary (BH)
SE: Right Travel Forward Control SF: Left Travel Reverse Control
SH: Bucket Open Control (LD) SI: Left Travel Forward Control
Auxiliary (BH)

For Electric Lever Control (Pilot Panel (L) (Lower Side))


Application ........... SA: Arm Retract Control (LD) SB: Boom Raise Control
Arm Roll-Out Control (BH)
SC: Arm Extend Control (LD) SD: Auxiliary
Arm Roll-In Control (BH)
SE: Auxiliary SF: Bucket Tilt-Out Control (LD)
Bucket Roll-Out Control (BH)
SH: Boom Lowering Control SI: Bucket Tilt-In Control (LD)
Bucket Roll-In Control (BH)

Pump and Oil Cooler Fan Motor Control (Pilot Panel (L))
Application ........... SA: Main Pump Displacement Angle Control SB: Power Decrease Control
(For Main Pump 2, 4, 5 and 6)
SC: Auxiliary SD: Auxiliary
SE: Power Increase Control SF: Main Pump Displacement Angle Control
(For Main Pump 3)
SH: Driving Oil Cooler Fan SI: Main Pump Displacement Angle Control
Pump Displacement Angle Control (For Main Pump 1)

Pump and Oil Cooler Fan Motor Control (Pilot Panel (R))
Application ........... SA: Main Pump Displacement Angle Control SB: Main Pump Displacement Angle Control
(For Main Pump 8, 10, 11 and 12) (For Main Pump 9)
SC: Auxiliary SD: Auxiliary
SE: Power Increase Control SF: Power Decrease Control
SH: Main Pump Displacement Angle Control SI: Driving Oil Cooler Fan
(For Main Pump 7) Pump Displacement Angle Control

NOTE: LD: Loading Shovel


BH: Backhoe

T1-2-9
GENERAL / Component Specifications
TRAVEL MODE SELECTOR SOLENOID VALVE
Maximum Flow Rate ........................................................ 60 L/min (16 US gpm)

FAST-FILLING SOLENOID VALVE


Maximum Flow Rate ........................................................ 60 L/min (16 US gpm)

PILOT SHUT-OFF SOLENOID VALVE


Maximum Flow Rate ........................................................ 60 L/min (16 US gpm)

PRESSURE REDUCING VALVE (FOR TRAVEL SPEED SELECTION)


Secondary Pilot Pressure Set Pressure .......................... 2.41±0.1 MPa (24.6±1 kgf/cm2, 350±15 psi)

PRESSURE REDUCING VALVE (FOR CUSHION CYLINDER)


Secondary Pilot Pressure Set Pressure .......................... 23.5±0.5 MPa (240±5 kgf/cm2, 3416±73 psi)

BOOM RAISE PRIORITY SELECTION VALVE/BOOM LOWER PRIORITY SELECTION VALVE


Type ................................................................................. Pilot Pressure Selection Type
Selection Pressure: Start of Opening Spool .................... 0.58 MPa (6 kgf/cm2, 84 psi)
Spool Fully Open.............................. 0.98 MPa (10 kgf/cm2, 142 psi)

ARM ROLL-OUT PRIORITY SELECTOR VALVE (BACKHOE)


Type ................................................................................. Pilot Pressure Selection Type
Selection Pressure: Start of Opening Spool .................... 5.9 MPa (60 kgf/cm2, 858 psi)

PILOT PRESSURE SELECTION VALVE (FOR STOPPING TRAVEL)


Selection Pressure: Start of Opening Spool .................... 11.8 MPa (120±10 kgf/cm2, 1715 psi)

DQR VALVE
Maximum Pressure.......................................................... 4 MPa (40 kgf/cm2, 582 psi)

T1-2-10
GENERAL / Component Specifications
ELECTRICAL COMPONENT
COOLANT TEMPERATURE SENSOR (LTA RADIATOR INLET COOLANT TEMPERATURE SENSOR (L) AND
(R), RADIATOR INLET COOLANT TEMPERATURE SENSOR (L) AND (R), LTA RADIATOR OUTLET
COOLANT TEMPERATURE SENSOR (L) AND (R), RADIATOR OUTLET COOLANT TEMPERATURE
SENSOR (L) AND (R))
Operating Temperature..................................... -30 to 120 °C (-22 to 248 °F)

COOLANT LEVEL CHECK SWITCH (COOLANT LEVEL CHECK SWITCH (L1), (L2), (R1), (R2))
Type .................................................................. Capacitance Type

COOLANT LEVEL WARNING SENSOR (COOLANT LEVEL WARNING SENSOR (L), (R))
Type .................................................................. Capacitance Type

AIR CLEANER WARNING SWITCH (AIR CLEANER WARNING SWITCH (L1), (L2), (R1), (R2))
Operating Pressure........................................... 6.2±0.6 kPa (635±58 mm H2O)

FUEL LEVEL SENSOR


Type .................................................................. Float Type
Resistance ........................................................ 80+12+2Ω (Float Position: EMPTY)
100-4Ω (Float Position: FULL)

FUEL LEVEL SWITCH (FUEL LEVEL SWITCH (H), (L))


Type .................................................................. Capacitance Type

HYDRAULIC OIL LEVEL SWITCH 1 (FOR LEVEL CHECK), 2 (FOR WARNING LED)
Type .................................................................. Float Switch

HYDRAULIC OIL LEVEL SWITCH (PUMP TRANSMISSION OIL LEVEL SWITCH (L), (R))
Type .................................................................. Capacitance Type

HYDRAULIC OIL TEMPERATURE SENSOR (FOR HYDRAULIC OIL TANK, PUMP TRANSMISSION OIL
TEMPERATURE SENSOR (L), (R), OIL COOLER OUTLET OIL TEMPERATURE SENSOR 1, 2)
Operating Temperature..................................... -30 to 120 °C (-22 to 248 °F)

AIR TEMPERATURE SENSOR (AMBIENT TEMPERATURE SENSOR, RADIATOR INLET AIR


TEMPERATURE SENSOR (L), (R), OIL COOLER AIR TEMPERATURE SENSOR 1, 2)
Operating Temperature..................................... -30 to 120 °C (-22 to 248 °F)

MAIN PRESSURE SENSOR (ARM CYLINDER BOTTOM SIDE PRESSURE SENSOR, ARM CYLINDER ROD
SIDE PRESSURE SENSOR)
Operating Pressure........................................... 0 to 34.3 MPa (0 to350 kgf/cm2, 0 to 4977 psi)

PILOT PRESSURE SENSOR


(FOR EHC VALVE INPUT CUSHION CYLINDED STROKE END PRESSURE DETECTION)
Operating Pressure........................................... 0 to 4.9 MPa (0 to 50 kgf/cm2, 0 to 711 psi)

PILOT PRESSURE SENSOR (FOR PILOT SHUT-OFF SOLENOID VALVE OUTPUT DETECTION)
Operating Pressure........................................... 0 to 5.4 MPa (0 to 55 kgf/cm2, 0 to 782 psi)

DRAIN PRESSURE SENSOR (FOR SWING MOTOR, MAIN PUMP P1 TO 12)


Operating Pressure........................................... 0 to 4.9 MPa (0 to 50 kgf/cm2, 0 to 711 psi)

PRESSURE SENSOR (OIL COOLER INLET OIL PRESSURE)


Operating Pressure........................................... 0 to 4.9 MPa (0 to 50 kgf/cm2, 0 to 711 psi)

T1-2-11
GENERAL / Component Specifications
PRESSURE SWITCH (GREASE) 1 (PRESSURE SWITCH (GREASE) 1 (AUTO LUBRICATION CIRCUIT)
Set-Pressure ..................................................... 17.6 MPa (180 kgf/cm2, 2560 psi)

PRESSURE SWITCH (GREASE) 2 (MANUAL-LUBRICATION)


Set-Pressure ..................................................... 23.5 MPa (240 kgf/cm2, 3413 psi)

CONTROL LEVER (FRONT ATTACHMENT/SWING)


Model ................................................................ S90JAM-YQ-21R2G-9340B
Mechanical Operation Angle............................. XY Axis±15°
Control Force .................................................... XY Axis About 2 to 8 N
Total Resistance................................................ 2 kΩ±15 %

TRAVEL LEVER (TRAVEL)


Model ................................................................ ERUP2-1.0-004
Mechanical Operation Angle............................. ±12.4°
Neutral Detection Angle .................................... ±3°
Control Force .................................................... About 6.5±1.0 to 15.3±2.3 N
Output Voltage .................................................. 1.0 to 4.0 V

CONTROL LEVER (BUCKET OPEN/CLOSE)


Model ................................................................ ERU2-1.0-002B
Mechanical Operation Angle............................. ±12.4°
Neutral Detection Angle .................................... ±3°
Control Force .................................................... 3.9±0.5 to 9.3±1.4 N
Output Voltage .................................................. 1.0 to 4.0 V

ACCELERATOR SENSOR
Total Resistance................................................ 5 kΩ±10 %
Output ............................................................... 0.4±0.4±0.1 V (Idle Position)
4.4±0.1 V (Full Position)

PUMP UNIT (FOR FOLDING STAIRWAY)


Model ................................................................ DU2.5NC424
Motor Maximum Output .................................... 2.4 kW
Pump Displacement.......................................... 2.43 cm3/rev (0.1 in3/rev)
Weight............................................................... 10.2 kg (22 lb)

T1-2-12
GENERAL / Component Specifications
ELECTRICAL MOTOR (FOR FUEL COOLER COOLING)
Model ................................................................ TD5019-824
Rated Voltage ................................................... DC24 V
Rated Current ................................................... 3.5 A
Rated Speed ..................................................... 2200 min-1

FILTER
Filtration
Suction Filter ..................................................... 177 µm
High Pressure Strainer...................................... 120 µm
Full-Flow Filter .................................................. 10 µm
Bypass Filter ..................................................... 5 µm
Drain Filter ........................................................ 10 µm
Pilot Filter .......................................................... 10 µm

T1-2-13
GENERAL / Component Specifications
OTHERS
LUBRICATOR
Grease Tank Capacity....................................... About 360 L (Wiggins Filling)
Grease Maximum Delivery Pressure................ 24.0 MPa (245 kgf/cm2, 3484 psi)
Grease Delivery Flow ....................................... 0.73 L/min (0.2 US gpm)

AIR CONDITIONER
Cooling Capacity............................................... 5.0 kW (4320 kcal/h)×3
Heating Ability ................................................... 3.8 kW (3323 kcal/h)×3
Refrigerant Quantity.......................................... 1400±50 g (3±0.1 lb)
Compressor Oil Quantity .................................. 320 cm3 (20 in3)
(Including Capacitor, Hose)

ELECTRICAL PUMP
Model ................................................................ GP-25
Rated Voltage ................................................... DC24 V
Rated Current ................................................... 10 A
Max. Delivery Flow Rate................................... 60 L/min (16 US gpm)

T1-2-14
GENERAL / Component Layout
MAIN COMPONENT Backhoe
5
4
NOTE: LD: Loading shovel 8
BH: Backhoe 3

Loading Shovel
6 M18N-01-020
7
5 8
4
9
3
10
2 11
1 12
13
14
15
16
17
46 18
19
45
20
44 21

43 22
42
23
41
24
40 25
39 26
38 27
37 28
36 29
35 30
34 33 32 31 T18N-01-03-001
1 - Bucket 13 - Grease Tank 25 - Suction Manifold (2 Used) 36 - Lower Roller
2 - Dump Cylinder (2 Used) (LD Only) 14 - Pilot Filter (R) 26 - Fast-Filling Device 37 - Upper Roller
3 - Bucket Cylinder (2 Used) 15 - Control Valve (6 Used) 27 - Boom Raise Priority Selector Valve, 38 - Accumulator (3 Used) (For
Boom Lower Priority Selector Valve Cushion Cylinder)
4 - Arm 16 - Hydraulic Oil Tank 28 - Swing Device (4 Used) 39 - Cushion Cylinder (2 Used)
5 - Arm Cylinder 17 - Muffler (4 Used) 29 - Center Joint 40 - Idler
(LD: 1 Used, BH: 2 Used)
6 - Boom Cylinder (2 Used) 18 - Air Cleaner (4 Used) 30 - Left Engine 41 - Air Compressor Unit
7 - Level Cylinder (LD Only) 19 - Coolant Reserve Tank (2 Used) 31 - Travel Brake Valve (4 Used) 42 - Pilot Filter (L)
8 - Boom 20 - Radiator, LTA Radiator (2 Used) 32 - Travel Device (2 Used) 43 - Battery (6 Used)
9 - Control Lever (Front 21 - Fuel Tank 33 - Pressure Reducing Valve (For 44 - Washer Tank
Attachment/Swing) Cushion Cylinder)
10 - High-Pressure Strainer (12 Used) 22 - Transmission Oil Cooler (2 34 - Folding Stairway 45 - Control Lever (Bucket
Used) Open/Close, LD Only)
11 - Oil Cooler Fan Motor (2 Used) 23 - Right Engine 35 - Pilot Pressure Selector Valve 46 - Control Lever (Travel)
12 - Oil Cooler (2 Used) 24 - Fuel Cooler (2 Used)

T1-3-1
GENERAL / Component Layout
LEFT FRAME

2
3
1

5
26
25 6

24 7
8
23 9

22
21
10
20
19

18
17
16
15
14
13

12

11 T18N-01-03-002

1 - Work Light 8 - Pilot Panel (L) 15 - Relay Box 21 - Condenser


(Upper Left of Cab) (With Fan Motor) (3 Used)
2 - Work Light 9 - Maintenance Light 16 - Isolation Switch 22 - Maintenance Light
(Upper Right of Cab) (Engine Room (L)) (Under Cab Room (Rear))
3 - Wiper Motor 10 - Emergency Switch 4 17 - Relay Panel 23 - Receiver-Dryer Condenser
(Engine Room (L2)) Fan Control Pressure Switch
(3 Used)
4 - Entrance Light 11 - Emergency Switch 3 18 - Air Conditioner Unit 24 - Horn (L)
(Cab Rear) (Engine Room (L1)) (3 Used)
5 - Maintenance Light 12 - Maintenance Light 19 - Working Light 25 - Work Light
(Under Cab Room (Front)) (Pump Room (L)) (Front Left (Under Left)) (Front Left (Middle Left))
(Optional)
6 - Control Box 13 - Emergency Switch 2 20 - Working Light 26 - Work Light
(Pump Room (L)) (Front Left (Under Right)) (Front Left (Middle Right))
(Optional)
7 - Battery (6 Used) 14 - Air Compressor Unit

T1-3-2
GENERAL / Component Layout
CAB

T18N-01-03-014

M18N-01-017

3
T18L-01-02-042

1 - Folding Stairway 2 - Entrance Light 3 - Atmospheric Temperature


Beacon Light/Alarm Sensor

T1-3-3
GENERAL / Component Layout
In Cab
1 2

M18G-01-044

T18G-01-02-053

Refer to the next page 4 5 6 7 8

10

11

12

13

14

15

16

24 23 22 21 20 19 18 17 T18N-01-02-001

1- Hour Meter 7- Emergency Switch 1 13 - Auto-Idle Switch 19 - Buzzer Stop Switch


2- Dome Light (Front) 8- Engine Control Dial (R) 14 - Fast-Filling System Switch 20 - Travel Mode Selector Switch
3- Dome Light (Rear) 9- Engine Start Switch (R) 15 - Auxiliary 21 - Maintenance Light Switch
4- Horn Switch 10 - Engine Stop Switch (R) 16 - Key Switch 22 - Work Light Switch
5- Pilot Shut-Off Lever 11 - Dome Light Switch 17 - Optional Switch 23 - Engine Stop Switch (L)
6- Engine Control Dial (L) 12 - Entrance Light Switch 18 - Auxiliary 24 - Engine Start Switch (L)

T1-3-4
GENERAL / Component Layout

1 2
3

10

T18G-01-02-055

11

12

T18M-01-02-006
13
1 - Indicator (Yellow) 5 - Wiper Switch 8 - Air Conditioner Control 11 - Display Unit
(Rear)
2 - Indicator (Red) 6 - Air Conditioner Control 9 - Air Conditioner Control 12 - IDU
(Side) (Front) (Information Display Unit)
3 - Display Contrast Switch 7 - Radio 10 - Keypad 13 - ELU
(Electric Lever Control Unit)
4 - Wiper Interval Switch

T1-3-5
GENERAL / Component Layout

1 2 3 4 5

T18G-01-02-030
6

T18G-01-02-028

7 8 9 10 11 12

13

14

15

T18G-01-02-026
18 17 16

Layout of Power Source Terminal


T146-01-03-023
1 - Electric Lever (Arm, Swing) 6 - Fuse Box (Cab) 11 - Data Link Connector 15 - Power Source Terminal
(ECM (R))
2 - Electric Lever (Bucket Close) 7 - DC-DC Converter 12 - Data Link Connector 16 - DLU (Data Logging Unit)
(Loading Shovel) (DLU)
3 - Electrical Lever (Travel) 8 - Cigar Lighter 13 - Buzzer 17 - Data Link Connector (MMS)
4 - Electric Lever (Bucket Open) 9 - ORBCOMM (Optional) 14 - DC-DC Converter 18 - Controller
(Loading Shovel) (Monitoring Camera)
5 - Electric Lever (Boom, 10 - Data Link Connector (ECM (Optional)
Bucket) (L))

T1-3-6
GENERAL / Component Layout
RELAY PANEL
1 2 3 4

17

6
16

T18N-01-03-010
7

15

14 8

13
10

12 11

T18N-01-03-011

1 - Starter Relay 1 (L) (Upper) 6 - Charge Relay (R) 10 - Prelub Relay (L) 14 - Prelub Timer Relay (L)
2 - Starter Relay 1 (L) (Lower) 7 - Prelub Timer Relay (R) 11 - Prelub Relay (R) 15 - Fuel Cooler Fan Motor
Relay
3 - Starter Relay 2 (L) 8 - Fusible Link (400 A) 12 - Fusible Link (250 A) (Folding 16 - Starter Relay 1 (R)
(Prelub Relay (L)) Stairway Motor Pump 2) (Upper)
4 - Charge Relay (L) 9 - Fusible Link (400 A) 13 - Fusible Link (250 A) (Folding 17 - Starter Relay 1 (R)
(Prelub Relay (R)) Stairway Motor Pump 1) (Lower)
5 - Starter Relay 2 (R)

T1-3-7
GENERAL / Component Layout
CONTROL BOX 1 2 3

21

20 4

5
19
6

18
7
17
8
T18N-01-03-010

9
10

16 11

12

15 13

14

T18N-01-03-012

1 - MC (Main Controller) 7 - Engine Stop Lamp (R) 12 - Auto-Lubrication Interval 17 - CSU (Contami. Sensing
Switch Unit)
2 - HMU (HYD. System 8 - Engine Warning Lamp (R) 13 - Fuse Box 2 (#21 to 40) 18 - EHU (Engine Heat-Balance
Monitoring Unit) Control Unit)
3 - MMS (Modular Mining 9 - Engine Maintenance Lamp 14 - Fuse Box 4 (#61 to 80) 19 - Engine Failure Code
System) (Optional) (R) Display Selection Switch
(L)
4 - Engine Maintenance Lamp 10 - Engine Troubleshooting 15 - Fuse Box 3 (#41 to 60) 20 - Engine Troubleshooting
(L) Switch (R) Switch (L)
5 - Engine Warning Lamp (L) 11 - Engine Failure Code 16 - Fuse Box 1 (#1 to 20) 21 - Limit Switch
Display Selection Switch
(R)
6 - Engine Stop Lamp (L)

T1-3-8
GENERAL / Component Layout
Relay Position

Fluorescent Light

2 3 4 5

6 7 8 9

10 11 12 13 14 15 16

17 18 19 20 21 22 23

24 25 26 27 28 29 30

31 32 33 34 35 36 37

38 39 40 41 42 43 44

45 46 47 48 49 50 51

T18P-01-03-005

1 - Box Light 14 - Work Light (5) 27 - Travel Mode Selection 40 - ELU PWM POWER (3)
2 - Horn Air Compressor (L1) 15 - Work Light (6) 28 - Fast Filling System 41 - Folding Stairway (1)
3 - Horn Air Compressor (R1) 16 - Folding Stairway 29 - Horn Air Compressor (L2) 42 - Folding Stairway
Beacon/Alarm (1) Beacon/Alarm (2)
4 - Wiper (1) 17 - Maintenance Light (1) 30 - Horn Air Compressor (R2) 43 - Fast Fill Panel Position
Detection
5 - Unused 18 - Maintenance Light (2) 31 - Horn 44 - Charge SIG (L)
6 - Wiper (3) 19 - Maintenance Light (3) 32 - Wiper (4) 45 - Engine Oil Reserve Pump
Unit (L)
7 - Main Air Compressor (Front) 20 - Maintenance Light (4) 33 - Washer Motor 46 - Charge SIG (R)
8 - Main Air Compressor (Side) 21 - Maintenance Light (5) 34 - Air Compressor Fan 47 - Engine Oil Reserve Pump
(Front) Unit (R)
9 - Main Air Compressor (Rear) 22 - Maintenance Light (6) 35 - Air Compressor Fan (Side) 48 - Engine Oil Refill System (L1)
10 - Work Light (1) 23 - Maintenance Light (7) 36 - Air Compressor Fan (Rear) 49 - Engine Oil Refill System (L2)
11 - Work Light (2) 24 - Entrance Light (1) 37 - Pilot Shut-Off Solenoid 50 - Engine Oil Refill System (R1)
Valve
12 - Work Light (3) 25 - Entrance Light (2) 38 - ELU PWM POWER (1) 51 - Engine Oil Refill System (R2)
13 - Work Light (4) 26 - Delayed Power OFF 39 - ELU PWM POWER (2)

T1-3-9
GENERAL / Component Layout
RELAY BOX

22 1
T18N-01-03-010

2
21

20
Detail A
19
14
3
13
A
12 4

6
11
7
10

8
T18N-01-03-009

18 17 16 15
T18N-01-03-008

1- Battery Relay (R2) 7- Fusible Link 7 (45 A) 13 - Fusible Link 5 (75 A) 18 - Fuse (No. 3) (30 A)
2- Battery Relay (R1) 8- Fusible Link 1 (75 A) 14 - Fusible Link 6 (75 A) 19 - Zener Diode (L)
3- Fusible Link 11 (75 A) 9- Fusible Link 2 (75 A) 15 - Circuit Breaker (R) (200 A) 20 - Zener Diode (R)
4- Fusible Link 10 (75 A) 10 - Fusible Link 3 (75 A) 16 - Circuit Breaker (L) (200 A) 21 - Battery Relay (L2)
5- Fusible Link 9 (75 A) 11 - Fusible Link 4 (75 A) 17 - Fuse (No. 4) (30 A) 22 - Battery Relay (L1)
6- Fusible Link 8 (45 A) 12 - Fusible Link 12 (45 A)

T1-3-10
GENERAL / Component Layout
PILOT PIPING (L)

T18N-01-03-010

Machine Front

TKCA-01-03-001
3

1 - Pilot Filter (L) 2 - Pilot Relief Valve (L) 3 - Accumulator (Pilot Circuit)

T1-3-11
GENERAL / Component Layout
Pilot Panel (L)

1 2 3

10

4
8

TKCA-01-03-002

1 - EHC Valve 4 - EHC Valve (L) 7 - Pressure Reducing Valve 9 - Pilot Shut-Off Solenoid Valve
(Electric Lever Control) (Main Pump, Oil Cooler Fan
Pump Control Circuit)
2 - Pilot Pressure Sensor 5 - Pilot Pressure Sensor 8 - Travel Mode Solenoid 10 - EHC Valve
(Travel Pressure) (Pilot Pressure) Valve (Electric Lever Control)
3 - DQR Valve 1 (Near Side) 6 - Fast-Filling Solenoid Valve
DQR Valve 2 (End)

T1-3-12
GENERAL / Component Layout
EHC Valve
(Electric Lever Control)

NOTE: LD: Loading shovel


BH: Backhoe

Upper Side
1 2 3 4

5 6 7 8 T18N-03-04-001

Lower Side
9 10 11 12

13 14 15 16 T18N-03-04-002

1 - LD: Bucket Close Solenoid 5 - Travel Right Reverse 9 - LD: Arm Extend Solenoid Valve 13 - Auxiliary
Valve Solenoid Valve BH: Arm Roll-In Solenoid Valve
BH: Auxiliary
2 - Swing Right Solenoid Valve 6 - Travel Right Forward 10 - LD: Arm Retract Solenoid Valve 14 - Auxiliary
Solenoid Valve BH: Arm Roll-Out Solenoid Valve
3 - Swing Left Solenoid Valve 7 - Travel Left Reverse 11 - Boom Raise Solenoid Valve 15 - LD: Bucket Tilt-Out
Solenoid Valve Solenoid Valve
BH: Bucket Roll-Out
Solenoid Valve
4 - LD: Bucket Open Solenoid 8 - Travel Left Forward 12 - Boom Lower Solenoid Valve 16 - LD: Bucket Tilt-In
Valve Solenoid Valve Solenoid Valve
BH: Auxiliary BH: Bucket Roll-In
Solenoid Valve

T1-3-13
GENERAL / Component Layout
Pilot Pressure Sensor

NOTE: LD: Loading shovel


BH: Backhoe

EHC Valve
(Upper) 1 2 3 4

T18N-03-04-001
5 6 7 8

EHC Valve
(Lower) 9 10 11 12

13 14 T18N-03-04-002

1 - LD: Bucket Close 5 - Right Travel Reverse 9 - LD: Arm Extend 13 - LD: Bucket Tilt-Out
BH: Auxiliary BH: Arm Roll-In BH: Bucket Roll-Out
2 - Right Swing 6 - Right Travel Forward 10 - LD: Arm Retract 14 - LD: Bucket Tilt-In
BH: Arm Roll-Out BH: Bucket Roll-In
3 - Left Swing 7 - Left Travel Reverse 11 - Boom Raise
4 - LD: Bucket Open 8 - Left Travel Forward 12 - Boom Lower
BH: Auxiliary

T1-3-14
GENERAL / Component Layout
EHC Valve (L) (Main Pump, Oil Cooler Fan Pump Control Circuit)

14 1
13
2
12
3
11
4
10
5
9 6
8
7

T18N-03-07-005

1 - Auxiliary 5 - Pilot Pressure Sensor 9 - Main Pump Displacement 12 - Pilot Pressure Sensor
(Power Decrease) Control Solenoid Valve (Power Increase)
(For Main Pump 1)
2 - Main Pump Displacement 6 - Oil Cooler Fan Speed 10 - Pilot Pressure Sensor 13 - Power Increase Solenoid
Control Solenoid Valve Selector Solenoid Valve (L) (For Main Pump 3) Valve (L)
(For Main Pump 2, 4, 5, 6)
3 - Pilot Pressure Sensor 7 - Pilot Pressure Sensor 11 - Main Pump Displacement 14 - Auxiliary
(For Main Pump 2, 4, 5, 6) (Oil Cooler Fan Pump) Control Solenoid Valve
(For Main Pump 3)
4 - Power Decrease Solenoid 8 - Pilot Pressure Sensor
Valve (L) (For Main Pump 1)

T1-3-15
GENERAL / Component Layout
PUMP ROOM (L)

T18N-01-03-010
Center Frame

1 2 3 4
10

8 7

TKCA-01-03-003
1- Main Pump P1 (Transmission 4- High-Pressure Strainer 7- Main Pump P5 (Transmission 9- High Pressure Strainer
Side) (For Main Pump P5, P6) Side) (For Main Pump P1, P2)
Main Pump P2 (Pump End Side) Main Pump P6 (Pump End Side)
2- Pump Transmission Oil Level 5- Pump Transmission Filter 8- 4-Unit Pump 10 - High-Pressure Strainer
Switch (L) (For Main Pump P3, P4)
3- Main Pump P3 (Transmission 6- Pump Transmission Oil
Side) Temperature Sensor (L)
Main Pump P4 (Pump End Side)

T1-3-16
GENERAL / Component Layout
Main Pumps P1 to P6

Main Pumps P1, P2


Main Pumps P1, P2 Main Pumps P3, P4

1 2 3 4
T18N-01-03-017

Main Pumps P3, P4


TKCA-01-03-013
Main Pumps P5, P6

5 6 7 8
T18N-01-03-018

Main Pumps P5, P6

9 10 11 12
T18N-01-03-019

1 - Drain Pressure Sensor 4 - Drain Pressure Sensor 7 - Drain Pressure Sensor 10 - Contamination Sensor
(Main Pump P1) (Main Pump P2) (Main Pump P4) (Main Pump P5 (L5))
2 - Contamination Sensor 5 - Contamination Sensor 8 - Contamination Sensor 11 - Contamination Sensor
(Main Pump P1 (L1)) (Main Pump P3 (L3)) (Main Pump P4 (L4)) (Main Pump P6 (L6))
3 - Contamination Sensor 6 - Drain Pressure Sensor 9 - Drain Pressure Sensor 12 - Drain Pressure Sensor
(Main Pump P2 (L2)) (Main Pump P3) (Main Pump P5) (Main Pump P6)

T1-3-17
GENERAL / Component Layout
4-Unit Pump (L)

TKCA-01-03-013
4-Unit Pump

1 2 3 4

T117-02-01-017

1 - Oil Cooler Fan Motor Drive 2 - Pilot Pump 3 - Air Compressor 4 - Pump Transmission Oil
Pump (Tandem Gear Pump) Drive Pump Circulation Pump
(Plunger Pump) (Tandem Gear Pump) (Gear Pump)

T1-3-18
GENERAL / Component Layout
(Blank)

T1-3-19
GENERAL / Component Layout
ENGINE ROOM (L)

T18N-01-03-010
Machine Front

1 2

T18N-01-03-024

3 4

T18N-01-03-025

1 - Work Light (Optional) 2 - Entrance Light 3 - Air Cleaner Warning Switch (L1) 4 - Air Cleaner Warning Switch (L2)

T1-3-20
GENERAL / Component Layout
Left Engine

Machine Front
1 2

6 5 4 T18L-01-02-031

Machine Front

10 9 8 7 T18L-01-02-032

1 - Prelub Pressure Switch (L) 4 - Prelub Motor (L) 7 - Alternator (L) 9 - Engine Oil Level Sensor (L)
2 - Engine Speed Sensor (L) 5 - ECM (L) 8 - Coolant Filter (2 Used) 10 - Oil Filter (4 Used)
3 - Starter 6 - Fuel Filter (3 Used)
Upper: Starter (L1)
Lower: Starter (L2)

T1-3-21
GENERAL / Component Layout
Radiator (L)

3
1 6
2
Machine Front
4

8
5
Left Engine
B

TKCA-01-03-004

View B 12
Section A

11
9 10
TKCA-01-03-009

T18N-01-03-023

1 - LTA Radiator Inlet 4 - Radiator Inlet 7 - LTA Radiator 10 - LTA Radiator Outlet
Coolant Temperature Coolant Temperature Coolant Temperature
Sensor (L) Sensor (L) Sensor (L)
2 - Coolant Level 5 - Coolant Level 8 - Radiator 11 - Radiator Front Side Air
Warning Sensor (L) Check Switch (L2) Temperature Sensor (L)
3 - Water Tank (L) 6 - Coolant Level 9 - Radiator Outlet 12 - Work Light
Check Switch (L1) Coolant Temperature
Sensor (L)

T1-3-22
GENERAL / Component Layout
Engine Oil Reserve Tank (L)

Machine Front

T18N-01-03-026
Left Frame 1

2 3 4

Machine Front

T18N-01-03-027

1 - Engine Oil 3 - Engine Oil Filling System 4 - Engine Oil 5 - Engine Oil
Reserve Tank (L) Level Switch (L) Reserve Pump Unit (L) Level Check Switch (L)
2 - Engine Oil Filling System
Solenoid Valve (L)

T1-3-23
GENERAL / Component Layout
FOLDING STAIRWAY

Switch Box

Switch Protection Plate: Open 1 Switch Protection Plate: Close

T18N-01-03-003 T18N-01-03-004
3 2

Inside of Switch Box


4 5
Switch Box

T18N-01-03-005

T18N-01-03-006

1 - Storage Switch 3 - Emergency Switch 4 - Isolation Switch 5 - Isolation Switch


(Motor Pump 2) (Motor Pump 1)
2 - Extend Switch

T1-3-24
GENERAL / Component Layout
1 2 3

Section B

Section A 4

5 Section C

11
6

7 8 9 10

B
C

12 13

Section D

14
D

T18N-01-03-007
1 - Folding Stairway Relay (2) 5 - Valve Unit 9- Limit Switch 2 12 - Folding Stairway Cylinder
(Extend Control for Stroke End)
2 - Folding Stairway Relay (3) 6 - Work Light 10 - Limit Switch 1 13 - Limit Switch 5
(Folding Stairway) (Extend Detection for Stroke End) (Manual Lock Detection)
3 - Folding Stairway Relay (4) 7 - Limit Switch 4 (Storage Detection) 11 - Folding Stairway Beacon 14 - Lock Lever
4 - Motor Pump Unit 8 - Limit Switch 3 Light/Alarm
(Detection Control for Stroke End)

T1-3-25
GENERAL / Component Layout
Valve Unit
1 2 3 4 5 6

14
9

13 12 11 10

15
T18L-01-02-034

3 2 11 6 14

P3

B
12
P1 A1
A2
8 10
P2
A3
4 5
7
M

T PF
1 15 13 9 T18L-01-02-035

1 - Overload Relief Valve 5 - Check Valve 9 - Check Valve 13 - Folding Stairway Solenoid
(Folding Stairway Cylinder Valve 2
Bottom Side)
2 - Orifice 6 - Folding Stairway Solenoid 10 - Throttle Valve 14 - Slow Return Valve
Valve 3
3 - Check Valve 7 - Main Relief Valve 11 - Folding Stairway Solenoid 15 - Overload Relief Valve
Valve 1 (Folding Stairway Cylinder
Rod Side)
4 - Check Valve 8 - Check Valve 12 - Check Valve

T1-3-26
GENERAL / Component Layout
CENTER FRAME

Machine T18N-01-03-028
Front

1 2

6
5

T18N-01-03-035
Pilot Piping

1 - Swing Device (Front Left) 3 - Center Joint 5 - Control Valves 4 to 6 7 - Swing Device (Rear Left)
2 - Swing Device (Front Right) 4 - Swing Device (Rear Right) 6 - Control Valves 1 to 3

T1-3-27
GENERAL / Component Layout
Center Joint

Machine Front

T18N-01-03-039

Section A 1 2

T18N-01-03-036

1 - Contamination Sensor 2 - Cushion Cylinder End


(Travel Motor) Pressure Sensor

T1-3-28
GENERAL / Component Layout
Swing Device (Front Left), (Rear Left)

Machine Front

T18N-01-03-039

Section B
1 2 5 6

4 7

3 8
T18N-01-03-037

1 - Contamination Sensor 3 - Drain Pressure Sensor 5 - Make-Up Valve 7 - Relief Valve


(Swing Motor Left Front) (Swing Motor Left Front) (Swing Motor Left Rear) (Swing Motor Left Rear)
2 - Make-Up Valve 4 - Relief Valve 6 - Contamination Sensor 8 - Drain Pressure Sensor
(Swing Motor Left Front) (Swing Motor Left Front) (Swing Motor Left Rear) (Swing Motor Left Rear)

T1-3-29
GENERAL / Component Layout
Swing Device (Right Front), (Right Rear)

Machine Front

T18N-01-03-041

Section C 1 2 5 6

4 7

3 8
T18N-01-03-038

1 - Contamination Sensor 3 - Drain Pressure Sensor 5 - Make-Up Valve 7 - Relief Valve


(Swing Motor Right Rear) (Swing Motor Right Rear) (Swing Motor Right Front) (Swing Motor Right Front)
2 - Make-Up Valve 4 - Relief Valve 6 - Contamination Sensor 8 - Drain Pressure Sensor
(Swing Motor Right Rear) (Swing Motor Right Rear) (Swing Motor Right Front) (Swing Motor Right Front)

T1-3-30
GENERAL / Component Layout
Arm Cylinder Pressure Sensor

Machine Front

T18N-01-03-040

View D

T18N-01-03-042
1 2

1 - Arm Cylinder Rod Side 2 - Arm Cylinder Bottom Side


Pressure Sensor Pressure Sensor

T1-3-31
GENERAL / Component Layout
PILOT PIPING
Control Valve Panel
(Loading Shovel)

1 2 3 4

10

T18N-01-03-028

9
6

8
7

T18N-01-03-043

1 - Manifold 4 - Manifold 7 - Control Valve 6 9- Control Valve 2


(Lower Right) (Middle Left)
2 - Boom Lower Priority 5 - Control Valve 4 8 - Control Valve 3 10 - Control Valve 1
Selector Valve (Upper Right) (Lower Left) (Upper Left)
3 - Boom Raise Priority 6 - Control Valve 5
Selector Valve (Middle Right)

T1-3-32
GENERAL / Component Layout
Control Valve Panel
(Backhoe)

1 2 3 4 5

11

T18N-01-03-028

10
7

9
8

T18N-01-03-044

1 - Manifold 4 - Boom Raise Priority 7 - Control Valve 5 10 - Control Valve 2


Selector Valve (Middle Right) (Middle Left)
2 - Arm Roll-Out Priority 5 - Manifold 8 - Control Valve 6 11 - Control Valve 1
Selector Valve (Lower Right) (Upper Left)
3 - Boom Lower Priority 6 - Control Valve 4 9 - Control Valve 3
Selector Valve (Upper Right) (Lower Left)

T1-3-33
GENERAL / Component Layout
CONTROL VALVE

NOTE: This drawing shows the front view of the


control valve.

Control Valve 4 (Upper Right) Control Valve 1 (Upper Left)

T118-05-02-044 T118-05-02-041

Control Valve 5 (Middle Right) Control Valve 2 (Middle Left)

T118-05-02-042
T118-05-02-045
Control Valve 3 (Lower Left)
Control Valve 6 (Lower Right)

T118-05-02-043
T118-05-02-046

T1-3-34
GENERAL / Component Layout
Control Valves 1, 4

Control Valve 1 (Upper Left)


Control Valve 4 (Upper Right)

1 14 21
8
2 15 22
9
3 16 23
10
4 17 24
11

25
5 12
26
6 13 18
27
19
28
7
20
T118-05-02-041
T118-05-02-044

Control Valve 4 (Upper Right) Control Valve 1 (Upper Left)


1 - Make-Up Valve (LD: Arm Extend, BH: Arm Roll-In) 14 - Make-Up Valve (LD: Bucket Tilt-Out, BH: Bucket Roll-Out)
2 - Overload Relief Valve (LD: Arm Extend, BH: Arm Roll-In) 15 - Overload Relief Valve (LD: Bucket Tilt-Out, BH: Bucket Roll-Out)
3 - Make-Up Valve (LD: Bucket Open) 16 - Make-Up Valve (Boom Lower)
4 - Overload Relief Valve (LD: Bucket Open) 17 - Overload Relief Valve (Boom Lower)
5 - Make-Up Valve (Boom Raise) 18 - Make-Up Valve (Right Swing)
6 - Overload Relief Valve (Boom Raise) 19 - Overload Relief Valve (Right Swing)
7 - Main Relief Valve 20 - Main Relief Valve
8 - Overload Relief Valve (LD: Arm Retract, BH: Arm Roll-Out) 21 - Overload Relief Valve (LD: Bucket Tilt-In, BH: Bucket Roll-In)
9 - Make-Up Valve (LD: Arm Retract, BH: Arm Roll-Out) 22 - Make-Up Valve (LD: Bucket Tilt-In, BH: Bucket Roll-In)
10 - Overload Relief Valve (LD: Bucket Close) 23 - Overload Relief Valve (LD: Arm Extend, BH: Arm Roll-In)
11 - Overload Relief Valve (LD: Bucket Close) 24 - Make-Up Valve (LD: Arm Extend, BH: Arm Roll-In)
12 - Overload Relief Valve (LD: Bucket Tilt-In, BH: Bucket Roll-In) 25 - Overload Relief Valve (Boom Raise)
13 - Make-Up Valve (LD: Bucket Tilt-In, BH: Bucket Roll-In) 26 - Make-Up Valve (Boom Raise)
27 - Overload Relief Valve (Left Swing)
28 - Make-Up Valve (Left Swing)

NOTE: LD: Loading shovel


BH: Backhoe

T1-3-35
GENERAL / Component Layout
Control Valves 2, 5

Control Valve 5 (Middle Right)


Control Valve 2 (Middle Left)

1 8 20
2 9
3 10 14
21
4 11 15 22

23
5 12 16
24
6 13 17
25
18
7 26
19
T118-05-02-045
T118-05-02-042

Control Valve 5 (Middle Right) Control Valve 2 (Middle Left)


1- Make-Up Valve (LD: Bucket Tilt-In, BH: Bucket Roll-In) 14 - Make-Up Valve (LD: Bucket Tilt-In, BH: Bucket Roll-In)
2- Overload Relief Valve (LD: Bucket Tilt-In, BH: Bucket Roll-In) 15 - Overload Relief Valve (LD: Bucket Tilt-In, BH: Bucket Roll-In)
3- Make-Up Valve (Boom Lower) 16 - Overload Relief Valve (LD: Bucket Close)
4- Overload Relief Valve (Boom Lower) 17 - Overload Relief Valve (LD: Bucket Close)
5- Make-Up Valve (LD: Arm Extend, BH: Arm Roll-In) 18 - Make-Up Valve (LD: Arm Retract, BH: Arm Roll-Out)
6- Overload Relief Valve (LD: Arm Extend, BH: Arm Roll-In) 19 - Overload Relief Valve (LD: Arm Retract, BH: Arm Roll-Out)
7- Main Relief Valve 20 - Main Relief Valve
8- Overload Relief Valve (LD: Bucket Tilt-Out, BH: Bucket Roll-Out) 21 - Overload Relief Valve (Boom Raise)
9- Make-Up Valve (LD: Bucket Tilt-Out, BH: Bucket Roll-Out) 22 - Make-Up Valve (Boom Raise)
10 - Overload Relief Valve (Boom Raise) 23 - Overload Relief Valve (LD: Bucket Open)
11 - Make-Up Valve (Boom Raise) 24 - Make-Up Valve (LD: Bucket Open)
12 - Overload Relief Valve (LD: Arm Retract, BH: Arm Roll-Out) 25 - Overload Relief Valve (LD: Arm Extend, BH: Arm Roll-In)
13 - Make-Up Valve (LD: Arm Retract, BH: Arm Roll-Out) 26 - Make-Up Valve (LD: Arm Extend, BH: Arm Roll-In)

T1-3-36
GENERAL / Component Layout
Control Valves 3, 6

Control Valve 6 (Lower Right) Control Valve 3 (Lower Left)

1 8 22
2 9
16
3 10
23
17
4 11 24
18
25
12 19

13 26
5 20
14
27
6 15 21
28
7
T118-05-02-046 T118-05-02-043

Control Valve 6 (Lower Right) Control Valve 3 (Lower Left)


1- Make-Up Valve (LD: Bucket Tilt-In, BH: Bucket Roll-In) 16 - Make-Up Valve (LD: Arm Retract, BH: Arm Roll-Out)
2- Overload Relief Valve (LD: Bucket Tilt-In, BH: Bucket Roll-In) 17 - Overload Relief Valve (LD: Arm Retract, BH: Arm Roll-Out)
3- Make-Up Valve (Boom Lower) 18 - Make-Up Valve (Boom Raise)
4- Overload Relief Valve (Boom Lower) 19 - Overload Relief Valve (Boom Raise)
5- Make-Up Valve (Right Swing) 20 - Make-Up Valve (LD: Bucket Tilt-Out, BH: Bucket Roll-Out)
6- Overload Relief Valve (Right Swing) 21 - Overload Relief Valve (LD: Bucket Tilt-Out, BH: Bucket
Roll-Out)
7- Main Relief Valve 22 - Main Relief Valve
8- Overload Relief Valve (LD: Bucket Tilt-Out, BH: Bucket Roll-Out) 23 - Overload Relief Valve (LD: Arm Extend, BH: Arm Roll-In)
9- Make-Up Valve (LD: Bucket Tilt-Out, BH: Bucket Roll-Out) 24 - Make-Up Valve (LD: Arm Extend, BH: Arm Roll-In)
10 - Overload Relief Valve (LD: Arm Extend, BH: Arm Roll-In) 25 - Overload Relief Valve (Boom Lower)
11 - Make-Up Valve (LD: Arm Extend, BH: Arm Roll-In) 26 - Make-Up Valve (Boom Lower)
12 - Overload Relief Valve (Boom Raise) 27 - Overload Relief Valve (LD: Bucket Tilt-In, BH: Bucket Roll-In)
13 - Make-Up Valve (Boom Raise) 28 - Make-Up Valve (LD: Bucket Tilt-In, BH: Bucket Roll-In)
14 - Overload Relief Valve (Left Swing)
15 - Make-Up Valve (Left Swing)

T1-3-37
GENERAL / Component Layout
HYDRAULIC OIL TANK

T18N-01-03-028
2

5
7

T18N-01-03-030

1 - Maintenance Light 3 - Hydraulic Oil Level Switch 1 5 - Oil Temperature Sensor 7 - Valve Limit Switch
(Level Indicator) (Hydraulic Oil) (R-Suction)
2 - Air Bleeding Solenoid Valve 4 - Hydraulic Oil Level Switch 2 6 - Valve Limit Switch
(Indicator) (L-Suction)

T1-3-38
GENERAL / Component Layout
Oil Pump

T18N-01-03-028

Hydraulic Oil Tank

T18N-01-03-029

Machine Front

1 - Oil Pump

T1-3-39
GENERAL / Component Layout
FUEL TANK

Machine Front

1 2 3 4

T18N-01-03-028

View A

5 6

Fuel Filter

T18N-01-03-032

T18N-01-03-031

1 - Fuel Level Sensor 3 - Fuel Level Switch (H) 5 - Fuel Cooler Fan Motor (R) 6- Fuel Cooler Fan Motor (L)
2 - Fuel Level Switch (L) 4 - Fuel Cooler

T1-3-40
GENERAL / Component Layout
Fuel Filter

1 2

T18N-01-03-033

3 4

T18N-01-03-034

1 - Lift Pump Drive Solenoid 2 - Lift Pump Drive Solenoid 3 - Water Sensor (L) 4 - Water Sensor (R)
Valve (L) Valve (R)

T1-3-41
GENERAL / Component Layout
TRAVEL ALARM, FAST-FILLING DEVICE

T18N-01-03-028 Counterweight Side

1 M18N-04-001

1 - Travel Alarm 2 - Fast-Filling Device

T1-3-42
GENERAL / Component Layout
Fast-Filling Device

1 2

Fast-Filling Panel

T18N-03-07-003

Fast-Filling Panel
5 6 7 8 9 10 11 12 13 14 15 16 17 18

T18N-03-07-002

31 30 29 28 27 26 25 24 23 22 21 20 19

1 - Lift Cylinder (2 Used) 9 - Auxiliary 17 - Engine Oil Filling (R) 25 - Gear Oil
(Reserve Tank (R)) (Left Front Swing Device)
2 - Fast-Filling Panel Position 10 - Gear Oil 18 - Engine Oil Out (R) 26 - Gear Oil
Detection Switch (Right Front Swing Device) (Reserve Tank (R)) (Left Rear Swing Device)
3 - Engine Oil Filling (L) 11 - Hydraulic Oil 19 - Fuel 27 - Gear Oil
(Reserve Tank (L)) (Right Rear Swing Device)
4 - Engine Oil Out (L) 12 - Engine Oil Reserve Tank 20 - Coolant (Right Radiator) 28 - Engine Oil
(Reserve Tank (L)) (R) Full Indicator (Left Engine)
5 - Engine Oil Reserve Tank 13 - Engine Oil Reserve Tank 21 - Auxiliary 29 - Transmission Oil
(L) Full Indicator (R) Shut-Off Valve Open (Left Pump)
Lamp
6 - Engine Oil Reserve Tank 14 - Engine Oil Reserve Tank 22 - Transmission Oil 30 - Auxiliary
(L) Shut-Off Valve Open (R) Filling System Power (Right Pump)
Lamp Switch
7 - Engine Oil Reserve Tank 15 - Engine Oil Reserve Tank 23 - Engine Oil (Right Engine) 31 - Coolant (Left Radiator)
(L) Filling System Power (R) Filling System
Switch Operation Switch
8 - Engine Oil Reserve Tank 16 - Fuel Full Indicator 24 - Grease
(L) Filling System
Operation Switch

T1-3-43
GENERAL / Component Layout
RIGHT FRAME

2
3
12 4

11

10

8
7

TKCA-01-03-011

1 - Maintenance Light 4 - Emergency Switch 7 7 - Valve Limit Switch 10 - Auto-Lubrication Device


(Oil Cooler Room) (Pump Room (R)) (Return-L)
2 - Maintenance Light 5 - Emergency Switch 6 8 - Valve Limit Switch 11 - Work Light
(Pump Room (R)) (Engine Room (R2)) (Return-U) (Front Right (Left))
3 - Maintenance Light 6 - Emergency Switch 5 9 - Pilot Panel (R) 12 - Work Light
(Engine Room (R)) (Engine Room (R1)) (Front Right (Right))

T1-3-44
GENERAL / Component Layout
OIL COOLER ROOM
Machine Front

1 2

T18N-01-03-054

TKCA-01-03-012

1 - Oil Cooler Front Side Air 2 - Oil Cooler Front Side Air
Temperature Sensor 1 Temperature Sensor 2

T1-3-45
GENERAL / Component Layout
Around Oil Cooler

Section A

TKCA-01-03-012
7 T18N-01-03-056
6
Machine Front

T18N-01-03-055
5 4
1 - Oil Cooler Inlet Oil 3 - Valve Limit Switch 5 - Oil Cooler Fan Motor 7 - Oil Cooler Outlet
Pressure Sensor (Return-U) (Front) Temperature Sensor 2
2 - Valve Limit Switch 4 - Oil Cooler Fan Motor 6 - Oil Cooler Outlet
(Return-L) (Rear) Temperature Sensor 1

T1-3-46
GENERAL / Component Layout
PILOT PIPING (R)

Machine Front
TKCA-01-03-012

TKCA-01-03-005

1 - Pilot Filter (R) 2 - EHC Valve (R) 3 - Pilot Relief Valve (R)
(Main Pump, Oil Cooler
Fan Pump Control Circuit)

T1-3-47
GENERAL / Component Layout
EHC Valve (R)

1
14
2
13
3
12
11 4

10 5
9
6

8 7

T18N-03-07-005

1 - Auxiliary 5 - Pilot Pressure Sensor 9 - Oil Cooler Fan Speed 12 - Pilot Pressure Sensor
(For Main Pump 9) Selector Solenoid Valve (R) (Power Increase)
2 - Main Pump Displacement 6 - Main Pump Displacement 10 - Pilot Pressure Sensor 13 - Power Increase Solenoid
Angle Control Solenoid Valve Angle Control Solenoid (Power Decrease) Valve (R)
(For Main Pumps 8, 10, 11, 12) Valve (For Main Pump 7)
3 - Pilot Pressure Sensor 7 - Pilot Pressure Sensor 11 - Power Decrease Solenoid 14 - Auxiliary
(For Main Pumps 8, 10, 11, 12) (For Main Pump 7) Valve (R)
4 - Main Pump Displacement 8 - Pilot Pressure Sensor
Angle Control Solenoid Valve (Oil Cooler Fan Pump)
(For Main Pump 9)

T1-3-48
GENERAL / Component Layout
AUTO-LUBRICATION DEVICE
1 2 3

5 4

TKCA-01-03-012

10 9 8 7 6

T18N-03-07-004

1 - Pressure Switch 2 4 - Vent Valve 7 - Pressure Gauge 9- Pressure Switch 1


(For Manual-Lubrication) (For Auto-Lubrication)
2 - Grease Pump 5 - Auto-Lubrication Solenoid 8 - Check Valve 10 - Auto-Lubrication Switch
Valve
3 - Pressure Reducing Valve 6 - Grease Tank

T1-3-49
GENERAL / Component Layout
PUMP ROOM (R)

Center Frame
TKCA-01-03-012
1 2 3
4

5
10

TKCA-01-03-006
1 - Main Pump P7 4 - High-Pressure Strainer 7 - Main Pump P11 9- Pump Transmission Oil
(Transmission Side) (For Main Pump P7, P8) (Transmission Side) Temperature Sensor (R)
Main Pump P8 Main Pump P12
(Pump End Side) (Pump End Side)
2 - Pump Transmission Oil 5 - High-Pressure Strainer 8 - 4-Unit Pump 10 - Pump Transmission Filter
Level Switch (R) (For Main Pump P9, P10)
3 - Main Pump P9 6 - High-Pressure Strainer
(Transmission Side) (For Main Pump P11, P12)
Main Pump P10
(Pump End Side)

T1-3-50
GENERAL / Component Layout
Main Pumps P7 to P12

Main Pumps P7, P8

Main Pumps P7, P8 Main Pumps P9, P10

1 2 3 4
T18N-01-03-017

Main Pumps P9, P10

TKCA-01-03-008
Main Pumps P11, P12

5 6 7 8
T18N-01-03-018

Main Pumps P11, P12

9 10 11 12
T18N-01-03-019

1 - Drain Pressure Sensor 4 - Drain Pressure Sensor 7 - Drain Pressure Sensor 10 - Contamination Sensor
(Main Pump P7) (Main Pump P8) (Main Pump P10) (Main Pump P11 (R5))
2 - Contamination Sensor 5 - Contamination Sensor 8 - Contamination Sensor 11 - Contamination Sensor
(Main Pump P7 (R1)) (Main Pump P9 (R3)) (Main Pump P10 (R4)) (Main Pump P12 (R6))
3 - Contamination Sensor 6 - Drain Pressure Sensor 9 - Drain Pressure Sensor 12 - Drain Pressure Sensor
(Main Pump P8 (R2)) (Main Pump P9) (Main Pump P11) (Main Pump P12)

T1-3-51
GENERAL / Component Layout
4-Unit Pump (R)

4-Unit Pump TKCA-01-03-006

1 2 3 4

T117-02-01-017

1 - Oil Cooler Fan Motor Drive 2 - Pilot Pump 3 - Auxiliary 4 - Pump Transmission Oil
Pump (Tandem Gear Pump) Circulation Pump
(Plunger Pump) (Gear Pump)

T1-3-52
GENERAL / Component Layout
ENGINE ROOM (R)

TKCA-01-03-012

Machine Front

T18N-01-03-052

3 2

T18N-01-03-053

1 - Work Light (Optional) 2 - Air Cleaner Warning Switch 3 - Air Cleaner Warning Switch
(R1) (R2)

T1-3-53
GENERAL / Component Layout
Right Engine

Machine Front
1 2

3
6 5 4
T18L-01-02-031

Machine Front

10 9 8 7 T18L-01-02-032

1 - Prelub Pressure Switch (R) 4 - Prelub Motor (R) 7 - Alternator (R) 9 - Engine Oil Level Sensor (R)
2 - Engine Speed Sensor (R) 5 - ECM (R) 8 - Coolant Filter (2 Used) 10 - Oil Filter (4 Used)
3 - Starter 6 - Fuel Filter (3 Used)
Upper: Starter (R1)
Lower: Starter (R2)

T1-3-54
GENERAL / Component Layout
Radiator (R)

5 1 2 3 4 6

Machine Front

8
Right Engine

TKCA-01-03-004

View B
11 12

Section A
TKCA-01-03-009

9 10

T18N-01-03-050

1 - LTA Radiator Inlet 4 - Radiator Inlet 7 - LTA Radiator 10 - LTA Radiator Outlet
Coolant Temperature Coolant Temperature Coolant Temperature
Sensor (R) Sensor (R) Sensor (R)
2 - Coolant Level 5 - Coolant Level 8 - Radiator 11 - Radiator Front Side Air
Warning Sensor (R) Check Switch (R2) Temperature Sensor (R)
3 - Water Tank 6 - Coolant Level 9 - Radiator Outlet 12 - Work Light
Check Switch (R1) Coolant Temperature
Sensor (R)

T1-3-55
GENERAL / Component Layout
ENGINE OIL RESERVE TANK (R)

Machine Front

T18N-01-03-051

1 Right Frame

2 3 4

5 Machine Front

T18N-01-03-027

1 - Engine Oil Reserve Tank (R) 3 - Engine Oil Filling System 4 - Engine Oil Reserve Pump 5 - Engine Oil Level Check
Level Switch (R) Unit (R) Switch (R)
2 - Engine Oil Filling System
Solenoid Valve (R)

T1-3-56
GENERAL / Component Layout
UNDERCARRIAGE

Machine Front 1

T18N-01-03-057

View A

2 5

T18N-01-03-058
7
1 - Cushion Cylinder 3 - Accumulator 5 - Pilot Pressure Selector 7 - Pressure Reducing Valve
(Cushion Cylinder) Valve
2 - Center Joint 4 - Manifold 6 - Relief Valve 8 - Manifold

T1-3-57
GENERAL / Component Layout
Travel Device (L)

1 2
Machine Front

13
3

7
8

12

T18N-01-03-059
11 10 9
1 - Brake Valve 5 - Travel Reverse Hose 8 - Drain Hose 11 - Travel Reduction Gear (L)
(Left Front Travel Motor) (Left Front Travel Motor) (Left Rear Travel Motor)
2 - Brake Valve 6 - Travel Reverse Hose 9 - Left Front Travel Motor 12 - Drive Tumbler (L)
(Left Rear Travel Motor) (Left Rear Travel Motor)
3 - Travel Forward Hose 7 - Drain Hose 10 - Left Rear Travel Motor 13 - Travel Mode Control Hose (L)
(Left Front Travel Motor) (Left Front Travel Motor)
4 - Travel Forward Hose
(Left Rear Travel Motor)

T1-3-58
GENERAL / Component Layout
Travel Device (R)
Machine Front

2 1

13
3

12

T18N-01-03-060
9 10 11

1 - Brake Valve 5 - Travel Reverse Hose 8 - Drain Hose 11 - Travel Reduction Gear (R)
(Right Front Travel Motor) (Right Front Travel Motor) (Right Rear Travel Motor)
2 - Brake Valve 6 - Travel Reverse Hose 9 - Right Front Travel Motor 12 - Drive Tumbler (R)
(Right Rear Travel Motor) (Right Rear Travel Motor)
3 - Travel Forward Hose 7 - Drain Hose 10 - Right Rear Travel Motor 13 - Travel Mode Control Hose (R)
(Right Front Travel Motor) (Right Front Travel Motor)
4 - Travel Forward Hose
(Right Rear Travel Motor)

T1-3-59
GENERAL / Component Layout
(Blank)

T1-3-60
MEMO

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MEMO

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SECTION 2
SYSTEM

CONTENTS
Group 1 Controller Group 4 Hydraulic System
Outline ...................................................... T2-1-1 Outline ...................................................... T2-4-1
MC: Main Controller.................................. T2-1-2 Pilot Circuit ............................................... T2-4-2
ELU: Electric Lever Control Unit ............... T2-1-8 Operation Control Circuit .......................... T2-4-3
IDU: Information Display Unit ............... T2-1-14 Main Circuit............................................... T2-4-8
ECM: Engine Control Module ................. T2-1-22 Oil Cooler Fan Motor Circuit ................... T2-4-32
DLU: Data Logging Unit.......................... T2-1-24 Air Conditioner Compressor Motor
CSU: Contamination Sensing Unit ........ T2-1-26 Circuit ................................................... T2-4-32
HMU: Hydraulic System Pump Transmission Oil Cooling Circuit ... T2-4-32
Monitoring Unit ..................................... T2-1-28 Travel Shock Damper/Travel Stop
EHU: Engine Heatbalance Circuit ................................................... T2-4-33
Control Unit .......................................... T2-1-30
Group 5 Electrical System
Group 2 Control System Outline ...................................................... T2-5-1
Outline ...................................................... T2-2-1 Electrical Power Circuit
Engine Control.......................................... T2-2-2 (Key Switch: OFF)................................... T2-5-2
Pump Control ......................................... T2-2-10 Accessory Circuit (Key Switch: ACC) ........ T2-5-6
Fast-Filling Panel Lower Control............. T2-2-16 Engine Start Circuit ................................... T2-5-8
Folding Stairway Control......................... T2-2-18 Charging Circuit (Key Switch: ON) .......... T2-5-18
Auto-Lubrication Control......................... T2-2-22 Engine Stop Circuit ................................. T2-5-28
Oil Cooler Fan Motor Speed Control....... T2-2-26 Surge Voltage Prevention Circuit ............ T2-5-34
Wiper Control ......................................... T2-2-28
Travel Mode Control ............................... T2-2-30

Group 3 ELU System


Outline ...................................................... T2-3-1
Pilot Shut-Off Control................................ T2-3-2
Pump Control ........................................... T2-3-4
Cushion Cylinder End Travel Regulation
Control.................................................... T2-3-6
Swing Stop Control ................................... T2-3-8

KCAT-2-1
(Blank)

KCAT-2-2
SYSTEM / Controller
OUTLINE
The controllers are controlled for each control respec-
tively. They are connected through CAN (network pro-
vided for machine) for monitoring all machine operating
conditions including the engine, and for indicating op-
erating information on the display in the cab.

• MC: Main Controller


• ELU: Electric Lever Control Unit
• IDU: Information Display Unit
• ECM: Engine Control Module
• DLU: Data Logging Unit
• CSU: Contamination Sensing Unit
• HMU: Hydraulic System Monitoring Unit
• EHU: Engine Heatbalance Control Unit

∗MMS: Modular Mining System

ECM (R) ECM (L)


Service Tool
(Palm)

J1939-CAN ORBCOMM
GPS Antenna (Optional)
DLU

Ke-CAN MMS Communicator Unit


ELU (Optional)
IDU MC

∗MMS
(Optional)
Display
EHU CAN
Keypad
HMU CSU

T18N-02-01-001

T2-1-1
SYSTEM / Controller
MC: MAIN CONTROLLER
Function Outline

• Auto-Idle Control • Auto-Lubrication Control


When all control levers are in neutral and the MC operates the auto-lubrication solenoid valve at
auto-idle switch is turned ON, MC sends the intervals set by the auto-lubrication interval switch
auto-idle signal to ECM. and lubricates the front joint pin, the swing bearing,
ECM reduces engine speed to auto-idle speed. and the center joint.

• Power Increase Control • Oil Cooler Fan Control


When engine speed is between 1800 to 2156 min-1 MC controls the oil cooler fan control solenoid valve
and MC receives the lever control signal from ELU, in response to the signal from the hydraulic oil tem-
MC controls the power increase solenoid valve, de- perature sensor, and changes the oil cooler fan mo-
livers pilot pressure oil to port Pz of the pump regu- tor speed at three stages.
lator, and increases pump driving torque.

• Power Decrease Control


When engine speed is less than 1650 min-1, MC
receives the engine protection signal from ECM or
MC receives the lever neutral signal from ELU, MC
controls the power decrease solenoid valve, delivers
pilot pressure oil to port Pf of the pump regulator,
and decreases pump driving torque.

• Fast-Filling Panel Lower Control


When the pilot shut-off switch is in the Lock position
and the fast-filling switch is turned ON, MC operates
the fast-filling solenoid valve, delivers pressure oil
from the pilot pump to the lift cylinder, and lowers the
fast-filling panel.
When the pilot shut-off switch is in the Unlock posi-
tion, the fast-filling panel cannot be lowered due to
this control.

T2-1-2
SYSTEM / Controller

Pilot Shut-Off Switch


To IDU, DLU

MC
Auto-Idle
Switch
ELU
Engine Speed Sensor (L)

Engine Speed Sensor (R)

Fast-Filling Switch

Fast-Filling Relay

ECM (L)
Fast-Filling
Solenoid Valve
Fast-Filling Panel
Position Detection
Switch Relay
ECM (R)
Fast-Filling Panel
Position Detection
Switch

To ELU Power In-


crease Sole-
noid Valve (L)

Pressure Switch 1
(Auto Lubrication) Power De-
crease Sole-
noid Valve (L)

Power In-
crease Sole-
noid Valve (R)

Pressure Switch 2 Power De-


(Manual Lubrication) crease Sole-
noid Valve (R)

Auto-Lubrication
Solenoid Valve
Auto-Lubrication
Interval Switch
3 min.
5 min.
10 min Oil Cooler Fan
15 min. Control Sole-
noid Valve (L)

Hydraulic Oil Temperature Sensor Oil Cooler


Fan Control
Solenoid
Power Increase Pressure Sensor (L) Valve (R)

Power Increase Pressure Sensor (R)

Power Decrease Pressure Sensor (L)


Oil Cooler Fan Control
Pressure Sensor (L)
Power Decrease Pressure Sensor (R)
Oil Cooler Fan Control
Pressure Sensor (R)
T18N-02-01-007

T2-1-3
SYSTEM / Controller
• Wiper Control
MC operates the wiper at slow speed, fast speed or
intermittently in response to the signal of the wiper
switch position. In the intermittent mode, the wiper is
operated at intervals set by the interval switch.

• Power Delay Shut-Off Control


MC shuts off the exciting current of the delayed
power off relay at the lapse of certain period
(Settable from 15 seconds to 10 minutes) after the
key switch is turned OFF.
Therefore, the battery relay is ON a certain period.
While the engine rotates due to inertia force, current
from the alternator flows to the battery and serge
voltage in the circuit is prevented.
Delay time setting can be performed on the monitor
display.

• Fuel Level Measurement


MC receives the signal from the fuel level sensor
and the fuel level switch. MC transmits the detected
data from the sensor to IDU through CAN. IDU out-
puts the detected data to the display. (Refer to IDU
Meter Indication.)

• Motion Alarm Control


MC receives the signal from the travel pilot pressure
sensor. When the received signal exceeds the set-
ting, MC judges that the machine is traveling and
sounds the travel alarm.

T2-1-4
SYSTEM / Controller

MC Wiper Motor

Key Switch

Washer Switch Fuse #75


Wiper Switch
・OFF Fuse #76
・INT.
・LOW
・HIGH Wiper Relay 4

From Battery
From Key Switch
Fuse Fuse
#77 #21 Wiper
Relay 1

Motor Relay
Washer
Wiper
Relay 3

Washer Motor

Interval Indicator (Red)


Switch
• 25 sec. Indicator (Yellow)
• 20 sec.
• 15 sec.
• 10 sec. Power Decrease
• 5 sec. Solenoid Valve (L)

Power Decrease
Solenoid Valve (R)

Fuel Level Sensor

Battery Delayed Power


Travel Pilot Pressure Sensor Off Relay

Travel Alarm
Fuel Level Switch (Hi)

Fuel Level Switch (Low) To DLU

CAN Monitor Display

TKCA-02-01-004

T2-1-5
SYSTEM / Controller
• Alarm Judgment
MC executes the following judgment.

1. Hydraulic oil level


2. Air cleaner filter clogging (left and right engines)
3. Alternator operation (left and right engines)
4. Pump transmission oil level (left and right en-
gines)
5. Emergency switch status (ON/OFF)
6. Valves opening/closing
7. Control box opening/closing
8. Folding stairway storing/extending
9. Hydraulic oil temperature
10. Fuel level
11. Pump transmission oil temperature

MC lights indicator (red) or (yellow) according to


judgment.
At the same time, IDU lights each indicator on the
monitor display in response to the information through
CAN.
NOTE: IDU also sounds the buzzer, if the hydraulic
oil level, pump transmission oil level or
valve opening/closing is abnormal.

• Diagnosing
Diagnosing is carried out on the sensors connected
to MC.
Failure information is transmitted to DLU and IDU
through CAN.
DLU logs failure information.
IDU outputs failure information on the display.

T2-1-6
SYSTEM / Controller

Air Bleed So-


lenoid Valve
Alternator
Line
Air Cleaner Switch (L)
Key Switch MC
ON Signal
Line

1 2 3 4
Air Cleaner Switch (R)
7 6 5

Valve Limit Switch Valve Limit Switch


(R-Suction) (Return-U)
Limit Switch
(Control Box Opening: ON)

Valve Limit Switch Folding Stairway Limit


(Return-L) Switch (5)
(Manual Lock Detection)
Valve Limit Switch
(L-Suction)

To ECM (R)
(Key-ON Signal)

To ECM (L) Folding Stairway Limit


(Key-ON Signal) Switch (4)
(Storage Detection) Hydraulic Oil Tem-
perature Sensor
Hydraulic Oil
Level Switch

Hydraulic Oil Level Fuel Level Sensor


Alarm Switch

Charge (L)
Indicator (Red)

Charge (R) Indicator (Yellow)

Pump Transmission
Oil Level Switch (L) CAN

Pump Transmission To IDU, DLU


Oil Level Switch (R)
1 - Emergency Switch
Engine Speed (Engine Room (L2))
Sensor (L) 2 - Emergency Switch
(Engine Room (L1))
Engine Speed 3 - Emergency Switch
Sensor (R)
(Pump Room (L))
4 - Emergency Switch
(Cab)
Pump Transmission Oil 5 - Emergency Switch
Temperature Sensor (L) (Engine Room (R1))
6 - Emergency switch
Pump Transmission Oil (Engine Room (R2))
Temperature Sensor (R) 7 - Emergency Switch
(Pump Room (R))
T18N-02-01-009

T2-1-7
SYSTEM / Controller
ELU: Electric Lever Control Unit
Function Outline
• Pilot Shut-Off Selection
When the pilot shut-off relay is shifted by the pilot
shut-off switch, the pilot shut-off solenoid valve is
operated or stopped.
Therefore, pilot pressure oil is delivered or shut off to
the EHC valve.

• Pilot Pressure Control by Control Lever System


ELU outputs the signal to the EHC valve in response
to the signal from the electric control lever.
The EHC valve delivers pilot pressure oil to the DQR
(Dual Quick Response) valve in response to the
signal.

Pump Control Function


• Main Pump Displacement Angle Control
ELU outputs the signal in response to the control
lever stroke to the main pump displacement angle
control solenoid valve.
The main pump displacement angle control solenoid
valve delivers pilot pressure oil to the pump regulator
in response to the signal, and controls the pump
displacement angle.

T2-1-8
SYSTEM / Controller

CAN
Pilot Shut-Off Switch To IDU, DLU

Front Attachment ELU Pilot Shut-Off Relay


System, Swing Pilot Shut-Off Solenoid Valve
Lever

EHC Valve
Travel Forward Sole- (Pump, Oil
Travel noid Valve (L) Cooler Fan
System Travel Reverse Sole- Motor Control
Lever noid Valve (L) Circuit)
Travel Forward Sole- Main Pump
noid Valve (R) Displacement
Travel Reverse Sole- Angle Control
noid Valve (R) Solenoid Valve
Cushion Cylinder End
(No. 1 Pump)
Pressure Sensor Bucket Open Solenoid
Valve (Loading Main Pump
Shovel) Displacement
Angle Control
MC Left Swing Solenoid Solenoid Valve
Valve (No. 3 Pump)
Main Pump
Right Swing Solenoid
Displacement
Valve
Angle Control
Bucket Close Solenoid EHC Valve Solenoid Valve
Folding Stairway Valve (Loading (Electrical (No. 2, 4, 5, and
Limit Switch 5 Shovel) Lever Con- 6 Pumps)
(Manual Lock Detection) trol)
Bucket Tilt-In Solenoid
Valve (Loading Shovel) EHC Valve
Bucket Roll-In Solenoid (Pump, Oil
Valve (Backhoe) Cooler Fan
EHC Valve Motor Control
Bucket Tilt -Out Solenoid (Electrical Circuit)
Valve (Loading Shovel) Lever Con-
Bucket Roll-Out Solenoid trol)
Valve (Backhoe) Main Pump
Displacement
Angle Control
Solenoid Valve
Folding Stairway (No. 7 Pump)
Limit Switch 4 Boom Lower Solenoid
(Storing Detection) Valve
Main Pump
Boom Raise Solenoid Displacement
Valve Angle Control
Arm Retract Solenoid Solenoid Valve
Valve (Loading Shovel) (No. 9 Pump)
Arm Roll-Out Solenoid
Fast-Filling Valve (Backhoe)
Panel Position Main Pump
Detection Switch Arm Extend Solenoid Displacement
Valve (Loading Shovel) Angle Control
Arm Roll-In Solenoid Solenoid Valve
Valve (Backhoe) (No. 8, 10, 11,
and 12 Pumps)
Fast-Filling Panel
Position Detection
Switch Relay
T18N-02-01-002

T2-1-9
SYSTEM / Controller
• Cushion Cylinder End Travel Limit Control
When the cushion cylinder reaches its stroke end
during travel operation, ELU receives the signal from
the cushion cylinder end pressure sensor. ELU stops
travel operation of the direction which the machine
traveled until then.
When travel operation is reversed and the cushion
cylinder leaves from the stroke end, travel operation
can be done.

• Swing Stop Control


ELU deactivates the swing lever control signal in
response to the signal from the fast-filling panel po-
sition defection switch and MC. Consequently, the
swing operation stops.

• Auto-Idle Control
When the electric control lever is in neutral, ELU
sends its signal to MC.
MC controls ECM and decreases the engine speed
auto-idle speed.

T2-1-10
SYSTEM / Controller

CAN
Pilot Shut-Off Switch To IDU, DLU

Front Attachment ELU Pilot Shut-Off Relay


System, Swing Pilot Shut-Off Solenoid Valve
Lever

EHC Valve
Travel Forward Sole- (Pump, Oil
Travel noid Valve (L) Cooler Fan
System Travel Reverse Sole- Motor Control
Lever noid Valve (L) Circuit)
Travel Forward Sole- Main Pump
noid Valve (R) Displacement
Travel Reverse Sole- Angle Control
noid Valve (R) Solenoid Valve
Cushion Cylinder End
(No. 1 Pump)
Pressure Sensor Bucket Open Solenoid
Valve (Loading Main Pump
Shovel) Displacement
Angle Control
MC Left Swing Solenoid Solenoid Valve
Valve (No. 3 Pump)
Main Pump
Right Swing Solenoid
Displacement
Valve
Angle Control
Bucket Close Solenoid EHC Valve Solenoid Valve
Folding Stairway Valve (Loading (Electrical (No. 2, 4, 5, and
Limit Switch 5 Shovel) Lever Con- 6 Pumps)
(Manual Lock Detection) trol)
Bucket Tilt-In Solenoid
Valve (Loading Shovel) EHC Valve
Bucket Roll-In Solenoid (Pump, Oil
Valve (Backhoe) Cooler Fan
EHC Valve Motor Control
Bucket Tilt -Out Solenoid (Electrical Circuit)
Valve (Loading Shovel) Lever Con-
Bucket Roll-Out Solenoid trol)
Valve (Backhoe) Main Pump
Displacement
Angle Control
Solenoid Valve
Folding Stairway (No. 7 Pump)
Limit Switch 4 Boom Lower Solenoid
(Storing Detection) Valve
Main Pump
Boom Raise Solenoid Displacement
Valve Angle Control
Arm Retract Solenoid Solenoid Valve
Valve (Loading Shovel) (No. 9 Pump)
Arm Roll-Out Solenoid
Fast-Filling Valve (Backhoe)
Panel Position Main Pump
Detection Switch Arm Extend Solenoid Displacement
Valve (Loading Shovel) Angle Control
Arm Roll-In Solenoid Solenoid Valve
Valve (Backhoe) (No. 8, 10, 11,
and 12 Pumps)
Fast-Filling Panel
Position Detection
Switch Relay
T18N-02-01-002

T2-1-11
SYSTEM / Controller
• Diagnosing
Failure of the sensors connected to ELU is diag-
nosed and stick phenomena in the EHC valve is
detected.
When the stick signal from the EHC valve and the
abnormal signal from the control lever/pedal are
detected, the pilot shut-off solenoid valve is turned
OFF and the operation is stopped automatically.
Failure information is transmitted to DLU and IDU
through CAN.
DLU logs failure information.
IDU outputs failure information on the display.

T2-1-12
SYSTEM / Controller

NOTE: LD: Loading Shovel


BH: Backhoe CAN
MC To IDU, DLU
Pilot Shut-Off Switch

ELU Pilot Shut-Off Relay


Front/Swing Con-
Pilot Shut-Off Solenoid Valve
trol Lever

Travel Forward Sole-


EHC Valve
noid Valve (L)
(Pump, Oil Cooler
Travel Travel Reverse Sole- Fan Motor Control
Control noid Valve (L) Circuit)
Pedal
Travel Forward Sole-
Main Pump Dis-
noid Valve (R)
placement Angle
Pilot Pressure Sensor Travel Reverse So- Control Solenoid
Travel Forward (Left) lenoid Valve (R) Valve
(No. 1 Pump)
Travel Reverse (Left) Main Pump Dis-
Bucket Open Solenoid
Valve (LD) placement Angle
Travel Forward (Right) Control Solenoid
Left Swing Solenoid Valve
Valve (No. 3 Pump)
Travel Reverse (Right)
Main Pump Dis-
Right Swing Solenoid
Bucket Open (LD) placement Angle
Valve
Control Solenoid
EHC Valve Valve
Left Swing Bucket Close Solenoid
(Electrical (No. 2, 4, 5, and 6
Valve (LD)
Lever Con- Pumps)
Right Swing Bucket Tilt-In Solenoid trol)
Valve (LD)
Bucket Roll-In Sole- EHC Valve
Bucket Close (LD) (Pump, Oil Cooler
noid Valve (BH) EHC Valve
Fan Motor Control
Bucket Tilt -In (LD) Bucket Tilt-Out Sole- (Electrical
Circuit)
Bucket Roll-In (BH) noid Valve (LD) Lever Con-
Bucket Roll-Out So- trol)
Bucket Tilt -Out (LD)
lenoid Valve (BH)
Bucket Roll-Out (BH) Main Pump Dis-
placement Angle
Boom Lower Control Solenoid
Valve
Boom Raise Boom Lower Solenoid (No. 7 Pump)
Valve
Arm Retract (LD) Main Pump Dis-
Arm Roll-Out (BH) Boom Raise Solenoid placement Angle
Valve Control Solenoid
Arm Extend (LD) Valve
Arm Roll-In (BH) Arm Retract Solenoid
Valve (LD) (No. 9 Pump)
Pilot Shut-Off Solenoid Valve Arm Roll-Out Solenoid
Valve (BH) Main Pump Dis-
Main Pump Displacement Angle placement Angle
Control (Main Pump 1) Arm Extend Solenoid Control Solenoid
Valve (LD) Valve
Main Pump Displacement Angle
Arm Roll-In Solenoid (No. 8, 10, 11, and
Control (Main Pump 3)
Valve (BH) 12 Pumps)
Main Pump Displacement Angle
Control (Main Pumps 2, 4, 5, and 6)
Main Pump Displacement Angle
Control (Main Pump 7)
Main Pump Displacement Angle
Control (Main Pump 9)
Main Pump Displacement Angle
Control (Main Pumps 8, 10, 11, and
12)

T18N-02-01-003

T2-1-13
SYSTEM / Controller
IDU: Information Display Unit
Function Outline
IDU is designed for data entry by the keypad, and
data display.

• Displaying Meters
IDU receives meter data from the controllers (MC,
ECM (L), ECM (R), DLU, and EHU) through CAN.
IDU outputs meter data on the display.

• Display Items
1- Engine Coolant Temperature (L)
2- Engine Speed (L)
3- Engine Oil Pressure (L)
4- Engine Coolant Temperature (R)
5- Engine Speed (R)
6- Engine Oil Pressure (R)
7- Fresh Air Temperature Keypad
8- Engine Oil Temperature (R) T18G-02-01-108

9- Fuel Level
1 2 3 4 5 6
10- Battery Voltage
11- Engine Oil Temperature (L)
12- Hydraulic Oil Temperature

TKCA-02-01-001
12 11 10 9 8
Display

T2-1-14
SYSTEM / Controller
(Blank)

T2-1-15
SYSTEM / Controller
Display Data Flow
1 2 3 4 5 6

TKCA-02-01-001
12 11 10 9 8
Display

1- Engine Coolant Temperature (L)


Coolant Temperature Sensor (L) →ECM (L) →CAN (J1939)→DLU→Ke-CAN→IDU
2- Engine Speed (L)
Engine Speed Sensor (L) →MC→Ke-CAN→IDU
3- Engine Oil Pressure (L)
Engine Oil Pressure Sensor (L) →ECM (L) →CAN (J1939)→DLU→Ke-CAN→IDU
4- Engine Coolant Temperature (R)
Coolant Temperature Sensor (R) →ECM (R) →CAN (J1939)→DLU→Ke-CAN→IDU
5- Engine Speed (R)
Engine Speed Sensor (R) →MC→Ke-CAN→IDU
6- Engine Oil Pressure (R)
Engine Oil Pressure Sensor (R) →ECM (R) →CAN (J1939)→DLU→Ke-CAN→IDU
7- Fresh Air Temperature
Fresh Air Temperature Sensor →DLU→Ke-CAN→IDU
8- Engine Oil Temperature (R)
Engine Oil Temperature Sensor (R) →ECM (R)→CAN (J1939)→DLU→Ke-CAN→IDU
9- Fuel Level
Fuel Level Sensor →MC→Ke-CAN→IDU
10- Battery Voltage
Battery → Fusible Link 1→ Fuse # 10 (Fuse Box 1) → Fuse # 3 (Fuse Box Cab) →IDU
11- Engine Oil Temperature (L)
Engine Oil Temperature Sensor (L) →ECM (L)→CAN (J1939)→DLU→Ke-CAN→IDU
12- Hydraulic Oil Temperature
Hydraulic Oil Temperature Sensor →MC→Ke-CAN→IDU

T2-1-16
SYSTEM / Controller
Coolant Temperature
Sensor (L)
ECM (L) DLU IDU
Engine Oil CAN
Pressure Sensor (L) (J1939)

Engine Oil
Temperature Sensor (L)

Coolant Temperature
Sensor (R)
ECM (R)
Engine Oil CAN
Pressure Sensor (R) (J1939)

Engine Oil
Temperature Sensor (R)

Ke-CAN

Fresh Air Temperature Sensor

Ke-CAN
Engine Speed Sensor (L)
MC

Engine Speed Sensor (R)


Ke-CAN

Hydraulic Oil Temperature Sensor

Fuel Level Sensor

Display
ELU

EHU

Keypad TKCA-02-01-002

T2-1-17
SYSTEM / Controller
• Fault Code Display • Maintenance History Output/Maintenance Record
IDU displays the fault codes on the display in re- The history of replacement, including hour meter
sponse to the abnormal signal from the controllers reading, quantity of maintenance times, and re-
through CAN. maining hours to next maintenance is displayed.
As a list of maintenance items is displayed, select
• Failure Information Display the concerned item and record the replacement data.
Failure information is displayed on the display by
entering data of the keypad connected to IDU. Setting Intervals and Warning ON/OFF
The intervals of replacement items are individually
• Buzzer Output set.
IDU sounds the buzzer in response to the specific The warnings ON/OFF of all replacement items are
alarm signal from the controllers through CAN. set at a time.

• Status Display • Life Data Display


The date on temperature and pressure in response IDU receives cumulative information, including cu-
to the signal from the controllers through CAN are mulative engine running hours and machine oper-
displayed on the display. ating hours from DLU through CAN, and displays it
on the display.
• Automatic Snapshot Display
At the occurrence of warning, the data on tempera- • Property (Machine Information) Display
ture and pressure for five minutes before warning The property of the machine, including controller
and one minute after warning are logged automati- configuration, hardware, and software (version) is
cally. displayed.
The log can be later checked by using the keypad.

• Manual Snapshot Display


Any data on temperature and pressure can be
checking manually when necessary. The date can
be logged and later checked.

• Maintenance History
Maintenance warning output
The warnings on the replacement of air filters, en-
gine oil, and hydraulic oil are output on the display at
every preset interval.

T2-1-18
SYSTEM / Controller
Coolant Temperature
Sensor (L)
ECM (L) DLU IDU
Engine Oil CAN
Pressure Sensor (L) (J1939)

Engine Oil
Temperature Sensor (L)

Coolant Temperature
Sensor (R)
ECM (R)
Engine Oil CAN
Pressure Sensor (R) (J1939)

Engine Oil
Temperature Sensor (R)

Ke-CAN

Fresh Air Temperature Sensor

Ke-CAN
Engine Speed Sensor (L)
MC

Engine Speed Sensor (R)


Ke-CAN

Hydraulic Oil Temperature Sensor

Fuel Level Sensor

Display
ELU

EHU

Keypad TKCA-02-01-002

T2-1-19
SYSTEM / Controller
• Processing and Check When Starting
IDU processes the following at the start of operation.
• Memory check
• Buzzer check
• System configuration check: Check of the con-
trollers connected to the CAN network.
• Level check: Check of coolant, engine oil, and
hydraulic oil levels
• Electric control lever check: Check of control lev-
ers for neutral position, model name setting, front
attachment setting, and multi lever setting.
• Maintenance warning: Warning of the items re-
quired to be maintained

• Other Settings
• Maintenance setting: Setting of replacement in-
terval and hours of consumable parts
• Snapshot setting: All delete of the recorded date
for manual snapshot
• Time setting: Setting of world standard time, local
standard time, and time difference
• Illumination OFF delay time setting: Setting of the
time until the working light comes off from the key
switch OFF

T2-1-20
SYSTEM / Controller
Coolant Temperature
Sensor (L)
ECM (L) DLU IDU
Engine Oil CAN
Pressure Sensor (L) (J1939)

Engine Oil
Temperature Sensor (L)

Coolant Temperature
Sensor (R)
ECM (R)
Engine Oil CAN
Pressure Sensor (R) (J1939)

Engine Oil
Temperature Sensor (R)

Ke-CAN

Fresh Air Temperature Sensor

Ke-CAN
Engine Speed Sensor (L)
MC

Engine Speed Sensor (R)


Ke-CAN

Hydraulic Oil Temperature Sensor

Fuel Level Sensor

Display
ELU

EHU

Keypad TKCA-02-01-002

T2-1-21
SYSTEM / Controller
ECM: Engine Control Module
Function Outline
• Fuel Injector Control
ECM operates the injector in response to the signal
from the engine control dial, the crank speed sensor,
the boost pressure sensor, and the common rail
pressure sensor, and controls the engine.

• Low Temperature Starting Control


(This control is for only the machine with optional
parts equipped.)
ECM excites the ether solenoid valve (optional) in
response to the signal from the engine intake-air
temperature sensor, and improves engine starting
ability.

• Auto-Idle Control
ECM operates the injector in response to the signal
from MC and reduces engine speed to auto-idle
speed.

• Failure Diagnosing Control


When ECM receives the erratic data from the engine
control dial, the crank speed sensor, the boost
pressure sensor, and the common rail pressure
sensor, ECM controls engine speed, fuel injection
amount, and engine stop.
Failure information is displayed by lighting and
blinking the indicator.

T2-1-22
SYSTEM / Controller

ECM (L) Injector (L)


Engine Control Dial (L)

Crank Speed Sensor (L) Engine Maintenance Indi-


cator (L)

Boost Pressure Sensor (L) Engine Stop Indicator (L)

Engine Warning Indicator


Common Rail Pressure Sensor (L) (L)

Ether Solenoid (L) (Op-


Engine Trouble- tional)
shooting Switch
(L) Engine Intake-Air Tem-
perature Sensor (L)
Engine Fault Code
Display Selection
Switch (L)

MC

ECM (R) Injector (R)


Engine Control Dial (R)

Crank Speed Sensor (R)


Engine Maintenance Indi-
cator (R)

Engine Stop Indicator (R)


Boost Pressure Sensor (R)

Engine Warning Indicator


Common Rail Pressure Sensor (R) (R)

Ether Solenoid (R) (Op-


tional)
Engine Trouble-
shooting Switch
(R) Engine Intake-Air Tem-
perature Sensor (R)
Engine Fault Code
Display Selection
Switch (R)

T18N-02-01-012

T2-1-23
SYSTEM / Controller
DLU: Data Logging Unit
Function Outline
• Monitor System • MMS Communication (Optional)
DLU monitors communication with connected units, Communication with the mine management system
and logs abnormality. -- MMS (Modular Mining System) can be done.
Warning information is sent to MMS in real time at
• Operating Hour Control the occurrence of warning.
DLU incorporates the internal clock and the GPS
receiver. • Satellite Communication (ORBCOMM) (Optional)
The internal clock is corrected to the standard time, The starting and finishing times of daily data can be
by using the GPS receiver. changed by using Palm or the display in the cab.
Log data from DLU is transmitted to the ORBCOMM
• Taking-In Basic Data terminal.
The data for ECM is taken in through CAN (J1939)
and transmitted to Ke-CAN.

• Warning Detection
Warning information with stamped times is logged.

• Operating Condition Detection


Operating data is handled every 30 minutes.

• Snapshot
At occurrence of warning, operating data every one
second for five minutes before warning and one
minute after warning is logged.
Log only one type of snapshot data a day even
when the same warning occurs several times a day.

• Service Tool Communication


The communication with Palm and a personal
computer can be done.
• Parameters Setting
The parameters in DLU are set by Palm.

T2-1-24
SYSTEM / Controller

ORBCOMM
Service Tool (Optional)

ECM (L) IDU


DLU
CAN
(J1939)

y Internal Clock
y GPS

Ke-
CAN
ECM(R)
CAN
(J1939)

Ke-
CAN
Ke-
CAN
ELU MC

MMS
COMM. Unit
(Optional)

Keypad MMS

(Optional)
Display

T18N-02-01-010

T2-1-25
SYSTEM / Controller
CSU: Contamination Sensing Unit
Function Outline
CSU senses the amount of contaminant (metal parti-
cles) by using the contamination sensors provided in
the drain circuits for main pumps P1 to P12, the
swing motor, and the travel motor.
CSU sends the detection signals from all contamina-
tion sensors to CAN at a cycle of one second.
If any resistance in contamination sensors is lowered
than the specified level, CSU lights the indicator
(yellow).
IDU receives this signal and displays the warning on
the display.
At the same time, DLU logs it.

T2-1-26
SYSTEM / Controller

Contamination
Sensor CSU
B (Power Consumption: MAX 1A)
Main Pump P1 (L1) W
CH1

B
Main Pump P2 (L2) W D/O (Open Collector) Indicator (Yellow)
CH2
•GND (0V) Output at Warning
B
Main Pump P3 (L3) W CH3

B MAIN POWER From Battery


Main Pump P4 (L4) W MAIN POWER GND
CH4

B
Main Pump P5 (L5) W CH5

B
Main Pump P6 (L6) W
CH6

B
Main Pump P7 (R1) W CH7

B
Main Pump P8 (R2) W
CH8

B
Main Pump P9 (R3) W
CH9
CAN
B
Main Pump P10 (R4) W
CH10 CAN_A To IDU, DLU

B
Main Pump P11 (R5) W
CH11
Contamination
Sensor
B B
Main Pump P12 (R6) W W Swing Motor
CH12 CH17 (Front Left)

B
W Swing Motor
CH18 (Rear Left)

B
W Swing Motor
CH19
(Front Right)

CH20 Swing Motor


(Rear Right)

B
W Travel Motor
CH21 (C/J)

T18N-02-01-004

T2-1-27
SYSTEM / Controller
HMU: Hydraulic System Monitoring Unit
Functions Outline
HMU monitors hydraulic drain pressure by using the
drain pressure sensors provided in the drain circuits
for main pumps P1 to P12, and four swing motors.
If the peak drain pressure exceeds the specified level
and its frequency exceeds the specified times, HMU
sends the signal to IDU and DLU through CAN.
IDU displays this abnormality message. At the same
time, DLU logs the frequency of abnormality.

T2-1-28
SYSTEM / Controller

HMU
SENSOR_5V

GND
CAN
Drain Pressure
Sensor
Main Pump P1 To IDU, DLU

Main Pump P2

Main Pump P3

Main Pump P4

Main Pump P5

Main Pump P6

Main Pump P7

Main Pump P8

Main Pump P9

Main Pump P10

Main Pump P11

Main Pump P12

Swing Motor (Front Left)

Swing Motor (Front Right)

Swing Motor (Rear Left)

Swing Motor (Rear Right)

T18N-02-01-005

T2-1-29
SYSTEM / Controller
EHU: Engine Heatbalance Control Unit
Function Outline
• Fuel Cooler Fan Control
1. EHU receives fuel temperature signals from ECM
(L) and ECM (R) through CAN.

2. When the fuel temperature signal from ECM (L) or


ECM (R) indicates 60°C or higher, EHU connects
the ground of the fuel cooler fan motor relay.

3. Current from the battery flows to fuel cooler fan


motors (L) and (R) through the fuel cooler fan
motor relay, and operates fuel cooler fan motors
(L) and (R).

T2-1-30
SYSTEM / Controller

Engine Oil Engine Oil


Level Check Level Check
Switch (L) Switch (R)

Engine Oil Level


Engine Oil Level Check Sensor (R)
Check Sensor (L)
LTA Radiator Inlet LTA Radiator Inlet
Coolant Temperature Coolant Temperature
Sensor (L) Sensor (R)

Radiator Inlet Coolant


Temperature Sensor (L) Radiator Inlet Coolant
Temperature Sensor (R)
Radiator Front Side
Air Temperature Radiator Front Side Air
Sensor (L) Temperature Sensor (R)
Coolant Level Check Coolant Level
Switch (L1) Check Switch (R1)
Coolant Level Check Coolant Level
Switch (L2) Check Switch (R2)
LTA Radiator Outlet
Coolant Temperature
Sensor (L)
Radiator Outlet
Coolant Temperature
Sensor (L) LTA Radiator Outlet Radiator Outlet Coolant
Coolant Temperature Temperature Sensor (R)
Engine (L) and Engine (R) Sensor (R)
Fuel Temperature Signals
From ECM (L) and ECM (R)
EHU

Ke-CAN

To IDU, DLU

From Battery

Fuel Cooler Fan


Motor Relay

Fuel Cooler
Fan Motor (L)

Fuel Cooler
Fan Motor (R)

T18N-02-01-014

T2-1-31
SYSTEM / Controller
(Blank)

T2-1-32
SYSTEM / Control System
OUTLINE
Signals from various sensors and switches enter MC
(Main Controller) and ECM (Engine Control Module).
MC and ECM process the signals and activate the
solenoid valves and the relays so that the engine, the
pumps, the oil cooler fan motor and the wipers are
controlled.
In addition, travel mode control as well as swing stop
control (while lowering the folding stairway or operating
the fast-filling system) are carried out by the electric
and hydraulic combined circuits.

MC
Input Output Control
Lever control signal from ELU Power increase solenoid valves Pump control (power increase control)
Engine speed sensors (L), (R) (L), (R) Pump control (power decrease control)
Power decrease solenoid valves
(L), (R)
Hydraulic oil temperature sensor Oil cooler fan speed select Oil cooler fan motor speed control
solenoid valves
Wiper switch Wiper relay 1 Wiper control
Interval switch Wiper relay 3
Wiper relay 4

ECM
Input Output Control
Engine control dials (L), (R) Fuel injectors (L), (R) Engine control (engine speed control)
Crank speed sensors (L), (R)
Engine intake-air temperature Fuel injectors (L), (R) Engine control (low temperature start
sensors (L), (R) Ether solenoid valves (L), (R) control)
Crank speed sensors (L), (R)
Auto-idle signal from MC Fuel injectors (L), (R) Engine control (auto-idle control)
Engine intake-air temperature Fuel injectors (L), (R) Engine control
sensors (L), (R) (engine protection control)
Engine oil pressure sensors (L),
(R)
Coolant level sensors (L), (R)
Coolant pressure sensors (L),
(R)
Fuel temperature sensors (L),
(R)
Crank speed sensors (L), (R)
Engine control dials (L), (R)

T2-2-1
SYSTEM / Control System
ENGINE CONTROL
Engine Speed Control

Purpose: The engine speed control controls the en-


gine speed and the output torque in re-
sponse to signals from engine control dial
and engine loads.

Operation: 4. ECM judges the engine loading status and con-


1. When the engine control dial is operated, the en- trols the fuel injector to the most appropriate in-
gine control dial sends electrical signals to ECM jection quantity.
according to the operating stroke. 5. The detected data from the crank speed sensor is
2. ECM operates the fuel injector in response to this transmitted to IDU via DLU through the Ke-CAN
signals and controls the engine speed. communication line.
3. At the same time, ECM receives signals from the
crank revolution sensor.

Crank Speed Sensor (L)


IDU
Fuel Injector (L)
J1939-CAN

Engine Control Dial (L)


DLU ECM
(L)

J1939-CAN
Crank Speed Sensor (R)

Fuel Injector (R)


Ke-CAN

Engine Control Dial (R)


ECM
(R)

T18N-02-02-001

T2-2-2
SYSTEM / Control System
(Blank)

T2-2-3
SYSTEM / Control System
Low Temperature Start Control
(Only Machine with Optional Parts Equipped)

Purpose: The low temperature start control warms


up the intake air when the intake air tem-
perature is low (-5 °C (23 °F) or less) by
injection the ether into the intake manifold
to improve the engine starting ability.

Operation:
1. When the key switch is turned to the ON position,
current from terminal M in the key switch flows to
engine stop switches (L) and (R) through fuse #12
of the fuse box (cab), emergency switches 1 to 7,
valve limit switches (return-U) and (return-L), and
valve limit switches (L-suction) and (R-suction).
2. Current from engine stop switch (L) flows to ECM
(L) and turns ECM (L) ON.
3. Current from engine stop switch (R) flows to ECM
(R) and turns ECM (R) ON.
4. When the intake air temperature is -5°C (23°F) or
less, the engine intake air temperature sensor
sends signals to ECM (L) and ECM (R).
5. ECM (L) and ECM (R) operate ether solenoid
valves (L) and (R) (optional).
6. ECM (L) and ECM (R) stop ether solenoid valves
(L) and (R) (optional) when the signal from crank
revolution sensors (L) and (R) becomes 500 min-1
or more.
7. As the ether is applied to the intake air, the engine
starting performance is improved.

T2-2-4
SYSTEM / Control System
Ether Bottle (L)
Engine Intake Air Temperature Sensor (L) (Optional)
Ether Solenoid
Valve (L) (Optional)
Crank Revolution Sensor (L) Ether Line (L)
(Optional)
Intake Manifold (L)

Fuel
Key Switch ON Signal Injector
ECM (L) (L)

Starter Motor (L)


Engine Intake Air Temperature Sensor (R)
Ether Bottle (R)
Crank Revolution Sensor (R)
(Optional)
Ether Solenoid Valve
(R) (Optional)
Ether Line (R)
(Optional)

Intake Manifold (R)

Fuel
Injector
(R)
Key Switch ON Signal
ECM (R)
Emergency
Switch 3
(Engine
Room (L1))

Air Bleed Solenoid


Valve Starter Motor (R)
Emergency Emergency Emergency
Switch 7 Switch 6 Switch 1
(Pump (Engine Emergency (Cab)
Room (R)) Room (R2)) Switch 2
(Pump Room (L))

Emergency Emergency
Switch 5 Switch 4
(Engine Room (R1)) (Engine Room (L2))
Valve Limit Switch Valve Limit Switch Fuse
(R-Suction) (Return-U) Box
Engine Stop (Cab)
Switch (R)

Valve Limit Switch Key Switch


(Return-L)

Engine Stop
Switch (L) Engine Start
Switch (L)

Valve Limit Switch


(L-Suction) Engine Start
Switch (R)

T18N-02-02-008

T2-2-5
SYSTEM / Control System
Auto-Idle Control

Purpose: The auto-idle control reduces fuel con-


sumption and noise level by decreasing
the engine speed when all control levers
are in neutral with the auto-idle switch ON.

Operation:
1. MC receives signals from the auto-idle switch and
control signals (front attachment/swing, and
travel) from ELU.
2. MC sends the signal to ECM (L) and ECM (R)
when the lever control signal from ELU becomes
zero with the auto-idle switch ON.
3. ECM (L) and ECM (R) reduce the engine speed to
the auto-idle speed (1400±50 min-1 (rpm)) by
controlling fuel injectors (L) and (R) at the lapse of
about three seconds after receiving signals from
MC.
4. Crank speed sensors (L) and (R) check the en-
gine speed and send the signal to ECM (L) and
ECM (R). Then, ECM (L) and ECM (R) can rec-
ognize that the engine speed is reduced to the
auto-idle speed.
5. MC sends auto-idle mode signals to IDU through
Ke-CAN. Then, IDU displays the auto-idle icon on
the monitor display.
6. When the control lever is operated and MC re-
ceives the lever control signal from ELU, MC
stops sending the signal to ECM (L) and ECM (R).
Then, ECM (L) and ECM (R) increase the engine
speed to the speed set by engine control dials (L)
and (R).

NOTE: In case signals from the accelerator sensor


are lower than the auto-idle speed
(1400±50 min-1 (rpm)), the auto-idle control
is not performed.

T2-2-6
SYSTEM / Control System

Lever Control Signal


(Front Attachment / Swing)
MC
ELU
Engine Control Dial (L)

D/0(24V) 1 Crank Speed Sensor (L)

Fuel Injector (L)


D/0(24V) 2

ECM
Lever Control (L)
Signal (Travel)

Engine Control Dial (R)

Crank Speed Sensor (R)

Fuel Injector (R)

ECM
(R)

PWM_0UT0
IDU Signal (Pilot Display)
Ke-CAN [Output]
y Auto-Idle Mode Signal

Auto-Idle Switch

T18N-02-02-002

T2-2-7
SYSTEM / Control System
Engine Protection Control

Purpose: When ECM detects a malfunction, the en-


gine protection control starts and prevents
the engine from damage.

Operation:
1. When ECM (L) and ECM (R) receive the mal-
function signals described below from each sen-
sor, ECM (L) and ECM (R) send them to DLU
through the Ke-CAN communication.
• Coolant temperature (L), (R): High
• Engine intake air temperature (L), (R): High
• Engine oil pressure (L), (R): Low
• Coolant level (L), (R): Low
• Fuel temperature (L), (R): High
• Crank case pressure (L), (R): High
• Coolant pressure (L), (R): Low
• Engine oil temperature: High
2. ECM (L) and ECM (R) reduce fuel injection
amount of fuel injectors (L) and (R) and de-
creases the engine speed to the specified valve.
3. MC receives the signal of engine malfunction from
DLU through the Ke-CAN communication.
4. MC stops the signal to power increase solenoid
valves (L) and (R) and sends the signal to power
decrease solenoid valves (L) and (R). Therefore,
the pump displacement angle is reduced and the
pump load is decreased.

T2-2-8
SYSTEM / Control System

Engine Intake-Air Temperature Sensor (L)

Crank Speed Sensor (L)

Fuel Injector (L)

Intake Manifold (L)

ECM (L)

J1939-CAN Sensors
・Coolant Temperature Sensor (L)
・Engine Oil Pressure Sensor (L)
・Coolant Level Sensor (L)
・Fuel Temperature Sensor (L)
Ke-CAN ・Crank Case Pressure Sensor (L)
・Coolant Pressure Sensor (L)
・Engine Oil Temperature Sensor (L)

DLU MC

P6 P4 P2 P12 P8 P10

P5 P1 P3 P11 P7 P9

Pilot Pump Power Increase Power Decrease Pilot Pump Power Increase Power Decrease
(L) Solenoid Valve Solenoid Valve (R) Solenoid Valve Solenoid
PowerValve
Decrease
(L) (L) (R) (R) Solenoid Valve
(R)
Engine Intake Air Temperature Sensor (R)
Crank Speed Sensor (R)
J1939-CAN
Fuel Injector (R)

Sensors
Intake Manifold(R) ・Coolant Temperature Sensor (R)
・Engine Oil Pressure Sensor (R)
・Coolant Level Sensor (R)
・Fuel Temperature Sensor (R)
・Crank Case Pressure Sensor (R)
ECM (R) ・Coolant Pressure Sensor (R)
・Engine Oil Temperature Sensor (R)

T18N-02-02-009

T2-2-9
SYSTEM / Control System
PUMP CONTROL
Power Increase Control (Speed Sensing)

Purpose: The power increase control controls the


pump delivery flow rate according to the
change of engine speed and efficiently
utilizes engine output power.

Operation:
1. Engine speed sensors (L) and (R) convert the
engine speed into the electrical signal and sends
it to MC.
2. When the engine speed is between 1800 and
2156 min-1, and MC receives the lever control
signal (front attachment/swing or travel) from ELU,
MC sends the signal in proportion to the engine
speed to power increase solenoid valves (L) and
(R).
3. Power increase solenoid valves (L) and (R) de-
liver pilot pressure oil in response to this signal to
the main pump regulator so that the pump driving
power is increased.
4. Therefore, the pump delivery flow rate and the
actuator speed increase. (Refer to COMPONENT
OPERATION/Pump Device.)
5. As the pump driving power increases and the en-
gine load increase, the engine speed is de-
creased.
This regulator operation continues until the en-
gine speed is decreased to 1800 min-1.

T2-2-10
SYSTEM / Control System

EHC Valve (L) EHC Valve (R)


(Pump, Oil Cooler (Pump, Oil Cooler Fan
Fan Motor Motor Control Circuit)
Control Circuit)

Power Increase Power Increase


Solenoid Valve Solenoid Valve
(L) (R)

ELU

Lever Control Signal


(Front Attachment/ Lever Control Signal
Swing) (Travel)

MC

Pilot Pilot
Power Increase Pump (L) Power Increase
Solenoid Valve Pump
Solenoid Valve
(L) (R) (R)

Engine Speed Engine Speed


Sensor (L) Engine (L) Sensor (R) Engine (R)

T18N-02-02-003

T2-2-11
SYSTEM / Control System
Power Decrease Control

Purpose: The power decrease control reduces the


main pump driving power when the engine
speed is 1650 min-1 or less, and protects
the engine from being overloaded.

Operation:
1. Engine speed sensors (L), (R) convert the engine
speed into the electrical signal, and sends it to
MC.
2. When the engine speed is 1650 min-1 or less, or
MC receives the lever neutral signal (front at-
tachment/swing or travel) from ELU, MC sends
the signal to power decrease solenoid valves (L),
(R) and shifts the power decrease solenoid valve.
3. As power decrease solenoid valves (L), (R) is
shifted, pilot pressure oil from the pilot pump is
delivered to the main pump regulator and the
pump driving power is decreased. (Refer to
COMPONENT OPERATION/Pump Device.)
4. As the pump driving power decreases, the engine
load is reduced and the engine speed is in-
creased. Thereby, the engine is protected from
being overloaded.
5. After the engine speed increases beyond 1750
min-1, MC stops the signal to power decrease
solenoid valves (L), (R) so that normal control is
performed.

T2-2-12
SYSTEM / Control System

EHC Valve (L) EHC Valve (R)


(Pump, Oil Cooler (Pump, Oil Cooler Fan
Fan Motor Motor Control Circuit)
Control Circuit)
Power Decrease
Solenoid Valve
(L) Power Decrease
Solenoid Valve
(R)

ELU

Lever Control Signal


(Front Attachment/ Lever Control Signal
Swing) (Travel)

MC

Pilot Pilot
Power Decrease Pump (L) Power Decrease
Solenoid Valve Pump
Solenoid Valve
(L) (R) (R)

Engine Speed Engine Speed


Sensor (L) Engine (L) Sensor (R) Engine (R)

T18N-02-02-003

T2-2-13
SYSTEM / Control System
Power Decrease Control (with Control Levers in
Neutral or at Start of Operation)

Purpose: The power decrease control always acti-


vates the power decrease control system
when the control levers are in neutral and
prevents the initial decrease in engine
speed caused by shifting the control lev-
ers.

Operation:
1. When the control levers are in neutral, lever con-
trol signals (front attachment/swing and travel)
from ELU to MC become zero. At the lapse of 0.5
second, MC sends the signal to power decrease
solenoid valves (L) and (R) and shifts the solenoid
valve.
2. When power decrease solenoid valves (L) and
(R) are shifted, pilot pressure oil is delivered to
the main pump regulator and the pump driving
power is decreased. (Refer to COMPONENT
OPERATION/Pump Device.)
During this control, power increase solenoid
valves (L) and (R) are OFF so that power in-
crease control is not operated.
3. When the control levers are operated, MC re-
ceives lever control signals (front attach-
ment/swing or travel) from ELU. At the lapse of
0.5 second, MC gradually turns power decrease
solenoid valves (L) and (R) OFF and power de-
crease control is stopped.
4. As power decrease control is activated for 0.5
second at the start of lever shifting, the initial de-
crease in engine speed can be prevented.
When the power decrease solenoid valve is OFF
and the engine speed is 1800 min-1 or more,
power increase solenoid valves (L) and (R) are
turned ON and power increase control is per-
formed.

T2-2-14
SYSTEM / Control System

EHC Valve (L) EHC Valve (R)


(Pump, Oil Cooler (Pump, Oil Cooler Fan
Fan Motor Motor Control Circuit)
Control Circuit)
Power Decrease
Solenoid Valve
(L) Power Decrease
Solenoid Valve
(R)

ELU

Lever Control Signal


(Front Attachment/ Lever Control Signal
Swing) (Travel)

MC

Pilot Pilot
Power Decrease Pump (L) Power Decrease
Solenoid Valve Pump
Solenoid Valve
(L) (R) (R)

Engine Speed Engine Speed


Sensor (L) Engine (L) Sensor (R) Engine (R)

T18N-02-02-003

T2-2-15
SYSTEM / Control System
FAST-FILLING PANEL LOWER CONTROL
Purpose: This prevents the fast-filling panel from
lowering for safety while the pilot control
shut-off lever is in the UNLOCK position.
When the fast-filling panel is lowered,
swing cannot be operated. Refer to Swing
Stop Control.

Operation:
• Pilot control shut-off lever: OFF (LOCK position) • Pilot control shut-off lever: ON (UNLOCK position)
1. When the pilot control shut-off switch is OFF, MC 1. When the pilot control shut-off switch is ON, MC
connects the ground circuit of the fast-filling relay. blocks the ground circuit of the fast-filling relay.
2. Under this condition, when the fast-filling switch is 2. Even if the fast-filling switch is turned ON under
turned ON, current from MC excites the fast-filling this condition, the fast-filling relay is not excited
relay. and the fast-filling panel is prevented from lower-
3. As current from the battery flows to the fast-filling ing.
solenoid valve via the fast-filling relay, the
fast-filling solenoid valve is operated. IMPORTANT: Even if the pilot shut-off switch is
4. Pilot pressure oil from the fast-filling solenoid ON while the fast-filling panel is
valve flows to the lift cylinder bottom side and lowering or when lowered fully, MC
lowers the fast-filling panel. operates the fast-filling solenoid
5. When the fast-filling panel is lowered and reaches valve continuously.
out of the detection range of the position detection At the same time, MC sends signals
switch, MC lights the alarm LED (red), and sends to IDU through the CAN communi-
signals to IDU through the CAN communication cation line and sounds the buzzer.
line, and displays the warning on the monitor.
6. At the same time, MC stops voltage signal to ELU,
and the swing function is not available. (Refer to
Swing Stop Control.)

T2-2-16
SYSTEM / Control System

Fast-Filling Switch

Fast-Filling Relay

MC
Fast-Filling
Solenoid Valve
Power Source for 24V
D/I (Max. 200mA)
Pilot Pump

D/O (O/C)
(Max.100mA)

Key Switch D/I (24V)


ON Signal

Pilot Control
Shut-Off Switch
Power Source for 24V
D/I
ON (Lever Control Available) D/I (24V)
OFF (Lever Control Unavailable) To ELU [Lever Control
(Available/Unavailable)]
Fast-Filling Panel
Position Detection
Switch Relay

Fast-Filling Panel
Position Detection Switch
Power Source for 24V
D/I
D/I (24V)
To ELU (Refer to Swing
Stop Control.)

D/O (24V)
Alarm LED (Red) (Max. 1.6A for SOL
and LAMP)
IDU (Information Display Controller)
(Output) CAN
y Fast-Filling Panel Position Signal
y Buzzer Signal
Lift Cylinder T18N-02-02-004

T2-2-17
SYSTEM / Control System
FOLDING STAIRWAY CONTROL
Purpose: The folding stairway control controls not to
operate the folding stairway when the pilot
shut-off lever is ON (UNLOCK position) for
safety.
In addition, before the folding stairway cyl-
inder reaches the stroke end, this decreases
operating speed in order to protect the fold-
ing stairway.

Operation:
• Extending Folding Stairway
1. When the pilot shut-off switch is OFF and the ex- 10. Therefore, folding stairway solenoid valve 3 is
tend switch is pushed, the ground circuits in fold- operated and the hydraulic circuit is blocked.
ing stairway relays 2, 3, and 4 are connected. 11. As pressure oil from folding stairway pump units 1
2. Current from the battery excites folding stairway and 2 flows to the folding stairway cylinder
relay 4. through only orifice A, operating speed of the
3. Therefore, current flowing from folding stairway folding stairway cylinder becomes slow.
relay 4 to folding stairway solenoid valve 2 is 12. When extension of the folding stairway is com-
blocked. Thus, folding stairway solenoid valve 2 pleted, limit switch 1 (extend stroke end detection)
stops. is turned OFF and blocks the ground circuits of
4. Folding stairway solenoid valve 2 blocks pressure folding stairway relays 2 and 3, and folding stair-
oil flowing from pilot pumps (L) and (R) to the way solenoid valve 1 and 3.
bottom side of the folding stairway cylinder in or- 13. As current from folding stairway relay 1 is blocked,
der to stabilize fold-in operation of the folding folding stairway solenoid valves 1 and 3 stop.
stairway. 14. As current from folding stairway relays 2 and 3 is
5. Current from the battery flows through folding blocked, folding stairway motors 1 and 2 stop so
stairway relay 1 and excites folding stairway re- that folding stairway pumps 1 and 2 stop.
lays 2 and 3.
6. Sol. b of folding stairway solenoid valve 1 is op-
erated at the same time.
NOTE: Although current flows to sol.a, as the
ground circuit is not connected, sol.a is not
operated.
7. Current from the battery flows to folding stairway
motors 1 and 2 through folding stairway relays 2
and 3, and operates folding stairway motors 1 and
2. Therefore, the battery power operates, folding
stairway pump units 1 and 2.
8. When pressure oil from folding stairway pump
units 1 and 2 flows to the rod side of the folding
stairway cylinder through orifice A and folding
stairway solenoid valve 3 so that the folding
stairway is extended.
9. While the folding stairway is extended, limit switch
2 (extend stroke end control) is turned ON and
connects the ground circuit of folding stairway
solenoid valve 3.

T2-2-18
SYSTEM / Control System

Pilot Shut-Off Switch MC


ELU
76-19
76-58

From Battery Limit Switch 2 (Extend Stroke End Folding Stairway 76-4
Control) Relay 4

Folding Stroke End: OFF


Stairway
Relay 1
Limit Switch 3
(Storage Stroke End
Control)

Limit Switch 1
(Extend Stroke
End Detection)
Folding Stairway
Limit Switch 5
Emergency
Storage (Manual Lock
Switch
Switch Detection)

Extend Switch

Limit Switch 4
Folding (Storage Detection) Folding Stairway Cylinder
Stairway
Relay 2

Folding
Stairway
Relay 3

Folding Stairway
Solenoid Valve 1
Holding
Valve

From Battery
Orifice A
Sol. b

Folding Stairway
Pump Unit 1

Folding Stairway
Motor 1

Folding Stairway
Motor 2

Folding Stairway
Pump Unit 2 Folding
Sol. a
Stairway So-
lenoid Valve 3

Folding Stairway
Solenoid Valve 3
Stop Valve
(Normally
Closed)
Folding Stairway Suction
Isolation Switch Manifold (L) Pilot Pilot T18N-02-02-010
Pump (L) Pump (R)

T2-2-19
SYSTEM / Control System
• Storage of Folding Stairway

1. When the pilot shut-off switch is OFF and the 11. As current from folding stairway relays 2 and 3 is
storage switch is pushed, the ground circuits in blocked, folding stairway motor 1 and 2 stops so
folding stairway relays 2 and 3 are connected. that folding stairway pumps 1 and 2 stop.
2. Current from the battery flows through folding 12. As the exciting current of folding stairway relay 4
stairway relay 1 and excites folding stairway re- is blocked at the same time, current from the
lays 2 and 3. battery flows to folding stairway solenoid valve 2
3. Sol. a of folding stairway solenoid valve 1 is op- through folding stairway relay 4.
erated at the same time. 13. Therefore, folding stairway solenoid valve 2 is
NOTE: Although current flows to Sol. b, as the operated.
ground circuit is not connected, Sol. b is not 14. As pressure oil from pilot pumps (L) and (R) is
operated. supplied to the bottom side of the folding stairway
cylinder, and the pushing force of the folding
4. Current from the battery flows to folding stairway stairway cylinder increases so that the folding
motors 1 and 2 through folding stairway relays 2 stairway is stored stably.
and 3, and operates folding stairway motors 1 and 15. The swing stop deactivation signal is sent from
2. Therefore, the battery power operates folding terminal 76-58 of MC to terminal 76-19 of MC and
stairway pump units 1 and 2. ELU through limit switch 4 (storage detection) and
5. When pressure oil from folding stairway pump limit switch 5 (manual lock detection).
units 1 and 2 flows to the bottom side of the fold- 16. Therefore, ELU unlocks the swing operation.
ing stairway cylinder so that the folding stairway is
stored.
6. While the folding stairway is stored, limit switch 3
(detection control for stroke end) is turned OFF
and the ground circuit is blocked. As current from
folding stairway relay 1 is blocked, Sol. a of fold-
ing stairway solenoid valve 1 stops.
7. Therefore, as folding stairway solenoid valve 1 is
neutral, the hydraulic circuit is blocked.
8. As pressure oil from only folding stairway pump
unit 2 flows to the folding stairway cylinder, oper-
ating speed of the folding stairway cylinder be-
comes slow.
9. When the folding stairway is stored completely,
limit switch 4 (storage detection) is turned ON and
connects the ground circuit of folding stairway
solenoid valve 2.
10. When the pilot shut-off lever of the folding stair-
way is locked, limit switch 5 (for detecting manual
lock) is turned OFF and blocks the ground circuits
of folding stairway relays 2, 3 and 4.

T2-2-20
SYSTEM / Control System

Pilot Shut-Off Switch MC


ELU
76-19
76-58

From Battery Limit Switch 2 (Extend Stroke End Folding Stairway 76-4
Control) Relay 4

Folding
Stairway
Relay 1
Limit Switch 3
(Storage Stroke
End Control)

Limit Switch 1
(Extend Stroke
End Detection)
Folding Stairway
Limit Switch 5
Emergency
Storage (Manual Lock
Switch
Switch Detection)

Extend Switch

Limit Switch 4
Folding (Storage Detection) Folding Stairway Cylinder
Stairway
Relay 2

Folding
Stairway
Relay 3

Folding Stairway
Solenoid Valve 1
Holding
Valve

From Battery
Orifice A
Sol. b

Folding Stairway
Pump Unit 1

Folding Stairway
Motor 1

Folding Stairway
Motor 2

Folding Stairway
Pump Unit 2 Folding
Sol. a
Stairway So-
lenoid Valve 3

Folding Stairway
Solenoid Valve 3
Stop Valve
(Normally
Closed)
Folding Stairway Suction
Isolation Switch Manifold (L)
Pilot Pilot T18N-02-02-011
Pump (L) Pump (R)

T2-2-21
SYSTEM / Control System
AUTO-LUBRICATION CONTROL
Purpose: The auto-lubrication control automatically
applies grease to the front attachment joint
pins, the swing bearing, and the center
joint at preset intervals.

Operation:
• Auto-Lubrication
1. When the auto-lubrication switch is set to the
AUTO position, current from terminal 76-13 of MC
is grounded via the auto-lubrication switch. MC
recognizes that the auto-lubrication switch is in
the AUTO position.
2. Current from terminal 48-18 of MC flows to
auto-lubrication solenoid valve at intervals preset
by the auto-lubrication interval switch, and the
auto-lubrication solenoid valve is operated.
3. Pressure oil from the pilot pump is supplied to the
vent valve and the grease pump drive motor via
the pressure reducing valve so that the grease
pump is operated.
4. As pilot pressure is routed to the vent valve, the
vent valve is closed the return circuit from the
grease pump to the grease tank is blocked.
Therefore, grease is applied to the front attach-
ment lubrication circuit.
5. Grease pressure in the front attachment lubrica-
tion circuit is routed to pressure switch 1.
When grease pressure in the front attachment
lubrication circuit increases beyond the set pres-
sure (17.7 MPa) set by pressure switch 1 pres-
sure switch 1 is turned ON. Terminal 48-38 of MC
is grounded via pressure switch 1. MC detects
that grease pressure in the front attachment lu-
brication circuit increases.
6. MC lights the indicator (red), and sends signals to
IDU through Ke-CAN so that the warning is dis-
played on the monitor.
7. MC operates the auto-lubrication solenoid valve
for 150 seconds at the preset intervals for inter-
mittent lubrication.

T2-2-22
SYSTEM / Control System

Auto-Lubrication
Switch
MC

76-13
Pressure Switch 1
(Auto-Lubrication)

48-38

76-26

Indicator (Red)
Pressure Switch 2
(Manual-Lubrication)

Ke-CAN IDU

Auto-Lubrication
Interval Switch
76-57 48-18
3 Min.
5 Min.
10 Min.
15 Min.

76-6
76-18
76-5
Key Switch ON Signal 76-71
(Fuse #15)

Pilot
Pump (L)

Pilot
Center Joint, Swing Bearing Pump (R)
Lubrication Circuits

Front Attachment
Lubrication Circuit
Grease Pump
Hose Reel Circuit
(Manual-Lubrication)
Vent Valve

Grease Tank Pressure Auto-Lubrication


Reducing Solenoid Valve
T18N-02-02-005
Valve

T2-2-23
SYSTEM / Control System
• Manual-Lubrication
1. In manual-lubrication mode, when the auto-lubri-
cation switch is set to the MANUAL position, MC
keeps the auto-lubrication solenoid valve ON.
This causes the grease pump to discharges
grease and allows the grease gun to apply
grease.
2. Pressure switch 2 checks if manual-lubrication is
made normally. When lubrication circuit pressure
increases beyond 23.5 MPa, pressure switch 2 is
turned ON.
3. Current from terminal 48-38 of MC is grounded
via pressure switch 2 and MC detects abnormal-
ity.
4. Current from terminal 48-18 of MC is stopped,
auto-lubrication solenoid valve is turned OFF, and
the grease pump is stopped.

NOTE: In manual-lubrication mode, the indicator


(red) is kept ON, and the warning is dis-
played on the monitor at all times.
When a grease gun is not used, the grease
pump is not operated as pressure in the
lubrication circuit increases.

T2-2-24
SYSTEM / Control System

Auto-Lubrication
Switch
MC

76-13
Pressure Switch 1
(Auto-Lubrication)

48-38

76-26

Indicator (Red)
Pressure Switch 2
(Manual-Lubrication)

Ke-CAN IDU

Auto-Lubrication
Interval Switch
76-57 48-18
3 Min.
5 Min.
10 Min.
15 Min.

76-6
76-18
76-5
Key Switch ON Signal 76-71
(Fuse #15)

Pilot
Pump (L)

Pilot
Center Joint, Swing Bearing Pump (R)
Lubrication Circuits

Front Attachment
Lubrication Circuit
Grease Pump
Hose Reel Circuit
(Manual-Lubrication)
Vent Valve

Grease Tank Pressure Auto-Lubrication


Reducing Solenoid Valve
T18N-02-02-005
Valve

T2-2-25
SYSTEM / Control System
OIL COOLER FAN MOTOR SPEED CON-
TROL

Purpose: The oil cooler fan motor speed control Oil Cooler Fan Motor Speed at Each Stage of Hydraulic Oil
controls the oil cooler fan motor speed at Temperature
three stages according to the hydraulic oil
Hydraulic Oil Pilot Oil Pressure from Oil Cooler
temperature and maintains the hydraulic
Temperature Solenoid Valve Fan Motor
oil temperature in the proper temperature
(°C) (Current from MC) Speed (min-1)
range.
49 °C (120 °F) 0 MPa 130
Operation: or Lower (0 kgf/cm2)
1. The hydraulic oil temperature sensor (for oil [50 mA]
cooler fan motor speed control) sends signals to 50 to 69 °C 1.76 MPa 620
MC according to the hydraulic oil temperature. (122 to 156 °F) (18.0 kgf/cm2)
2. MC controls the oil cooler fan motor speed control [281 mA]
solenoid valve according to the hydraulic oil 70 °C (158 °F) 3.51 MPa 960
temperature and delivers pilot pressure to the oil or Higher (35.8 kgf/cm2)
cooler fan motor drive pump regulator (Pi). (Refer [400 mA]
to COMPONENT OPERATION/Pump Device.)
3. Therefore, the delivery flow rate of the oil cooler NOTE: Oil cooler fan motor speeds described
fan motor drive pump is controlled, and the oil above are those at the rated engine speed
cooler fan motor speed is adjusted. (1800 min-1).
4. The detection data from the hydraulic oil tem-
perature sensor is sent to IDU through Ke-CAN.

T2-2-26
SYSTEM / Control System

EHC Valve (L)


Oil Cooler Fan Motor (Pump/Oil Cooler Fan
Motor Control Circuit)

Oil Cooler Fan Motor


Drive Pump (L) Oil Cooler Fan
Control Speed
Solenoid Valve (L)

Oil Cooler Fan


Control Speed
Pump Transmission (L) Solenoid Valve (L)

Engine (L)

Hydraulic Oil
Temperature Sensor EHC Valve (L)
(Pump/Oil Cooler Fan
Motor Control Circuit)
MC
IDU

Ke-CAN

Oil Cooler Fan Motor


Drive Pump (R) Oil Cooler Fan
Control Speed
Solenoid Valve (R)

Oil Cooler Fan


Control Speed
Pump Transmission (R) Solenoid Valve (R)

Engine (R)

T18N-02-02-006

T2-2-27
SYSTEM / Control System
WIPER CONTROL
Intermittent Operation Fast Speed Operation

Purpose: The intermittent operation operates the Purpose: The fast speed operation operates the
wiper at intervals set by the interval switch. wiper at fast speed.

Operation: Operation:
1. The interval switch sends electric signals to MC at 1. When the wiper switch is set to the HIGH position,
the set intervals. MC receives electrical signals.
2. When the wiper switch is set to the INT. position, 2. MC outputs current from terminal 48-16 of MC
MC receives electrical signals. and turns wiper relay 3 ON.
3. MC outputs current from terminal 48-4 of MC at 3. As wiper relay 3 is ON, current from fuse #76 op-
intervals set by the interval switch and turns wiper erates the wiper motor to run at fast speed.
relay 1 ON for about one second.
4. As wiper relay 1 is ON, current from fuse #75 op-
erates the wiper motor one turn at slow speed. Washer Operation

Purpose: The washer operation operates the


Slow Speed Operation washer, and operates the wiper at slow
speed.
Purpose: The slow speed operation operates the
wiper at slow speed. Operation:
1. When the washer switch is pushed, the washer
Operation: motor relay is turned ON and electrical signals
1. When the wiper switch is set to the LOW position, from terminal 48-40 of MC are grounded.
MC receives electrical signals. 2. When the washer motor relay is turned ON, cur-
2. MC outputs current from terminal 48-4 of MC and rent from fuse #77 operates the washer motor
turns wiper relay 1 ON. and sprays washer fluid.
3. As wiper relay 1 is ON, current from fuse #75 op- At the same time, wiper relay 1 is turned ON and
erates the wiper motor to run at slow speed. the wiper motor is operated at slow speed.
3. The wiper motor is continuously operated for five
seconds at slow speed after releasing the washer
switch.

T2-2-28
SYSTEM / Control System

Figure A

(Serial No.1031 and up)

From Battery
Fuse #75

Fuse #76
Key Switch ON Wiper Motor
Signal

Window 76-71
Washer Switch
Wiper Switch 76-59
・HIGH
Wiper Relay 4
・LOW 76-47
・INT. 48-4
76-68 Wiper Relay 1
・OFF
48-40

From Battery
From Key MC
Switch

Fuse Fuse
#77 #21
48-16
Wiper Relay 3

Figure B
Window
Washer From Fuse #75 (Up to serial No.1030)
Motor Relay

Wiper Relay 2

Washer Motor
Wiper Motor
Wiper Interval
Switch
・25 sec
76-59
・20 sec
・15 sec 76-35
・10 sec
・5 sec 76-68

Wiper Relay 4
From Terminal 48-4
Wiper Relay 1

T18G-02-01-026

NOTE: Refer to Figure A for the machine (Serial No.1031 and up).
Refer to Figure B for the machine (Up to serial No.1030).

T2-2-29
SYSTEM / Control System
TRAVEL MODE CONTROL
Purpose: The travel mode control shifts fast or slow Travel Mode
travel speed by adjusting the travel motor Switch
displacement angle with the travel mode
switch.

Travel Mode Switch Circuit

• Slow Mode
1. When the travel mode switch is OFF (slow), cur- LED Power
rent from fuse #22 does not flow to the travel Source
(For Switch)
mode relay.
2. Therefore, the contact of the travel mode solenoid
Key Switch
valve is located at #4 side. At this time, IDU dis- ON Signal
plays the slow travel mode mark on the monitor.
Fuse #22
• Fast Mode
1. When the travel mode switch is ON (fast), current
from travel mode relay is grounded.
Travel Mode
2. Therefore, the contact of the travel mode relay is Relay
located at the #5 side. IDU
3. As the travel mode solenoid valve circuit is Fuse #44
grounded, the travel mode solenoid valve is acti-
vated. From Battery
At the same time, IDU displays the fast travel
mode mark on the monitor.

Travel Mode
Display

Travel Mode
Solenoid
From Pilot Pump Valve

To Travel Motor Speed


Control Valve
T18G-02-01-027

T2-2-30
SYSTEM / Control System
(Blank)

T2-2-31
SYSTEM / Control System
Operation

• Slow Mode Operation


1. When the travel mode switch is OFF (slow), the 4. Accordingly, as the main pressure from the con-
travel mode solenoid valve is OFF. trol valve acts on the slow side tilt piston and the
2. Therefore, pilot pressure is reduced by the pres- travel motor displacement angle is increased,
sure reducing valve to the reducing valve set travel speed becomes slow.
pressure and acts on the spool ends in the travel 5. The pilot pressure also acts on the parking brake
mode switch valve. and releases the parking brake. (Refer to COM-
3. However, the spool in the travel mode switch PONENT OPERATION / Travel Device.)
valve does not move as the travel mode switch
valve set pressure is higher than the reduced pilot
pressure.

Pressure
Reducing Valve

Travel Mode
Solenoid
Travel Mode
Valve
Switch

Center Joint
Pilot
Pump

From Control Valve From Control Valve

Travel Mode Travel Mode


Switch Valve Switch Valve

Tilt Piston

Parking Brake Parking Brake


Left Travel Motor Right Travel Motor T141-02-01-008

T2-2-32
SYSTEM / Control System
• Fast Mode Operation
1. When the travel mode switch is ON (fast), the 4. Accordingly, as the main pressure from the con-
travel mode solenoid valve is ON. trol valve acts on the fast side tilt piston and the
2. Therefore, pilot pressure acts on the spring side travel motor displacement angle is decreased,
in the pressure reducing valve. travel speed becomes fast.
Then, the pilot pressure acts on the spool ends in 5. The pilot pressure also acts on the parking brake
the travel mode switch valve without being re- and releases the parking brake.
duced by the pressure reducing valve.
3. As the pilot pressure is not reduced, the spool in
the travel mode switch valve is shifted.

Pressure
Travel Mode Reducing Valve
Solenoid Valve

Travel Mode
Switch

Center Joint

Pilot Pump

From Control Valve From Control Valve

Travel Mode Travel Mode


Switch Valve Switch Valve

Tilt Piston

Parking Brake Parking Brake


Left Travel Motor Right Travel Motor T141-02-01-007

T2-2-33
SYSTEM / Control System
(Blank)

T2-2-34
SYSTEM / ELU System
OUTLINE
ELU (Electric Lever Control Unit) receives the signals
from the control lever, sensors and switches. ELU
makes arithmetic operation and controls the pumps
and the control circuits by operating the solenoid
valves and the relays.

Input Output Control


Pilot Shut-Off Switch Pilot Shut-Off Solenoid Valve Pilot Shut-Off Control
Control Lever Signal Main Pump Displacement Angle Control Main Pump Displacement
Solenoid Valve (For Main Pumps 1 to 12) Angle Control
Control Lever Signal (Left Travel) Travel Forward Solenoid Valve (Left/Right) Cushion Cylinder End
Control Lever Signal (Right Travel) Travel Reverse Solenoid Valve (Left/Right) Travel Limit Control
Cushion Cylinder End Pressure Sensor Main Pump Displacement Angle Control
Signal Solenoid Valve (For Main Pumps 1 to 12)
Control Lever Signal (Swing) Swing Solenoid Valve (Left/Right) Swing Stop Control
Folding Stairway Storage
Detection Limit Switch Signal
Fast-Filling Panel Position Detection
Switch Signal

T2-3-1
SYSTEM / ELU System
PILOT SHUT-OFF CONTROL

Purpose: The pilot shut-off switch operates the pilot


shut-off solenoid valve by operating the Ke-CAN
pilot shut-off lever. Pressure oil from the
pilot pump is delivered to the pilot circuit.
ELU IDU

Operation:
1. When the pilot shut-off lever is turned ON with the
Pilot Pressure Sensor
key switch in the ON position, the pilot shut-off
switch is turned ON. Current from terminal M in
the key switch flows to ELU and MC through fuse To Pilot Circuit
#20 in the fuse box (cab) and the pilot shut-off
switch, and excites the pilot shut-off relay at the Pilot Shut-Off
Relay
same time.
2. ELU and MC recognize the pilot shut-off release
signals respectively, and send them to IDU
through CAN. Pilot Shut-Off
3. When ELU recognizes the pilot shut-off release Solenoid Valve
signal, ELU outputs the voltage signal.
4. The voltage signal from ELU goes to the pilot
shut-off solenoid valve through the pilot shut-off
relay. Pilot Pump
5. Therefore, the pilot shut-off solenoid valve is
operated and pressure oil from the pilot pump is
delivered to the pilot circuit.
6. When an alarm signal is sent from the pilot
pressure sensor to ELU, ELU stops outputting the
voltage signal to the pilot shut-off solenoid valve
and stops the pilot shut-off solenoid valve.
Pilot Shut-Off
Switch MC

Fuse #20 in
Fuse Box (Cab)

Key Switch
T18G-02-01-007

T2-3-2
SYSTEM / ELU System
(Blank)

T2-3-3
SYSTEM / ELU System
PUMP CONTROL
Main Pump Displacement Control

Purpose: This adjusts the pump delivery flow rate


according to the control lever stroke and
efficiently uses engine output power.

Operation:
1. When operating the control lever, ELU receives
the signal according to the control lever stroke.
2. ELU sends the electric signal current to the main
pump displacement angle control solenoid valve
according to the control lever stroke.
3. The main pump displacement angle control
solenoid valve delivers pilot pressure oil to the
main pump regulator according to the electric
signal current and controls the pump delivery flow
rate.
4. Therefore, the delivery flow rate from each pump
is regulated to 100 to 425 L/min.
5. ELU detects pilot pressure from the main pump
displacement angle control solenoid valve to the
pump regulator, and sends the detected value to
IDU through Ke-CAN.

Maximum flow rate of each main pump when operating the control lever:
Max. Flow Rate (L/min)
Operation
MP1 MP2 MP3 MP4 MP5 MP6 MP7 MP8 MP9 MP10 MP11 MP12
Travel Right 100 375 - - - - - - 375 375 - -
Travel Left - - 100 375 - - 375 375 - - - -
Swing - - - - 425 425 - - - - 425 425
Boom Raise 375 375 375 375 425 425 375 375 375 375 425 425
Boom Lower 375 375 - - 425 425 - - 375 375 425 425
LD: Arm Extend 100 100 100 100
375 375 425 425 375 375 425 425
BH: Arm Roll-In 375 375 375 375

LD: Arm Retract 100 100 100 100


375 375 - - 375 375 - -
BH: Arm Roll-Out 375 375 375 375

LD: Bucket Tilt-In 375 375


375 375 375 425 425 375 375 375 425 425
BH: Bucket Roll-In 100 100

LD: Bucket Tilt-Out


100 375 - - 425 425 - - 100 375 425 425
BH: Bucket Roll-Out

Bucket Open/Close
- - 375 375 - - 375 375 - - - -
(LD Only)

NOTE: LD: Loading Shovel


BH: Backhoe

T2-3-4
SYSTEM / ELU System
EHC Valve(L) EHC Valve(R)
(Pump, Oil Cooler Fan (Pump, Oil Cooler Fan
Motor Control Circuit) Motor Control Circuit)
Main Pump Main Pump
Displacement Main Pump Displacement Displacement Control
Control Solenoid Control Solenoid Valve Solenoid Valve (For
Valve(For No.3 (For No.2, 4, 5, 6 Main No.8, 10, 11, 12 Main
Main Pump) Pumps) Pumps)

Main Pump
Displacement Front Travel Main Pump
Control Solenoid Displacement
Valve (For No.1 Control Solenoid
Valve (For No.9 Main Pump
Main Pump) Displacement
Main Pump)
Control Solenoid
Valve (For No.7
Ke-CAN Main Pump)

IDU ELU

Pilot Pressure Pilot Pressure


Sensor Sensor

Pilot Pump (L) Pilot Pump (R)


Main Pump
Main Pump Displacement Control
Displacement Control Solenoid Valve (For
Solenoid Valve (For No.8, 10, 11, 12 Main
No.3 Main Pump) Pumps)

Main Pump Main Pump


Displacement Control Displacement Control
Solenoid Valve (For Solenoid Valve (For
No.1 Main Pump) No.9 Main Pump)

Main Pump Main Pump


Displacement Control Displacement Control
Solenoid Valve (For Solenoid Valve (For
No.2, 4, 5, 6 Main No.7 Main Pump)
Pumps)

Regulator Regulator

P6 P2 P4 P12 P8 P10

P5 P1 P3 P11 P7 P9

Pump Transmission (L) Pump Transmission (R)

Left Engine Right Engine

T18N-02-03-001

T2-3-5
SYSTEM / ELU System
CUSHION CYLINDER END TRAVEL
REGULATION CONTROL
Purpose: This protects the track links and the shoes
from abnormal tension and shocks due to
sand and stone caught when traveling.

Operation:
1. When the cushion cylinder approaches its stroke Travel Regulation Control
end when traveling forward, ELU receives the As cushion cylinder
Travel regulation
signal from the cushion cylinder end pressure approaches stoke end
sensor. Left forward¯ Right forward ¯
1 Forward (↑↑)
2. ELU stops the electric signal current to the travel Left reverse{ Right reverse {
forward solenoid valve and the main pump Left forward¯ Right forward {
2 Spin right (↑↓)
displacement angle control solenoid valve. ELU Left reverse{ Right reverse ¯
sends the electric signal current to only the Left forward{ Right forward ¯
3 Spin left (↓↑)
corresponding travel reverse solenoid valve. ELC Left reverse¯ Right reverse {
sends the detected value from the cushion Left forward{ Right forward {
4 Reverse (↓↓)
cylinder end pressure sensor to IDU through Left reverse¯ Right reverse ¯
Ke-CAN. Left forward{ Right forward {
5 Turn left (↓↓)
3. Therefore, the travel forward solenoid valve and Left reverse¯ Right reverse {
DQR valve 2 stop, the travel spool in the control Left forward¯ Right forward {
6 Turn right (↓↓)
valve returns to the neutral position and the main Left reverse{ Right reverse {
pump displacement control is stopped. Left forward{ Right forward {
7 Turn right (↓↓)
4. When traveling reverse, ELU sends the electrical Left reverse{ Right reverse ¯
signal current and operates the travel reverse Left forward{ Right forward ¯
8 Turn left (↓↑)
solenoid valve, and delivers pilot pressure oil to Left reverse{ Right reverse {
DQR valve 1 so that DQR valve 1 is operated. ↑: Forward {: Operation is enabled.
5. DQR valve 1 delivers pilot pressure oil to the ↓: Reverse ¯: Operation is disabled.
control valve and shifts the travel spool into the
travel reverse position.
6. When traveling reverse, when the cushion
cylinder leaves from the stroke end, ELU does not
receive the signal from the cushion cylinder end
pressure sensor. Then, travel control and main
pump displacement controls are recovered.

T2-3-6
SYSTEM / ELU System

IDU Travel Reverse Solenoid Valve (Right)


Ke-CAN
Travel Forward Solenoid Valve (Right)
ELU
Left Travel Lever Travel Reverse Solenoid Valve (Left)
Travel Forward Solenoid Valve (Left)
Travel Forward Travel Forward
EHC Valve (Right) (Left)
(Swing, Travel,
Bucket
Open/Close) DQR
Right Travel Lever
Valve 2

Cushion Cylinder End


Pressure Sensor

DQR
Valve 1

Travel Reverse Travel Reverse


(Right) (Left)

Main Pump EHC Valve(R)


Displacement Control (Pump, Oil Cooler
Solenoid Valve Fan Motor Control
Circuit)

EHC Valve(L)
(Pump, Oil Cooler
Fan Motor Control
Circuit)

Regulator Main Pump Regulator


Displacement Control
P6 P2 P4 P12 P8 P10
Solenoid Valve

P5 P1 P3 P11 P7 P9

Pump Transmission (L) Pump Transmission (R)

Left Engine Right Engine

T18N-02-03-002

T2-3-7
SYSTEM / ELU System
SWING STOP CONTROL

Purpose: This stops swing operation when the


fast-filling panel or the folding stairway is
lowered in order not to damage.

Operation:
1. When the fast-filling panel is lowered, the
fast-filling panel position detection switch is
turned ON. The ground circuit of the fast-filling
panel position detection switch relay is
connected.
2. The fast-filling panel position detection switch
relay is excited. The voltage signal which is sent
from terminal 76-56 of MC to terminal 76-2 of ELU
through the fast-filling panel position detection
switch relay is turned ON.
3. When the folding stairway is lowered, ELU
receives the voltage signal (0V) from MC.
4. During swing operation under this condition, ELU
judges that the signal from the control lever is
disabled and swing operation cannot be done.
At the same time, the swing stop signal is sent to
IDU through Ke-CAN.
5. When the fast-filling panel is stored, the fast-filling
panel position detection switch is turned OFF. The
ground circuit of the fast-filling panel position
detection switch relay is disconnected.
6. The fast-filling panel position detection switch
relay is unexcited.
7. The voltage signal (24V) is sent from terminal
76-56 of MC to terminal 76-2 of ELU through the
fast-filling panel position detection switch relay,
and swing operation becomes available.
8. When the folding stairway is stored and the pilot
shut-off lever of the folding stairway is locked, the
voltage signal (24V) is sent from terminal 76-58 of
MC to ELU through limit switches 4 and 5, and
swing operation becomes available.

T2-3-8
SYSTEM / ELU System
Limit Switch 5
(For Manual Lock)

Swing

MC
IDU
76-58
Ke-CAN
76-19
ELU

76-59

Fast-Filling Panel Position Detection Switch


Limit Switch 4 76-56
(For Storage Detection)

76-2 76-17

Fast-Filling Panel Position


Detection Switch Relay
Swing
(Left) Swing
Swing (Left)
(Right)
DQR
Valve 2

EHC Valve

Shuttle
Valve

EHC Valve
DQR
Valve 1
Swing
(Right)

Pilot Shut-Off
Solenoid Valve

T18N-02-03-003

T2-3-9
SYSTEM / ELU System
(Blank)

T2-3-10
SYSTEM / Hydraulic System
OUTLINE

The hydraulic circuit consists of the pilot circuit, the


main circuit, the oil cooler fan motor circuit, the air
conditioner compressor motor circuit, the pump trans-
mission oil cooling circuit, and the travel shock
damper/travel stop circuit.
• Air conditioner compressor motor circuit:
• Pilot circuit: This drives the air conditioner compressor motor by
This delivers pressure oil from the pilot pump to the using pressure oil from the air conditioner com-
operation control circuit, the pump oil cooler fan pressor drive pump.
control circuit, the travel mode control circuit, the
travel parking brake release circuit, the swing park- • Pump transmission oil cooling circuit:
ing brake release circuit, the oil cooler fan motor This delivers transmission oil to the oil cooler by us-
speed control circuit, the fast-filling panel control ing the pump transmission oil circulation pump, and
circuit, the auto-lubrication control circuit, and the lubricates and cools the transmission.
folding stairway control circuit.
• Travel shock damper/Travel stop circuit:
• Main circuit: This absorbs external loads applied to the front
This controls pressure oil from the main pump by the idlers in order to reduce shock loads and stops travel
control valve and drives the actuators such as cyl- function if an excessive load is applied.
inders and motors.

• Oil cooler fan motor circuit:


This drives the oil cooler fan motor by using pressure
oil from the oil cooler fan motor drive pump.

T2-4-1
SYSTEM / Hydraulic System
PILOT CIRCUIT

Pressure oil from pilot pumps of left and right engines


is used in order to operate the following circuits:

• Operation control circuit


• Pump and oil cooler fan motor control circuits (Refer
to SYSTEM/Control System.)
• Travel mode control circuit (Refer to SYS-
TEM/Control System and COMPONENT OPERA-
TION/Travel Device.)
• Travel parking brake release circuit (Refer to
COMPONENT OPERATION/Travel Device.)
• Swing parking brake release circuit (Refer to
COMPONENT OPERATION/Swing Device.)
• Oil cooler fan motor speed control circuit (Refer to
SYSTEM/Control System.)
• Fast-filling panel control circuit (Refer to SYS-
TEM/Control System.)
• Auto-lubrication circuit (Refer to SYSTEM/Control
System.)
• Folding stairway circuit (Refer to SYSTEM/Control
System.)

Six accumulators are provided in the pilot circuit and


deliver pressure oil to the pilot circuit for a while after
the engine stops.
The pilot relief valve keeps pilot pressure in the cir-
cuit at the set pressure of 3.9 MPa (40 kgf/cm2).

T2-4-2
SYSTEM / Hydraulic System
OPERATION CONTROL CIRCUIT

DQR Valve 2

EHC Valve
(Swing, Travel, Bucket
Open/Close Operation
Control Circuits)

Shuttle Valve

DQR Valve 1

EHC Valve
(Boom, Arm, Bucket
Operation Control Boom Lower
Circuits) Priority
Selector Boom Raise
Valve Priority Selector
Valve
Arm Roll-Out
Priority Selector Auto-Lubrication Control Circuit
Pilot Shut-Off Valve
Solenoid Valve (Only Backhoe)

Swing Parking
Brake Release
Circuit

EHC Valve (R)


Accumulator (Pump, Oil Cooler Fan
Travel Parking Motor Control Circuits)
Brake Release
Folding Stairway Circuit
Control Circuit

EHC Valve (L)


(Pump, Oil
Cooler Fan
Motor Control
Pilot Relief Circuits)
Valve (L)
Travel Speed Mode
Selector Circuit Pilot Relief
Valve (R)
Fast-Filling Panel
Pilot Filter (L)
Control Circuit Pilot Filter
Pilot (R)
Pump (R)
Pilot
Pump (L)

4-Unit Pump 4-Unit Pump T18N-02-04-001


(Left) (Right)

T2-4-3
SYSTEM / Hydraulic System
Operation Control Circuit

The operation control circuit consists of two systems


as described below.

Control lever system:


Pressure oil from the left and right pilot pumps is de-
livered to the EHC valve through each pilot check
valve and pilot shut-off solenoid valve.
When the control lever is operated, the EHC valve is
operated and. Pressure oil from the pilot pump serves
as a signal pressure to the DQR (Dual Quick Re-
sponse) valve.
(Refer to Control System.)

DQR valve system:


Pressure oil from the pilot pump is delivered to the
DQR valve.
When the DQR valve is operated by the signal pres-
sure from the EHC valve, pressure oil from the pilot
pump is routed to the spool end in the control valve
and operates the control valve.

T2-4-4
SYSTEM / Hydraulic System
Control Lever Bucket Open Bucket Close
Travel Travel (Loading (Loading
Arm Swing Bucket Boom (Left) (Right) Shovel) Shovel)

ELU

1 2 3 4 5 6 7 8 9 10 11 12 13 14
To Control Valve
14 4 3 13

EHC Valve DQR


Valve 2

9 10 11 12 Shuttle
Valve
2 1 7 8

DQR
Valve 1

EHC Valve
To Control Valve

Boom Lower
Priority Selector
Valve Boom Raise
Priority Selector
5
Valve
6

To Control
Pilot Shut-Off Solenoid Valve Valve
Pilot Check Pilot Check
Valve (Left) Valve (Right)

Pilot Pump Pilot Pump Arm Roll-Out Priority T18N-02-04-002


(Left) (Right) Selector Valve
(Only Backhoe)

1 - Arm Retract (Loading Shovel)/ 5 - Bucket Tilt-Out (Loading Shovel)/ 9 - Left Travel Forward 13 - Bucket Open
Arm Roll-Out (Backhoe) Bucket Roll-Out (Backhoe) (Loading Shovel)
2 - Arm Extend (Loading Shovel)/ 6 - Bucket Tilt-In (Loading Shovel)/ 10 - Left Travel Reverse 14 - Bucket Close
Arm Roll-In (Backhoe) Bucket Roll-In (Backhoe) (Loading Shovel)
3 - Swing Left 7 - Boom Raise 11 - Right Travel Forward
4 - Swing Right 8 - Boom Lower 12 - Right Travel Reverse

T2-4-5
SYSTEM / Hydraulic System
1. When the control lever is operated, ELU receives
signals according to the control lever stroke.
2. ELU operates the EHC valve in response to these
signals and hydraulic oil pressure is generated.
This pressure is routed to the DQR valve and
moves the spool in the DQR valve.
3. When the DQR valve spool is moved, hydraulic oil
pressure is generated according to the DQR valve
spool movement (stroke).
The pressure is routed to the spool in the control
valve and movies the spool until the pressure is
balanced with spring force.
Therefore, the spool in the control valve is not
controlled by pilot pressure oil through the EHC
valve, but by pilot pressure oil through the DQR
valve.
4. When the spool is moved, main pressure oil from
the control valve is delivered, and operates each
motor and cylinder.
5. Returning oil from the control valve is routed to
the hydraulic oil tank through the other port in the
DQR valve.
(Refer to COMPONENT OPERATION/DQR
Valve.)

T2-4-6
SYSTEM / Hydraulic System

Hydraulic Piping

Control Lever

DQR Valve

Spool

Port T

ELU
Port P

Pilot Pump

Actuator
From Pilot Shut-Off
Solenoid Valve

Control Valve
Spring

EHC Valve

Spool Main Hydraulic Oil Tank


Pump

T18G-02-02-002

T2-4-7
SYSTEM / Hydraulic System
MAIN CIRCUIT

The main circuit consists of the following circuits. Suction Circuit

Suction circuit: This is located between the hydraulic For total of 12 main pumps (MP1 to 12), two main
oil tank and the pump, and draws hy- pumps are arranged in tandem, and six main pumps
draulic oil. are installed to left and right engines respectively.
Delivery circuit: This is located between the pump and Left and right suction manifolds are connected re-
the control valve, and delivers hy- spectively to the hydraulic oil tank through the suction
draulic oil. pipings. Each main pump draws hydraulic oil through
Return circuit: This is located between the control the suction manifold.
valve and the hydraulic oil tank, and The folding stairway pump unit draws hydraulic oil
returns hydraulic oil to hydraulic oil through suction manifold (L).
tank. 6 suction filters are provided in the hydraulic oil tank.

Folding Stairway
Pump
Front of Main Pump
Front View of Main Pump (Right Engine)
(Left Engine)
MP3 MP9
MP1 (Transmission MP7 (Transmission Side)
(Transmission Side) Side) (Transmission Side) MP10
MP2 MP4 MP8 (Pump End Side)
(Pump End Side) (Pump End (Pump End
Side) Side)
MP5
(Transmission
Side) MP11
MP6 (Transmission Side)
(Pump End MP12
Side) (Pump End Side)

MP6 MP2 MP4 MP12 MP8 MP10

MP5 MP1 MP3 MP11 MP7 MP9

Suction Manifold (L) Hydraulic Oil Tank Suction Manifold (R)

T18N-02-04-003

Suction Filter

T2-4-8
SYSTEM / Hydraulic System
(Blank)

T2-4-9
SYSTEM / Hydraulic System
Delivery Circuit (Main Pump)

6 main pumps are provided in left and right engines


respectively.
Hydraulic oil from 12 main pumps in total is delivered
to 6 control valves through the high-pressure strainer.
Hydraulic oil from main pumps (P1 to 6) of the left
engine is delivered to control valves 1 to 3, and hy-
draulic oil from main pumps (P7 to 12) of the right
engine is delivered to control valves 4 to 6.
Main pumps deliver hydraulic oil to control valves as
follows:

• Upper left control valve 1:


From main pumps 5 and 6 (MP5 and 6 of left en-
gine)
• Middle left control valve 2:
From main pumps 3 and 4 (MP3 and 4 of left en-
gine)
• Lower left control valve 3:
From main pumps 1and 2 (MP1 and 2 of left engine)
• Upper right control valve 4:
From main pumps 7 and 8 (MP7 and 8 of right en-
gine)
• Center right control valve 5:
From main pumps 9 and 10 (MP9 and 10 of right
engine)
• Lower right control valve 6:
From main pumps 11 and 12 (MP11 and 12 of right
engine)

NOTE: If the machine is driven with one engine,


operating speed of each actuator is halved,
but its driving force remains unchanged as
two-engine driving force.

T2-4-10
SYSTEM / Hydraulic System

Control Valve 1 Control Valve 4


(Upper Left) (Upper Right)

Control Valve 2 Control Valve 5


(Middle Left) (Middle Right)

Control Valve 3 Control Valve 6


(Lower Left) (Lower Right)

High-Pressure High-Pressure
Strainer Strainer

MP6 MP2 MP4 MP8 MP10


MP12
MP5 MP1 MP3 MP7 MP9
MP11
MP3
MP7 MP9
(Transmission Side)
MP1 (Transmission Side) (Transmission Side)
MP4
(Transmission Side) MP8 MP10
(Pump End Side)
MP2 (Pump End Side) (Pump End Side)
(Pump End Side) MP5
(Transmission Side)
MP11
MP6
(Transmission Side)
(Pump End Side)
MP12
Front of Main Pump Front of Main Pump (Pump End Side)
(Left Engine) (Right Engine)
T18N-02-04-004

T2-4-11
SYSTEM / Hydraulic System
Return Circuit

Returning oil from control valve 2 (middle left), control


valve 3 (lower left), control valve 4 (upper right), and
control valve 5 (middle right) flows back to the hy-
draulic oil tank through the oil cooler and the full-flow
filter.
When returning oil temperature is low (with high vis-
cosity), oil flow resistance in the oil cooler increases.
Therefore, the low-pressure relief valve is opened so
that returning oil flows back to the hydraulic oil tank
through the low-pressure relief valve and the full-flow
filter.
Returning oil from control valve 1 (upper left) and
control valve 6 (lower right) flows back to the hydrau-
lic oil tank through the low-pressure relief valve, the
full-flow filter, and the bypass filter.

T2-4-12
SYSTEM / Hydraulic System
Oil Cooler

Control Valve 1 (Upper Left)


Control Valve 4 (Upper Right)

Control Valve 2
(Middle Left)

Control Valve 5
(Middle Right)

Control Valve 6
(Lower Right)

Control Valve 3 (Lower Left)

Bypass Filter
Low-Pressure
Relief Valve

Hydraulic Oil Tank

Full-Flow Filter

TKCA-02-04-001

T2-4-13
SYSTEM / Hydraulic System
Single Operation Control Circuit

Loading shovel
• During boom operation
When raising the boom, control valves 1 to 6 are
operated and deliver pressure oil to two boom cyl-
inders and the level cylinder. When lowering the
boom, control valves 2 and 4 are not operated.

• During arm operation


When extending the arm, control valves 1 to 6 are
operated and deliver pressure oil to the arm cylinder.
When retracting in the arm, control valves 1 and 6
are not operated.

• During bucket operation


When tilting in the bucket, control valves 1 to 6 are
operated and deliver pressure oil to two bucket cyl-
inders. When tilting out the bucket, control valves 2
and 4 are not operated.

• During bucket open/close operation


Control valves 2 and 4 are operated and deliver
pressure oil to two dump cylinders.

• During swing operation


Control valves 1 and 6 are operated and deliver
pressure oil to four swing motors.

• During travel operation


When operating left travel, control valves 2 and 4
are operated and deliver pressure oil to two left
travel motors. When operating right travel, control
valves 3 and 5 are operated and deliver pressure oil
to two right travel motors.

T2-4-14
SYSTEM / Hydraulic System

Dump
Cylinder Arm Level
Boom Bucket Cylinder Cylinder Bucket Boom
Cylinder Cylinder Cylinder Cylinder
Swing Motor

Swing Motor

Control Valve 1 (Upper Left)


Control Valve 4 (Upper Right)
Bucket
Arm
Arm Extend/
Boom Lower Bucket
Open/Close
Boom
Bucket Tilt-In/
Boom Raise
Swing
Travel
(Left)
Control Valve 2 (Middle Left)
Control Valve 5 (Middle Right)
Travel
(Left)
Boom Raise/ Bucket
Bucket Tilt-In
Bucket Boom
Open/Close

Arm Arm

Travel
(Right)
Control Valve 3 (Lower Left)
Travel Control Valve 6 (Lower Right)
(Right)
Bucket
Arm
Arm Extend/
Boom Lower
Boom

Boom
Bucket
Swing

Travel Motor (Left) Travel Motor (Right)

T18N-02-04-006

T2-4-15
SYSTEM / Hydraulic System
Backhoe
• During boom operation
When raising the boom, control valves 1 to 6 are
operated and deliver pressure oil to two boom cyl-
inders. When lowering the boom, control valves 2
and 4 are not operated.

• During arm operation


When rolling in the arm, control valves 1 to 6 are
operated and deliver pressure oil to two arm cylin-
ders. When rolling out the arm, control valves 1 and
6 are not operated.

• During bucket operation


When rolling in the bucket, control valves 1 to 6 are
operated and deliver pressure oil to two bucket cyl-
inders. When rolling out the bucket, control valves 2
and 4 are not operated.

• During swing operation


Control valves 1 and 6 are operated and deliver
pressure oil to four swing motors.

• During travel operation


When operating left travel, control valves 2 and 4
are operated and deliver pressure oil to two left
travel motors. When operating right travel, control
valves 3 and 5 are operated and deliver pressure oil
to two right travel motors.

T2-4-16
SYSTEM / Hydraulic System

Bucket
Arm Cylinder Arm
Boom Cylinder Cylinder Boom
Cylinder Cylinder
Swing Motor

Swing Motor

Control Valve 1 (Upper Left)


Control Valve 4 (Upper Right)
Bucket
Arm
Arm
Roll-In/Boom
Lower Auxiliary
Boom
Bucket Roll-In/
Boom Raise
Swing
Travel
(Left)

Control Valve 2 (Middle Left)


Control Valve 5 (Middle Right)
Travel
(Left)
Boom Raise/ Bucket
Bucket Roll-In

Auxiliary Boom

Arm Arm

Travel
(Right)

Control Valve 3 (Lower Left)


Travel Control Valve 6 (Lower Right)
(Right)
Bucket
Arm
Arm Roll-In/
Boom Boom Lower

Boom
Bucket
Swing

Travel Motor (Left) Travel Motor (Right)

T18N-02-04-007

T2-4-17
SYSTEM / Hydraulic System
Combined Operation Control Circuit

• Combined operation of travel with front attachment


or swing
During combined operation of travel and front at-
tachment or swing, pressure oil from control valves
2 and 4 is delivered to left travel motors, and pres-
sure oil from control valves 3 and 5 is delivered to
right travel motors.

The travel spools in the four control valves for travel


operation are located in the foremost upstream side
in all circuits. The control valves are not provided
with the parallel circuit where pressure oil flows to
the downstream side. Therefore, during front at-
tachment or swing operation, control valves 1 and 6
are operated.

For loading shovel, combined operation of travel


and swing, boom, arm extend or bucket becomes
available. For backhoe, combined operation of travel
and swing, boom, arm or bucket becomes available.
The boom circuits of control valves 1 and 6 are pro-
vided with the parallel circuit. Pressure oil from the
parallel circuit flows to the boom spool only when
switched to the boom raise operation. The boom can
be raised during combined operation of travel and
swing.

NOTE: The arm and bucket open/close spools of


loading shovel are located behind the travel
spool without a parallel circuit. Therefore,
combined operation of arm retract and
bucket open/close is not possible.

T2-4-18
SYSTEM / Hydraulic System

NOTE: LD: Loading shovel


BH: Backhoe

Swing Motor Swing Motor

Control Valve 1 (Upper Left)

Bucket
Arm Extend: LD, Control Valve 4 (Upper Right)
Arm Roll-In: BH/
Boom Lower
Arm
Boom Bucket
Open/Close
(Only LD)
Swing
Bucket Tilt-In: LD,
Bucket Roll-In: BH/
From Main Pumps 5, 6 Boom Raise
Control Valve 2 (Middle Left)
Travel (Left)
From Main Pumps 3, 4

Travel From Main Pumps 7, 8


(Left)
Control Valve 5 (Middle Right)
Bucket

Bucket Bucket
Open/Close
(Only LD)
Boom
Arm

Arm

Travel (Right)

Control Valve 3 (Lower Left) From Main Pumps 9, 10


From Main Pumps 1, 2
Control Valve 6 (Lower Right)
Travel
(Right)
Bucket
Arm
Arm Extend: LD,
Arm Roll-In: BH/
Boom Lower
Boom

Boom
Bucket
Swing

From Main Pumps 11, 12

Travel Motor (Left) Travel Motor (Right)

T18N-02-04-008

T2-4-19
SYSTEM / Hydraulic System
• Combined operation of travel and arm (Loading
shovel)

Control valves 2 to 5 have a tandem circuit and give


priority to the travel function. Therefore, pressure oil
is not delivered to the arm spool during combined
operation of arm and travel.

Control valves 1 and 6 without the travel spool have


the arm extend spool. Therefore, the arm extend
spools of control valves 1 and 6 are operated and
combined operation of arm extend and travel be-
comes possible.
Combined operation of arm retract and travel is not
possible.

NOTE: The control valve spool for bucket


open/close operation is equipped with con-
trol valves 2 and 4. Therefore, combined
operation of bucket open/close and travel is
not possible.

T2-4-20
SYSTEM / Hydraulic System

Arm Cylinder

Control Valve 1 (Upper Left)

Control Valve 4 (Upper Right)


Arm Extend

Arm Extend

Arm Retract

Travel
(Left)

Control Valve 2 (Middle Left)


Control Valve 5 (Middle Right)
Travel
(Left)

Arm Retract

Arm Extend
Travel
(Right)

Control Valve 3 (Lower Left)


Control Valve 6 (Lower Right)
Travel
(Right)
Arm Retract

Arm Extend
Arm Extend

Travel Motor (Left) Travel Motor (Right)

T18N-02-04-009

T2-4-21
SYSTEM / Hydraulic System
• Combined operation of travel and arm (Backhoe)

Combined operation of travel and arm roll-in:


Control valves 2 to 5 have a tandem circuit and give
priority to the travel function.
Therefore, pressure oil is not delivered to the arm
roll-in spool located behind the travel spools during
combined operation of travel and arm roll-in.
However, as control valves 1 and 6 without the travel
spools have the arm roll-in spools, combined opera-
tion of travel and arm roll-in becomes possible.

T2-4-22
SYSTEM / Hydraulic System

Arm Cylinder

Control Valve 1 (Upper Left)

Control Valve 4 (Upper Right)


Arm Roll-In

Travel (Left)

Control Valve 2 (Middle Left)


Control Valve 5 (Middle Right)

Travel (Left)

Travel (Right)

Control Valve 3 (Lower Left)


Control Valve 6 (Lower Right)

Travel (Right)

Arm Roll-In

Travel Motor (Left) Travel Motor (Right)

T18N-02-04-010

T2-4-23
SYSTEM / Hydraulic System
Combined operation of travel and arm roll-out:
The travel pilot circuits of control valves 2 and 3 have
the arm roll-out priority selector valve.

1. During arm roll-out operation arm roll-out priority


valve receives signal pressure from the DQR
valve 1 and is shifted.
2. Therefore, pressure oil from the DQR valve 1 to
the travel spools of control valves 2 and 3 is
blocked.
3. Therefore, the travel spools are not operated.
Pressure oil from the main pump is delivered to
the arm roll-out spool located behind the travel
spools and operates the arm cylinder.
4. The travel pilot circuits of control valves 4 and 5
do not have the arm roll-out priority selector valve.
Therefore, during travel operation, the travel
spools of control valves 4 and 5 are operated and
deliver pressure oil to the travel motor.
5. Pressure oil from the main pump is not delivered
to the arm roll-out spools located behind the travel
spools.
6. As described above, during combined operation
of travel and arm roll-out, pressure oil from control
valves 2 and 3 operates the arm cylinder, and
pressure oil from control valves 4 and 5 operates
the travel motor.

T2-4-24
SYSTEM / Hydraulic System
From DQR Valves 1, 2 Arm Cylinder

Left Travel Left Travel Right Travel Right Travel


Reverse Forward Forward Reverse

Arm Roll-Out
From DQR
Valve 1
Control Valve 4 (Upper Right)
(D) (C) (B) (A)
Arm Roll-Out Arm Roll-Out
Control Valve 1 (Upper Left) Priority Selector
Valve

Control Valve 5 (Middle Right)

Control Valve 2 (Middle Left)

(C)
(D)

Arm Roll-Out

Arm Roll-Out

Control Valve 6 (Lower Right)

Control Valve 3 (Lower Left)

(A)
(B)

Arm Roll-Out

Travel Motor (Left) Travel Motor (Right)

T18N-02-04-011

T2-4-25
SYSTEM / Hydraulic System
• Combined operation of boom raise/bucket tilt-In
(Loading shovel)

1. During combined operation of boom raise and


bucket tilt-in, ELU operates the EHC valve.
2. Pilot pressure shifts the boom raise spool and the
bucket tilt-in spool of DQR valve 2 through the
EHC valve.
3. When the boom raise spool of DQR valve 2 is
shifted, pilot pressure from DQR valve 2 shifts the
boom and the boom raise/bucket tilt-in spools of
control valves 1 to 6 to the boom raise side. The
boom raise priority selector valve is also shifted.
4. When the bucket tilt-in spool of DQR valve 2 is
shifted, pilot pressure of DQR valve 2 shifts the
bucket spools of control valves 1, 3, 5, and 6 to
the bucket tilt-in side.
5. When the boom raise priority selector valve is
shifted, pilot pressure (K) and pilot pressure (J) to
the boom raise/bucket tilt-in spool of control
valves 2 and 4 are blocked. Consequently, the
boom raise/bucket tilt-in spools of control valves 2
and 4 are shifted to the boom raise side.
6. Pressure oil flows to the boom cylinder from the
boom and the boom raise/bucket tilt-in spools of
control valves 1 to 6.
7. The bucket spools of control valves 1 and 6 are
located behind the boom spool without a parallel
circuit. Therefore, pressure oil flows to the bucket
cylinder from the bucket spools of control valves 3
and 5.

T2-4-26
SYSTEM / Hydraulic System

Bucket Boom

Bucket Tilt-In Boom Raise


Signal Signal

ELU Control Valve 1 (Upper Left) Control Valve 4 (Upper Right)

Bucket Tilt-In
BMU (G) / Boom Raise
Bucket Spool
Spool
EHC Valve Boom
Spool
(A) (L) (D)

BKC
From Main Pumps 5, 6
From Main Pumps 7, 8
Control Valve 2 From Main Pumps 3, 4
Pilot Shut-Off Solenoid Valve (Middle Left) Control Valve 5 (Middle Right)
Bucket
From Right and Spool
Left Pilot Pumps Pilot Pressure Boom
(Bucket Tilt-In) (K) Spool (I)
(B)
Pilot Pressure (C) (B) (A) (G) (H) (I) (J)
(Boom Rise) Boom (E)
(F) (E) (D) Raise/
Bucket
Tilt-In
Spool

From Main Pumps


From Main Pumps 1, 2 9, 10
BMU Control Valve 3
BKC (Lower Left) Control Valve 6 (Lower Right)

DQR Valve 2

Bucket (J)
Spool

(C) Boom
Spool
(F)
(H) Boom
Spool

Bucket
Spool
From Main Pumps 11, 12
(K)

(L)
T18N-02-04-012

Boom Raise
Priority Selector Valve
NOTE: BMU: Boom Raise
BKC: Bucket Tilt-In

T2-4-27
SYSTEM / Hydraulic System
• Combined operation of boom raise/bucket roll-In
(Backhoe)

1. During combined operation of boom raise and


bucket roll-in, ELU operates the EHC valve.
2. Pilot pressure shifts the boom raise spool and the
bucket roll-in spool of DQR valve 2 through the
EHC valve.
3. When the boom raise spool of DQR valve 2 is
shifted, pilot pressure from DQR valve 2 shifts the
boom and the boom raise/bucket roll-in spools of
control valves 1 to 6 to the boom raise side. The
boom raise priority selector valve is also shifted.
4. When the bucket roll-in spool of DQR valve 2 is
shifted, pilot pressure of DQR valve 2 shifts the
bucket spools of control valves 1, 3, 5, and 6 to
the bucket roll-in side.
5. When the boom raise priority selector valve is
shifted, pilot pressure (K) and pilot pressure (J) to
the boom raise/bucket roll-in spool of control
valves 2 and 4 are blocked. Consequently, the
boom raise/bucket roll-in spools of control valves
2 and 4 are shifted to the boom raise side.
6. Pressure oil flows to the boom cylinder from the
boom and the boom raise/bucket roll-in spools of
control valves 1 to 6.
7. The bucket spools of control valves 1 and 6 are
located behind the boom spool without a parallel
circuit. Therefore, pressure oil flows to the bucket
cylinder from the bucket spools of control valves 3
and 5.

T2-4-28
SYSTEM / Hydraulic System

Bucket Boom

Bucket Roll-In Boom Raise


Signal Signal

ELU Control Valve 1 (Upper Left) Control Valve 4 (Upper Right)

Bucket
BMU (G) Roll-In/
Bucket Boom Raise
Spool Spool
EHC Valve Boom
Spool
(A) (L) (D)

BKC
From Main Pumps 5, 6
From Main Pumps 7, 8
Control Valve 2 From Main Pumps 3, 4
Pilot Shut-Off Solenoid Valve (Middle Left) Control Valve 5 (Middle Right)
Bucket
From Left and Right Spool
Pilot Pumps Pilot Pressure Boom
(Bucket Roll-In) (K) Spool (I)
Pilot Pressure (C) (B) (A) (B)
(G) (H) (I) (J)
(Boom Rise)
Boom Raise/ (E)
(F) (E) (D) Backet
Roll-In Spool

From Main Pumps


From Main Pumps 1, 2 9, 10
BMU Control Valve 3
(Lower Left) Control Valve 6 (Lower Right)
BKC
DQ Valve 2

Bucket (J)
Spool
Boom
(C) Spool

(F)
(H) Boom
Spool

Bucket
Spool
From Main Pumps 11, 12
(K)

(L)
T18N-02-04-012

Boom Raise
Priority Selector
NOTE: BMU: Boom Raise Valve
BKC: Bucket Roll-In

T2-4-29
SYSTEM / Hydraulic System
• Combined operation of boom lower and, arm extend
(LD), or arm roll-in (BH)

1. During combined operation of boom lower and,


arm extend (LD) or arm roll-in (BH), ELU operates
the EHC valve.
2. Pilot pressure shifts the boom lower spool of DQR
valve 2, and the arm extend spool (LD) spool or
the arm roll-in (BH) spool of DQR valve 1 through
the EHC valve.
3. When the boom lower spool of DQR valve 2 is
shifted, pilot pressure from DQR valve 2 shifts the
boom and the arm extend (LD) or arm roll-in
(BH)/boom lower spools of control valves 1, 3, 5,
and 6 to the boom lower side. The boom lower
priority selector valve is also shifted.
4. When the arm extend (LD) and arm roll-in (BH)
spools of DQR valve 1 are shifted, the arm spools
of control valves 2 to 5 are shifted to the arm ex-
tend (LD) and arm roll-in (BH) sides.
5. When the boom lower priority selector valve is
shifted, the arm extend (LD), arm roll-in (BH) pilot
pressure (I) and pilot pressure (J) to arm extend
(LD) and arm roll-in (BH)/boom lower spool is
blocked. Consequently, the arm extend (LD), arm
roll-in (BH)/boom lower spools of control valves 1
and 6 are shifted to the boom lower side.
6. Pressure oil flows to the boom cylinder from the
boom and arm extend (LD), arm roll-in (BH)/boom
lower spools of control valves 1, 3, 5, and 6.
7. Pressure oil flows to the arm cylinder from the
arm spools of control valves 2 to 5.

NOTE: LD: Loading Shovel


BH: Backhoe

T2-4-30
SYSTEM / Hydraulic System

Arm Swing Bucket Boom

Arm Extend (LD),


Arm Roll-In (BH)
Boom Lower
Signal
Signal Arm Extend (LD),
Arm Roll-In (BH)/
ELU Boom Lower Spool
Control Valve 1
ARC (Upper Left) Control Valve 4 (Upper Right)

BMD
(G)
EHC Valve (I)
Boom Arm
Spool Spool
(A)

From Main
From Main Pumps 5, 6 Pumps 7, 8
Pilot Shut-Off Solenoid Valve From Main Pumps 3, 4
Control Valve 2
(Middle Left) Control Valve 5 (Middle Right)
From Left and
Right Pilot Pumps Boom
Spool
Pilot
Pressure Arm
(Boom (D) (C) (B) (A)
Spool (C)
Lower)
Arm
Spool (H)
(E)

From Main From Main


Pumps 1, 2 Pumps 9, 10
BMD DQR Valve 2 Control Valve 3
(Lower Left) Control Valve 6 (Lower Right)
Arm
DQR Valve 1 Spool

ARC (F)
(J) (D)
(B)

Boom
Boom
Spool
Spool
Arm Extend (LD),
Arm Roll-In (BH)
Boom Lower From Main Boom Lower Spool
Priority Selector Valve Pumps 11, 12
(I)
Pilot Pressure
(Arm Extend (LD),
Arm Roll-In (BH)) (J)

(H) (G) (F) (E) T18N-02-04-013

NOTE: BMD: Boom Lower


ARC: Arm Extend (LD), Arm Roll-In (BH)

T2-4-31
SYSTEM / Hydraulic System
OIL COOLER FAN MOTOR CIRCUIT PUMP TRANSMISSION OIL COOLING CIR-
CUIT
Pressure oil from the oil cooler fan motor drive pump
drives the oil cooler fan motor. The pump transmission oil circulation pump draws
pressure oil from the pump transmission through the
filters. The pressure oil is routed to the pump trans-
AIR CONDITIONER COMPRESSOR MO- mission oil cooler and is returned to the pump trans-
TOR CIRCUIT mission after being cooled.

Pressure oil from the air conditioner compressor drive


pump drives the air conditioner compressor drive mo-
tor.

Oil Cooler Fan


Motor (Front)
Air Conditioner
Compressor
Drive Motor

Oil Cooler Fan


Motor (Rear)

Pump Transmission Oil


Circulation Pump (R)

Pump Transmission Oil


Circulation Pump (L)

Air Conditioner
Compressor Drive
Pump

Oil Cooler Fan Motor


Oil Cooler Fan Motor Drive Pump (R)
Drive Pump (L)

Pump Transmission (Left Engine) Pump Transmission (Right Engine)

Pump Transmission Pump Transmission TKCA-02-04-002


Oil Cooler (L) Oil Cooler (R)

T2-4-32
SYSTEM / Hydraulic System
TRAVEL SHOCK DAMPER/TRAVEL STOP
CIRCUIT

Purpose Operation
This protects the • When subjected to ordinary shocks:
front idlers from shocks applied. When operating the travel lever, ELU operates the
Depending on shocks applied to the front idlers, this EHC valve. (Refer to Operation Control Circuit.)
functions as follows. Pilot pressure is routed to the DQR valve through
• When ordinary shocks are applied: the EHC valve. Pressure oil from the pilot pump
The accumulators reduces shocks. shifts the travel spool in the control valve through
• When excessive shocks are applied: the DQR valve. Therefore, main pressure is de-
Refer to Cushion Cylinder End Travel Limit Con- livered to left and right travel motors and the ma-
trol in ELU System. chine starts traveling, causing the machine to
travel. At the same time, main pressure for travel
is reduced and is delivered to the cushion cylinder.
When shocks are applied to the front idler, the
cushion piston is pushed. Consequently, hydraulic
oil behind the cushion piston flows to the accu-
mulator. The bladder in the accumulator is con-
tracted and reduces shocks

Cushion Piston

Travel Stop Valve


Cushion Cylinder Relief Valve

Cushion Cylinder End


Pressure Sensor Pressure Accumulator
Reducing
Valve

Pilot Pump

T18N-02-04-015

Control Valve Center Joint Pilot Pressure


Travel Spool Control Valve

T2-4-33
SYSTEM / Hydraulic System
(Blank)

T2-4-34
SYSTEM / Electrical System
OUTLINE
The electrical circuit is broadly divided into the main
circuit, the monitor circuit, and the control circuit.

• Main Circuit
Operates the main motor and the accessory related
circuits.

• Control Circuit (Refer to SYSTEM/Control System.)


Functions to control the machine.
(Refer to the SYSTEM section.)

• Monitor Circuit
Displays the machine operating conditions.
(Refer to the electrical circuit diagrams.)

The functions and construction of the main circuits


below are explained here.

• Main Circuit

• Electrical Power Circuit: It supplies electric power


to all electrical systems on the machine.

• Accessory Circuit: It is operated when the key


switch is in the ACC position.

• Engine Start Circuit: It operates the starter and


starts the engine.

• Charging Circuit: It charges the batteries and


supplies current generated by the alternator in
order to operate all the electrical components.

• Engine Stop Circuit: Stop circuit by using the


emergency switch, the limit switch, and the engine
stop switch.

• Surge Voltage Prevention Circuit: It protects the


electrical equipment from surge voltage
developed when the engine stops.

T2-5-1
SYSTEM / Electrical System
ELECTRICAL POWER CIRCUIT
(KEY SWITCH: OFF)
The battery minus terminal is grounded to the body.
Current flows as shown below when the key switch is
in the OFF position.

Battery relays (L1, L2, R1, R2) terminal A

Fusible link #1 → Fuse box 1


Fuse box 3
Battery → Fusible link #7 → ECM (L) power connector terminals A, C, D
Fusible link #8 → ECM (R) power connector terminals A, C, D
Fusible link #10 → Folding stairway relay (2) terminal #3
Folding stairway relay (3) terminal #3
Fusible link (250 A) → Folding stairway motor (2)
Fusible link (250 A) → Folding stairway motor (1)

Fuse #1 → MC (Main power source)


Fuse #2 → Delayed power OFF relay terminals #1, #3
Fuse box 1 → Fuse #3 → EHU (Main power source)
Fuse #4 → MMS communication unit (main power source) (optional)
Fuse #5 → HMU (Main power source)
Fuse #6 → Horn air compressor relay (L1) terminal #3
Fuse #7 → Horn air compressor relay (R1) terminal #3
Fuse #8 → Folding stairway relay (1) terminal #3
Folding stairway alarm/flash light (1) terminal #12
Fuse #9 → Limit switch (fluorescent light switch) (electrical equipment box door)
Fuse #10 → Fuse box (Cab)
Fuse #11 → C/U main power left engine terminal #1 (optional)
C/U main power right engine terminal #1 (optional)
Fuse #12 → C/U (Ke-CAN) terminal A optional)

Fuse #1 → Key switch terminal B


Fuse #2 → ELU (main power source)
Fuse box → Fuse #3 → IDU (main power source)
(Cab) Fuse #4 → DLU (main power source)
Fuse #5 → ORBCOMM terminal #2 (main power source) (optional)
Fuse #6 → Radio (backup power source)

NOTE: The LED light in the electrical equipment


box is enabled even when the engine
stops.

T2-5-2
SYSTEM / Electrical System
Limit Switch
(Fluorescent Light Switch) Fuse Box
(Cab)
To MC LED
Delayed Power OFF Relay
Terminals #1 and #3
To EHU Folding Stairway Relay To ELU
MMS (1) Terminal #3 To IDU
Communication Folding Stairway
C/U Main Power Source To DLU
Unit (Optional) Alarm/Flash Light (1)
Terminal #12 Left Engine Terminal #1 ORBCOMM
To HMU Horn Air Compressor (Optional) Terminal #2 (Optional)
Relay (L1) Terminal #3 C/U Main Power Source
Horn Air Compressor Right Engine Terminal #1 To Radio
Relay (R1) Terminal #3 (Optional)
C/U (Ke-CAN)
Terminal A Key Switch
(Optional)
Fuse Box 1

Engine Oil Refill Main


Switch (R) Terminal #1
ECM (L) ECM (R)
(Data Link) (Data Link)
Engine Oil Refill Main
Switch (L) Terminal #1

Fuse Box 3

Folding Stairway Relay (2)

Fusible Link #7

Folding Stairway Relay (3)


Fusible Link #8
Fusible Link 1
Fusible Link #10

Fusible Link (250 A)

Fusible Link (250 A)

Battery Relay (L1)

Battery Relay (L2)

Battery Relay (R1)

Battery Relay (R2)

Battery
Folding Stairway Folding Stairway
Motor 1 Motor 2

T18N-02-05-001

T2-5-3
SYSTEM / Electrical System

Fuse #42 → Engine oil refill main switch (L) terminal #1


Fuse box 3 → Fuse #43 → Engine oil refill main switch (R) terminal #1
Fuse #54 → ECM (L) (data link)
Fuse #55 → ECM (R) (data link)

T2-5-4
SYSTEM / Electrical System
Limit Switch
(Fluorescent Light Switch) Fuse Box
(Cab)
To MC LED
Delayed Power OFF Relay
Terminals #1 and #3
To EHU Folding Stairway Relay To ELU
MMS (1) Terminal #3 To IDU
Communication Folding Stairway
C/U Main Power Source To DLU
Unit (Optional) Alarm/Flash Light (1)
Terminal #12 Left Engine Terminal #1 ORBCOMM
To HMU Horn Air Compressor (Optional) Terminal #2 (Optional)
Relay (L1) Terminal #3 C/U Main Power Source
Horn Air Compressor Right Engine Terminal #1 To Radio
Relay (R1) Terminal #3 (Optional)
C/U (Ke-CAN)
Terminal A Key Switch
(Optional)
Fuse Box 1

Engine Oil Refill Main


Switch (R) Terminal #1
ECM (L) ECM (R)
(Data Link) (Data Link)
Engine Oil Refill Main
Switch (L) Terminal #1

Fuse Box 3

Folding Stairway Relay (2)

Fusible Link #7

Folding Stairway Relay (3)


Fusible Link #8
Fusible Link 1
Fusible Link #10

Fusible Link (250 A)

Fusible Link (250 A)

Battery Relay (L1)

Battery Relay (L2)

Battery Relay (R1)

Battery Relay (R2)

Battery
Folding Stairway Folding Stairway
Motor 1 Motor 2

T18N-02-05-001

T2-5-5
SYSTEM / Electrical System
ACCESSORY CIRCUIT (KEY SWITCH:
ACC)
1. When the key switch is turned to the ACC position,
terminal B in the key switch is connected to
terminal ACC.

2. Current from terminal ACC flows to fuses #13,


#14, #15, and #16 in the fuse box (cab).

3. Current through fuse #13 powers the radio.

4. Current through fuse #14 excites horn air


compressor relays (L2) and (R2), and the horn
relay.

5. Current through horn air compressor relays (L2)


and (R2) excites horn air compressor relays (L2)
and (R2).

6. Current from each relay powers the horn and the


horn compressor.

7. Current through fuse #15 powers the cigarette


lighter.

8. Current through fuse #16 powers power source


terminal (1).

T2-5-6
SYSTEM / Electrical System

Fuse Box 1
Fuse #7
Fuse #6 Fuse Box
(Cab)
Fuse Box 1
Fuse #10

Horn Air Key Switch


Compressor Relay (L2) To Radio
Horn Air
Compressor Relay (L1)
Cigarette
Lighter

Fusible Link 1

Power Source
Terminal (1)

Horn Air Horn Air


Compressor Relay (R2) Compressor Relay (R1)

Horn Relay

Horn Switch

Horn (R) Horn (L)

Horn Air Compressor (R)


Horn Air Compressor (L)

Battery

Horn Pressure
Horn Pressure Switch (L1)
Switch (R1)
Horn Pressure
Horn Pressure Switch (L2)
Switch (R2)
T18N-02-05-002

T2-5-7
SYSTEM / Electrical System
ENGINE START CIRCUIT
Voltage Applied to Starter

1. When the key switch is turned to the ON position,


current from terminal M in the key switch excites
battery relays (L1, L2, R1, and R2) through fuse
#11 in the fuse box (cab) and fuse #26 in fuse box
2.

2. With battery relays (L1, L2, R1, and R2) excited,


current from the battery flows to terminal B of
starters (L1, L2, R1, and R2) of left and right
engines through battery relays (L1, L2, R1, and
R2).

3. Current from terminal M flows to engine start


switches (L) and (R) through fuse #12 in the fuse
box (cab), emergency switches 1 to 7, valve limit
switches (return-U), (return-L), and valve limit
switches (L-suction), (R-suction) respectively.

4. Current from valve limit switches (L-suction) and


(R-suction) flow to ECM (L) and ECM (R) through
engine stop switches (L) and (R) respectively.
Therefore, the engine can start.

T2-5-8
SYSTEM / Electrical System

Air Bleed
Solenoid
ECM (R) Valve
Emergency Switches 1 to 7

ECM (L)

Engine Stop Valve Limit Valve Limit Valve Limit


Switch (R) Switch Switch Switch
(R-Suction) (Return-L) (Return-U)

Valve Limit
Switch
(L-Suction)
Engine Stop
Switch (L)

Alternator (L) Engine Start


Prelub Timer Relay (R) Switch (L)

Starter
(L1)
(Upper
Side)
Prelub Timer Relay (L)
Engine Start
Switch (R)

Starter Fuse Box 3


(L2) Fuse #47
(Lower
Side)
Fusible Link 4

Fuse Box 2
Battery Relay (L1) Fuse #26

Circuit Breaker (L)


(200 A) Battery Relay (L2)
Alternator (R)

Battery Relay (R1)

Circuit Breaker (R)


(200 A) Battery Relay (R2) Fuse Box
(Cab)
Starter (R1)
(Upper Side)

From Battery
Starter (R2)
Key Switch
(Lower Side)
T18N-02-05-003

T2-5-9
SYSTEM / Electrical System
Left Engine Start
• Left engine prelub circuit
1. When engine start switch (L) is pushed, current
from terminal M in the key switch flows to terminal
#3 in prelub timer relay (L) through engine start
switch (R) and operates prelub timer relay (L).

2. Current from terminal #6 in prelub timer relay (L)


excites prelub relay (L).

3. As prelub relay (L) is excited, current from the


battery flows to prelub motor (L) and IDU through
battery relays (L1, L2) and prelub relay (L).

4. Prelub motor (L) rotates and the engine oil


pressure of engine (L) increases.

5. At the same time, IDU lights PRELUB on the


Display TKCA-02-05-001
display.

6. When the engine oil pressure increases, prelub


pressure switch (L) is turned OFF. Consequently,
current from terminal #4 in prelub timer relay (L) is
blocked and prelub timer relay (L) stops flowing
current from terminal #6 to prelub relay (L).
Prelub T18N-02-05-018
7. When current from terminal #6 in prelub timer
relay (L) stops, the excited current to prelub relay
(L) is blocked and prelub relay (L) is turned OFF.
Consequently, current from the battery is blocked
and prelub motor (L) is stopped.

8. At the same time, IDU turns off PRELUB on the


display.

T2-5-10
SYSTEM / Electrical System

From Key Switch


Engine Start Terminal M
Switch (L)
Engine
Start
Switch (R)
Prelub Timer Relay (L)

Prelub Pressure Switch (L)

Prelub Timer Relay (R)

To IDU
Prelub Pressure Switch (R)

Prelub Relay (L)

From
Battery

Prelub Relay (R)

Prelub Motor (L) Prelub Motor (R)

Starter Relay 1 (L) Starter Relay 1 (R)


(Upper Side) (Upper Side)

Starter Relay 1 (L) Starter Relay 1 (R)


(Lower Side) (Lower Side)

T18N-02-05-004

To Starter To Starter
Relay 2 (L) Relay 2 (R)

T2-5-11
SYSTEM / Electrical System
• Left Engine Start Circuit
After the prelub operation, prelub timer relay (L) 9. When engine oil reserve pump unit relay (L) is
flows the excited current to starter relay 1 (L) and excited, current from fusible link 4 to engine oil
starts the engine as follows. reserve pump unit (L) is blocked. Therefore,
engine oil reserve pump unit (L) is turned OFF.
1. Voltage from the battery has already been applied
to terminals B in starters (L1) (upper side) and 10. When the left engine speed is 500 min-1 or more,
(L2) (lower side). Therefore, when current flows to the signal is sent from crank speed sensor (L) to
terminals S in starters (L1) (upper side) and (L2) ECM (L).
(lower side), starters (L1) (upper side) and (L2)
(lower side) can rotate immediately. 11. ECM (L) excites starter relay 2 (L).

2. When the prelub operation finishes, current from 12. As starter relay 2 (L) is excited, the ground circuits
terminal #5 in prelub timer relay (L) flows and in starter relays 1 (L) (upper side) and (lower side)
excites starter relays 1 (L) (upper side) and (lower are blocked. Therefore, current exciting starter
side). relays 1 (L) (upper side) and (lower side) is
blocked.
3. Current from the battery flows to terminals S in
starters (L1) (upper side) and (L2) (lower side) 13. Therefore, as current to terminals S in starters
through battery relays (L1, L2), fusible link 11, (L1) (upper side) and (L2) (lower side) is blocked,
starter relays 1 (L) (upper side), and (lower side) starters (L1) (upper side) and (L2) (lower side) are
respectively. stopped.

4. Current to terminals S in starters (L1) (upper side)


and (L2) (lower side) excites the starter coil and
connects terminal B to terminal M. Consequently,
when the starter rotates, the pinion gear meshes
with the ring gear in the engine while rotating so
that the left engine starts.

5. When the left engine starts, alternator (L) starts


generating.

6. Current from terminal AC in alternator (L) excites


charge relay (L).

7. As charge relay (L) is excited, the ground circuit


between charge SIG relay (L) and engine oil
reserve pump unit relay (L) is connected.
Therefore, charge SIG relay (L) and engine oil
reserve pump unit relay (L) are excited.

8. When charge SIG relay (L) is excited, current


from terminal M in the key switch to MC is blocked.
Therefore, MC detects that the engine starts.

T2-5-12
SYSTEM / Electrical System

From Key Switch


Engine Start Terminal M
Switch (L)
Engine Start
Prelub Timer Relay (L) Switch (R)

Prelub Timer Relay (R)

Fusible Link11 MC

Charge SIG Relay (L)


Starter Relay 1 (L)
(Upper Side)

Starter Relay 1 (L) Engine Oil Reserve


(Lower Side) Fuse Box 3
Fuse #58 Pump Unit Relay (L)

Engine Oil Reserve


Charge Relay (L)
Pump Unit Switch (L)
Starter Relay 2 (L)
From EHU

Fusible Link
4 Fuse Box 2
Fuse #40

ECM (L) Fuse Box 2


Alternator (L) Battery Relay (L1) Fuse #26

Battery Relay (L2)

Battery Relay (R1)


Crank Speed
Sensor (L) Fuse Box 1
Battery Relay (R2) (Cab)

Starter (L1)
(Upper Side)
From
Starter (L2)
Battery Key Switch
(Lower Side)

T18N-02-05-006

T2-5-13
SYSTEM / Electrical System
Right Engine Start
• Right Engine Prelub Circuit
1. When engine start switch (R) is pushed, current
from terminal M in the key switch flows to terminal
#3 in prelub timer relay (R) through engine start
switch (L) and operates prelub timer relay (R).

2. Current from terminal #6 in the prelub timer relay


(R) excites prelub relay (R).

3. As prelub relay (R) is excited, current from the


battery flows to prelub motor (R) and IDU through
battery relays (R1, R2) and prelub relay (R).

4. Prelub motor (R) rotates and the engine oil


pressure of engine (R) increases.
Display TKCA-02-05-001
5. At the same time, IDU lights PRELUB on the
display.

6. When the engine oil pressure increases, prelub


pressure switch (R) is turned OFF. Consequently,
current from terminal #4 in prelub timer relay (R)
is blocked and prelub timer relay (R) stops flowing
current from terminal #6 to prelub relay (R).

7. When current from terminal #6 in prelub timer


relay (R) stops, the excited current to prelub relay
T18N-02-05-018
(R) is blocked and prelub relay (R) is turned OFF.
Consequently, current from the battery is blocked
and prelub motor (R) is stopped.

8. At the same time, IDU turns off PRELUB on the


display.

T2-5-14
SYSTEM / Electrical System

Engine Start Engine Start


Switch (L) Switch (R) From Key
Switch
Terminal M

Prelub Timer Relay (L)

Prelub Pressure Switch (L)

Prelub Timer Relay (R)

Prelub Pressure Switch (R)

Prelub Relay (L)

To IDU

Prelub Relay (R)


From
Battery

Prelub Motor (L) Prelub Motor (R)

Starter Relay 1 (L) Starter Relay 1 (R)


(Upper Side) (Upper Side)

Starter Relay 1 (L) Starter Relay 1 (R)


(Lower Side) (Lower Side)

T18N-02-05-005

To Starter To Starter
Relay 2 (L) Relay 2 (R)

T2-5-15
SYSTEM / Electrical System
• Right Engine Start Circuit
After the prelub operation, prelub timer relay (R) 9. When engine oil reserve pump unit relay (R) is
flows the excited current to starter relay 1 (R) and excited, current from fusible link 4 to engine oil
starts the engine as follow. reserve pump unit (R) is blocked. Therefore,
engine oil reserve pump unit (R) is turned OFF.
1. Voltage from the battery has already been applied
to terminals B in starters (R1) (upper side) and 10. When the right engine speed is 500 min-1 or more,
(R2) (lower side). Therefore, when current flows the signal is sent from crank speed sensor (R) to
to terminals S in starters (R1) (upper side) and ECM (R).
(R2) (lower side), starters (R1) (upper side) and
(R2) (lower side) can rotate immediately. 11. ECM (R) excites starter relay 2 (R).

2. When the prelub operation finishes, current from 12. As starter relay 2 (R) is excited, the ground
terminal #5 in prelub timer relay (R) flows and circuits in starter relays 1 (R) (upper side) and
excites starter relays 1 (R) (upper side) and (lower (lower side) are blocked. Therefore, current
side). exciting starter relays 1 (R) (upper side) and
(lower side) is blocked.
3. Current from the battery flows to terminals S in
starters (R1) (upper side) and (R2) (lower side) 13. Therefore, as current to terminals S in starters
through battery relays (R1, R2), fusible link 9, (R1) (upper side) and (R2) (lower side) is blocked,
starter relays 1 (R) (upper side), and (lower side) starters (R1) (upper side) and (R2) (lower side)
respectively. are stopped.

4. Current to terminals S in starters (R1) (upper side)


and (R2) (lower side) excites the starter coil and
connects terminal B to terminal M. Consequently,
when the starter rotates, the pinion gear meshes
with the ring gear in the engine while rotating so
that the right engine starts.

5. When the right engine starts, alternator (R) starts


generating.

6. Current from terminal AC in alternator (R) excites


charge relay (R).

7. As charge relay (R) is excited, the ground circuit


between charge SIG relay (R) and engine oil
reserve pump unit relay (R) is connected.
Therefore, charge SIG relay (R) and engine oil
reserve pump unit relay (R) are excited.

8. When charge SIG relay (R) is excited, current


from terminal M in the key switch to MC is blocked.
Therefore, MC detects that the engine starts.

T2-5-16
SYSTEM / Electrical System

From Key
Engine Start Switch
Switch (L) Terminal M

Prelub Timer Relay (R)

Engine Start
Switch (R)

Prelub Timer Relay (R)

Fusible Link 9

MC

Charge SIG Relay (R)


Starter Relay 1 (R)
(Upper Side)

Starter Relay 1 (R) Engine Oil Reserve


Fuse Box 3
(Lower Side) Pump Unit Relay (R)
Fuse #59

Engine Oil Reserve


Charge Relay (R) Pump Unit Switch (R)
Starter Relay 2 (R)
From EHU

Fusible Link 4
Fuse Box 2
Fuse #40

Fuse Box 2
Alternator (R) ECM (R) Battery Relay (L1) Fuse #26

Battery Relay (L2)

Battery Relay (R1)

Crank Speed
Sensor (R) Battery Relay (R2) Fuse Box
(Cab)

Starter (R1)
(Upper Side)
From
Battery Key Switch

Starter (R2)
(Lower Side) T18N-02-05-007

T2-5-17
SYSTEM / Electrical System
CHARGING CIRCUIT (KEY SWITCH: ON)
1. When the key switch is in the ON position, 5. Current from terminal B in alternator (R) flows to
terminal B is connected to terminals ACC and M the battery through circuit breaker (R) (200 A),
in the key switch. terminal (R), battery relays (R1, R2), and terminal
(main) so that the battery is charged.
2. Current from terminal M in the key switch flows to
battery relays (L1, L2, R1, and R2) through fuse 6. At the same time, current from each terminal
#11 in fuse box (cab) and fuse #26 in fuse box 2, flows to each circuit through the fusible link, fuse
so that the battery relay is kept ON. boxes 1 to 4, and fuse box (cab).

3. When the engine starts, each alternator starts


rotating and generating electricity.

4. Current from terminal B in alternator (L) flows to


the battery through circuit breaker (L) (200 A),
terminal (L), battery relays (L1, L2), and terminal
(main) so that the battery is charged.

Terminal Connected to Remarks


Terminal (Main) Fusible link 1 (75 A) -
Fusible link 8 ECM (L) power source
Fusible link 7 ECM (R) power source
Folding stairway relays (2), (3) Folding stairway circuit ground signal
Folding stairway motor 1 Power source
Folding stairway motor 2 Power source
Terminal (R) Fusible link 2 -
Fusible link 3 -
Terminal (L) Fusible link 4 -
Fusible link 5 -
Fusible link 6 -

T2-5-18
SYSTEM / Electrical System

To T2-5-27 To T2-5-23
To T2-5-25 To T2-5-21
Fusible Link
Terminal (Main)

Fusible
Link 8

Fusible
Link 7

Terminal (L)
Circuit
Breaker Terminal (R) Circuit Breaker
(L) (200 A) (R) (200 A) Battery Relay (L1)

Battery Relay (L2)

Battery Relay (R1)

Battery Relay (R2)

From From
Alternator (L) Alternator (R)
Terminal B Terminal B From Key Switch
Terminal M

Folding Stairway
Relay (2)
ECM (L)

Folding Stairway
Relay (3)
ECM (R)
Isolation
Battery Switch

Folding Stairway Folding Stairway


Motor 1 Motor 2

T18N-02-05-008

T2-5-19
SYSTEM / Electrical System

Fusible link Through fuse box Connected to Remarks


#1 Fuse box 1 #1 MC terminal #76-55 Main power source
#2 Delayed power OFF terminal #1 Ground circuit
#3 EHU (L) terminal #76-55 Main power source
#4 MMS communication unit (optional) terminal B Main power source
#5 HMU terminal #76-55 Main power source
#6 Horn air compressor relay (L1) terminal #3 Power source
#7 Horn air compressor relay (R1) terminal #3 Power source
#8 Folding stairway relay (1) terminal #3 Power source
Folding stairway alarm terminal #12 Power source
#9 Limit switch (fluorescent light switch) terminal #2 Power source
#10 Fuse box (cab) -
#11 C/U engine (L) (optional) terminal #1 Main power source
C/U engine (R) (optional) terminal #1 Main power source
#12 C/U Ke-CAN (optional) terminal A Main power source
Fuse box 3 #42 Engine oil refill main switch (L) terminal #1 Power source
#43 Engine oil refill main switch (R) terminal #1 Power source
#54 ECM(L) Data link
#55 ECM(R) Data link

Through fuse box Connected to Remarks


Fuse box 1 Fuse box (cab) #1 Key switch terminal B Main power source
Fuse #10 #2 ELU terminals #76-55, #76-56, #76-57 Main power source
#3 IDU terminal CN1-55 Main power source
#4 DLU terminals #76-13, #76-26 Main power source
#5 ORBCOMM (optional) terminal #2 Main power source
#6 Radio terminal #1 Backup

T2-5-20
SYSTEM / Electrical System

Fuse Box (Cab)

Key Switch

To Horn Circuit
Cigarette Lighter

Power Source
Terminal (1)
To T2-5-27
Fuse Box 3
To T2-5-25
Fuse Box 1
To T2-5-23

From T2-5-19

T18N-02-05-009

T2-5-21
SYSTEM / Electrical System

Fusible link Through fuse box Connected to Remarks


#2 Fuse box 2 #31 A/C main relay (front) terminal #3 Power source
#32 A/C main relay (side) terminal #3 Power source
#33 A/C main relay (rear) terminal #3 Power source
Fuse box 3 #56 EHU SOL_VB terminal #48-12 Solenoid power source
#57 EHU PWM_VB terminal #48-13 PWM power source
Fuse box 4 #69 Maintenance light relay 3 terminal #3 Power source
#70 Maintenance light relay 4 terminal #3 Power source
#3 Fuse box 2 #30 Travel alarm terminal A Power source
#34 A/C fan relay (front) terminal #3 Power source
#35 A/C fan relay (side) terminal #3 Power source
#36 A/C fan relay (rear) terminal #3 Power source
Fuse box 3 #48 Power source terminal 1 Power source
#49 DC/DC converter terminal 1+IN Power source
#50 DC/DC converter terminal 2+IN Power source
Fuse box 4 #73 Entrance light relay 1 terminals #1, #3 Power source
#74 Entrance light relay 2 terminal #1 Power source

T2-5-22
SYSTEM / Electrical System
Fuse Box 2

Fuse Box 3

Fuse Box 4

To T2-5-25

To T2-5-27
To T2-5-21

From
T2-5-19
T18N-02-05-010

T2-5-23
SYSTEM / Electrical System

Fusible link Through fuse box Connected to Remarks


#4 Fuse box 2 #37 DLU service tool terminal J Power source
#38 ORBCOMM (optional) terminal #1 Power source
#39 MMS communication unit (optional) terminal A Power source
Fuse box 3 #44 Travel mode selector relay terminal #3 Power source
#45 Folding stairway relay 4 terminals #1, #3 Power source
#46 Dome LED light Power source
(cab/F, R) terminal #2
#47 Emergency switch 1 terminal #8 Power source
#53 ELU PWM power relay (1) terminal #3 Power source
ELU terminal #48-1 Solenoid power source
#58 Engine oil reserve pump unit relay (L) terminals Main power source
#1, #3
#59 Engine oil reserve pump unit relay (R) terminals Main power source
#1, #3
#60 Oil pump Power source
Fuse box 4 #67 Maintenance light relay 1 terminals #1, #3 Power source
#68 Maintenance light relay 2 terminal #3 Power source
#77 Washer motor relay terminal #3 Power source
#78 Fast-filling system relay terminal #3 Power source
#79 CSU terminal #9 Main power source

T2-5-24
SYSTEM / Electrical System
Fuse Box 2

Fuse Box 3

Fuse Box 4

To T2-5-27 To T2-5-23
To T2-5-21

From T2-5-19

T18N-02-05-011

T2-5-25
SYSTEM / Electrical System

Fusible link Through fuse box Connected to Remarks


#5 Fuse box 4 #61 Work light relay 1 terminals #1, #3 Power source
#62 Work light relay 2 terminal #3 Power source
#63 Work light relay 3 terminal #3 Power source
#64 Work light relay 4 terminal #3 Power source
#65 Work light relay 5 terminal #3 Power source
#66 Work light relay 6 terminal #3 Power source
#6 Fuse box 3 #41 Seat suspension air compressor terminal #2 Power source
#51 MC terminal #48-12 Solenoid power source
#52 MC terminal #48-13 PWM power source
Fuse box 4 #71 Maintenance light relay 5 terminal #3 Power source
#72 Maintenance light relay 6 terminal #3 Power source
#75 Wiper motor circuit breaker 1 (10 A)/motor (L) Power source
#76 Wiper motor circuit breaker 2 (20 A)/motor (H) Power source
#80 Maintenance light relay 7 terminal #3 Power source

T2-5-26
SYSTEM / Electrical System
Fuse Box 3

Fuse Box 4

To T2-5-25

To T2-5-23
To T2-5-21

T18N-02-05-012

From T2-5-19

T2-5-27
SYSTEM / Electrical System
ENGINE STOP CIRCUIT
Engine Stopping with Emergency Switch

1. When emergency switches 1 to 7 which are


provided at several locations on the machine are
turned to the emergency stop position, current
from terminal M in the key switch to ECM (L) and
ECM (R) is blocked.

2. ECM (L) and ECM (R) control the electronic


governor in engines (L), (R) and stop supplying
fuel.

3. Engines (L) and (R) stop.

4. At the same time, as current to engine start


switches (L) and (R) are blocked, the starter
motor does not rotate. Therefore, the engine can
not start.

5. Only when emergency switch 1 in the cab is set to


the emergency stop position, the air bleed
solenoid valve of the hydraulic oil tank is operated
and releases the pressure inside the hydraulic oil
tank.

NOTE: The figure in T2-5-29 shows the status


when emergency switch 1 is turned to the
emergency stop position.

T2-5-28
SYSTEM / Electrical System

Emergency
Switch 3 Air Bleed
(Engine Room L1) Solenoid Valve
ECM (R)
Emergency Emergency Emergency
Switch 7 Switch 6 Emergency Switch 1
(Engine Room R) (Engine Room R2) Switch 2 (Cab)
(Engine Room L)

Emergency Emergency
Switch 5 Switch 4
ECM (L) (Engine Room R1) (Engine Room L2)
Engine Stop Valve Valve Limit
Switch (R) Limit Switch Switch
(R Suction) (Return-U)

Valve Limit Switch


Engine Stop (Return-L)
Switch (L)
Valve
Alternator (L) Limit Switch
(L-Suction)

Engine Start
Prelub Timer Relay (R)
Switch (L)

Starter (L1)
(Upper Side)
Engine
Prelub Timer Relay (L) Start
Switch (R)

Starter (L2)
(Lower Side)
Fuse Box 3
Fuse #47

Fusible Link 4
Alternator (R)
Fuse Box 2
Battery Relay (L1) Fuse #26

Circuit Breaker
(L) (200 A) Battery Relay (L2)

Fuse Box
(Cab)
Circuit Breaker
(R) (200 A)
Starter (R1)
(Upper Side) Battery Relay (R1)

Battery Relay (R2)


Starter (R2)
(Lower Side)
From Battery
Key Switch
T18N-02-05-013

T2-5-29
SYSTEM / Electrical System
Engine Stopping with Valve Limit Switch

1. The valve limit switch is provided to the butterfly


valves in the suction piping and the return piping.
When the butterfly valve is closed, the valve limit
switch is turned OFF. So that current from
terminal M in the key switch to ECM (L) and ECM
(R) is blocked.

2. ECM (L) and ECM (R) control the electronic


governor in engines (L) and (R) and stop
supplying fuel.

3. Engines (L) and (R) stop.

4. At the same time, as current to engine start


switches (L) and (R) are blocked, the starter
motor does not rotate. Therefore, the engine can
not start.

NOTE: The figure in T2-5-31 shows the status


when the valve limit switch (return-U) is
OFF.

T2-5-30
SYSTEM / Electrical System

Emergency
Switch 3 Air Bleed
(Engine Room L1) Solenoid Valve
ECM (R)
Emergency Emergency Emergency
Switch 7 Switch 6 Emergency Switch 1
(Engine Room R) (Engine Room R2) Switch 2 (Cab)
(Engine Room L)

Emergency Emergency
Switch 5 Switch 4
ECM (L) (Engine Room R1) (Engine Room L2)
Engine Stop Valve Valve Limit
Switch (R) Limit Switch Switch
(R-Suction) (Return-U)

Valve Limit Switch


Engine Stop (Return-L)
Switch (L)
Valve Limit
Alternator (L) Switch
(L-Suction)

Engine Start
Prelub Timer Relay (R)
Switch (L)

Starter (L1)
(Upper Side)
Engine
Prelub Timer Relay (L)
Start
Switch (R)

Starter (L2)
(Lower Side)
Fuse Box 3
Fuse #47

Fusible Link 4
Alternator (R)
Fuse Box 2
Battery Relay (L1)
Fuse #26

Circuit Breaker (L)


(200 A) Battery Relay (L2)

Fuse Box
(Cab)
Circuit Breaker (R)
(200 A)
Starter (R1)
(Upper Side) Battery Relay (R1)

Battery Relay (R2)


Starter (R2)
(Lower Side) From Battery
Key Switch
T18N-02-05-014

T2-5-31
SYSTEM / Electrical System
Engine Stopping with Engine Stop Switch

1. When engine stop switch (L) or (R) is pushed,


current from terminal M in the key switch, where
the engine stop switch was pushed, to ECM is
blocked.

2. ECM (L) or (R) controls the electronic governor in


the engine and stops supplying fuel.

3. The engine stops.

NOTE: The figure in T2-5-33 shows the status


when engine stop switch (R) is pushed.

T2-5-32
SYSTEM / Electrical System

Emergency
Switch 3 Air Bleed
(Engine Room L1) Solenoid Valve
ECM (R)
Emergency Emergency Emergency
Switch 7 Switch 6 Emergency Switch 1
(Engine Room R) (Engine Room R2) Switch 2 (Cab)
(Engine Room L)

Emergency Emergency
Switch 5 Switch 4
ECM (L) (Engine Room R1) (Engine Room L2)
Engine Stop Valve Valve Limit
Switch (R) Limit Switch Switch
(R-Suction) (Return-U)

Valve Limit Switch


Engine Stop (Return-L)
Switch (L)
Valve Limit
Alternator (L) Switch
(L-Suction)

Engine Start
Prelub Timer Relay (R)
Switch (L)

Starter (L1)
(Upper Side)
Engine
Prelub Timer Relay (L)
Start
Switch (R)

Starter (L2)
(Lower Side)
Fuse Box 3
Fuse #47

Fusible Link 4
Alternator (R)
Fuse Box 2
Battery Relay (L1) Fuse #26

Circuit Breaker (L)


(200 A) Battery Relay (L2)

Fuse Box
Circuit Breaker (R) (Cab)
(200 A)
Starter (R1)
(Upper Side) Battery Relay (R1)

Battery Relay (R2)


Starter (R2)
(Lower Side) From Battery
Key Switch
T18N-02-05-015

T2-5-33
SYSTEM / Electrical System
SURGE VOLTAGE PREVENTION CIRCUIT
When stopping the engine by turning the key switch 5. When the key switch is turned to the ACC or OFF
OFF, current from terminal M in the key switch to position, current from fuse #15 to MC is blocked.
terminal S in the battery relay is blocked and the MC turns the delayed power OFF relay OFF (the
battery relay is turned OFF. When the key switch is ground circuit is blocked) after the duration preset
turned OFF, the engine still coasts for a while, so that in the monitor display is passed.
the alternator is kept generating electricity. In this case,
when the battery relay is turned OFF, as the generated 6. Therefore, after the key switch is turned OFF, the
current from terminal B in the alternator does not flow delayed power OFF relay is kept ON for the
to the battery through terminal B in the battery relay, duration preset in the monitor display so that
surge voltage (voltage buildup) is developed in the current from fuse #2 keeps the battery relay ON.
circuit. In order to protect the electrical equipment such Consequently, the generated current from
as MC from surge voltage, the surge voltage terminal B in left and right alternator flows to the
prevention circuit is provided. battery in order to prevent the occurrence of
surge voltage in the circuit.
1. Current from the battery flows normally to
terminals #1 and #3 in the delayed power OFF
relay. When the key switch is in the ON position,
current from terminal M in the key switch flows to
fuses #15 and #26.

2. Current from fuse #26 flows to terminal S in the


battery relay. Current from fuse #15 flows to MC.
MC recognizes it as power-ON.

3. When current flows to MC, MC grounds current


from terminal #2 in the delayed power OFF relay
to MC terminals #48-9. Therefore, the delayed
power OFF relay is turned ON.

4. Current from terminal #5 in the delayed power


OFF relay flows to terminal S in the battery relay.
When the battery relay is turned ON, current from
terminal B in left and right alternators is charged
in the battery.

T2-5-34
SYSTEM / Electrical System

Fuse Box (Cab)

Fuse #11

Fuse #1

Key Switch
Fuse Box 1

Fuse #2
Fuse Box 2
Delayed Power Fuse #26
OFF Relay Fuse #15
Fuse #10

MC Fusible Link 1

Battery Relay (L1)

Battery Relay (L2)

Battery Relay (R1)

Battery Relay (R2)

Alternator (L)

Battery

Alternator (R)

T18N-02-05-016

T2-5-35
SYSTEM / Electrical System
(Blank)

T2-5-36
MEMO

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MEMO

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SECTION 3
COMPONENT OPERATION

CONTENTS
Group 1 Pump Device Group 5 D Q R Valve
Outline ...................................................... T3-1-1 Outline ...................................................... T3-5-1
Main Pump ............................................... T3-1-2 Port Location ............................................ T3-5-2
Regulator.................................................. T3-1-4 Construction ............................................. T3-5-3
4-Unit Pump ........................................... T3-1-30 Operation .................................................. T3-5-4
Contamination Sensor ............................ T3-1-32
Group 6 Travel Device
Group 2 Swing Device Outline ...................................................... T3-6-1
Outline ...................................................... T3-2-1 Travel Motor.............................................. T3-6-2
Swing Motor ............................................. T3-2-2 Travel Mode Selection .............................. T3-6-4
Swing Parking Brake ................................ T3-2-4 Brake Valve............................................... T3-6-6
Swing Reduction Gear.............................. T3-2-5 Parking Brake ........................................... T3-6-7
Valve Unit ................................................. T3-2-6 Travel Reduction Gear .............................. T3-6-8

Group 3 Control Valve Group 7 Others (Upperstructure)


Outline ...................................................... T3-3-1 Fast-Filling System ................................... T3-7-1
Valve and Valve Section Layout................ T3-3-2 Air Conditioning System............................ T3-7-3
Pilot Port Layout ....................................... T3-3-4 Auto-Lubrication Device............................ T3-7-6
Main Relief Valve...................................... T3-3-6 Oil Cooler Fan Motor................................. T3-7-8
Make-Up Valve ......................................... T3-3-7 Accumulator.............................................. T3-7-9
Hydraulic Circuit ....................................... T3-3-8 EHC Valve .............................................. T3-7-10

Group 4 Control Equipment Group 8 Others (Undercarriage)


Outline ...................................................... T3-4-1 Swing Bearing........................................... T3-8-1
Electric Lever............................................ T3-4-2 Cushion Cylinder ...................................... T3-8-2
EHC Valve (For Electric Lever Control) .... T3-4-6 Accumulator.............................................. T3-8-2
Center Joint .............................................. T3-8-6

KCAT-3-1
(Blank)

KCAT-3-2
COMPONENT OPERATION / Pump Device
OUTLINE
Both right and left engines are equipped with one The main pump is a 2-unit swash plate type variable
pump device. The pump device consists of a trans- displacement plunger pumps and supplies high pres-
mission, a 4-unit pump, and six main pumps. Power sure oil to the main circuit.
from the engine is distributed by gears in the trans- The 4-unit pump consists of one swash plate type
mission and transmitted to each pump. variable displacement plunger pump and three gear
pumps.

Right Engine Left Engine

Main Pump 9 Main Pump 3


(Transmission (Transmission
Side) Side)
Main Pump 10 Main Pump 4
(Pump End (Pump End
Side) Side)

Main Pump 5
Main Pump (Transmission
11(Transmission Side)
Side) Main Pump 6
Main Pump 12 (Pump End
(Pump End Side) Side)
Main Pump Main Pump
7(Transmission 1(Transmission
Side) T117-02-01-001 Side) T117-02-01-001
Main Pump 8 Main Pump 2
4-Unit Pump (Pump End 4-Unit Pump (Pump End
Transmission Side) Transmission Side)

T3-1-1
COMPONENT OPERATION / Pump Device
MAIN PUMP
Construction

The main pump is a swash plate type variable dis- The engine power is transmitted to the shaft via the
placement plunger pump. Each main pump is in- transmission. When the shaft is rotated, both the
stalled on one shaft. Then, two main pumps are ar- cylinder block and plungers are rotated. The plung-
ranged in tandem by connecting each shaft with a ers slide along the shoe plate surface and recipro-
coupling. The cylinder block, in which the plungers cate in the cylinder block bores as the swash plate
are installed, is splined to the shaft. is tilted. Hydraulic oil is drawn or delivered by this
plunger reciprocation.

Main Pumps 1, 3, 5, 7, 9, and 11 Main Pumps 2, 4, 6, 8, 10, and 12

Shaft Servo Piston Servo Piston

Swash Shoe Plunger Cylinder Valve Plate Coupling Valve Plate Cylinder Plunger Shoe Swash
Plate Plate Block Block Plate Plate

T117-02-01-002

T3-1-2
COMPONENT OPERATION / Pump Device
Flow Rate Increasing / Decreasing Operation

The pump delivery flow rate is controlled by chang-


ing the displacement angle of the swash plate, which
changes the plunger stroke. Pressure oil from the
regulator moves the servo piston. As the swash plate
is connected to the servo piston, the displacement
angle of the swash plate is changed according to the
movement of the servo piston.

Servo Piston

Shaft

Valve Plate
Cylinder Block

T117-02-01-003
Plunger

Swash Plate

T3-1-3
COMPONENT OPERATION / Pump Device
REGULATOR
The regulator is located on the pump casing and con-
trols the pump delivery flow rate. Two kinds of the
regulators, one for the main pump and one for the oil
cooler fan motor drive pump, are provided.

Regulator Operation
• Torque Constant Control • Power Decrease Control (Main pump only)
Torque constant control controls the pump deliv- When engine speed is reduced to 1650 min-1 or
ery flow rate according to own pump delivery slower, power decrease control pressure Pf from
pressure (P) in order to maximize utilization of the power decrease solenoid valve minimizes the
the engine horsepower. This control includes the pump displacement angle. Therefore, the pump
following two operations. output is reduced.
(1) Overload Prevention Operation • Power Increase Control (Main pump only)
When own pump delivery pressure (P) in- When engine speed increase to 1850 min-1 or
creases, the pump displacement angle is faster, power increase control pressure Pz from
reduced and the pump delivery flow rate de- the power increase solenoid vale increases the
creases. pump displacement angle. Therefore, the pump
(2) Flow Rate Recovery Operation output is increased.
When own pump delivery pressure (P) de- • Minimum Flow Rate Signal Priority Control
creases, the pump displacement angle is in- When more than two control signals are deliv-
creased and the pump delivery flow rate in- ered to the regulator at the same time, the regu-
crease. lator is controlled by the minimum flow rate sig-
• Flow Rate Control nal.
Regulator for main pump: When a control lever is
operated, flow rate control pressure Pi from the NOTE: The regulator port symbols correspond to
solenoid valve for main pump displacement angle the symbols used on the hydraulic circuit
control changes the pump displacement angle diagram as follows.
and controls the pump delivery flow rate.
Regulator for oil cooler fan motor drive pump: Symbol on Hydraulic
Flow rate control pressure Pi from the oil cooler Regulator Port Symbol
Circuit Diagram
fan speed control solenoid valve changes the Pi i1 to i14
pump displacement angle.
Pf j1, j3, j5, j7, j9, j11
Pz k1 to k12
Psv p1 to p14

T3-1-4
COMPONENT OPERATION / Pump Device

Pi Pf Psv Pz

T141-04-04-004

Pz Psv Pi

P - Own Pump Delivery Pressure Pf - Power Decrease Control Pressure


(from Power Decrease Solenoid Valve)
Psv - Pump Servo Assist Pressure Pz - Power Increase Control Pressure
(from Pilot Pump) (from Power Increase Solenoid Valve)
Pi - Flow Rate Control Pressure
(Main Pump: from Solenoid Valve for Main Pump
Displacement Angle Control,
Oil Cooler Fan Motor Drive Pump: from Oil Cooler Fan
Speed Control Solenoid Valve)

T3-1-5
COMPONENT OPERATION / Pump Device
Section (Main Pump Regulator)

A
B

T18B-02-02-006
A B

Section A-A
1 2 3 4 5 6 7 8 9 1 11

Pi

14 13 12

T117-02-01-006

1- Inner Spring 5- Pin 9 - Pin 12 - Feedback Lever


2- Sleeve 6- Pin 10 - Pilot Piston 13 - Pin
3- Spool 7- Lever 1 11 - Spring 14 - Servo Piston
4- Pin 8- Hole

T3-1-6
COMPONENT OPERATION / Pump Device

Section B-B

15 16 17 18 19 20 21 22 23
Pz

Pf

24

T117-02-01-007

15 - Piston 18 - Pin 21 - Outer Spring 24 - Pin


16 - Compensating Piston 19 - Hole 22 - Inner Spring
17 - Lever 2 20 - Compensating Rod 23 - Piston

T3-1-7
COMPONENT OPERATION / Pump Device
Section (Oil Cooler Fan Motor Drive Pump Regulator)

A
B

A B T146-03-01-004

Section A-A
1 2 3 5 6 25 7 8 9 10 11

Pi

14 13 12

T146-03-01-008

1- Inner Spring 6- Pin 10 - Pilot Piston 13 - Pin


2- Sleeve 7- Lever 1 11 - Spring 14 - Servo Piston
3- Spool 8- Hole 12 - Feedback Lever 25 - Pin
5- Pin 9- Pin

T3-1-8
COMPONENT OPERATION / Pump Device

Section B-B

15 16 17 18 19 20 21 22

24

T146-03-01-005

15 - Piston 18 - Pin 20 - Compensating Rod 22 - Inner Spring


16 - Compensating Piston 19 - Hole 21 - Outer Spring 24 - Pin
17 - Lever 2

T3-1-9
COMPONENT OPERATION / Pump Device
Link Mechanism

• Main Pump Regulation Accordingly, when lever 1 (7) or lever 2 (17) rotates,
Movement of pilot piston (10) is transmitted to lever 1 pin (5) comes in contact with the hole inside on the
(7) via pin (9) and lever 1 (7) rotates around pin (4) rotated lever and feedback lever (12) rotates around
secured in the supporting plug. Movement of com- pin (13) installed in servo piston (14). When servo
pensating rod (20) is transmitted to lever 2 (17) via pin piston (14) is moved, feedback lever (12) is moved via
(24) and lever 2 (17) rotates around pin (18) secured pin (13). As lever 1 (7) and lever 2 (17) do not move at
in the housing. Pin (5) is installed to feedback lever this time, feedback lever (12) rotates around pin (5)
(12) and both ends of pin (5) are inserted into the and spool (3) is moved.
holes on lever 1 (7) and lever 2 (17).

NOTE: : Displacement angle decrease


18 : Displacement angle increase
24
17
Housing 19

12
20
6
5
7
8
4
9

Supporting
3 Plug

13

10

14
T117-02-01-009

3- Spool 7- Lever 1 12 - Feedback Lever 18 - Pin


4- Pin 8- Hole 13 - Pin 19 - Hole
5- Pin 9- Pin 14 - Servo Piston 20 - Compensating Rod
6- Pin 10 - Pilot Piston 17- Lever 2 24- Pin

T3-1-10
COMPONENT OPERATION / Pump Device
Oil Cooler Fan Motor Drive Pump Regulator

Movement of pilot piston (10) is transmitted to lever 1 Accordingly, when lever 1 (7) or lever 2 (17) rotates,
(7) via pin (9) and lever 1 (7) rotates around pin (25) pin (5) comes in contact with the hole inside on the
secured in the supporting plug. Movement of com- rotated lever and feedback lever (12) rotates around
pensating rod (20) is transmitted to lever 2 (17) via pin pin (13) installed in servo piston (14). When servo
(24) and lever 2 (17) rotates around pin (18) secured piston (14) is moved, feedback lever (12) is moved
in the housing. Pin (5) is installed to feedback lever via pin (13). As lever 1 (7) and lever 2 (17) do not
(12) and both ends of pin (5) are inserted into the move at this time, feedback lever (12) rotates around
holes on lever 1 (7) and lever 2 (17). pin (5) and spool (3) is moved.

NOTE: Displacement angle decrease


Displacement angle increase
18
24
17
Housing 19

12
20
6
5
7
8
2
4
9

Supporting
3 Plug

13

10

14 T142-02-01-005

3- Spool 8- Hole 13 - Pin 19 - Hole


5- Pin 9- Pin 14 - Servo Piston 20 - Compensating Rod
6- Pin 10 - Pilot Piston 17 - Lever 2 24 - Pin
7- Lever 1 12 - Feedback Lever 18 - Pin 25 - Pin

T3-1-11
COMPONENT OPERATION / Pump Device
Constant Torque Control
(Main Pump, Oil Cooler Fan Motor Drive Pump)

NOTE: The constant torque control has the two 5. According to movement of servo piston (14), the
following functions. pump displacement angle is reduced so that the
・ Overload Prevention Operation pump delivery flow rate is reduced.
As load (pressure) increases, the pump 6. As servo piston (14) moves, feedback lever (12)
delivery flow rate is reduced so that the is moved via pin (13). As compensating rod (20)
engine is not overloaded. and lever 2 (17) do not move, feedback lever (12)
・ Flow Rate Recovery Operation is rotated around pin (5) counterclockwise and
As load (pressure) decreases, the pump spool (3) is moved to the left. When the notches
delivery flow rate is increased so that on spool (3) and sleeve (2) close thoroughly, own
the engine output can be effectively util- pump delivery pressure P does not act on the
ized. large chamber of servo piston (14) and servo
piston (14) stops moving.
• Overload Prevention Operation 7. Consequently, the pump delivery flow rate de-
creases from Q1 to Q2 and the pump loads is
1. When own pump delivery pressure (P) increases reduced.
from P1 to P2, compensating piston (16) pushes
compensating rod (20) to the right until the oil
pressure force balances with outer spring (21)
and inner spring (22).
2. Compensating rod (20) moves lever 2 (17) via
pin (24). Lever 2 (17) rotates around pin (18) se-
cured in the housing counterclockwise.
3. As pin (5) installed in feedback lever (12) is in-
serted into hole (19) on lever 2 (17), feedback Delivery
Flow
lever (12) is rotated around pin (13) by lever 2 Rate
(17) clockwise and spool (3) is moved to the
right.
4. When spool (3) is moved, own pump delivery
pressure P acts on the large chamber of servo
Delivery Pressure
piston (14) through spool (3). Although own pump T141-03-01-001

delivery pressure P acts on the small chamber,


servo piston (14) moves to the right due to the
difference in the pressure receiving area between
the servo piston ends.

T3-1-12
COMPONENT OPERATION / Pump Device

1 2 16 3 17 18 5 19 20 21 22
Pz

Pf

Small Chamber Pressure


Large Chamber
P2

14 13 12 24

18
24 T117-02-01-010

Housing 17
19

12
20

14

13

T117-02-01-009

1- Spring 12 - Feedback Lever 17 - Lever 2 21 - Outer Spring


2- Sleeve 13 - Pin 18 - Pin 22 - Inner Spring
3- Spool 14 - Servo Piston 19 - Hole 24 - Pin
5- Pin 16 - Compensating Piston 20 - Compensating Rod

T3-1-13
COMPONENT OPERATION / Pump Device
• Flow Rate Recovery Operation

1. When own pump delivery pressure (P) decreases


from P2 to P1, compensating piston (16) returns
with compensating rod (20) together to the left
until the oil pressure force balances with outer
spring (21) and inner spring (22).
2. Compensating rod (20) moves lever 2 (17) via
pin (24). Lever 2 (17) rotates around pin (18) se-
cured in the housing clockwise.
3. As pin (5) installed in feedback lever (12) is in-
serted into hole (19) on lever 2 (17), feedback
lever (12) is rotated around pin (13) by lever (17)
counterclockwise and spool (3) is moved to the
left.
4. When spool (3) is moved, the large chamber of
servo piston (14) is connected to the hydraulic oil
tank through spool (3). As own pump delivery
Delivery
pressure (P) acts on the small chamber, servo Flow
piston (14) moves to the left. Rate
5. According to movement of servo piston (14), the
pump displacement angle increases so that the
pump delivery flow rate increases.
6. As servo piston (14) moves, feedback lever (12)
Delivery Pressure
is moved via pin (13). As compensating rod (20) T141-03-01-001

and lever 2 (17) do not move, feedback lever (12)


is rotated around pin (5) clockwise and spool (3)
is moved to the right. When the notches on spool
(3) and sleeve (2) close thoroughly, the large
chamber of servo piston (14) is not connected to
the hydraulic oil tank and servo piston (14) stops
moving.
7. Consequently, the pump delivery flow rate in-
creases from Q2 to Q1.

T3-1-14
COMPONENT OPERATION / Pump Device

2 16 3 17 18 19 5 20 21 22 Pz

Pf

Large Chamber Small Chamber Pressure


P2

14 13 12 24

Housing 18 T117-02-01-011
24
17
19

20
12

14

13

T117-02-01-009

2- Sleeve 13 - Pin 18 - Pin 21 - Outer Spring


3- Spool 14 - Servo Piston 19 - Hole 22 - Inner Spring
5- Pin 16 - Compensating Piston 20 - Compensating Rod 24 - Pin
12 - Feedback Lever 17 - Lever 2

T3-1-15
COMPONENT OPERATION / Pump Device
Flow Rate Control

• Main Pump Regulator

Flow rate control consists of functions of increasing


flow rate and decreasing flow rate.

• Flow Rate Increasing Function


1. When a control lever is operated, flow rate con-
trol pressure Pi acts on pilot piston (10). As
pressure Pi increases, pilot piston (10) is moved
to the right until pilot piston (10) balances with
spring (11).
2. Pilot piston (10) moves lever 1 (7) via pin (9).
Lever 1 (7) rotates around pin (4) secured in the
supporting plug counterclockwise.
3. As pin (5) installed in feedback lever (12) is in-
serted into hole (8) on lever 1 (7), feedback lever
(12) is rotated around pin (13) by lever 1 (7)
counterclockwise and spool (3) is moved to the
left.
4. When spool (3) is moved, the large chamber of
servo piston (14) is connected to the hydraulic oil
tank through spool (3). As own pump delivery
pressure (P) acts on the small chamber, servo
piston (14) moves to the left.
5. According to movements of servo piston (14), the
pump displacement angle increases so that the
pump delivery flow rate increases.
Delivery
6. As servo piston (14) moves, feedback lever (12) Flow
is moved via pin (13). As pilot piston (10) and Rate
lever 1 (7) do not move, feedback lever (12) is
rotated around pin (5) clockwise and spool (3) is
moved to the right. When the notches on spool
(3) and sleeve (2) close thoroughly, the large
chamber of servo piston (14) is not connected to Flow Rate Control Pressure
the hydraulic oil tank, and servo piston (14) stops T141-03-01-002

moving.
7. Consequently, the pump delivery flow rate in-
creases.

T3-1-16
COMPONENT OPERATION / Pump Device

2 3 4 7 8 5 10 11

Pi

14 13 12 9

Housing T117-02-01-012

12

7
4

Supporting Plug

14

13
10

T117-02-01-009

2 - Sleeve 5 - Pin 9 - Pin 12 - Feedback Lever


3 - Spool 7 - Lever 1 10 - Pilot Piston 13 - Pin
4 - Pin 8 - Hole 11 - Spring 14 - Servo Piston

T3-1-17
COMPONENT OPERATION / Pump Device
• Flow Rate Decreasing Function

1. When a control lever is returned to neutral and


flow rate control pressure Pi is reduced, pilot pis-
ton (10) is moved to the left until pilot piston (10)
balances with spring (11).
2. Pilot piston (10) moves lever 1 (7) via pin (9).
Lever 1 (7) rotates around pin (4) secured in the
supporting plug clockwise.
3. As pin (5) installed in feedback lever (12) is in-
serted into hole (8) on lever 1 (7), feedback lever
(12) is rotated around pin (13) by lever 1 (7)
clockwise and spool (3) is moved to the right.
4. When spool (3) is moved, own pump delivery
pressure (P) acts on the large chamber of servo
piston (14) through spool (3). Although own pump
delivery pressure (P) acts on the small chamber,
servo piston (14) moves to the right due to the
Delivery
difference in the pressure receiving areas be- Flow
tween the servo piston ends. Rate
5. According to movement of servo piston (14), the
pump displacement angle is reduced so that the
pump delivery flow rate is reduced.
6. As servo piston (14) moves, feedback lever (12)
is moved via pin (13). As pilot piston (10) and Flow Rate Control Pressure
lever 1 (7) do not move, feedback lever (12) is T141-03-01-002

rotated around pin (5) counterclockwise and


spool (3) is moved to the left. When the notches
on spool (3) and sleeve (2) close thoroughly, own
pump delivery pressure (P) does not act on the
large chamber of the servo piston (14) and servo
piston (14) stops moving.
7. Consequently, the pump delivery flow rate de-
creases.

T3-1-18
COMPONENT OPERATION / Pump Device

2 3 4 7 5 8 10 11

Pi

14 13 12 9

T117-02-01-013

12

7
5
4

Supporting
Plug
14

13
10

T117-02-01-009
2 - Sleeve 5 - Pin 9 - Pin 12 - Feedback Lever
3 - Spool 7 - Lever 1 10 - Pilot Piston 13 - Pin
4 - Pin 8 - Hole 11 - Spring 14 - Servo Piston

T3-1-19
COMPONENT OPERATION / Pump Device
• Oil Cooler Fan Motor Drive Pump Regulator

Flow rate control consists of functions of increasing


flow rate and decreasing flow rate.

NOTE: Refer to SYSTEM / Hydraulic System / Pi-


lot Circuit and Oil Cooler Fan Motor Circuit.

Flow Rate Decreasing Function (Fan Motor Slow


Speed)

1. Flow rate control pressure Pi from the oil cooler


fan speed control solenoid valve acts on pilot pis-
ton (10). When pressure Pi is high, pilot piston
(10) is moved to the right until pilot piston (10)
balances with spring (11).

2. Pilot piston (10) moves lever 1 (7) via pin (9).


Lever 1 (7) rotates around pin (25) secured in the
supporting plug counterclockwise.
3. As pin (5) installed in feedback lever (12) is in-
serted into hole (8) on lever 1 (7), feedback lever
(12) is rotated around pin (13) by lever 1 (7)
clockwise and spool (3) is moved to the right.
4. When spool (3) is moved, own pump delivery
pressure (P) acts on the large chamber of servo
piston (14) through spool (3). Although own pump
delivery pressure (P) acts on the small chamber,
servo piston (14) moves to the right due to the
difference in the pressure receiving areas be-
tween the servo piston ends.
5. According to movement of servo piston (14), the
pump displacement angle is reduced so that the
pump delivery flow rate is reduced.
6. As servo piston (14) moves, feedback lever (12)
is moved via pin (13). As pilot piston (10) and
lever 1 (7) do not move, feedback lever (12) is
rotated around pin (5) counterclockwise and
spool (3) is moved to the left. When the notches
on spool (3) and sleeve (2) close thoroughly, own
pump delivery pressure (P) does not act on the
large chamber of the servo piston (14) and servo
piston (14) stops moving.
7. Consequently, when flow rate control pressure Pi
is high, the pump delivery flow rate decreases.

T3-1-20
COMPONENT OPERATION / Pump Device

2 3 7 25 5 8 10 11

Pi

14 13 12 9

Housing T146-03-01-006

12

7
25
9 Supporting
3 Plug

13

10
14
T142-02-01-005
2 - Sleeve 7 - Lever 1 10 - Pilot Piston 13 - Pin
3 - Spool 8 - Hole 11 - Spring 14 - Servo Piston
5 - Pin 9 - Pin 12 - Feedback Lever 25 - Pin

T3-1-21
COMPONENT OPERATION / Pump Device
• Flow Rate Increasing Function (Oil Cooler Fan Mo-
tor Fast Speed)

1. Flow rate control pressure Pi from the oil cooler 6. As servo piston (14) moves, feedback lever (12)
fan speed control solenoid valve acts on pilot is moved via pin (13). As pilot piston (10) and
piston (10). When pressure Pi is reduced, pilot lever 1 (7) do not move, feedback lever (12) is
piston (10) is returned to the left until pilot piston rotated around pin (5) clockwise and spool (3) is
(10) balances with spring (11). moved to the right. When the notches on spool
(3) and sleeve (2) close thoroughly, the large
2. Pilot piston (10) moves lever 1 (7) via pin (9). chamber of servo piston (14) is not connected to
Lever 1 (7) rotates around pin (25) secured in the the hydraulic oil tank, and servo piston (14) stops
supporting plug clockwise. moving.

3. As pin (5) installed in feedback lever (12) is in- 7. Consequently, the pump delivery flow rate in-
serted into hole (8) on lever 1 (7), feedback lever creases.
(12) is rotated around pin (13) by lever 1 (7)
counterclockwise and spool (3) is moved to the
left.

4. When spool (3) is moved, the large chamber of


servo piston (14) is connected to the hydraulic oil
tank through spool (3). As own pump delivery
pressure (P) acts on the small chamber, servo
piston (14) moves to the left.

5. According to movements of servo piston (14), the


pump displacement angle increases so that the
pump delivery flow rate increases.

T3-1-22
COMPONENT OPERATION / Pump Device

2 3 5 7 25 8 9 10 11

Pi

14 13 12

Housing T146-03-01-007

12

5
7
25

3 9
Supporting
Plug

13

10
14
T142-02-01-005
2 - Sleeve 7 - Lever 1 10 - Pilot Piston 13 - Pin
3 - Spool 8 - Hole 11 - Spring 14 - Servo Piston
5 - Pin 9 - Pin 12 - Feedback Lever 25 - Pin

T3-1-23
COMPONENT OPERATION / Pump Device
Power Decrease Control (Main Pump Only)

Main pumps (1, 3, 5, 7, 9, and 11) are controlled. 6. As servo piston (14) moves, feedback lever (12)
When engine speed is reduced to 1650 min-1 or is moved via pin (13). As compensating rod (20)
slower, power decrease control pressure Pf from and lever 2 (17) do not move, feedback lever (12)
the power decrease solenoid valve minimizes the is rotated around pin (5) counterclockwise and
pump displacement angle. Therefore, the pump spool (3) is moved to the left. When the notches
output is reduced. on spool (3) and sleeve (2) close thoroughly, own
1. Power decrease control pressure (Pf) acts on pump delivery pressure (P) does not act on the
piston (15). Piston (15) moves compensating large chamber of servo piston (14) and servo
piston (16) and compensating rod (20) to the piston (14) stops moving.
right until they balance with outer spring (21) and 7. Therefore, the pump flow rate and pressure
inner spring (22). curve (P-Q curve) varies as illustrated below.
2. Compensating rod (20) moves lever 2 (17) via Accordingly, constant torque control (overload
pin (24). Lever 2 (17) is rotated around pin (18) prevention operation and flow rate recovery op-
secured in the housing counterclockwise. eration) is performed in conformity with the varied
3. As pin (5) installed in feedback lever (12) is in- P-Q curve.
serted into hole (19) on lever 1 (17), feedback
lever (12) is rotated around pin (13) by lever 2
(17) clockwise and spool (3) is moved to the
right.
4. When spool (3) is moved, own pump delivery
Delivery
pressure (P) acts on the large chamber of servo Flow
piston (14) through spool (3). Although own pump Rate
delivery pressure (P) acts on the small chamber,
servo piston (14) moves to the right due to the
difference in pressure receiving area between the
servo piston ends.
5. According to movement of servo piston (14), the
pump displacement angle is reduced so that the Pump Delivery Pressure
pump delivery flow rate is reduced. T141-03-01-004

T3-1-24
COMPONENT OPERATION / Pump Device

15 2 16 3 17 18 5 19 20 21 22 Pz

Pf

14 13 12 24

Housing 18 T117-02-01-014
24
17
19

20
12

14

13

T117-02-01-009

2- Sleeve 13 - Pin 17 - Lever 2 21 - Outer Spring


3- Spool 14 - Servo Piston 18 - Pin 22 - Inner Spring
4- Pin 15 - Piston 19 - Hole 24 - Pin
12 - Feedback Lever 16 - Compensating Piston 20 - Compensating Rod

T3-1-25
COMPONENT OPERATION / Pump Device
Power increase Control (Main Pump Only)

When engine speed increase to 1800 min-1 or faster, 6. As servo piston (14) moves, feedback lever (12)
power increase control pressure Pz from the power is moved via pin (13). As compensating rod (20)
increase solenoid valve increases the pump dis- and lever 2 (17) do not move, feedback lever (12)
placement angle. Therefore, the pump output is in- is rotated around pin (5) clockwise and spool (3)
creased. is moved to the right. When the notches on spool
(3) and sleeve (2) close thoroughly, the large
1. When power increase control pressure (Pz) in- chamber of servo piston (14) is not connected to
creases, piston (23) moves compensating rod the hydraulic oil tank and servo piston (14) stops
(20) to the left until they balance with own pump moving.
delivery oil pressure (P) acting on compensating 7. Therefore, when power decrease control pres-
piston (16). sure (Pz) acts, the pump flow rate and pressure
2. Compensating rod (20) moves lever 2 (17) via curve (P-Q curve) varies as illustrated below. Ac-
pin (24). Lever 2 (17) is rotated around pin (18) cordingly, constant torque control (overload pre-
secured in the housing clockwise. vention operation and flow rate recovery opera-
3. As pin (5) installed in feedback lever (12) is in- tion) is performed in conformity with the varied
serted into hole (19) on lever 2 (17), feedback P-Q curve.
lever (12) is rotated around pin (13) by lever 2
(17) counterclockwise and spool (3) is moved to
the left.
4. When spool (3) is moved, the large chamber of
servo piston (14) is connected to the hydraulic oil
tank via spool (3). As own pump delivery pres-
Delivery
sure (P) acts on the small chamber, servo piston Flow
(14) moves to the left. Rate
5. According to movement of servo piston (14), the
pump displacement angle increases so that the
pump delivery flow rate increases.

Pump Delivery Pressure


T141-03-01-004

T3-1-26
COMPONENT OPERATION / Pump Device

2 16 3 17 18 19 5 20 21 22 23 Pz

Pf

14 13 12 24

Housing 18 T117-02-01-015
24
17
19

20
12

14

13

T117-02-01-014

2- Sleeve 13 - Pin 18 - Pin 22 - Inner Spring


3- Spool 14 - Servo Piston 19 - Hole 23 - Piston
5- Pin 16 - Compensating Piston 20 - Compensating Rod 24 - Pin
12 - Feedback Lever 17 - Lever 2 21 - Outer Spring

T3-1-27
COMPONENT OPERATION / Pump Device
Minimum Flow Rate Signal Priority Control

When both pump flow rate increase and decrease


signals arrive at the same time, this regulator oper-
ates so that the priority is given to the flow rate de-
crease signal.

The flow rate and the power decrease / increase


control signal pilot pressure are transmitted to feed-
back lever (12) and spool (3) via hole (8 or 19) on
lever 1 (7) or lever 2 (17), and pin (5).
(Refer to Flow Rate Control and Power Decrease /
Increase Control.)

Pin (5) comes in contact with the small displacement


angle side of hole (8 or 19) on lever 1 (7) or lever 2
(17) so that priority is given to flow rate and power
decrease control.

T3-1-28
COMPONENT OPERATION / Pump Device
7 5 8
3

Pi

12
T117-02-01-013

3 17 5 19

Pz

PG

T117-02-01-014
3 - Spool 7 - Lever 1 12 - Feedback Lever 19 - Hole
5 - Pin 8 - Hole 17 - Lever 2

T3-1-29
COMPONENT OPERATION / Pump Device
4-UNIT PUMP
Construction

The 4-unit pump consists of four pumps connected The third pump located from the pump transmission
in tandem. One unit is located in the right and left is a gear pump. The pump on the left engine drives
pump devices. Both side pump units are identical in the air conditioner compressor. The pump on the
construction. However, only the third pump located right engine is an auxiliary gear pump.
from the pump transmission is different in function. The pump located furthest front from the transmis-
The first pump located from the pump transmission sion is a gear pump and supplies the transmission
is a swash plate type variable displacement plunger lubrication oil.
pump and drives the oil cooler fan. The engine power is transmitted to the shaft through
The second pump located from the transmission is a the pump transmission. When the shaft is rotated,
gear pump and supplies pressure oil to the pilot cir- four pumps are rotated at the same time.
cuits.

A B C D

T117-02-01-017

Left 4-Unit Pump Right 4-Unit Pump


A. Oil Cooler Fan Motor Drive Pump (Plunger Pump) A. Oil Cooler Fan Motor Drive Pump (Plunger Pump)
B. Pilot Pump (Tandem Gear Pump) B. Pilot Pump (Tandem Gear Pump)
C. Air Conditioner Compressor Drive Pump (Tandem Gear C. Auxiliary
Pump)
D. Pump Transmission Oil Circulation Pump (Gear Pump) D. Pump Transmission Oil Circulation Pump (Gear Pump)

T3-1-30
COMPONENT OPERATION / Pump Device
Oil Cooler Fan Motor Drive Pump

The oil cooler fan motor drive pump is a plunger


pump. The operational principle is similar to that of
the main pump.

The oil cooler fan motor drive pump regulator con- The operational principle of this regulator is similar to
trols the pump delivery flow rate by changing the that of the main pump with the only difference in the
pump displacement angle when the regulator re- condition under which flow rate control pressure Pi
ceives flow rate control pressure Pi from the oil operates.
cooler fan speed control solenoid valve.

Psv Upper

Right Left

Pi Lower

T118-05-02-026

Psv - Pump Servo Assist Pressure (from Pilot Pump)


Pi - Flow Rate Control Pressure (from Oil Cooler Fan Speed Control Solenoid Valve)

Pilot Pump, Air Conditioner Compressor Drive


Pump / Auxiliary Pump, and Pump Transmission
Oil Circulation Pump
Inlet Port
These pumps are all gear pumps. The shaft drives
the drive gears and the driven gears are driven by Driven Gear Drive Gear
the drive gears. Hydraulic oil drawn into the pump
fills the spaces between the gear teeth and the hous-
ing, and is delivered to the output side along the
housing inner surface.

Housing

Outlet Port

T137-02-03-005

T3-1-31
COMPONENT OPERATION / Pump Device
CONTAMINATION SENSOR
12 main pumps are equipped with one contamination
sensor. When hydraulic oil is contaminated, electrical
resistance of the oil varies and it detects which main
pump has failed.

If hydraulic oil is contaminated with metal pieces, the


sensor magnet attracts metal pieces and the resis-
tance value of current from the contamination sensor
(connector terminal #2) is reduced. CSU checks the
resistance value of current from the contamination Contamination Sensor
sensor. When either valve is below the specification,
T118-05-02-002
CSU lights the indicator LED (yellow) in the cab. At the
same time, CSU sends the signal to IDU through the Terminal #2 Terminal #1
CAN communication and displays the alarm.

The abnormal main pump can be identified by check-


ing 12 indicators on the contamination sensor ampli-
fier.

NOTE: The CSU is located in the controller box.


NOTE: Besides the main pumps, the following de-
vices are equipped with the contamination
sensors.
Swing Motor: On the upper of each swing
motor (4 used in total)
Travel Motor: On the upper of the center
joint (commonly used for the right and left
travel motors)

Magnet

T18G-03-01-017

T3-1-32
COMPONENT OPERATION / Swing Device
OUTLINE
The swing device consists of the valve unit, the swing The swing motor is driven by the pressure oil from the
motor, and the swing reduction gear. pump and transmits its output to the reduction gear.
The swing reduction gear is a planetary gear type. It
converts the swing motor output to slow large torque
and outputs it to the shaft. The valve unit has a built-in
relief valve which protects the swing circuit from being
overloaded.

Valve Unit

Swing Motor

Swing
Reduction
Gear

T144-03-02-001

T3-2-1
COMPONENT OPERATION / Swing Device
SWING MOTOR
The swing motor consists of the parking brake section The swing motor is a swash plate type axial plunger
and the motor section. motor.
It consists of shaft (4), swash plate (3), shoe (2),
The parking brake is a wet-type spring set hydraulic plunger (5), rotor (6), valve plate (7), housing (1), and
released multi-disc brake and mainly consists of brake the parking brake. Shoe (2) is crimped on plunger (5)
piston (10), friction plate (8), and plate (9). which is inserted into rotor (6). Rotor (6) is splined to
shaft (4).

Parking
Brake
8

6 1

5
2

3 Motor

W117-02-04-005

1- Housing 4 - Shaft 7 - Valve Plate 9 - Plate


2- Shoe 5 - Plunger 8 - Friction Plate 10 - Brake Piston
3- Swash Plate 6 - Rotor

T3-2-2
COMPONENT OPERATION / Swing Device
Operational Principle

Swing speed varies depending on the amount of


pressure oil delivered to the swing motor. When
pressure oil is delivered to port A, the plungers are
pushed so that the shoes slide along the swash
plate and develops the rotation force. This rotation
force is transmitted to the swing reduction gear
through the shaft. The returning oil flows back to the
hydraulic oil tank from port B at the opposite side. If
pressure oil is delivered from port B, the motor ro-
tates in the opposite direction.

Plunger

Shoe

T115-02-03-003

Swash Plate Shaft

T3-2-3
COMPONENT OPERATION / Swing Device
SWING PARKING BRAKE
Construction
The swing parking brake consists of coupling (4),
friction plate (5), plate (6), piston (2), and spring (1).
Coupling (4) is splined to shaft (3). Plate (6) is
splined to coupling (4). Friction plate (5) is splined
to casing (7).

Operation
When the pilot shut-off lever is in the LOCK position,
the brake release pressure is not routed to the pis-
ton chamber. Therefore, piston (2) is pushed by Pilot Shut-Off So- 1
Swing Motor
spring (1). As friction plate (5) and plate (6) are se- lenoid Valve
(UNLOCK
cured together, shaft (3) does not rotate. Position)
When the pilot shut-off lever is in the UNLOCK po- 2
3
sition, the brake release pressure is routed to the
piston chamber. Therefore, piston (2) is raised
against spring (1). Then, friction plate (5) is re- Relief Valve
leased from plate (6), and shaft (3) can rotate. 3.9 MPa
2
(40 kgf/cm , Brake Release Pressure:
569 psi) More than 2,6 MPa
2
(27 kgf/cm , 569 psi)
Pilot Pump T18N-03-02-001

1 2 3 4

Piston Chamber

Brake Release
6 Pressure (from Pilot
Shut-Off Valve)

T144-03-02-002

1 - Spring 3 - Shaft 5 - Friction Plate 7 - Casing


2 - Piston 4 - Coupling 6 - Plate

T3-2-4
COMPONENT OPERATION / Swing Device
SWING REDUCTION GEAR
The swing reduction gear is a two-stage planetary
reduction gear. The shaft of the swing motor rotates
first stage sun gear (7), whose rotation is transmitted
to second stage sun gear (5) after rotation speed is
reduced between first stage planetary gear (1) and
first stage carrier (6). The rotation of second stage sun
gear (5) is transmitted to shaft (3) after rotation speed
is reduced between second stage planetary gear (2)
and second stage carrier (4).

2
5

T117-02-02-007

1 - First Stage Planetary Gear 3 - Shaft 5 - Second Stage Sun Gear 7 - First Stage Sun Gear
2 - Second Stage Planetary 4 - Second Stage Carrier 6 - First Stage Carrier
Gear

T3-2-5
COMPONENT OPERATION / Swing Device
VALVE UNIT
The valve unit consists of relief valve (2) and make-up Then, when the pressure at port AV (BV) increases
valve (1). further, the pressure in piston chamber (9) moves
piston (6) to the left and increases the spring (5)
Relief Valve force.
When piston (6) reaches the stroke end, the spring
The relief valve prevents the swing circuit pressure (5) force stops increasing.
from increasing over the set pressure when starting Then, when the pressure at port AV (BV) increases
or stopping the swing operation. more than spring (5) force, main poppet (4) is
When the pressure at port AV (BV) increases, the opened again and the pressure oil flows from port
pressure is routed to piston chamber (9) through AV (BV) to the hydraulic oil tank.
orifice (3) of main poppet (4) and acts on pilot pis- As described above, main poppet (4) is opened in
ton (7). When the pressure (force) overcomes the two stages so that shock loads in the circuit are re-
spring (8) force, and pilot piston (7) is moved to the duced.
right, the pressure in piston chamber (9) is reduced.
The differential pressure arises between the front Make-Up Valve
and the rear of main poppet (4). Therefore, if the
pressure of main poppet (4) overcomes the spring When the swing motor is driven by inertia force of
(5) force due to this differential pressure, main the upperstructure when stopping the swing opera-
poppet (4) is opened and the pressure oil flows tion, the swing motor is rotated more than the
from port AV (BV) to the hydraulic oil tank. When stroke driven by the oil pressure from the pump, so
pilot piston (7) is moved to full stroke, the differential that cavitation occurs in the swing motor. The
pressure between the front and the rear of main make-up valve draws hydraulic oil from port M (re-
poppet (4) disappears so that main poppet (4) is turn circuit) in order to supply insufficient oil so that
closed. the occurrence of cavitation is prevented.

Make-Up Circuit

Port AV (BV)
to Hydraulic Oil Tank T117-02-02-003

T3-2-6
COMPONENT OPERATION / Swing Device

Relief Valve
3 4 5 6 7 8

Port AV (BV)

To Hydraulic Oil Tank


9 T117-02-02-004

Make-Up Valve
10 11

Make-Up Circuit

Port AV (BV) T117-02-02-005

1 - Make-Up Vale 4 - Main Poppet 7 - Pilot Piston 10 - Poppet


2 - Relief Valve 5 - Spring 8 - Spring 11 - Spring
3 - Orifice 6 - Piston 9 - Piston Chamber

T3-2-7
COMPONENT OPERATION / Swing Device
(Blank)

T3-2-8
COMPONENT OPERATION / Control Valve
OUTLINE
The control valve regulates oil pressure, flow rate and
direction in the main hydraulic circuit. One main relief
valve is provided on each of 6 control valves. The
control valve consists of four valve sections. The ma-
jor parts of the control valve are the overload relief
valve, the make-up valve, and the spools. Each spool
is operated by pilot oil pressure.

T3-3-1
COMPONENT OPERATION / Control Valve
VALVE AND VALVE SECTION LAYOUT

NOTE: The illustration shows the control valve viewed from the front side.
Control Valve 4 (Upper Right) Control Valve 1 (Upper Left)
Make-Up Valve Make-Up Valve
Overload
Relief Valve
13
1

14
2
Overload
Relief Valve
3 15

4 16

Main Relief Main Relief Overload


Valve Valve Relief Valve

T118-05-02-044 T118-05-02-041
Control Valve 5 (Center Right) Control Valve 2 (Center Left)
Make-Up Valve Make-Up Valve
Overload
Relief Valve
Main Relief
Valve
5 17

6 Overload 18
Relief Valve
7 19

8 20

Main Relief Overload


Valve Relief Valve

T118-05-02-045 T118-05-02-042

Control Valve 6 (Lower Right) Control Valve 3 (Lower Left)


Make-Up Valve Make-Up Valve
Overload
Relief Valve Main Relief
Valve
9 21

10 Overload 22
Relief Valve
11 23

12 24

Main Relief
Overload
Valve
Relief Valve

T118-05-02-046 T118-05-02-043

T3-3-2
COMPONENT OPERATION / Control Valve

Control Valve 4 (Upper Right) Control Valve 1 (Upper Left)


1 - Arm Section 13 - Bucket Section
2 - Bucket Open/Close Section (Only LD) 14 - Boom Lower/Arm Extend (LD), Arm Roll-In (BH) Section
3 - Boom Raise/Bucket Tilt-In (LD), Bucket Roll-In (BH) Sec- 15 - Boom Section
tion
4 - Left Travel Section 16 - Swing Section

Control Valve 5 (Center Right) Control Valve 2 (Center Left)


5 - Bucket Section 17 - Left Travel Section
6 - Boom Section 18 - Boom Raise/Bucket Tilt-In (LD), Bucket Roll-In (BH)
Section
7 - Arm Section 19 - Bucket Open/Close Section (Only LD)
8 - Right Travel Section 20 - Arm Section

Control Valve 6 (Lower Right) Control Valve 3 (Lower Left)


9- Bucket Section 21 - Right Travel Section
10 - Boom Lower/Arm Extend (LD), Arm Roll-In (BH) Section 22 - Arm Section
11 - Boom Section 23 - Boom Section
12 - Swing Section 24 - Bucket Section

NOTE: LD: Loading Shovel


BH: Backhoe

T3-3-3
COMPONENT OPERATION / Control Valve
PILOT PORT LAYOUT

NOTE: The illustration shows the control valve viewed from the front side.

Control Valve 4 (Upper Right) Control Valve 1 (Upper Left)

1 5 25 29

2 6 26 30

3 7 27
31

4 8 28 32

T118-05-02-044 T118-05-02-041
Control Valve 5 (Center Right) Control Valve 2 (Center Left)

9 13
33 37
10 14
34 38
11 15
35 39
12 16
36 40

T118-05-02-045 T118-05-02-042

Control Valve 6 (Lower Right) Control Valve 3 (Lower Left)

17 21
41 45
18 22
42 46
19 23
43 47
20 24
44 48

T118-05-02-046 T118-05-02-043

T3-3-4
COMPONENT OPERATION / Control Valve

Control Valve 4 (Upper Right) Control Valve 1 (Upper Left)


1- Arm Extend (LD), Arm Roll-In (BH) 25 - Bucket Tilt-Out (LD), Bucket Roll-Out (BH)
2- Bucket Open (Only LD) 26 - Boom Lower
3- Boom Raise 27 - Boom Lower
4- Left Travel Reverse 28 - Right Swing
5- Arm Retract (LD), Arm Roll-Out (BH) 29 - Bucket Tilt-In (LD), Bucket Roll-In (BH)
6- Bucket Close (Only LD) 30 - Arm Extend (LD), Arm Roll-In (BH)
7- Bucket Tilt-In (LD), Bucket Roll-In (BH) 31 - Boom Raise
8- Left Travel Forward 32 - Left Swing

Control Valve 5 (Center Right) Control Valve 2 (Center Left)


9- Bucket Tilt-In (LD), Bucket Roll-In (BH) 33 - Left Travel Forward
10 - Boom Lower 34 - Bucket Tilt-In (LD), Bucket Roll-Out (BH)
11 - Arm Extend (LD), Arm Roll-In (BH) 35 - Bucket Close (Only LD)
12 - Right Travel Forward 36 - Arm Retract (LD), Arm Roll-Out (BH)
13 - Bucket Tilt-Out (LD), Bucket Roll-Out (BH) 37 - Left Travel Reverse
14 - Boom Raise 38 - Boom Raise
15 - Arm Retract (LD), Arm Roll-Out (BH) 39 - Bucket Open (Only LD)
16 - Right Travel Reverse 40 - Arm Extend (LD), Arm Roll-In (BH)

Control Valve 6(Lower Right) Control Valve 3 (Lower Left)


17 - Bucket Tilt-In (LD), Bucket Roll-In (BH) 41 - Right Travel Reverse
18 - Boom Lower 42 - Arm Retract (LD), Arm Roll-Out (BH)
19 - Boom Lower 43 - Boom Raise
20 - Right Swing 44 - Bucket Tilt-Out (LD), Bucket Roll-Out (BH)
21 - Bucket Tilt-Out (LD), Bucket Roll-Out (BH) 45 - Right Travel Forward
22 - Arm Extend (LD), Arm Roll-In (BH) 46 - Arm Extend (LD), Arm Roll-In (BH)
23 - Boom Raise 47 - Boom Lower
24 - Left Swing 48 - Bucket Tilt-In (LD), Bucket Roll-In (BH)

NOTE: LD: Loading Shovel


BH: Backhoe

T3-3-5
COMPONENT OPERATION / Control Valve
MAIN RELIEF VALVE OVERLOAD RELIEF VALVE
The main relief valve is located in the circuit between port The overload relief valves are located in the circuit
P (pump port) and port T (tank port) and prevents the pres- between the actuator port and port T (tank port) and
sure in the main circuit from rising higher than the set prevents the pressure oil in cylinders and motors
pressure. The pressure oil in pump port P acts on pilot from rising higher than the set pressure. Operational
poppet (7) through orifice (2) in main poppet (1) and orifice principle of the overload relief valve is the same as
(6) in sleeve (5). the main relief valve.
When the oil pressure increases higher than spring (8) set
pressure, pilot poppet (7) opens and a small quantity of
pressure oil flows to port T through the outer surface of
sleeve (9). At this time, a pressure difference arises be-
tween port P and spring chamber (4). If the force to push
main poppet (1) rightward due to the pressure difference
overcomes the spring (3) force, main poppet (1) opens
and the pressure oil in port P directly flows to port T. When
the pressure oil in port P decreases, main poppet (1) is
closed again by the spring (3) force.

NOTE: The main relief valve and the over load relief
valve are similar in form and construction.

1 2 3 4 5 6 7 8

Port P

Port T

T145-02-03-001

1 - Main Poppet 3 - Spring 5 - Sleeve 7 - Pilot Poppet


2 - Orifice 4 - Spring Chamber 6 - Orifice 8 - Spring
9 - Sleeve

T3-3-6
COMPONENT OPERATION / Control Valve
MAKE-UP VALVE
The make-up valves are located in the circuit between the
actuator port and port T (tank port). It draws hydraulic oil
from port T when the pressure oil decreases lower than
that in the hydraulic oil tank.
The pressure oil in the actuator port acts on poppet (1). As
poppet (1) is kept in contact with sleeve (2), pressure oil
cannot flow to port T. When the pressure oil in the actuator
port decreases lower than that in the hydraulic oil tank, the
pressure oil from port T opens poppet (1) and flows to the
actuator port so that cavitation is prevented. When the
pressure oil in the actuator port increases again, poppet
(1) is closed by the pressure oil acting on poppet (1) and
the spring (3) force.

1 2 3

Actuator Port

Port T
T145-02-03-002

1 - Poppet 2 - Sleeve 3 - Spring

T3-3-7
COMPONENT OPERATION / Control Valve
HYDRAULIC CIRCUIT Control Valve 4(Upper Right)
Control Valve 1 (Upper Left)
Arm
Bucket
Parallel Bucket Open/Close (only LD)
Arm Extend (LD), Circuit
Arm Roll-In (BH) / Boom Raise / Bucket Tilt-In
Boom Lower (LD), Bucket Roll-In (BH)

Boom Left Travel

Port T
Swing
Control Valve 5 (Center Right)
Port T Port P
Bucket
Control Valve 2
(Center Left)
Boom
Left Travel Parallel
Circuit Arm
Boom Raise/Bucket Tilt-In
(LD), Bucket Roll-In (BH)
Right Travel
Bucket Open/Close
(only LD)

Arm
Port T

Port P Control Valve 6 (Lower Right)


Port T

Control Valve3 Bucket


(Lower Left)
Parallel Arm Extend (LD),
Right Travel Circuit Arm Roll-In (BH) /
Arm Boom Lower

Boom
Boom
Swing

Bucket
Port T
Port P

MP6 MP2 MP4


MP12 MP8 MP10
MP5 MP1 MP3
MP3 MP11 MP7 MP9
MP4
MP1 MP7 MP9
MP2 MP8 MP10
MP5
MP6 MP11
MP12

Main Pump Front Main Pump Front T118-02-02-002

View (Left Engine) View (Right Engine)


NOTE: LD: Loading Shovel
BH: Backhoe

T3-3-8
COMPONENT OPERATION / Control Valve
The pressure oil from the main pumps is regulated by 6 The circuit in the control valve consists of tandem
control valves as follows: and parallel circuits. As the parallel circuit is pro-
• Control Valve 1 (Upper Left): vided, combined operation of cylinder(s) and mo-
If controls pressure oil from main pumps MP5 and MP6. tor(s) can be performed. Parallel circuits are located
• Control Valve 2 (Center Left): in each control valve as follows:
If controls pressure oil from main pumps MP3 and MP4. • Control Valve 1 (Upper Left):
• Control Valve 3 (Lower Left): Swing and Boom Sections
If controls pressure oil from main pumps MP1 and MP2. • Control Valve 2 (Center Left):
• Control Valve 4 (Upper Right): Boom Raise/Bucket Tilt-In (LD): Bucket Roll-In
If controls pressure oil from main pumps MP7 and MP8. (BH), Bucket Open/Close (only LD), and Arm Sec-
• Control Valve 5 (Center Right): tions
If controls pressure oil from main pumps MP9 and • Control Valve 3 (Lower Left):
MP10. Arm, Boom, and Bucket Sections
• Control Valve 6 (Lower Right): • Control Valve 4 (Upper Right):
If controls pressure oil from main pumps MP11 and Bucket Tilt-In (LD): Bucket Roll-In (BH)/Boom
MP12. Raise, Bucket Open/Close (only LD), and Arm
Sections
When the spools are in neutral (the control levers are in • Control Valve 5 (Center Right):
neutral), the pressure oil from the main pumps returns to Arm, Boom, and Bucket Sections
the hydraulic oil tank through the neutral circuit. When the • Control Valve 6 (Lower Right):
spools are operated (the control levers are operated), the Swing and Boom Sections
pressure oil from main pumps flows to cylinders and the
motors through the spools. The main relief valve prevents the pressure in the
main circuit (between the main pump and cylinders
and/or motors) from rising higher than the set pres-
sure.
The overload relief valve protects the circuits be-
tween the control valves and cylinders and/or mo-
tors from surge pressures developed by external
loads.

NOTE: LD: Loading Shovel


BH: Backhoe

T3-3-9
COMPONENT OPERATION / Control Valve
(Blank)

T3-3-10
COMPONENT OPERATION / Control Equipment
OUTLINE
The spools in the control valves are operated by the
electric lever, ELU, and the EHC valve (for electric
lever control).
DQR Valve

Electric Lever
Spool

Port T

ELU
Port P
Pilot
Pump Actuator
From Pilot Shut-Off
Solenoid Valve Control Valve

Spring
EHC Valve
(For Electric Lever Control)

Spool Main Pump Hydraulic Oil Tank T18G-02-02-002

T3-4-1
COMPONENT OPERATION / Control Equipment
ELECTRIC LEVER
When operating the electric lever, command current is
sent to ELU according to the lever stroke by the con-
troller.

Front Attachment, Swing

-
15° 15°

Controller +
To ELU
X TKCA-03-04-001

T3-4-2
COMPONENT OPERATION / Control Equipment
Front Attachment, Swing

90%±2%
+4 %
88% -2% Short Zone

Output Voltage Ratio


About 3°

50%±1.5%

+2 %
12% -4%

10%±2%

Center

±15°

Mechanical Control
Angle

1 3
Short Zone 4 Short Zone

Resistor for Calibration 30°±5° Resistor for Calibration

Electrical Turning Angle

Total Resistance 2 kΩ±15%

+ Direction on Axis XY TKCA-03-04-002

Color of Connecting Terminal


(ISO Lever Pattern)
Left Lever Right Lever
Terminal Swing Arm Boom Bucket
#1 Black Black Black Black
#2 Yellow White Yellow White
#3 Red Red Red Red
#4 Blue Brown Blue Brown

T3-4-3
COMPONENT OPERATION / Control Equipment
Travel, Bucket Open/Close
12.4°±1° 12.4°±1°

Controller

To ELU

T18G-03-04-002

T3-4-4
COMPONENT OPERATION / Control Equipment
Travel
(Control Curve: 25±5°C (77±9°F))

Control Torque Output Voltage Ratio


N⋅m v
100
16.0 VOUT
15.3±2.3 80±7.5

Output
12.0 50±5
Voltage
Ratio
20±7.5
8.0 0
6.5±1.0 12.4±1 0 12.4±1 deg

4.0 T18M-03-04-004

Neutral Switch Voltage


0
12.4±1 0 12.4±1 deg
T18M-03-04-003

deg
T18G-03-04-006

Bucket Open/Close
(Control Curve: 25±5°C(77±9°F))

Control Torque Output Voltage Ratio


N⋅m v
100
16.0 VOUT
80±7.5

Output
12.0 50±5
Voltage
Ratio
9.3±1.4 20±7.5
8.0
0
12.4±1 0 12.4±1 deg
4.0 T18M-03-04-004
3.9±0.6

0 Neutral Switch Voltage


12.4±1 0 12.4±1 deg
T18L-03-04-001

deg
T18G-03-04-006

T3-4-5
COMPONENT OPERATION / Control Equipment
EHC VALVE (FOR ELECTRIC LEVER CONTROL)
The EHC valve consists of eight proportional solenoid valves.

EHC Valve (Upper Side)

1 2 3 4

5 6 7 8
T18N-03-04-001

EHC Valve (Lower Side)

9 10 11 12

13 14 15 16 T18N-03-04-002

1 - LD: Bucket Close Sole- 5- Right Travel Reverse 9- LD: Arm Extend Solenoid Valve 13 - Auxiliary
noid Valve Solenoid Valve BH: Arm Roll-In Solenoid Valve
BH: Auxiliary
2 - Right Swing Solenoid 6- Right Travel Forward 10 - LD: Arm Retract Solenoid Valve 14 - Auxiliary
Valve Solenoid Valve BH: Arm Roll-Out Solenoid
Valve
3 - Left Swing Solenoid Valve 7- Left Travel Reverse 11 - Boom Raise Solenoid Valve 15 - LD: Bucket Tilt-Out Solenoid
Solenoid Valve Valve
BH: Bucket Roll-Out Sole-
noid Valve
4 - LD: Bucket Open Sole- 8- Left Travel Forward 12 - Boom Lower Solenoid Valve 16 - LD: Bucket Tilt-In Solenoid
noid Valve Solenoid Valve Valve
BH: Auxiliary BH: Bucket Roll-In Solenoid
Valve

NOTE: LD: Loading Shovel


BH: Backhoe

T3-4-6
COMPONENT OPERATION / Control Equipment
Proportional Solenoid Valve
The proportional solenoid valve is controlled by a
current signal from ELU and delivers pressure in
proportion to current.

• When in neutral:
Spool (1) is pushed to the right by spring (2). Output
port (S) is connected to tank port (T3).

• When excited:
Solenoid (3) pushes spool (1) to the left in proportion
to current through solenoid (3).
Pilot pressure oil flows to output port (S) from port
(P) and pressure at output port (S) increases.
This pressure at output port (S) acts on step part (a)
of spool (1).
Spool (1) is pushed to the right due to the pressure
receiving area difference of step part (a).
When pressure at output port (S) increases and
overcomes the force to push spool (1) to the right,
spool (1) is moved back to the right. The oil passage
from port (P) to output port (S) is closed.
Then, pressure at output port (S) stops increasing.

T3 S P 1 2 3

a
T107-02-07-005

1 - Spool 2 - Spring 3 - Solenoid

T3-4-7
COMPONENT OPERATION / Control Equipment
(Blank)

T3-4-8
COMPONENT OPERATION / DQR Valve
OUTLINE
The DQR (Dual Quick Response) valve improves the Then, pressure oil from the pilot pump directly is routed
response characteristics of the control valve spool to the control valve spool ends so that the control valve
when the control lever is operated. A large amount of spools are moved.
pilot pressure oil is required in order to move the Two DQR valves are provided on the pilot panel (L),
spools in the maximum 6 units of the control valves. the structure and operation of their valves are the
Therefore, secondary pilot pressure from the EHC same.
valve operates the DQR valve.

DQR Valve

TKCA-03-05-001

T3-5-1
COMPONENT OPERATION / DQR Valve
PORT LOCATION

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

DQR Valve 2

16

17

DQR Valve 1

T18N-03-05-002

32 31 30 29 28 27 26 25 24 23 22 21 20 19 18

1 - Port P 9- Boom Lower Port 17 - Port T 25 - LD: Arm Retract Port


(From Pilot Pump) (To Control Valve) (To Hydraulic Oil Tank) BH: Arm Roll-Out Port
(To Control Valve)
2 - Right Travel Forward Port 10 - LD: Bucket Tilt-In Port 18 - Right Swing Port 26 - LD: Arm Extend Port
(From EHC Valve) BH: Bucket Roll-In Port (From EHC Valve) BH: Arm Roll-In Port
(From EHC Valve) (To Control Valve)
3 - Right Travel Forward Port 11 - LD: Bucket Tilt-In Port 19 - Right Swing Port 27 - LD: Arm Extend Port
(To Control Valve) BH: Bucket Roll-In Port (To Control Valve) BH: Arm Roll-In Port
(To Control Valve) (From EHC Valve)
4 - Bucket Open Port (Only LD) 12 - Left Travel Forward Port 20 - Bucket Close Port (Only LD) 28 - Left Travel Reverse Port
(From EHC Valve) (From EHC Valve) (From EHC Valve) (To Control Valve)
5 - Bucket Open Port (Only LD) 13 - Left Travel Forward Port 21 - Bucket Close Port (Only LD) 29 - Left Travel Reverse Port
(To Control Valve) (To Control Valve) (To Control Valve) (From EHC Valve)
6 - Boom Raise Port 14 - Left Swing Port 22 - LD: Bucket Tilt-Out Port 30 - Right Travel Reverse Port
(From EHC Valve) (To Control Valve) BH: Bucket Roll-Out Port (To Control Valve)
(From EHC Valve)
7 - Boom Raise Port 15 - Left Swing Port 23 - LD: Bucket Tilt-Out Port 31 - Right Travel Reverse Port
(To Control Valve) (From EHC Valve) BH: Bucket Roll-Out Port (From EHC Valve)
(To Control Valve)
8 - Boom Lower Port 16 - Port T 24 - LD: Arm Retract Port 32 - Port P
(From EHC Valve) (To Hydraulic Oil Tank) BH: Arm Roll-Out Port (From Pilot Pump)
(From EHC Valve)

NOTE: LD: Loading Shovel


BH: Backhoe

T3-5-2
COMPONENT OPERATION / DQR Valve
CONSTRUCTION
The DQR valve is the 7-spool type and consists of the NOTE: The following figure shows the valve status
adapter, the spool, and the spring. when the control lever is in neutral.

A A A A A A A

A A A A A A A

Signal Port
(From EHC Valve)
Adapter

Spool
Port T
(To Hydraulic Oil Tank)
Output Port
(To Control Valve
Spool End)
Plug

Port P Spring
(From Pilot Pump)
Plug
Section
A to A T18M-03-05-004

T3-5-3
COMPONENT OPERATION / DQR Valve
OPERATION
When the control lever is in neutral:
The spool in the DQR valve is kept raised by the
spring so that pressure oil from port P is fully blocked
by the spool.
As the output port is connected to port T, pressure in
the output port is equal to that in the hydraulic oil
tank.
Accordingly, the control valve is kept in neutral.

When the control lever is operated:


When a control lever is operated, the signal pressure
from EHC valve is routed to the DQR valve in re-
sponse to the control lever strokes and the spool is
pushed downward.
Pilot pump pressure oil from port P passes through
the notch on the spool and flows to the output port so
that pressure in the output port increases.
Pressure oil in the output port is also routed to the
spring chamber through the passage in the spool.
As the spool section area on which the signal pres-
sure from the EHC valve acts and that in the spring
chamber are equal, the spool is raised until pressure
in the spring chamber [spring force which is equiva-
lent to 0.15 MPa (1.5 kgf/cm2, 21 psi) plus output port
pressure] balances with the signal pressure from the
EHC valve.
Therefore, pressure oil in response to the signal
pressure from the EHC valve is supplied to the con-
trol valve spool from the DQR valve.
When the control lever is returned to neutral, the
signal pressure is not supplied to the DQR valve from
the EHC valve and the DQR valve spool is raised by
the spring force.
As, the output port is connected to port T, pressure oil
from the control valve spool flows back to the hy-
draulic oil tank from port T through the DQR valve
spool.
Therefore, the control valve spools are returned to
the neutral position.

T3-5-4
COMPONENT OPERATION / DQR Valve
When control lever is in neutral: When control lever is operated:

Signal Port
(From the Pilot Valve)

Spool
Output Port
(To Control Valve Spool) Spool
Port T
(To Hy-
draulic
Oil Tank)

Passage
Output Port

Port P Notch
Port P
(From Pilot
Pump)

T18B-03-05-003
Spring T18B-03-05-004
Spring

Spool

Output Port

Port P

T18B-03-05-005

Spring (Set Pressure: 0.15 MPa Spring Chamber


2
(1.5 kgf/cm , 21 psi))

T3-5-5
COMPONENT OPERATION / DQR Valve
(Blank)

T3-5-6
COMPONENT OPERATION / Travel Device
OUTLINE
The travel device consists of the travel motors and the The travel motor is driven by the pressure oil from the
travel reduction gear. pump and rotates the travel reduction gear. The travel
Both right and left travel devices are equipped with reduction gear reduces the travel motor speed and
two travel motors. Two brake valves separated from increases torque before rotating the drive tumbler. The
the travel motors are installed to the rear side of the brake valve protects the travel circuit from overloads
track frame. and/or cavitation in the circuit and prevents the ma-
chine from running away on a slope.

Front Side

Brake Valve

Travel Mode Control Hose

Travel Forward Hose

Travel Reverse Hose

Drain Hose

Drive Tumbler

Travel Motor
Travel Reduction Gear

Rear Side

T117-03-01-001

NOTE: The above figure shows the left travel device.

T3-6-1
COMPONENT OPERATION / Travel Device
TRAVEL MOTOR
The travel motor is a swash plate type variable dis-
placement axial plunger motor and equipped with
parking brake (7) and the travel mode selector valve. Travel Mode Selector Valve
The major parts of the travel motor are shaft (1),
swash plate (2), shoe (9), plunger (5), rotor (3), valve
plate (6), and housing (8). Shoe (9) is crimped to the
end of plunger (5), which is inserted into the bore of
rotor (3). Rotor (3) is splined to shaft (1).

T141-03-05-002

2 3 4 5 6 7

10 9 8 T117-03-01-002

1 - Shaft 4 - Tilt Piston 7 - Parking Brake 9 - Shoe


2 - Swash Plate 5 - Plunger 8 - Housing 10 - Shoe Plate
3 - Rotor 6 - Valve Plate

T3-6-2
COMPONENT OPERATION / Travel Device
Operational Principle
Travel speed varies depending on both the amount
of oil supplied to the travel motor and the displace-
ment angle of the swash plate.
When pressure oil is routed into port A on the valve
plate, pressure oil enters one half of the rotor and
pushes the plungers.
The plunger pushes the shoe against the swash
plate. As the swash plate is tilted, the shoe slides
along the plate along the plate surface. Therefore,
the rotor rotates.
This rotation is transmitted to the reduction gear via
the shaft.
As the rotor rotates, the plunger reaches port B and
pressure oil is returned to the hydraulic oil tank.
Whether forward travel or reverse travel depends
on whether pressure oil is supplied to port A or port
B.

Rotor Valve Plate


Port B Port A

Shaft

Shoe Plunger
Shoe Plate
T117-03-01-003

T3-6-3
COMPONENT OPERATION / Travel Device
TRAVEL MODE SELECTION
Slow Speed
Ports PA and PB of the travel mode selector valve As main pressure pushes the slow speed side of
are connected to the travel main circuit. When the tilt piston and the displacement angle of the
travel operation either forward or reverse is made, travel motor is turned to the maximum, the travel
main pressure oil passes through port PA or PB, speed is changed to the slow speed mode.
pushes the shuttle and enters port P. Hydraulic oil in the fast speed side of the tilt piston
When the travel mode selector switch is turned OFF is routed into port DR via port SB through the pas-
(slow speed), pilot pressure acts on port PS of the sage in the spool and flows back to the hydraulic oil
travel mode control valve after being reduced to 2.4 tank. (Refer to SYSTEM / Control System.)
MPa (24.6 kgf/cm2, 350 psi).
Although the spool is pushed to the right by pres-
sure of 2.4 MPa (24.6 kgf/cm2, 350 psi), as the
spring force overcomes, the spool does not move.
The main pressure from port PA or PB and acts on
the slow speed side of the tilt piston through the
notch on the spool from port SA.
Spool
Spring Pilot Pressure from Pressure Reducing Valve
2
Travel Mode (2.4 MPa (24.6 kgf/cm , 350 psi))
Selector Valve

SA SB

PS
DR

PB
Shuttle PA

T141-03-05-007

From port SA To port SB


Parking Brake

Tilt Piston Travel Mode


Selector Valve

Tilt Piston Tilt Piston


(Slow Speed (Fast Speed Side)
Side)

Control Valve

T141-03-05-003
T118-03-06-002

T3-6-4
COMPONENT OPERATION / Travel Device
Fast Speed
When the travel mode selector switch is turned ON Hydraulic oil in the slow speed side of the tilt piston
(fast speed), pilot pressure acts on port PS of the is routed to port DR via port SA through the pas-
travel mode selector valve without being reduced. sage in the spool and flows back to the hydraulic oil
Pilot pressure (force) without being reduced over- tank. (Refer to SYSTEM / Control System.)
comes the spring force so that the spool is pushed
to the left.
Main pressure is routed from port PA or PB to port
SB through the notch on the spool and acts on the
fast speed side of the tilt piston.
As main pressure pushes the fast side of the tilt
piston and the displacement angle of the travel mo-
tor is turned to the minimum, the travel speed is
changed to the fast speed mode.

Spring Spool
Travel Mode Selector Valve Pilot Pressure from Pressure Reducing
2
Valve (3.9 MPa (40 kgf/cm , 569 psi))

SA
SB

PS
DR

PB
PA

Shuttle P

T141-03-05-008
To Port SA From Port SB
Parking Brake

Tilt Piston

Tilt Piston Tilt Piston


(Slow Speed (Fast Speed
Side) Side) Travel Mode
Selector Valve

Control Valve

T18C-03-05-002
T118-03-06-002

T3-6-5
COMPONENT OPERATION / Travel Device
BRAKE VALVE
The brake valve consists of counterbalance valve (10)
and relief valve (11).

When Traveling Circuit Protection


When pressure oil from the control valve is routed If pressure in the circuit increases over the set
to port AV, pressure oil flows into port AM after pressure, relief valve (11) opens and relieves high-
passing through the clearance around spool (5) and pressure oil to the low-pressure side in order to
opening check valve (4). protect the travel motor from being overloaded.
As the returning oil from port BM is blocked by check Relief valve (11) buffers shock pressure developed
valve (6) and spool (5), it cannot flow to port BV. by inertia force of the machine when stopping trav-
Therefore, pressure in port AV increases gradually eling.
and acts on chamber (1) through orifice (3), so that When the travel motor draws hydraulic oil like a
spool (5) is moved to the right. pump, check valve (4 or 6) opens and prevents the
Consequently,the returning oil from port BM flows occurrence of cavitation (make-up operation) in the
to port BV through the notch on spool (5) and the circuit.
travel motor rotates.
Control Valve
When Descending Slope
While traveling down slope, the travel motor is forci-
3 7 10
bly rotated by the machine own weight, so that the
travel motor draws pressure oil like a pump. 4 6
When pressure oil in port AM is drawn into the
travel motor, pressure in port AV and chamber (1)
decreases. 11
Therefore, as spool (5) is returned to the left, the
returning oil from port BM is restricted, the travel 11
motor is braked.
Once the returning oil from port BM is restricted,
pressure in port AV increases again and spool (5) is
moved to the right.
Then, the machine is prevented from running away
due to this repetition of hydraulic oil braking operation. T141-03-05-004

1 2 3 4 5 6 7 8 9
AV BV

10

AM BM

11

T144-03-05-002
1 - Chamber 4 - Check Valve 7 - Orifice 10 - Counterbalance Valve
2 - Spring 5 - Spool 8 - Spring 11 - Relief Valve
3 - Orifice 6 - Check Valve 9 - Chamber

T3-6-6
COMPONENT OPERATION / Travel Device
PARKING BRAKE
The parking brake consists of the coupling, the friction When the pilot shut-off lever is in the Unlock position,
plate, the plate, the piston, and the spring. The cou- the pilot pressure is routed to port PR. Then, pilot
pling, the plate, and the friction plates are splined to pressure pushes the piston against the spring. There-
the shaft, the coupling, and the casing, respectively. fore, the friction plate and the plate are separated
When the pilot shut-off lever is in the Lock position, from each other, so that the shaft rotates.
the pilot pressure is not routed to port PR. Then, the
piston is pushed by the springs, and the friction plate
and the plate are pushed so that the shaft does not
rotate.

Friction Plate Plate

Pilot Pressure
PR

Shaft
Spring

Coupling

Piston

Casing T117-03-01-004

Pilot Shut-Off
Solenoid Valve Spring
(Unlock Position)
Piston

Shaft

Relief Valve: 3.9 MPa Pilot Pressure: More than 1.9 MPa
2
2
(40 kgf/cm , 569 psi) (19 kgf/cm , 270 psi)

Pilot Pump T18N-03-02-001

T3-6-7
COMPONENT OPERATION / Travel Device
TRAVEL REDUCTION GEAR
The travel reduction gear consists of spur gear and
two-stage reduction planetary gear. Shaft (5) of the
travel motor rotates spur gear (7) via pinion gear (6).
After the first stage reduction takes place between
pinion gear (6) and spur gear (7), first stage sun gear
(4) is rotated. Rotation of first stage sun gear (4) is
transmitted to second stage sun gear (2) after the
second stage reduction takes place between first
stage planetary gear (8) and first stage carrier (3).
Rotation of second stage sun gear (2) is transmitted
to drive tumbler (10) after the third stage reduction
takes place between second stage planetary gear (9)
and second stage carrier (1).

1 2 3 4 5 6

9 8 7
10
T141-03-05-001

1 - Second Stage Carrier 4 - First Stage Sun Gear 7 - Spur Gear 9 - Second Stage Planetary
Gear
2 - Second Stage Sun Gear 5 - Shaft 8 - First Stage Planetary Gear 10 - Drive Tumbler
3 - First Stage Carrier 6 - Pinion Gear

T3-6-8
COMPONENT OPERATION / Others (Upperstructure)
FAST-FILLING SYSTEM

Coolant, hydraulic oil, fuel, and engine oil can be sup- NOTE: Quick couplers made by Wiggins Co. (op-
plied through the fast-filling panel. tional) are installed on the fast-filling panel.
The fast-filling system consists of the fast-filling switch,
the fast-filling panel, the fast-filling solenoid valve, the
lift cylinder and the proximity switch.

Lift Cylinder Proximity Switch

Fast-Filling Panel

T18N-03-07-003

T3-7-1
COMPONENT OPERATION / Others (Upperstructure)
Fast-Filling Panel

3 4 5 6 7 8 9 10 11 12 13 14 15 16

T18N-03-07-002

29 28 27 26 25 24 23 22 21 20 19 18 17

1 - Engine Oil Filling (L) 9 - Hydraulic Oil 16 - Engine Oil Out (R) 6 - Gear Oil
(Reserve Tank (L)) (Reserve Tank (R)) (Left Front Swing Device)
2 - Engine Oil Out (L) 10 - Engine Oil Reserve Tank 17 - Fuel 7 - Gear Oil
(Reserve Tank (L)) (R) Full Indicator (Left Rear Swing Device)
3 - Engine Oil Reserve Tank 11 - Engine Oil Reserve Tank 18 - Coolant (Right Radiator) 8 - Gear Oil
(L) Full Indicator (R) Shut-Off Valve Open (Right Rear Swing Device)
Lamp
4 - Engine Oil Reserve Tank 12 - Engine Oil Reserve Tank 19 - Auxiliary 9 - Engine Oil
(L) Shut-Off Valve Open (R) Filling System Power (Left Engine)
Lamp Switch
5 - Engine Oil Reserve Tank 13 - Engine Oil Reserve Tank 20 - Transmission Oil 10 - Transmission Oil
(L) Filling System Power (R) Filling System (Right Pump) (Left Pump)
Switch Operation System
6 - Engine Oil Reserve Tank 14 - Fuel Full Indicator 21 - Engine Oil (Right Engine) 11 - Auxiliary
(L) Filling System
Operation Switch
7 - Auxiliary 8 - Engine Oil Filling (R) 22 - Grease 12 - Coolant (Left Radiator)
(Reserve Tank (R))
8 - Gear Oil
(Right Front Swing Device)

T3-7-2
COMPONENT OPERATION / Others (Upperstructure)
AIR CONDITIONING SYSTEM

The air conditioning system consists of the compres- Compressor motor (8) is driven by pressure oil from
sor drive pump, compressor motor (8), air conditioner the compressor drive pump when the engine starts.
units (1, 2, and 3), compressors (4, 7, and 9), con- When the air conditioner switch in the cab is turned
densers (13, 14, and 15), receiver dryers (10, 11, and ON, the compressor clutch is turned ON so that the
12), hot water outlet hose (5), and hot water inlet hose compressor is operated, and the cooler is operated.
(6).

1
2
3
4 6

15

14

13

View A

12 A
11
10

9
8
7 TKCA-03-07-001

1- Air Conditioner Unit (Front) 5- Hot Water Outlet Hose 9- Compressor (Rear) 13 - Condenser (Rear)
2- Air Conditioner Unit (Side) 6- Hot Water Inlet Hose 10 - Receiver Dryer (Rear) 14 - Condenser (Side)
3- Air Conditioner Unit (Rear) 7- Compressor (Front) 11 - Receiver Dryer (Side) 15 - Condenser (Front)
4- Compressor (Side) 8- Compressor Motor 12 - Receiver Dryer (Front)

T3-7-3
COMPONENT OPERATION / Others (Upperstructure)
Cooling Operation
The cooling circuit consists of compressor (10), • Thermo Sensor Tube
condenser (1), receiver dryer (9), expansion valve It checks air temperature after passing through
(3), evaporator (5), thermistor (6), thermo sensor the evaporator and adjusts the orifice on the ex-
tube (4), and blower fan (2). The cooling circuit is pansion valve in response to air temperature
charged with refrigerant. Air from the fresh and / or change in order to control the refrigerant flow
circulation air inlet is sent to evaporator (5) by blower rate.
fan (2). As evaporator (5) is cool, air is cooled while • Thermistor
passing through evaporator (5). Then, cooled air is It stops the compressor if temperature on the fin
sent into the cab from the vents. surface of the evaporator falls lower than 0 °C.
Each component functions as follows: • Blower Fan
• Compressor It sends air from the fresh and/or circulation air
It draws, compresses refrigerant from the low inlet to the evaporator.
pressure circuit (between the evaporator and the
compressor), and sends it to the condenser. (Re- Heating Operation
frigerant generates heat when compressed.) During heating operation, valve (8) is opened so that
• Condenser high-temperature engine coolant circulates through
It cools hot refrigerant. heater (7). Therefore, heater (7) becomes hot. Air
• Receiver Dryer from blower fan (2) is warmed as it passes through
It removes moisture from refrigerant and stores heater (7) and is sent into the cab from the vents.
refrigerant.
• Expansion Valve Dehumidifying and Heating Operation
It atomizes high-pressure liquid refrigerant into During dehumidifying and heating operation, the
low-pressure gas via an orifice. cooling and heating systems are operated at the
• Evaporator same time. Air from blower fan (2) is cooled and de-
It vaporizes refrigerant and absorbs heat from humidified at evaporator (5) and air is warmed at
atmosphere. heater (7) before being sent into the cab.

T3-7-4
COMPONENT OPERATION / Others (Upperstructure)

1 2 3 4 5 6
Fresh Air Inlet Vent

Air
Conditioner
Unit

Fresh / Circulation
Air Changeover
Fan
Damper
Circulation Air Inlet
Air Mix 8 7
Damper

1 9
From Hot To Hot Water
Water Outlet Inlet Port
Port
T117-02-05-002

1 - Condenser 4 - Thermo Sensor Tube 7 - Heater 9 - Receiver Dryer


2 - Blower Fan 5 - Evaporator 8 - Valve 10 - Compressor
3 - Expansion Valve 6 - Thermistor

T3-7-5
COMPONENT OPERATION / Others (Upperstructure)
AUTO-LUBRICATION DEVICE

The auto-lubrication device automatically greases the This system can be shifted to in either the auto or the
joint pins in the front attachment, the swing bearing, manual lubrication mode, or turned OFF by operating
and the center joint. The major components are the the auto-lubrication switch. When the switch is in the
grease tank, the grease pump, the auto-lubrication auto-lubrication mode position, grease is automati-
solenoid valve, the pressure reducing valve, the vent cally supplied at the interval set by the auto-lubrication
valve, the auto-lubrication interval switch, the interval switch. When the switch is OFF, greasing
auto-lubrication switch, the auto-lubrication pressure stops. When the switch is in the manual lubrication
switch, and the manually-operated lubrication pres- mode position, the auto-lubrication function does not
sure switch. operate. Greasing can be accomplished by grease
gun.

NOTE: Refer to SYSTEM / Control System for the


system operation.

T3-7-6
COMPONENT OPERATION / Others (Upperstructure)

5 4

9 8 7 6

T18N-03-07-004

1 - Pressure Switch 2 4 - Vent Valve 6 - Grease Tank 8 - Pressure Switch 1


(Manual Lubrication) (Auto-Lubrication)
2 - Grease Pump 5 - Auto-Lubrication Solenoid 7 - Pressure Gauge 9 - Auto-Lubrication Switch
Valve
3 - Pressure Reducing Valve

T3-7-7
COMPONENT OPERATION / Others (Upperstructure)
OIL COOLER FAN MOTOR

The oil cooler fan motor is a inclined-shaft type, fixed


displacement axial plunger motor. The operational
principle of this motor is the same as the travel motor.
(Refer to Travel Device.)

Drive Disc

Rotor

W118-02-09-002

T3-7-8
COMPONENT OPERATION / Others (Upperstructure)
ACCUMULATOR

The accumulator is provided in the pilot circuit in order


to buffer fluctuations in oil pressure, and to maintain
pilot pressure for a short time period after the engine
is stopped.
The accumulator mainly consists of body (5), holder
(4), bladder (2), which encloses nitrogen gas (N2),
and poppet (1). 6
1

• Pressure oil from the pilot pump enters the


Nitrogen Gas
accumulator through port A. Pilot pressure (N2)
compresses the nitrogen gas in bladder (2) until 5 2
they balance against each other.
4
• When pressure oil supply is stopped due to
engine stall or any other reasons, bladder (2)
starts expanding and accumulated oil is supplied Pilot Pressure Oil
to the pilot circuit through port A. 3

T105-02-10-003

1 - Poppet 4 - Holder
2 - Bladder 5 - Body
3 - Oil Port 6 - Gas Plug

T3-7-9
COMPONENT OPERATION / Others (Upperstructure)
EHC VALVE

The EHC valve consists of eight proportional solenoid


valves.

Left Frame
1 - Auxiliary
2 - Main Pump Displacement Angle Control
(For Main Pumps 2, 4, 5, and 6)
3 - Power Decrease
4 - Oil Cooler Fan Motor Drive Pump
8 1 Displacement Angle Control
5 - Main Pump Displacement Angle Control
7 (For Main Pump 1)
2
6 - Main Pump Displacement Angle Control
(For Main Pump 3)
6 3 7 - Power Increase
8 - Auxiliary
5 4

T18N-03-07-005

Right Frame

16
9

15
10
9 - Auxiliary
14 11 10 - Main Pump Displacement Angle Control
(For Main Pumps 8, 10, 11, and 12)
12 11 - Main Pump Displacement Angle Control
(For Main Pumps 9)
13
12 - Main Pump Displacement Angle Control
(For Main Pumps 7)
13 - Oil Cooler Fan Motor Drive Pump
Displacement Angle Control
14 - Power Decrease
15 - Power Increase
16 - Auxiliary
T18N-03-07-005

T3-7-10
COMPONENT OPERATION / Others (Upperstructure)
Proportional Solenoid Valve
The proportional solenoid valve is excited by a cur- The pressure at output port (5) acts on stepped
rent signal from ELU and MC, and delivers pressure flanges (a) on spool (1). The right side flange has a
oil in proportion to the current signal value. larger diameter so that spool (1) is pushed to the
right. When pressure at output port (S) overcomes
• When in neutral: the force to push spool (1) to the right, spool (1) is
Spool (1) is pushed to the right by spring (2) force moved back to the right and the passage from port
so that output port (S) is connected to tank port (P) to output port (S) is closed. Then, pressure at
(T3). output port (S) stops increasing.
• When excited:
Solenoid (3) pushes spool (1) to the left in propor-
tion to the current value flowing through solenoid (3)
Pilot pressure oil flows to output port (S) from port
(P) and increases pressure at output port (S).

T3 S P 1 2 3

a
T107-02-07-005

1 - Spool 2- Spring 3- Solenoid

T3-7-11
COMPONENT OPERATION / Others (Upperstructure)
(Blank)

T3-7-12
COMPONENT OPERATION / Others (Undercarriage)
SWING BEARING
The swing bearing supports the upperstructure on the
undercarriage and allows the upperstructure to rotate
smoothly. The bearing is a three-row-roller-type bear-
ing and consists of retaining ring (7), support ring (8),
nose ring (4), three types of rollers (1, 2, and 6), and
seals (3 and 5). Retaining ring (7) and support ring (8)
are bolted to the upperstructure. Nose ring (4) is bolted
to the undercarriage. The internal gear on nose ring (4)
meshes with the swing reduction gear shaft.

1 2 3

6 5 T115-03-03-001

1 - Radial Roller 3 - Seal 5 - Seal 7 - Retaining Ring


2 - Support Roller 4 - Nose Ring 6 - Retaining Roller 8 - Support Ring

T3-8-1
COMPONENT OPERATION / Others (Undercarriage)
CUSHION CYLINDER
The cushion cylinder consists of two single-acting The travel stop pilot valve is installed to the stroke end
pistons. The front part is a cushion piston to reduce of the cushion piston. When the cushion piston
impact loads and the rear part is an adjuster piston to reaches the stroke end, the travel stop pilot valve is
adjust track sag. The cushion piston stores pressure shifted and stops the travel function. (Refer to SYS-
oil in the piston chamber. When the cushion piston is TEM / Hydraulic System / Travel Shock Damper/Travel
pushed by an external shock load, this stored pressure Stop Circuit.)
oil reduces the external shock load. The adjuster pis-
ton adjusts the track sag depending on the amount of
grease supplied in the piston chamber.

Adjuster Piston Grease Signal Pressure Cushion Piston

Hydraulic
Oil

Travel
Device Side Front Idler Side

T115-03-03-002
Piston Chamber Travel Stop Piston Chamber
Pilot Valve

ACCUMULATOR
The accumulator consists of the shell, the bladder, the
gas valve and the oil port assembly.
Hydraulic oil is filled in the shell. High-pressure
nitrogen gas is sealed in the bladder. The bladder
contracts until the gas pressure balances with pres-
sure oil from the oil port assembly.

Oil Port Assembly Shell Bladder Gas Valve

T115-03-03-003

T3-8-2
COMPONENT OPERATION / Others (Undercarriage)
(Blank)

T3-8-3
COMPONENT OPERATION / Others (Undercarriage)
Shock Damper / Travel Stop Operation
Main pressure oil from the right travel forward circuit If the external load increases further, relief valve (4) is
is routed into accumulators (3) and both right and left opened and the cushion piston is moved to the stroke
cushion cylinders (6) after being reduced by pressure end. Therefore, travel stop pilot valve (9) is shifted.
reducing valve (2). When an external load is applied Pressure oil from travel stop pilot valve (9) shifts pilot
to the front idler, the cushion piston is pushed so that pressure control valve (8). Pressure oil from pilot
pressure oil in the piston chamber flows into accu- pressure control valve (8) is converted into electrical
mulators (3). The bladder in accumulator (3) con- signals by the pressure sensor, and sent to ELU. ELU
tracts and reduces the external load. receives these signals and stops travel function. (Refer
to SYSTEM/ELU SYSTEM / Cushion Cylinder End
Travel Regulation Control.)

Right Travel Forward Circuit

Drain Circuit
Pilot Circuit
PS 1 2

Pressure Sensor

8 4

9 6

1 - Center Joint 4 - Relief Valve 6 - Cushion Cylinder 8 - Pilot Pressure Control Valve
2 - Pressure Reducing Valve 5 - Stop Valve 7 - Grease Fitting 9 - Travel Stop Pilot Valve
3 - Accumulator

T3-8-4
COMPONENT OPERATION / Others (Undercarriage)

From Right Cushion Cylinder


1

Drain

3 From Right
Cushion Cylinder

Pilot Pressure
2 to Travel Motor

3
4 8
5

7 T18N-03-08-002

T3-8-5
COMPONENT OPERATION / Others (Undercarriage)
CENTER JOINT
The center joint is a 360° rotating joint. The center joint
allows pressure oil to flow to the travel motor without
twisting hoses when the upperstructure rotates. The
body and the spindle are secured to the upperstructure
and the swing center on the undercarriage, respec-
tively.
Pressure oil flows into each port of the body is routed
into the travel motors via oil passages and oil ports of
the spindle. The seals are installed between the spin-
dle and the body and prevents oil leaks from oil ports.

Seal

Body

Spindle

T145-03-02-001

T3-8-6
MEMO

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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Tel: 81-29-982-7084
Fax: 81-29-831-1162
E-mail: dc@hitachi-kenki.com

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