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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
• This manual contains the revision information
to the 3, July 2009.

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 1.0197 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 Layout
Group 3 Component Specifications
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)2007
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
WORKSHOP MANUAL
SECTION 1 GENERAL SECTION 3 UNDERCARRIAGE
Group 1 Precautions for Disassem- Group 1 Swing Bearing
bling and Assembling Group 2 Travel Device
Group 2 Tightening Group 3 Travel Brake Valve
Group 3 Painting Group 4 Drive Tumbler
Group 4 Bleed Air from Hydraulic Group 5 Center Joint
Oil Tank Group 6 Adjuster Cylinder
SECTION 2 UPPERSTRUCTURE Group 7 Front Idler
Group 1 Cab Group 8 Upper and Lower Roller
Group 2 Counterweight Group 9 Track
Group 3 Pump Device Group 10 Accumulator
Group 4 Control Valve Group 11 Welding Repair Procedure
Group 5 Swing Device SECTION 4 FRONT ATTACHMENT
Group 6 DQR Valve Group 1 Front Attachment
Group 7 Shuttle Valve Group 2 Cylinder
Group 8 8-Spool Solenoid Valve Unit Group 3 Bushing and Point
Group 9 Oil Cooler Fan Motor
Group 10 Compressor Drive Motor
Group 11 Air Conditioner
Group 12 Lift Cylinder
(Fast-Filling/System)
Group 13 Lift Cylinder
(Sliding Fold-In Ladder)
SECTION 1
GENERAL

CONTENTS
Group 1 Specifications
Specifications ...........................................T1-1-1
Working Range ........................................T1-1-2

Group 2 Component Layout


Main Component Layout...........................T1-2-1
Electrical Component Layout ....................T1-2-8
Engine....................................................T1-2-20
Radiator .................................................T1-2-21
Air Cleaner .............................................T1-2-22
Pump Device..........................................T1-2-23
Control Valve..........................................T1-2-24
Swing Device .........................................T1-2-27
Travel Device .........................................T1-2-28
Center Joint............................................T1-2-28
Oil Cooler ...............................................T1-2-29
EHC Valve (For Main Pump Control) ......T1-2-30
EHC Valve (For Electric Lever Control)...T1-2-31
Sliding Fold-In Ladder ............................T1-2-32
Auto-Lubrication System ........................T1-2-34

Group 3 Component Specifications


Engine......................................................T1-3-1
Engine Accessories ..................................T1-3-3
Hydraulic Component ...............................T1-3-4
Electrical Equipment.................................T1-3-8
Filter.......................................................T1-3-10
Others ....................................................T1-3-10

18LT-1-1
(Blank)

18LT-1-2
GENERAL / Specifications
SPECIFICATIONS
A
F
C

J I
H G

T18L-01-01-004

Model EX2500-6 Hydraulic Excavator


Type of Front-End Attachment Loader Front Backhoe Front
3 3 3 3 3
Bucket Capacity (Heaped) PCSA 15.0 m (19.6 yd ) PCSA 15.0 m (19.6 yd ), CECE 13.2 m
Operating Weight 249000 kg (549000 lb) 248000 kg (547000 lb)
Cummins Engine QSKTA50-CE
Engine -1
1044 kW/1800 min (1420 PS/1800 rpm)
A: Overall Width 7560 mm (24 ft 10 in)
B: Cab Height *7250 mm (23 ft 9 in)
C: Rear End Swing Radius 6290 mm (20 ft 8 in)
D: Minimum Ground Clearance *800 mm (2 ft 7 in)
E: Counterweight Clearance *2140 mm (7 ft 0 in)
F: Overall Width of Upperstructure 6730 mm (22 ft 1 in)
G: Undercarriage Length 7870 mm (25 ft 10 in)
H: Undercarriage Width 6000 mm (19 ft 8 in)
I: Sprocket Center to Idler Center 6120 mm (20 ft 1 in)
J: Track Shoe Width 1000 mm (3 ft 3 in) (Grouser shoe)
2
Ground Pressure 176 kPa (1.79 kgf/cm , 25.5 psi)
–1
Swing Speed 3.8 min (rpm)
Travel Speed (Fast/Slow) 2.3/1.6 km/h (1.4/1.0 mph)
Gradeability 30° (tanθ = 0.58)
NOTE: * The dimensions do not include the height of the shoe lug.

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

A
G
C B

T18L-01-01-002

Category
Loading Shovel
Item
A: Minimum Digging Distance 5340 mm (17 ft 6 in)
B: Minimum Level Crowding Distance 7980 mm (26 ft 2 in)
C: Level Crowding Distance 4980 mm (16 ft 4 in)
D: Maximum Digging Reach 14060 mm (46 ft 2 in)
E: Maximum Cutting Height 15010 mm (49 ft 3 in)
F: Maximum Dumping Height 10350 mm (33 ft 11 in)
G: Maximum Digging Depth 3720 mm (12 ft 2 in)

NOTE: *The dimensions do not include the height of the shoe lug.

T1-1-2
GENERAL / Specifications

Backhoe

B
A

T18L-01-01-003

Category
Backhoe
Item
A: Maximum Digging Reach 17080 mm (55 ft 11 in)
B: Maximum Digging Reach (on ground) 16500 mm (54 ft 2 in)
C: Maximum Digging Depth 8600 mm (28 ft 1 in)
D: Maximum Cutting Height 16060 mm (52 ft 8 in)
E: Maximum Dumping Height 10330 mm (33 ft 11 in)
NOTE: *The dimensions do not include the height of the shoe lug.

T1-1-3
GENERAL / Specifications
(Blank)

T1-1-4
GENERAL / Component Layout
MAIN COMPONENT LAYOUT
Loading Shovel

7
8
6
5
9
10
11
12
13
14
15 16 17 18

1 19

39 20

38 21
37 22
36 23
35 24
34 25
33 26
32
31 27
30 29 28
T18L-01-02-001

1 - Arm Cylinder 11 - Center Joint 21 - Sub-Hydraulic Oil Tank 31 - Travel Brake Valve
2 - Level Cylinder 12 - Main Hydraulic Oil Tank 22 - Pump Device 32 - Relief Valve (Accumulator)
3 - Bucket Cylinder 13 - Air Bleeding Solenoid 23 - Engine Oil Reserve Tank 33 - Reducing Valve
Valve (Accumulator)
4- Dump Cylinder 14 - Control Valve 24 - Engine 34 - Accumulator (Adjuster)
5- Bucket 15 - Bypass Filter 25 - Accumulator (Pilot Circuit) 35 - Swing Bearing
6- Arm 16 - High Pressure Strainer 26 - Radiator 36 - Adjuster Cylinder
7- Boom 17 - Fuel Cooler 27 - Shuttle Valve (Travel) 37 - Compressor Motor
8- Boom Cylinder 18 - Oil Cooler 28 - Pilot Pressure Selector 38 - Compressor
Valve (For Air Conditioner)
9 - Swing Device 19 - Pump Transmission Cooler 29 - Accumulator (Adjuster) 39 - Washer Tank
10 - Auto-Lubrication Device 20 - Oil Cooler Fan Motor 30 - Travel Device
(Lubricator)

T1-2-1
GENERAL / Component Layout
Backhoe

4
5
3
2 6

M18L-01-005

1 - Bucket 3 - Bucket Cylinder 5 - Boom Cylinder 6- Boom


2 - Arm 4 - Arm Cylinder

T1-2-2
GENERAL / Component Layout
Pump and Components

1 2

6 5 4 3
T18L-01-02-003

1 - Main Pump 1 4- 4-Unit Pump 6- Transmission Oil Filter 8- Pilot Filter


(Transmission Side)
Main Pump 2
(Pump End Side)
2 - Main Pump 3 5 - Transmission Oil Pump 7- Pilot Relief Valve 9 - EHC Valve
(Transmission Side) Bypass Check Valve (Main Pump Control)
Main Pump 4
(Pump End Side)
3 - Main Pump 5
(Transmission Side)
Main Pump 6
(Pump End Side)

T1-2-3
GENERAL / Component Layout
Pilot Panel (Operation Circuit)

A
2 1

T18L-01-02-008
3 4 9
View A View B

T18L-01-02-019

8 7 6 10

1 - Compressor Pump Relief 4 - Travel Mode Solenoid 7 - EHC Valve (For Front) 9- DQR Valve
Valve Valve (For Travel/Swing)
2 - Accumulator (Pilot Circuit) 5 - Pilot Shut-Off Solenoid 8 - DQR Valve (For Front) 10 - EHC Valve
Valve (For Travel/Swing)
3 - Reducing Valve 6 - Check Valve
(Pilot Circuit)

T1-2-4
GENERAL / Component Layout
Undercarriage

7 1

T18L-01-02-016
5 4 3

1 - Adjuster Cylinder 3 - Accumulator 5 - Center Joint 7 - Relief Valve


(For Adjuster Cylinder)
2 - Valve 4 - Pilot Pressure Selector 6 - Check Valve
Valve

T1-2-5
GENERAL / Component Layout
Fast Filling System

1 2 3

T18L-01-02-020

View A 6 4 1 5

T18L-01-02-015

1 - Lift Cylinder (2 Used) 3 - Slow Return Valve 5 - Fast-Filling Solenoid Valve 6- Proximity Switch
2 - Check Valve 4 - Fast-Filling Panel

T1-2-6
GENERAL / Component Layout
Fast-Filling Panel

1 2 3 4 5 6 7 8

16

15 9

M18L-01-012

14 13 12 11 10

1 - Engine Oil Reserve Tank 5 - Fuel Fill Indicator 9 - Grease 13 - Coolant


Fill Indicator (Radiator Outside)
2 - Engine Oil Reserve Tank 6 - Hydraulic Oil 10 - Gear Oil (Rear Side Swing 14 - Engine Oil In
Shut-Off Valve Open Device) (Reserve Tank)
Indicator
3 - Engine Oil Reserve Tank 7 - Gear Oil (Front Side Swing 11 - Fuel 15 - Coolant
Filling System Power Device) (Radiator Engine Side)
Switch
4 - Engine Oil Reserve Tank 8 - Pump Transmission Oil 12 - Engine Oil Out 16 - Engine Oil
Filling System Control (Reserve Tank) (Engine Oil Pan)
Switch

T1-2-7
GENERAL / Component Layout
ELECTRICAL COMPONENT LAYOUT
1 2 3

4
5
6 7
8
9
10
11
32
12
13

31

14
30

15
16
17
18
29
28 19
27 20
26
21
25

24
T18L-01-02-037
23 22

1 - Work Light (on the Cab) 9 - Emergency Switch 5 17 - Emergency Switch 3 25 - Fuel Level Switch
2 - Entrance Light 10 - Maintenance Light 18 - Travel Alarm 26 - Entrance Light
(Engine Compartment)
3 - Air Conditioner 11 - Valve Limit Switch 19 - Proximity Switch (Fast 27 - Maintenance Light
(Delivery Circuit) Filling System) (Under Cab Compartment)
4 - Work Light (Front Right) 12 - Maintenance Light 20 - Fast Filling Panel 28 - Electrical Equipment Box
(Pump Compartment) Raise/Lower Solenoid
Valve (Fast Filling System)
5 - Battery 13 - Work Light (Rear Right) 21 - Work Light (Rear Left) 29 - Receiver-Dryer Condenser
Fan Control Pressure
Switch
6 - Air Bleeding Solenoid Valve 14 - Emergency Switch 4 22 - Valve Limit Switch 30 - Work Light (Front Left)
(Suction Circuit)
7 - Hydraulic Oil Level Switch 1 15 - Engine Oil Reserve Tank 23 - Work Light (Rear Left) 31 - Condenser (Fan Motor)
(Level Indicator) Level Switch
8 - Hydraulic Oil Level Switch 2 16 - Hydraulic Oil Temperature 24 - Emergency Switch 2 32 - Horn
(Alarm Light) Sensor

T1-2-8
GENERAL / Component Layout
Electrical Component

T18L-01-02-040 T18L-01-02-041

3 4 T18L-01-02-043

1 T18L-01-02-042 2 T18L-01-02-044

1 - Air Temperature Sensor 2- Air Temperature Sensor 3- Air Temperature Sensor (1) 4- Air Temperature Sensor (2)
(Outside of Cab) (In Front of Radiator) (In Front of Oil Cooler) (In Front of Oil Cooler)

T1-2-9
GENERAL / Component Layout
Battery Compartment

1 2 3 4 A 5 6 7 8 B

9
14
10

13
11

12

Cross Section A Cross Section B


T18L-01-02-036

16
15

17

M18L-07-042

1 - Cover Switch 6 - Starter Relay 2 10 - Battery Relay (1) 14 - Battery Relay (3)
2 - Engine Oil Fill System 7 - Starter Relay 1 (Upper) 11 - Circuit Breaker 15 - Auto-Lubrication Mode
Relay (1) Switch
3 - Engine Oil Fill System 8 - Starter Relay 1 (Lower) 12 - Battery 16 - Auto-Lubrication Grease
Relay (2) Pressure Switch
4 - Alternator Relay 9 - Battery Relay (2) 13 - PRELUB Relay 17 - Auto-Lubrication Grease
Pressure Switch (Manual)
5 - PRELUB Timer Relay

T1-2-10
GENERAL / Component Layout
Battery Compartment (Fusible Link)

Cross Section A A B Cross Section B

C
1
3

4 5

2
6

T18L-01-02-045

Cross Section C

7 8 9 10 11 12

13 14 15 16
T18L-01-02-046

1 - Fusible Link (250 A) 5 - Fusible Link (30 A) 9 - Fusible Link 3 (75 A) 13 - Fusible Link 7 (45 A)
(Sliding Fold-In Ladder (Zener Diode) (Fuse Box) (Optional)
Motor (Front))
2 - Fusible Link (250 A) 6 - Fusible Link (10 A) 10 - Fusible Link 4 (75 A) 14 - Fusible Link 8 (75 A)
(Sliding Fold-In Ladder (Engine Oil Reserve Tank (Fuse Box) (Engine Starter Relay)
Motor (Rear)) Valve)
3 - Fusible Link (400 A) 7 - Fusible Link 1 (75 A) 11 - Fusible Link 5 (75 A) 15 - Fusible Link 9 (45 A)
(PRELUB Relay) (Fuse Box) (Fuse Box) (ECM Main Power)
4 - Fusible Link (5 A) 8 - Fusible Link 2 (75 A) 12 - Fusible Link 6 (75 A) 16 - Fusible Link 10 (75 A)
(PRELUB Signal) (Fuse Box) (Fuse Box) (Sliding Fold-In Ladder
Relay)

T1-2-11
GENERAL / Component Layout
Cab Inside

1
2

T18M-01-02-004 T18G-01-02-053

29 3 4 5

28 6

27 7

8
26 9
25 10
24
11
23
22 12

21 13
20
14

T18M-01-02-005
19 18 17 16 15 13

1 - Monitor Display 9 - Dome Light Switch 16 - Travel Speed Switch 23 - Air Conditioner Control
(Front)
2 - Hour Meter 10 - Entrance Light Switch 17 - Maintenance Switch 24 - Wiper/Washer Switch
3 - Left Control Lever/Horn 11 - Auto-Idle Switch 18 - Work Light Switch 25 - Wiper Interval Switch
Switch
4 - Right Control Lever/Horn 12 - Fast Filling System Switch 19 - Engine Stop Switch 26 - Display Contrast Switch
Switch
5 - Pilot Control Shutoff Lever 13 - Auxiliary 20 - Radio 27 - Key Pad
6 - Emergency Switch 14 - Key Switch 21 - Air Conditioner Control 28 - Engine Warning Lamp
(Rear) (Yellow)
7 - Engine Control Dial 15 - Buzzer Stop Switch 22 - Air Conditioner Control 29 - Engine Stop Lamp (Red)
(Side)
8 - Engine Start Switch

T1-2-12
GENERAL / Component Layout

1 2 3 4 5

M18M-01-006

8 T18M-01-02-006

1 - Electric Lever (Left) 3 - Electric Lever (Travel) 5 - Electric Lever (Right) 7 - IDU
2 - Electric Lever 4 - Electric Lever 6 - Monitor Display 8 - ELU
(Bucket Close) (LD Only) (Bucket Open) (LD Only)

NOTE: LD: Loading Shovel

T1-2-13
GENERAL / Component Layout

T18G-01-02-030

A A 1

M18M-01-007

2 3 4 5 6 7
Cross Section A-A
8

10

T18G-01-02-026
13 12 11

Layout of Power Source Terminal T146-01-03-023

1 - Fuse Box (Cab) 5- Data Link Connector 9- DC/DC Converter 13 - Controller


(Auxiliary) (View Camera)
2 - DC/DC Converter 6 - Data Link Connector 10 - Power Source Terminal
(ECM)
3 - Cigar Lighter 7 - Data Link Connector (DLU) 11 - DLU
4 - ORBCOMM (Optional) 8 - Buzzer 12 - Data Link Connector
(MMS)

T1-2-14
GENERAL / Component Layout
Electrical Equipment Box

T18L-01-02-038

10 11 12 13

5
Relay Arrangement
(Refer to T1-2-16 to 17.)

4
3

T18M-01-02-007

1 - Fuse Box 2 5 - Auto Lubricator Interval 9- Fault code INC/DEC 13 - Box Light
Switch Switch
2 - Fuse Box 1 6 - Engine Fault Indicator 10 - HMU
3 - Fuse Box 4 7 - MC 11 - CSU
4 - Fuse Box 3 8 - Engine Diagnostic Switch 12 - Limit Switch (Box Light)

T1-2-15
GENERAL / Component Layout
Relay Arrangement in Electrical Equipment Box

1 2 3 4 5 6

7
8

9
10
40 11
39 12
13
38
14
37 15
36 16
35 17
18
34
19
33
20
21
22
23
24

25

26
32 31 30 29 28 27 T18M-01-02-007

T1-2-16
GENERAL / Component Layout

1 - Wiper Relay 3 (L5) 11 - Work Light Relay 3 (3) 21 - Washer Motor Relay (21) 31 - ELU PWM Power (26)
(Fast Speed Control) (Upper Cab Work Relay 1 (Key ON
Light (L)(R)) Signal)
2 - A/C Main Relay (L6) 12 - Work Light Relay 4 (4) 22 - A/C Fan Relay (Front) (22) 32 - ELU Pilot Solenoid (25)
(Front) (Right Frame Front Relay
Work Light (L)(R))
3 - Air Horn Compressor (L1) 13 - Work Light Relay 5 (5) 23 - A/C Fan Relay (Side) (23) 33 - Air Horn Compressor (17)
Relay (L1) (Engine Frame Rear Relay (L2)
Work Light (L)(R))
4 - Air Horn Compressor (L2) 14 - Work Light Relay 6 (6) 24 - A/C Fan Relay (Rear) (24) 34 - Air Horn Compressor (18)
Relay (R1) (Optional) (Center L/R Side Relay (R2) (Option)
Work Light)
5 - Wiper Relay 1 (L3) 15 - Entrance Light Relay (7) 25 - Sliding Fold-In (32) 35 - Horn Relay (19)
(Slow Speed Control) Ladder Alarm and
Flash Light Relay 2
6 - *Wiper Relay 2 (L4) 16 - Maintenance Light (8) 26 - Sliding Fold-In (31) 36 - Wiper Relay 4 (20)
(Slow Speed Control) Relay (Engine Room) Ladder Alarm and (Slow Speed Control)
Flash Light Relay 1
7 - A/C Main Relay (Side) (L7) 17 - Fast Filling Panel (13) 27 - Engine Oil Reserve (30) 37 - Maintenance Light (9)
Position Relay (Store Tank Pumping Unit Relay (Pump Room
Signal) Relay and Radiator Room)
8 - A/C Main Relay (L8) 18 - Delayed Power Off (14) 28 - Sliding Fold-In (29) 38 - Maintenance Light (10)
(Rear) Relay Ladder Relay Relay (Cab Bed)
9 - Work Light Relay 1 (1) 19 - Travel Speed Select (15) 29 - ELU PWM Power (28) 39 - Maintenance Light (11)
(Left Frame Front Relay Relay 3 (Emergency Relay (Control Valve
Work Light (L)) Switch Signal) and Oil Cooler Room)
10 - Work Light Relay 2 (2) 20 - Fast Filling Device (16) 30 - ELU PWM Power (27) 40 - Charge Signal Relay (12)
(Left Frame Front Relay Relay 2 (Gate Lock
Work Light (R)) Switch Signal)

*Wiper Relay 2 (Up to serial No.1087)


NOTE: Numbers in parentheses correspond to the numbers used in the electric circuit diagram.

T1-2-17
GENERAL / Component Layout
LEDs for Contamination Sensor Amplifier

2 4 6
1 3 5
Auxiliary

Auxiliary 7 9
8
Auxiliary

T146-05-02-049

T18M-01-02-007

1 - Main Pump 1 4 - Main Pump 4 6- Main Pump 6 8- Rear Swing Motor


2 - Main Pump 2 5 - Main Pump 5 7- Front Swing Motor 9- Travel Motor
3 - Main Pump 3

T1-2-18
GENERAL / Component Layout
Contamination Sensors Layout
3 4

1 2

6
Machine
Front

A
T18L-01-02-006

T18L-01-02-021

View A Cross Section B


7 8

T18L-01-02-007
B
T18L-01-02-017

1 - Contamination Sensor 4 - Contamination Sensor 6 - Contamination Sensor 8- Contamination Sensor


(Main Pump 1) (Main Pump 4) (Main Pump 6) (Front Swing Motor)
2 - Contamination Sensor 5 - Contamination Sensor 7 - Contamination Sensor 9 - Contamination Sensor
(Main Pump 2) (Main Pump 5) (Rear Swing Motor) (Travel Motor)
3 - Contamination Sensor
(Main Pump 3)

T1-2-19
GENERAL / Component Layout
ENGINE

1 2

5 4 T18L-01-02-031

9 8 7 6
T18L-01-02-032

1 - PRELUB Pressure Switch 4 - Cummins ECM 6- Alternator (Cummins) 8 - Engine Oil Level Sensor
2 - Engine Speed Sensor 5 - Fuel Filter (3 Used) 7- Coolant Filter (2 Used) 9 - Engine Oil Filter (4 Used)
3 - Starter (Cummins)

T1-2-20
GENERAL / Component Layout
RADIATOR

1
A

4 5

B
3
2

T18L-01-02-025
C

Cross Section A View B Cross Section C

6 8 9
T18L-01-02-026

1 - Water Tank 4 - Coolant Temperature 6- Coolant Level Sensor 8- Coolant Temperature


Sensor (LTA In) Sensor (Radiator Out)
2 - LTA Cooler 5 - Coolant Temperature 7- Coolant Level Switch 9 - Coolant Temperature
Sensor (Radiator In) Sensor (LTA Out)
3 - Radiator

T1-2-21
GENERAL / Component Layout
AIR CLEANER

T18L-01-02-027

1 - Air Cleaner 2- Air Cleaner Restriction Switch

T1-2-22
GENERAL / Component Layout
PUMP DEVICE
1 2 3

T18L-01-02-003

View A

T18L-01-02-029

1 - Pump 1 Drain Pressure 3 - Pump 3 Drain Pressure 4- Pump 5 Drain Pressure 5- Pump Transmission Oil
Sensor (Transmission Side) Sensor (Transmission Side) Sensor (Transmission Side) Temperature Switch
Pump 2 Drain Pressure Pump 4 Drain Pressure Pump 6 Drain Pressure
Sensor (Pump End Side) Sensor (Pump End Side) Sensor (Pump End Side)
2 - Pump Transmission Level
Switch

T1-2-23
GENERAL / Component Layout
CONTROL VALVE

NOTE: This drawing indicates the arrangement


viewed from the base machine front.

Control Valve (Lower-Right) Control Valve (Upper) Control Valve (Lower-Left)

1 2 3 4 5 6 7 18 19 20 21 22 23 24 31 32 33 34 35 36 37

T18L-01-02-048

9 10 11 12 13 14 16 17 25 26 27 28 29 30 38 39 40 41 42 43

T1-2-24
GENERAL / Component Layout
Control Valve (Lower-Right) Control Valve (Upper)
1 - Overload Relief Valve (Boom Raise) 18 - Main Relief Valve
2 - Make-Up Valve (Boom Raise) 19 - Overload Relief Valve (Boom Raise)
3 - Overload Relief Valve (Bucket Tilt-In) 20 - Make-Up Valve (Boom Raise)
4 - Make-Up Valve (Bucket Tilt-In) 21 - Overload Relief Valve (LD: Bucket Open, BH: Bucket Roll-In)
5 - Overload Relief Valve (LD: Arm Extend, BH: Arm Roll-In) 22 - Make-Up Valve (LD: Bucket Open, BH: Bucket Roll-In)
6 - Make-Up Valve (LD: Arm Extend, BH: Arm Roll-In) 23 - Overload Relief Valve (LD: Arm Extend, BH: Arm Roll-In)
7 - Overload Relief Valve (Right Swing) 24 - Make-Up Valve (LD: Arm Extend, BH: Arm Roll-In)
9 - Make-Up Valve (Boom Lower) 25 - Make-Up Valve (Boom Lower)
10 - Overload Relief Valve (Boom Lower) 26 - Overload Relief Valve (Boom Lower)
11 - Make-Up Valve (Bucket Tilt-Out) 27 - Overload Relief Valve (LD: Bucket Close)
12 - Overload Relief Valve (Bucket Tilt-Out) 28 - Overload Relief Valve (LD: Bucket Close, BH: Bucket Roll-Out)
13 - Make-Up Valve (BH: Arm Roll-Out) 29 - Make-Up Valve (LD: Arm Retract, BH: Arm Roll-Out)
14 - Overload Relief Valve (BH: Arm Roll-Out) 30 - Overload Relief Valve (LD: Arm Retract, BH: Arm Roll-Out)
16 - Overload Relief Valve (Left Swing)
17 - Main Relief Valve

Control Valve (Lower-Left)


31 - Main Relief Valve
32 - Overload Relief Valve (LD: Arm Extend, BH: Arm Roll-In)
33 - Make-Up Valve (LD: Arm Extend, BH: Arm Roll-In)
34 - Overload Relief Valve (Boom Raise)
35 - Make-Up Valve (Boom Raise)
36 - Overload Relief Valve (Bucket Tilt-In)
37 - Make-Up Valve (Bucket Tilt-In)
38 - Make-Up Valve (LD: Arm Retract, BH: Arm Roll-Out)
39 - Overload Relief Valve (LD: Arm Retract, BH: Arm Roll-Out)
40 - Make-Up Valve (Boom Lower)
41 - Overload Relief Valve (Boom Lower)
42 - Make-Up Valve (Bucket Tilt-Out)
43 - Overload Relief Valve (Bucket Tilt-Out)

NOTE: LD: Loading Shovel


BH: Backhoe

T1-2-25
GENERAL / Component Layout

1 A 2

View A

T18L-01-02-033
B

View B

4 3
T18L-01-02-028

1 - Arm Rod Pressure Sensor 2- Arm Bottom Pressure Sensor 3- Pressure Sensor (Travel) 4- Shuttle Valve (Travel)

T1-2-26
GENERAL / Component Layout
SWING DEVICE

3 4

T18L-01-02-007
2

1 - Swing Motor 2- Swing Motor Drain 3- Relief Valve 4- Make-Up Valve


Pressure Sensor

T1-2-27
GENERAL / Component Layout
TRAVEL DEVICE

1 2

T18L-01-02-011

CENTER JOINT

T18L-01-02-017

1 - Travel Motor 2 - Brake Valve 3 - Travel Reduction Gear 4 - Travel Motor Drain
Pressure Sensor

T1-2-28
GENERAL / Component Layout
OIL COOLER
Machine Front Side

Cross Section A Cross Section B

1 4

5 7

6 8
T18L-01-02-047

1 - Oil Cooler (Front) 3 - Oil Cooler Hydraulic Oil 5 - Oil Cooler Bypass Check 7 - Oil Cooler Bypass Check
Temperature Sensor (2) Valve (Front) Valve (Rear)
(IN)
2 - Oil Cooler Hydraulic Oil 4 - Oil Cooler (Rear) 6 - Oil Cooler Hydraulic Oil 8 - Oil Cooler Hydraulic Oil
Temperature Sensor (1) Temperature Sensor (1) Temperature Sensor (2)
(IN) (OUT) (OUT)

T1-2-29
GENERAL / Component Layout
EHC VALVE (FOR MAIN PUMP CONTROL)

1 2

7
3

T18L-01-02-004

1 - Main Pump Displacement 3 - Main Pump Displacement 5 - Oil Cooler Fan Control 7 - Auxiliary
Control (No.3, 5, 6 Main Control (No.1, 2, 4 Main
Pump) Pump)
2 - Power Decrease Control 4 - Power Increase Control 6 - Auxiliary 8 - Auxiliary

T1-2-30
GENERAL / Component Layout
EHC VALVE (FOR ELECTRIC LEVER
CONTROL)

EHC Valve (Center Side) EHC Valve (Left Side)

1 2 3 4 10 11 12 13

9 8 7 6 5 T18L-01-02-023
17 16 15 14 T18L-01-02-022

1 - Boom Lower 6 - Auxiliary 10 - LD: Bucket Close 14 - Right Travel Reverse


BH: Auxiliary
2 - Arm Extend 7 - Arm Retract 11 - Left Travel Forward 15 - Left Swing
3 - Bucket Tilt-Out 8 - Bucket Tilt-In 12 - Left Travel Reverse 16 - Right Swing
4 - Auxiliary 9 - Boom Raise 13 - Right Travel Forward 17 - LD: Bucket Open
BH: Auxiliary
5 - Pilot Shut-Off Pressure
Sensor

NOTE: LD: Loading Shovel


BH: Backhoe

T1-2-31
GENERAL / Component Layout
SLIDING FOLD-IN LADDER

4
1 5
6
2
3 7

8
Cross Section Cross Section
A-A C-C A View B

9
B 10

11

12

C C

13

14

T18L-01-02-039
1 - Sliding Fold-In Ladder 5- Limit Switch 9- Valve Unit 12 - Limit Switch (Lock Lever)
Relay (2) (Expansion Slowdown)
2 - Sliding Fold-In Ladder 6 - Limit Switch 10 - Work Light 13 - Sliding Fold-In Ladder
Relay (3) (Storage Slowdown) (Sliding Fold-In Ladder) Cylinder
3 - Sliding Fold-In Ladder 7 - Limit Switch 11 - Sliding Fold-In Ladder 14 - Lock Lever
Relay (4) (Storage Detection) Beacon/Alarm
4 - Limit Switch 8 - Motor Pump Unit
(Expansion Detection)

T1-2-32
GENERAL / Component Layout
Valve Unit (For Sliding Fold-In Ladder)
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
10
8 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 - Sliding Fold-In Ladder
(For Cylinder Bottom Side) Solenoid Valve 2
2 - Orifice 6 - Sliding Fold-In Ladder 10 - Throttle Valve 14 - Slow Return Valve
Solenoid Valve 3
3 - Check Valve 7 - Main Relief Valve 11 - Sliding Fold-In Ladder 15 - Overload Relief Valve
Solenoid Valve 1 (For Cylinder Rod side)
4 - Check Valve 8 - Check Valve 12 - Check Valve

T1-2-33
GENERAL / Component Layout
AUTO-LUBRICATION SYSTEM

Lubricator Panel Grease Tank


4

1
3 6

2
5

M18L-07-015

T146-01-03-026

T18L-01-02-024

T18M-03-07-006

1 - Pressure Switch 3 - Auto-Lubrication 5 - Grease Pump 7 - Auto-Lubrication


(Auto Lubrication) ON/OFF Switch Interval Switch
2 - Pressure Switch 4 - Vent Valve 6 - Auto-Lubrication
(Manual Lubrication) Solenoid Valve

T1-2-34
GENERAL / Component Specifications
ENGINE
Manufacturer ................................................ CUMMINS ENGINE COMPANY, Inc
Model............................................................ QSKTA50
Type.............................................................. Diesel, 4 cycle, 60° V, water-cooled,
direct injection type (With turbocharger and after-cooler)
Cyl. No.-bore × stroke .................................. 16-159×159 mm (16-6.3×6.3 in)
Piston displacement ..................................... 50 L
-1
Rated output (Gross).................................... 1044 kW/1800 min (1420 PS/1800 rpm)
Compression ratio ........................................ 15.0
Weight .......................................................... Dry: 5526 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 side)
Overall length × width × height ..................... 2803×1471×1785 mm (110×58×70 in)

Cooling System
Thermostat ................................................... Engine line: Cracking temp: 82 °C (180 °F)
Full open temp: 94 °C (201 °F)
Aftercooler line: Cracking temp: 46 °C (115 °F)
Full open temp: 57 °C (135 °F)
Water pump .................................................. Centrifugal type
Coolant capacity ........................................... 140 L (37.0 US gal) (engine line only)
30 L (7.9 US gal) (after cooler line only)
47.2 L (12.5 US gal) (reserve tank only)

Lubrication System
Type .............................................................. Screw pump
Oil filter.......................................................... Paper element, spin-on type for full-flow and bypass filters
Lubrication oil capacity ................................. 151 L (39.9 US gal) (High),
121 L (32.0 US gal) (Low)

Starting System
Model ............................................................ 50MT-400
Voltage⋅Output .............................................. DC24 V ⋅ 9 kW×2

Auxiliary Starting System


Type .............................................................. Ether (Optional)

Engine Stop System


Stop method ................................................. Cummins electronic control

Alternator
Type .............................................................. AC generator with diode rectifier
Voltage⋅Output .............................................. DC24 V⋅140 A

Supercharging System
Type .............................................................. Exhaust-gas driven type

Performance
Fuel consumption ratio ................................. 217 g/kW⋅h (160 g/PS⋅h) at rated output
Injection timing.............................................. Variable (MCRS electronic control)
-1
Max. output torque (Gross)........................... 6382 N⋅m (650 kgf⋅m, 4710 lbf⋅ft)/1300 min
-1
No load speed............................................... 2050±30 min

T1-3-1
GENERAL / Component Specifications
Engine Performance Curve (QSKTA50)
Test Conditions: The engine operating with fuel system, water pump, and 4.5 kPa inlet air restriction with 148.1
mm inner diameter, and with 6.8 kPa exhaust restriction with 197.9 mm inner diameter; not in-
cluded are alternator, fan, optional equipment and driven components.

Curves shown above represent gross engine performance capabilities obtained and corrected in accordance
with SAE J1995 conditions of 100 kPa barometric pressure [91 m (300 ft) altitude] 25 °C (77 °F) inlet air tem-
perature, and 1 kPa water vapor pressure with SAE No.2 diesel fuel.

Torque Torque
(lbf·ft) (N·m)

Engine Speed (min-1 )

Output Output
(HP) (kW)

Engine Speed (min-1 )

Fuel Consumption Fuel Consumption


Ratio Ratio
(lb/HP·h) (g/kW·h)

Engine Speed (min-1 )

T18L-01-03-001

T1-3-2
GENERAL / Component Specifications
ENGINE ACCESSORIES
Radiator Assembly
Type.............................................................. Radiator/Inter-cooler tandem type assembly
Weight .......................................................... 1480 kg (3260 lb)

Radiator After-cooler
Fin type ......................................................... Plate fin Plate fin
Capacity........................................................ 99.8 L (26.4 US gal) 118.8 L (31.4 US gal)

Fuel Cooler
Fin type ......................................................... Wavy fin
Capacity........................................................ 0.5 L (0.13 US gal)
Weight .......................................................... 1.2 kg (2.7 lb)

Battery
Capacity........................................................ 176 Ah (5 hours)
Voltage.......................................................... 12 V
Weight .......................................................... 66 kg (146 lb)

Oil Cooler
Fin type ......................................................... Plate fin
Capacity........................................................ 37 L (9.8 US gal)
Weight .......................................................... 300 kg (660 lb)

Pump Transmission Cooler


Fin type ......................................................... Corrugated
Capacity........................................................ 2 L (0.5 US gal)

T1-3-3
GENERAL / Component Specifications
HYDRAULIC COMPONENT
Pump Device
Gear Ratio .................................................... Engine vs Main pump: 0.86
Engine vs 4-unit pump: 1.089

Main Pump (MP1 to 4)


Type.............................................................. Swash plate type,
variable displacement tandem plunger pump
Model............................................................ K3V280DTH14ZL
3 3
Theoretical displacement ............................. 250 cm (15 in )/rev×2
Maximum flow rate ....................................... 375 L/min (99 gpm)×2

Main Pump (MP5, 6)


Type.............................................................. Swash plate type,
variable displacement tandem plunger pump
Model............................................................ K3V280DTH18ZL
3 3
Theoretical displacement ............................. 280 cm (17 in )/rev×2
Maximum flow rate ....................................... 425 L/min (112 gpm)×2

4-Unit Pump
Model............................................................ K3V112S (Fan Motor Drive Pump)
KFP4156 (Pilot Pump / Compressor Pump /
Transmission Oil Pump)

Fan Motor Drive Pump


Type.............................................................. Swash plate type, variable displacement plunger pump
3 3
Theoretical displacement ............................. 112 cm (6.8 in )/rev
Maximum flow rate ....................................... 199 L /min (53 gpm)

Pilot Pump / Compressor Pump / Transmission Oil Pump


Type.............................................................. Tandem gear pump
3 3
Maximum flow rate (Transmission side)....... 56 cm (3.4 in )/ rev
3 3
(Center side)................. 45 cm (2.7 in )/ rev
3 3
(Top side)...................... 13 cm (0.8 in )/ rev

Control Valve
Type.............................................................. Pilot operated, multi block
Model............................................................ KSV 1000
2
Main relief set pressure ................................ 29.4 MPa (300 kgf/cm , 4270 psi)
2
Overload relief set pressure ......................... 30 MPa (320 kgf/cm , 4550 psi)
2
16 MPa (170 kgf/cm , 2420 psi) (Bucket open / close)

Swing Device
Type.............................................................. Two-stage reduction planetary gear
Gear Ratio .................................................... 13.358

T1-3-4
GENERAL / Component Specifications
Swing Motor
Type.............................................................. Swash plate type, fixed displacement axial plunger motor
Model............................................................ MX750
3 3
Theoretical Displacement............................. 750 cm (45.8 in )/rev
2
Relief set pressure ....................................... 27.4 MPa (280 kgf/cm , 3980 psi)
+0 +0 2 +0
Parking brake release pressure ................... 1.8 -0.4 MPa (18 -0.4 kgf/cm , 256 -57 psi)

Travel Device
Type.............................................................. Two-stage reduction planetary gear
Gear ratio ..................................................... 134.917

Travel Motor
Type.............................................................. Swash plate type, variable displacement axial plunger motor
Model............................................................ M3B/027BA
3 3
Theoretical displacement (Slow) .................. 1027 cm (63 in )/rev
3 3
(Fast)................... 718 cm (44 in )/rev
+0.2 +2.2 2 +30
Parking brake release pressure ................... 1.7 -0 MPa (17.4 -0 kgf/cm , 247 -0 psi)

Travel Brake Valve


Type.............................................................. VBR-12ST
Flow rate....................................................... 660 L/min (174 gpm)

Oil Cooler Fan Motor


Model............................................................ A2FM63/61 W
3 3
Theoretical displacement ............................. 63.0 cm (3.9 in )/rev

Compressor Motor
Model............................................................ MSF-46
3 3
Theoretical displacement ............................. 46.1 cm (2.8 in )/rev

T1-3-5
GENERAL / Component Specifications
Boom Cylinder (Loading Shovel) (Backhoe)
Rod diameter................................................ 230 mm (9.1 in) 230 mm (9.1 in)
Cylinder bore ................................................ 310 mm (1 ft 0.2 in) 310 mm (1 ft 0.2 in)
Stroke ........................................................... 2400 mm (7 ft 10.5 in) 3040 mm (9 ft 11.7 in)
Fully retracted length.................................... 4475 mm (14 ft 8.2 in) 4340 mm (14 ft 3 in)
Metal plating thickness................................. 30 µm (1.18 µin) 30 µm (1.18 µin)

Arm Cylinder (Loading Shovel) (Backhoe)


Rod diameter................................................ 210 mm (8.3 in) 210 mm (8.3 in)
Cylinder bore ................................................ 280 mm (11 in) 280 mm (11 in)
Stroke ........................................................... 2275 mm (7 ft 5.6 in) 2310 mm (7 ft 7 in)
Fully retracted length.................................... 3505 mm (11 ft 6 in) 3555 mm (11 ft 8 in)
Metal plating thickness................................. 30 µm (1.18 µin) 30 µm (1.18 µin)

Level Cylinder
Rod diameter................................................ 230 mm (9.1 in)
Cylinder bore ................................................ 310 mm (1 ft 0.2 in)
Stroke ........................................................... 1050 mm (3 ft 5.3 in)
Fully retracted length .................................... 2385 mm (7 ft 9.9 in)
Metal plating thickness ................................. 30 µm (1.18 µin)

Bucket Cylinder (Loading Shovel) (Backhoe)


Rod diameter................................................ 180 mm (7.1 in) 170 mm (6.7 in)
Cylinder bore ................................................ 250 mm (9.8 in) 230 mm (9.1 in)
Stroke ........................................................... 1825 mm (5 ft 11.9 in) 2105 mm (6 ft 11 in)
Fully retracted length.................................... 3980 mm (13 ft 0.7 in) 3195 mm (10 ft 5.8 in)
Metal plating thickness................................. 30 µm (1.18 µin) 30 µm (1.18 µin)

Dump Cylinder
Rod diameter................................................ 130 mm (5.1 in)
Cylinder bore ................................................ 215 mm (8.5 in)
Stroke ........................................................... 495 mm (1 ft 7.5 in)
Fully retracted length .................................... 1325 mm (4 ft 4.2 in)
Metal plating thickness ................................. 30 µm (1.18 µin)

Lift Cylinder Fast Filling Device Sliding Fold-In Ladder


Rod diameter................................................ 30 mm (1.2 in) 40 mm (1.6 in)
Cylinder bore ................................................ 50 mm (2.0 in) 65 mm (2.6 in)
Stroke ........................................................... 175 mm (6.9 in) 880 mm (2 ft 10.6 in)
Fully retracted length.................................... 375 mm (1 ft 2.8 in) 1160 mm (3 ft 9.7 in)
Metal plating thickness................................. 30 µm (1.18 µin) 30 µm (1.18 µin)

T1-3-6
GENERAL / Component Specifications
EHC Valve
For Main Pump Control (Pump Room)
Application ........................SA: Auxiliary SB: Auxiliary
SC: Oil Cooler Fan Motor Speed Control SD: Power Increase Control
SE: Flow Cutoff Control SF: Power Decrease Control
SH: Auxiliary SI: Flow Cutoff Control

For Electric Lever Control (Main Frame Left Side)


Application ........................SA: Left Swing Control SB: Right Swing Control
SC: Travel Right Reverse Control SD: Travel Right Forward Control
SE: Travel Left Reverse Control SF: Travel Left Forward Control
SH: Bucket Open Control (LD) SI: Bucket Close Control (LD)

For Electric Lever Control (Main Frame Center Side)


Application ........................SA: Arm Roll-In Control SB: Bucket Roll-In Control
SC: Auxiliary SD: Auxiliary
SE: Bucket Roll-Out Control SF: Arm Roll-Out Control
SH: Boom Raise Control SI: Boom Lower Control

Travel Mode Selection Solenoid Valve


Max. input flow ............................................. 60 L/min (15.8 US gpm)

Fast Filling Panel Control Solenoid Valve


Max. input flow.............................................. 60 L/min (15.8 US gpm)

Pilot Shut-Off Solenoid Valve


Max. input flow.............................................. 60 L/min (15.8 US gpm)

Reducing Valve (Travel Mode)


2
Secondary pressure...................................... 2.75±0.15 MPa (28±1.5 kgf/cm , 398±21 psi)

Pilot Pressure Control Valve (Adjuster)


2
Cracking pressure ........................................ 11.8±1.0 MPa (120±10 kgf/cm , 1710±142 psi)

DQR Valve
2
Control pressure ........................................... 4 MPa (40 kgf/cm , 569 psi)

T1-3-7
GENERAL / Component Specifications
ELECTRICAL EQUIPMENT
Coolant Level Switch (For Level Indicator and Warning Indicator)
Type .............................................................. Capacitance switch

Air Filter Restriction Switch


Operating pressure....................................... 6.2±0.6 kPa (635±58 mmH2O)

Fuel Level Sensor (For Warning)


Type .............................................................. Float type

Fuel Level Switch (For Fast Filling System Fuel Fill Indicator,
Engine Oil Reserve Tank Level Check Switch)
Type .............................................................. Capacitance type

Pump Transmission Oil Level Switch (For Warning)


Type .............................................................. Capacitance type

Hydraulic Oil Level Switch (For Warning)


Type .............................................................. Float switch

Atmospherical Temperature Sensor (For Cab Front, Radiator Front and Oil Cooler Front)
Coolant Temperature Sensor (For Radiator Inlet and Radiator Outlet)
Hydraulic Oil Temperature Sensor (For Hydraulic Oil Tank, Oil Cooler Outlet and
Main Pump Transmission)
Operating temperature ................................. -30 to 120 °C (-22 to 248 °F)

Main Pressure Sensor (For Arm Cylinder Bottom and Arm Cylinder Rod)
2
Operating pressure....................................... 0 to 34.3 MPa (0 to 350 kgf/cm , 0 to 4990 psi)

Drain Pressure Sensor (For Oil Cooler Inlet, Swing Motor and Main Pump P1 To 8)
2
Operating pressure....................................... 0 to 4.9 MPa (0 to 50 kgf/cm , 0 to 710 psi)

Pilot Pressure Sensor (EHC Valve and Travel Alarm)


2
Operating pressure....................................... 0 to 4.9 MPa (0 to 50 kgf/cm , 0 to 710 psi)

Pressure Switch (Grease) (Auto Lubrication Circuit)


2
Set Pressure................................................. 17.6 MPa (180 kgf/cm , 2559 psi)

Pressure Switch (Grease) (Manual Lubrication Circuit)


2
Set Pressure................................................. 23.5 MPa (240 kgf/cm , 3410 psi)

T1-3-8
GENERAL / Component Specifications
Control Lever (Front Attachment/Swing)
Model............................................................ S90JAM
Mechanical control angle.............................. XY Axis ±15° to ±20°
Control force ................................................. XY Axis About 2 N to 8 N
All resistance ................................................ 2 kΩ±15 %

Control Lever (Travel)


Model............................................................ ERUP2
Mechanical control angle.............................. ±12.4°
Neutral detection angle ................................ ±3°
Control force ................................................. About 21 N to 29 N
Output voltage .............................................. 1.0 to 4.0 V

Control Lever (Bucket Open/Close)


Model............................................................ ERU2
Mechanical control angle.............................. ±12.4°
Neutral detection angle ................................ ±3°
Control force ................................................. 40 to 63 N
Output voltage .............................................. 1.0 to 4.0 V

Accelerator Sensor
Resistance.................................................... 5 kΩ±20 %
Output........................................................... 0.4±0.1 V at Slow idle
4.4±0.1 V at Fast idle

Pump Unit (For Sliding Fold-In Ladder)


Model............................................................ DU2.5NC
Maximum output ........................................... 2.4 kW

T1-3-9
GENERAL / Component Specifications
FILTER
Suction Filter................................................. 177 µm
High Pressure Strainer ................................. 95 µm
Full-flow Filter ............................................... 10 µm
Bypass Filter ................................................. 5 µm
Drain Filter .................................................... 10 µm
Pilot Filter...................................................... 10 µm

OTHERS
Lubrication Device
Capacity........................................................ 200 kg (440 lb)
2
Maximum Pressure ...................................... 24.0 MPa (245 kgf/cm , 3490 psi)
3
Displacement................................................ 240 mL (14 in )/min)

Air Conditioner
Cooling ability................................................ 5.0 kW (4320 kcal/h)×3
Heating ability ............................................... 3.8 kW (3323 kcal/h)×3
Charged Refrigerant Amount........................ 1400±50 g (3±0.1 lb)
3 3
Compressor Oil Volume................................ 320 cm (19.5 in )
(Incl. the volume in the compressor and hoses)

T1-3-10
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 Main Circuit ..............................................T2-4-8
IDU: Information Display Unit ................T2-1-14 Pump Transmission Oil Cooler Circuit ....T2-4-14
ECM: Engine Control Module Oil Cooler Fan Motor Circuit ...................T2-4-14
(Engine Controller) ...............................T2-1-20 Air Conditioner Compressor Motor
DLU: Data Logging Unit..........................T2-1-22 Circuit...................................................T2-4-14
CSU: Contamination Sensing Unit ........T2-1-24 Travel-Shock Absorber/Travel Stop
HMU: Hydraulic System Monitoring Unit Circuit...................................................T2-4-15
(Pump/Swing Motor Drain Pressure
Monitoring) ...........................................T2-1-26 Group 5 Electrical System
Outline .....................................................T2-5-1
Group 2 Control System Power Source Circuit (Key Switch: OFF) ..T2-5-2
Outline .....................................................T2-2-1 Accessory Circuit (Key Switch: ACC) ........T2-5-4
Engine Control .........................................T2-2-2 Engine Start Circuit (Key Switch: ON) .......T2-5-6
Pump Control .........................................T2-2-10 Charging Circuit .....................................T2-5-12
Fast-Filling Panel Lower Control.............T2-2-16 Engine Stop Circuit .................................T2-5-22
Sliding Fold-In Ladder Control ................T2-2-18 Surge Voltage Protection Circuit .............T2-5-28
Auto-Lubrication Control.........................T2-2-22
Oil Cooler Fan Motor Speed Control .......T2-2-26
Wiper Control .........................................T2-2-28
Travel Mode Control ...............................T2-2-30

Group 3 ELU System


Outline .....................................................T2-3-1
Pilot Control 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

18LT-2-1
(Blank)

18LT-2-2
SYSTEM / Controller
OUTLINE
Controllers are arranged by function. They are con-
nected through CAN for monitoring all machine oper-
ating conditions including the engine, and for indicating
operating 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

∗MMS: Modular Mining System

ECM(C2) ECM(C1) ECM(P)

J1939-CAN Service
Tool
GPS Antenna
DLU

Orbcumm
Ke-CAN
(Optional)
IDU ELU MC
MMS
COMM. UNIT MMS
(Optional)
(Optional)

Display
CAN
Keypad
HMU CSU

T18M-02-01-001

T2-1-1
SYSTEM / Controller
MC: MAIN CONTROLLER
Functions

• Auto-Idle Control • Auto-Lubrication Control


When all control levers are in neutral and auto-idle MC activates the auto-lubrication solenoid valve at
switch is ON, MC send auto-idle signal to ECM. intervals set by the auto-lubrication interval switch to
ECM reduce the engine speed to auto-idle speed. lubricate front joint pins, swing bearing, and center
joint.
• Power Increase Control
When the engine speed is between 1800 to 2156 • Oil Cooler Fan Control
-1
min , and MC receives lever control signal from ELU, MC controls the oil cooler fan speed select solenoid
MC controls the power increase solenoid valve to valve in response to signal from hydraulic oil tem-
deliver pilot pressure oil to port Pz of the pump perature sensor to change the oil cooler fan motor
regulator, thus increasing pump absorption horse- speed at four stages.
power.

• Power Decrease Control


-1
When engine speed is less than 1650 min or ECM
send the engine protection signal or MC receives
lever control signal from ELU, MC controls the power
decrease solenoid valve to deliver pilot pressure oil
to Pf port of pump regulator, thus decreasing pump
absorption horsepower.

• Fast-Filling Panel Lower Control


When the fast-filling switch is turned ON with the pi-
lot control shut-off lever LOCK, MC activates the
fast-filling solenoid valve to supply pressure oil from
pilot pump to lift cylinder, thus lowering the fast-filling
panel.
When the pilot control shutoff lever is UNLOCK, MC
controls that the fast-filling panel does not lower.

T2-1-2
SYSTEM / Controller

Pilot Control Shut-Off


Lever Limit Switch To IDU, DLU

MC
Auto-Idle
Switch ELU
Engine Speed Sensor

Fast-Filling Switch

ECM

Fast-Filling Fast-Filling
Panel Position Solenoid Power Increase
Monitor Switch Valve Solenoid Valve

To ELU
Power Decrease
Solenoid Valve

Pressure Switch 1
(Auto-Lubrication)
Auto-Lubrication
Solenoid Valve

Pressure Switch 2
(Manual Oil Cooler Fan
Lubrication) Speed Select
Solenoid Valve

Auto-Lubrication
Interval Switch
3 min.
5 min.
10 min.
15 min.

Hydraulic Oil Temperature Sensor

Power Increase Pressure Sensor


Oil Cooler Fan Control
Pressure Sensor

Power Decrease Pressure Sensor

T18L-02-01-001

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

• Power Delay Shut-Off Control


MC shuts off the exciting current at the power
shut-off delay relay at the lapse of certain period
(Settable from 15 second to 10 minute) after turn-ON
of the key switch. As a result, the battery relay is
turned OFF to shut off the current from battery.
Time setting can be perform on the monitor display.

• Fuel Level Measurement


MC receives signal from the fuel level sensor and
fuel level switch, then transmits the detected data
from the sensor to IDU through CAN. IDU outputs
the detected data to the display. (Refer to Section
“IDU meter Indication”.)

• Motion Alarm Control


MC receives signal from travel pilot pressure sensor,
and sounds travel alarm when the received signal
reaches the setting or higher, which indicates that
the machine is traveling.

T2-1-4
SYSTEM / Controller

Wiper Motor
MC
Wiper Relay 2

Key Switch

Washer Switch Fuse #75


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

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

Washer Mo-
tor Relay Wiper
Relay 3

Washer Motor
Warning Light LED Red

Wiper Warning Light LED Yellow


Interval
Switch Power Decrease
• 25 sec. Solenoid Valve
• 20 sec.
• 15 sec.
• 10 sec.
• 5 sec.

Fuel Level Sensor

Battery
Travel Pilot Pressure Sensor
Power Shut-Off
Delay Relay

Travel Alarm
Fuel Level Switch (Hi)

Fuel Level Switch (Low) To IDU, DLU

CAN

Monitor
IDU Display

Power Shut-Off T18M-02-01-003


Delay Time Setting
(15 second to
10 minute)

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

1. Hydraulic oil level


2. Air cleaner filter clogging (LED Yellow)
3. Alternator operation
4. Pump transmission oil level
5. Emergency switch status (ON/OFF)
6. Valves opening/closing
7. MC turns ON warning light LED red or LED yellow
according to judgment.
At the same time, IDU turns on warning light on
the monitor display in response to information
through CAN.
NOTE: IDU also sounds buzzer, if judgment the
hydraulic oil level, pump transmission oil
level or hydraulic oil tank valve are abnor-
mal.

• Failure Diagnosis
Failure diagnosis is carried out through sensors
connected to MC.
Failure information is transmitted to DLU and IDU via
CAN.
DLU logs failure information.
IDU indicates failure information on the display.

T2-1-6
SYSTEM / Controller

Air Release
Solenoid Valve
Alternator
Line
Key Switch Air Cleaner Switch
ON Signal MC
Line

2 1
5 4 3

Valve Limit
Switch
(Return (1))
Valve Limit Switch
(Return
(2)) Valve Limit
Switch
(Suction)

To ECM
(Key ON)

Warning Light LED Red

Warning Light LED Yellow


Hydraulic Oil
Level Switch

To IDU, DLU

Hydraulic Oil Level


Alarm Switch CAN

1 - Emergency Switch
Charge
(Cab)
2 - Emergency Switch
(Engine Room (Front))
3 - Emergency Switch
(Engine Room (Rear))
Pump Transmission
4 - Emergency Switch
Oil Level Alarm
Switch (Pump Room Front)
5 - Emergency Switch
(Pump Room Rear)

Engine Speed
Sensor

T18L-02-01-006

T2-1-7
SYSTEM / Controller
ELU: ELECTRIC LEVER CONTROL UNIT
Functions
• Pilot Control Shutoff Valve Selection
Actuates or stops the lever lock solenoid by select-
ing the pilot control shut-off valve relay with the pilot
control shut-off lever limit switch to deliver or shuts
off pilot pressure oil to control solenoid valve.

• Pilot Pressure Control by Control Valve


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

Pump control functions


• Positive Control
ELU transmits signal to the positive control valve
according to the control lever stroke.
The positive control valve delivers pilot pressure oil
to the pump regulator in response to signal so as to
control the pump displacement angle.

T2-1-8
SYSTEM / Controller

Pilot Control Shut-Off CAN


Lever Limit Switch MC To IDU, DLU

Pilot Control
ELU Shut-Off Relay
Front/Swing Con- Lever Lock Solenoid
trol Lever

EHC Valve
(For Electric Lever
Control)
Arm Extend
Travel Control (BH: Roll-Out)
Lever Solenoid Valve
Swing Right So-
lenoid Valve
Bucket Open So-
lenoid Valve
(LD Only)
Bucket Close So-
lenoid Valve
(LD Only)
Boom Raise
Solenoid Valve

Bucket Tilt-Out
Solenoid Valve
Cushion Cylinder End
Pressure Sensor Travel Reverse
Solenoid Valve (R)
Arm Retract
(BH: Roll-In)
Solenoid Valve
Travel Forward
Solenoid Valve (L)

Travel Reverse
Sliding Fold-In Ladder Storage Solenoid Valve (L)
Detection Limit Switch
Boom Lower
Solenoid Valve

Fast-Filling Panel Position Travel Forward


Detection Switch Solenoid Valve (R)

Bucket Tilt-In EHC Valve


Solenoid Valve (For Main Pump
Control)
Swing Left
Solenoid Valve
Main Pump Dis-
placement Control
(No.1, 2, 4 Main
Pump)
Main Pump Dis-
placement Control
(No.3, 5, 6 Main
Pump)

T18L-02-01-002

NOTE: LD: Loading Shovel


BH: Backhoe

T2-1-9
SYSTEM / Controller
• Cushion Cylinder End Travel Limit Control
When the cushion cylinder reaches its stroke end
during travel, ELU receives signal from the cushion
cylinder end pressure sensor. Then, ELU stops
travel control which operated direction.
When travel is reversed and the cushion cylinder
leaves from the stroke end, travel control resume.

• Swing Stop Control


ELU deactivates swing lever control signal in re-
sponse to signal from the concentrated fast-filling
panel position detection switch or sliding fold-in
ladder storage detection limit switch. As a result,
swing stops.

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

T2-1-10
SYSTEM / Controller

Pilot Control Shut-Off CAN


Lever Limit Switch MC To IDU, DLU

Pilot Control
ELU Shut-Off Relay
Front/Swing Con- Lever Lock Solenoid
trol Lever

EHC Valve
(For Electric Lever
Control)
Arm Extend
Travel Control (BH: Roll-Out)
Lever Solenoid Valve
Swing Right So-
lenoid Valve
Bucket Open So-
lenoid Valve
(LD Only)
Bucket Close So-
lenoid Valve
(LD Only)
Boom Raise
Solenoid Valve

Bucket Tilt-Out
Solenoid Valve
Cushion Cylinder End
Pressure Sensor Travel Reverse
Solenoid Valve (R)
Arm Retract
(BH: Roll-In)
Solenoid Valve
Travel Forward
Solenoid Valve (L)

Travel Reverse
Sliding Fold-In Ladder Storage Solenoid Valve (L)
Detection Limit Switch
Boom Lower
Solenoid Valve

Fast-Filling Panel Position Travel Forward


Detection Switch Solenoid Valve (R)

Bucket Tilt-In EHC Valve


Solenoid Valve (For Main Pump
Control)
Swing Left
Solenoid Valve
Main Pump Dis-
placement Control
(No.1, 2, 4 Main
Pump)
Main Pump Dis-
placement Control
(No.3, 5, 6 Main
Pump)

T18L-02-01-002

NOTE: LD: Loading Shovel


BH: Backhoe

T2-1-11
SYSTEM / Controller
• Failure Diagnosis
Diagnoses failure of sensors connected to ELU, and
detects stick phenomena in control solenoid valve.
When receiving stick signal from the control sole-
noid valve or control lever/pedal, the lever lock so-
lenoid valve is deactivated, thus stopping control
automatically.
Failure information is transmitted through CAN to
DLU and IDU.
DLU logs failure information.
IDU outputs failure information to the display.

T2-1-12
SYSTEM / Controller

Pilot Control Shut-Off CAN


Lever Limit Switch MC To IDU, DLU

Pilot Control
ELU Shut-Off Relay
Front/Swing Con- Lever Lock Solenoid
trol Lever

EHC Valve
(For Electric Lever
Arm Extend Control)
Travel Control (BH: Roll-Out)
Lever Solenoid Valve
Swing Right So-
lenoid Valve
Pilot Pressure Sensor Bucket Open So-
Travel Reverse (R) lenoid Valve
(LD Only)
Bucket Close So-
Bucket Tilt-Out lenoid Valve
(LD Only)
Bucket Close
Boom Raise
(LD Only)
Solenoid Valve
Bucket Open
(LD Only) Bucket Tilt-Out
Solenoid Valve
Swing Right
Travel Reverse
Solenoid Valve (R)
Boom Raise
Arm Retract
Arm Extend (BH: Roll-In)
(BH: Roll-Out) Solenoid Valve
Travel Forward
Bucket Tilt-In Solenoid Valve (L)

Travel Forward (R) Travel reverse


Solenoid Valve (L)
Swing Left Boom Lower
Solenoid Valve
Travel Reverse (L)
Travel Forward
Solenoid Valve (R)
Travel Forward (L)
Bucket Tilt-in EHC Valve
Boom Lower Solenoid Valve (For Main Pump
Control)
Swing Left
Arm Retract
Solenoid Valve
(BH: Roll-In) Main Pump Dis-
placement Control
(No.1, 2, 4 Main
Pump)

Main Pump Dis-


placement Control
(No.3, 5, 6 Main
Pump)

T18L-02-01-003

NOTE: LD: Loading Shovel


BH: Backhoe

T2-1-13
SYSTEM / Controller
IDU: INFORMATION DISPLAY UNIT
Functions
IDU is designed for data entry by the keypad, and
data display.

• Displaying METERS
IDU receives meter data from controllers (MC, ECM
and DLU) through CAN.
IDU indicates the meter data on the display.

• Display Items
1- Hydraulic Oil Temperature
2- Engine Coolant Temperature
3- Engine Speed
4- Engine Oil Pressure
5- Engine Oil Temperature
6- Battery Voltage
7- Fuel Level Keypad
T18G-02-01-108
8- Atmospheric Temperature
1 2 3

7 6 T18M-02-01-007
Display

T2-1-14
SYSTEM / Controller
Display Data Flow

1- Hydraulic Oil Temperature


Hydraulic Oil Temperature Sensor → MC → ke-CAN → IDU
2- Engine Coolant Temperature
Coolant Temperature Sensor → ECM → CAN (J1939) → DLU → ke-CAN → IDU
3- Engine Speed
Engine Speed Sensor → MC → ke-CAN → IDU
4- Engine Oil Pressure
Engine Oil Pressure Sensor → ECM → CAN (J1939) → DLU → ke-CAN → IDU
5- Engine Oil Temperature
Engine Oil Temperature Sensor → ECM → CAN (J1939) → DLU → ke-CAN → IDU
6- To Battery Voltage A
Power Source → DLU → ke-CAN → IDU
7- Fuel Level
Fuel Level Sensor → MC → ke-CAN → IDU
Fuel Level Switch → MC → ke-CAN → IDU
8- Atmospheric Temperature
Atmospheric Temperature Sensor → DLU → ke-CAN → IDU

T2-1-15
SYSTEM / Controller

ECM (C2)
Engine Coolant ECM (C1)
Temperature Sensor
ECM (P) DLU IDU
J1939
CAN
Engine Oil Pressure Sensor

Engine Oil
Temperature Sensor

ke-CAN

Atmospheric Temperature Sensor

ke-CAN
Engine Speed Sensor
MC
Hydraulic Temperature Sensor
ke-CAN
Fuel Level Sensor

Fuel Level Switch 1

Fuel Level Switch 2

Display
ELU

Keypad T18M-02-01-008

T2-1-16
SYSTEM / Controller
• Fault Code Indication • Maintenance Log Output/Maintenance Record
IDU indicates fault codes on the display in response Indicates the log of replacement, including hour
to abnormality signal from controllers through CAN. meter reading, number of maintenance times, and
remaining hours to next maintenance.
• Failure Information Indication Indicates a list of maintenance items, so select the
IDU indicates failure information on the display by concerned item to log the replacement data.
entering data using the keypad.
Setting Intervals And Warning ON/OFF
• Buzzer Output Set intervals of replacement items individually.
IDU sounds buzzer in response to the specific alarm Can set alarm ON/OFF of all replacement items at a
signal from controllers through CAN. time.

• Status Indication • Life Data Display


IDU indicates temperature and pressure data etc. on IDU receives cumulative information, including cu-
the display in response to signal from controllers mulative engine running hours and machine oper-
through CAN. ating hours, from DLU through CAN, and indicates it
on the display.
• Automatic Snapshot Indication
At the occurrence of warning, automatically logs • Property (Machine Information) Indication
temperature and pressure data for five minutes be- Indicates the property of the machine, including
fore warning and one minute after warning. controller configuration, hardware and software
The log can be later checked using the keypad. (version).

• Manual Snapshot Indication


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

• Maintenance Log
Maintenance warning output
Alert to the replacement of air filters, engine oil and
hydraulic oil on the display at every preset interval.

T2-1-17
SYSTEM / Controller
• Starting Processing and Check
IDU processes the following at the start of operation.
• Memory check
• Buzzer Check
• System configuration check: Checks controllers
connected to CAN network.
• Level check: Checks coolant, engine oil, and hy-
draulic oil levels
• Electric control lever check: Checks control levers
for neutral position, model name setting, front
setting and multi lever.
• Maintenance warning: Alerts to items required to
be maintained.

• Other Settings
IDU can set and change the following items.
• Maintenance settings: Sets change interval and
hours of consumable parts.
• Snapshot settings: Format a record date of man-
ual snapshot.
• Time settings: Sets world standard time, local
standard time and time difference.
• Working light off delay time settings: Set up the
delay time of working light off from the setting
time.

T2-1-18
SYSTEM / Controller
(Blank)

T2-1-19
SYSTEM / Controller
ECM: ENGINE CONTROL MODULE
(Engine Controller)
Functions
• Fuel Injector Control
ECM operates the fuel injector in response to signal
from the accelerator sensor, crank speed sensor,
boost pressure sensor and common rail pressure
sensor in order to control the engine.

• Low Temperature Starting Control


ECM excitation the ether solenoid valve in response
to signal from the engine intake air temperature
sensor to improve engine starting ability.

• Auto-Idle Control
ECM operates the fuel injector in response to signal
from MC in order to reduce the engine speed down
to the auto-idle speed.

• Failure Diagnosis Control


When ECM receives erratic data from the
accelerator sensor, crank speed sensor, boost
pressure sensor and common rail pressure sensor,
ECM controls the fuel injector to adjust the engine
speed, fuel injection quantity and engine stop.
Also, failure is indicated by warning light (lighting
and blinking).

T2-1-20
SYSTEM / Controller

ECM (C2)
ECM (C1) Fuel Injector
ECM (P)
Accelerator Sensor

Engine
Crank Speed Sensor Maintenance
Indicator

Engine Stop
Boost Pressure Sensor Indicator

Engine
Warning Light
Common Rail Pressure Sensor

Ether Solenoid
Valve
Engine Failure Diagnosis Switch
Engine Intake Air
Temperature
Sensor
Engine Failure Code INC / DEC Switch

MC

T18M-02-01-009

T2-1-21
SYSTEM / Controller
DLU: DATA LOGGING UNIT
Functions
• Monitor System • MMS Communication (Optional)
DLU monitors communication with connected units, Communicates with the mine management system
and logs abnormality if any. -- MMS (Modular Mining System).
Sends warning information to MMS in real time at
• Operating Hour Control the occurrence of warning.
DLU incorporates the internal clock and GPS
receiver. • Satellite Communication (Orbcumm) (Optional)
The internal clock is corrected to the standard time, Can change the starting and finishing times of daily
using the GPS receiver. data, using the palm or the display in the cab.
Log data from DLU is transmitted to the Orbcumm
• Basic Data Retrieval terminal.
Retrieves data for ECM through CAN (J1939) line
then transmitted to the ke-CAN line.

• Warning Detection
Logs warning information with stamped time.

• Operating Condition Detection


Processes operating data every 30 minutes.

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

• Service Tool Communication


Can communicate with the palm and a personal
computer.

• Parameters Setting
Sets parameters in DLU using the palm.

T2-1-22
SYSTEM / Controller

Service Orbcomm
Tool (Optional)

ECM (C2)
ECM (C1)
ECM (P)
DLU IDU
CAN
(J1939)

y Internal Clock
y GPS

Ke-
CAN

Ke-
CAN
Ke-CAN
ELU MC

MMS
COMM. Unit
(Optional)

MMS
Keypad

(Optional)
Display

T18M-02-01-010

T2-1-23
SYSTEM / Controller
CSU: CONTAMINATION SENSING UNIT
Functions
CSU senses the amount of contaminant (metal
particles) with contamination sensors provided in the
drain circuits for main pumps, swing motors and drain
circuit.
Also, sends detection signals from all contamination
sensors to CAN at a cycle of one second.
If any resistance in contamination sensors is lowered
than the specified level, CSU turns ON the warning
light LED yellow.
IDU receives this signal, and indicates the warning
on the display.
At the same time, DLU logs it.

T2-1-24
SYSTEM / Controller

CSU
(Power Consumption: MAX 1A)
Contamination
Sensor
B
Main Pump P1 W
CH1
D/O (Open Collector) Warning light LED Yellow
•GND (0V) Output at Warning

B
Main Pump P2 W
CH2 MAIN POWER From Battery
MAIN POWER GND

B
Main Pump P3 W CAN
CH3

CAN_A To IDU, DLU

B
Main Pump P4 W Contamination
CH4
Sensor
B
W Swing Motor
CH17 (Front)

B
Main Pump P5 W CH5
B
W Swing Motor
CH18 (Rear)

B
Main Pump P6 W
CH6

B
W Travel Motor
CH21 (C/J)

T18L-02-01-004

T2-1-25
SYSTEM / Controller
HMU: HYDRAULIC SYSTEM MONITORING
UNIT
(Pump / Swing Motor Drain Pressure
Monitoring Unit)
Functions
For monitoring, HMU receives hydraulic drain
pressure data from drain pressure sensors provided
in drain circuits for main pumps and swing motors.
If peak drain pressure is increased to the specified
level or higher, and its frequency exceeds the
specified times, HMU sends signal together with
temperature and pressure sensor frequency data to
DLU through CAN.
At the same time, DLU logs the frequency of
abnormality.
IDU indicates the temperature and pressure sensor
frequency data on the monitor display through CAN.

T2-1-26
SYSTEM / Controller

HMU

SENSOR_5V

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

Main Pump P2 Oil Cooler Outlet


Temperature Sensor
(Front)
Oil Cooler Outlet
Temperature Sensor
Main Pump P3 (Rear)
Oil Cooler Front Air
Temperature Sensor
(Front)
Main Pump P4 Oil Cooler Front Air
Temperature Sensor
(Rear)
Oil Cooler Inlet Pressure
Main Pump P5 Sensor (Front)

Oil Cooler Inlet Pressure


Sensor (Rear)

Main Pump P6

Swing Motor
(Front)

Swing Motor
(Rear)

T18L-02-01-005

T2-1-27
SYSTEM / Controller
(Blank)

T2-1-28
SYSTEM / Control System
OUTLINE
Signals from any of various sensors and switches en-
ter MC (Main Controller), and ECM (Electronic Control
Module).
MC, ECU, and ECM process signals and activate so-
lenoid valves and relays so that the engine, pumps, oil
cooler fan motor, and wipers are controlled in response
to signals.
In addition, travel mode control as well as swing stop
control (while lowering the sliding fold-in ladder or op-
erating 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 valve Pump control (power increase control)
Engine speed sensor Power decrease solenoid valve Pump control (power decrease control)
Hydraulic oil temperature sensor Oil cooler fan speed select Oil cooler fan motor speed control
solenoid valve
Wiper switch Wiper relay 1 Wiper control
Interval switch Wiper relay 3
Wiper relay 4

ECM
Input Output Control
Accelerator sensor Fuel Injector Engine control (engine speed control)
Crank revolution sensor
Engine inlet air temperature sen- Fuel Injector Engine control (low temperature start
sor Ether Solenoid Valve control)
Crank revolution sensor
Auto-idle signal from MC Fuel Injector Engine control (auto-idle control)
Radiator inlet temperature sen- Fuel Injector Engine control
sor (engine protection control)
Engine inlet air temperature sen-
sor
Engine oil pressure sensor
Coolant level sensor
Coolant pressure sensor
Fuel temperature sensor
Crank revolution sensor
Engine control dial

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

Function: Controls the engine speed and output


torque in response to signals from engine
control dial and engine loads.

Operation:
1. When the engine control dial is activated, the en- 4. ECM judges the current engine loading status,
gine control dial sends electrical signals to ECM thus control the fuel injector to the most appropri-
according to the operating stroke. ate injection quantity.
2. ECM operates the fuel injector in response to sig- 5. The detected data from the crank revolution
nals in order to control the engine speed. sensor is transmitted to IDU via DLU through
3. At the same time, ECM receives signals from the CAN line.
crank revolution sensor.

Crank Revolution Sensor


IDU
Fuel Injector
J1939-CAN

Engine Control Dial


DLU ECM

Ke-CAN

T18M-02-02-001

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

T2-2-3
SYSTEM / Control System
Low Temperature Start Control

Function: Warms up the intake air when the intake


air temperature is low (-5 °C (23 °F) or
lower) by injection the ether into the intake
manifold to improve the engine starting
ability.

Operation:
1. When the key switch is turned ON position, en-
gine inlet air temperature sensor send electrical
signal to ECM.
2. Press the engine start switch, though, intake air
temperature is low (-5 °C (23 °F) or lower), ECM
excitation the ether solenoid valve and rotate the
starter motor.
3. ECM degauss the ether solenoid valve, when
electrical signal from the crank revolution sensor
-1
500 min and above.
4. With the ether into the intake air, improvement the
engine ignition performance.
5. When engine dose not start, press the engine
stop switch then press the engine start switch
again.

T2-2-4
SYSTEM / Control System

Engine Intake Air Temperature Sensor


Crank Speed Sensor

Ether Bottle
Ether Solenoid Valve

Ether Line

Intake Manifold

Key Switch Fuel Injector


ON Signal
Engine Start
Switch
ECM

Engine Stop
Switch

Starter Motor
T18M-02-02-002

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

Function: Reduces fuel consumption 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/swing, and travel) from ELU.
2. MC send signal to ECM when lever control signal
from ELU becomes zero with the auto-idle switch
ON.
3. ECM reduce the engine speed to the auto-idle
-1
speed of 1400±50 min (rpm) by control the fuel
injector at the lapse of about three seconds after
receiving signals from MC.
4. The crank revolution sensor check the engine
speed and send signal to ECM. Then, ECM can
recognize that the engine speed is reduced to the
auto-idle speed.
5. MC send auto-idle mode signals to IDU via CAN.
Then, IDU display the auto-idle icon on to the
monitor display.
6. When the control lever is operated and MC re-
ceive lever control signal from ELU, MC stop
sending signal to ECM.
Then, ECM increase the engine speed to the
speed set by the fuel lever.

NOTE: In case signals from the accelerator sensor


are lower than the auto-idle speed of
-1
1400±50 min (rpm), the auto-idle control is
inoperative.

T2-2-6
SYSTEM / Control System

Lever Control Signal


(Front / Swing)
MC
ELU Engine Control Dial

D/0(24V) 1 Crank Speed Sensor

Fuel Injector
D/0(24V) 2

Lever Control
Signal (Travel)

Auto-Idle Switch

Ke-CAN IDU Signal (Pilot Display)


[Output]
y Auto-Idle Mode Signal

T18M-02-02-003

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

Function: When ECM detects a malfunction, the en-


gine protection control starts in order to
prevent the engine from damage.

Operation:
1. When ECM receives the malfunction signals be-
low from each sensor, ECM sends the information
to CAN.
• Coolant temperature (High)
• Engine intake air temperature (High)
• Engine oil pressure (Low)
• Coolant level (Low)
• Fuel temperature (High)
• Clank case pressure (High)
• Coolant pressure (Low)
• Engine oil temperature (High)
2. ECM reduces fuel injection amount of the injector
and decreases the engine speed.
3. MC receives the information of engine malfunc-
tion by using CAN.
MC stop the signal to the power increase solenoid
valve and sends the signal to the power decrease
solenoid valve. Therefore, the pump displacement
angle is reduced and the pump load decreases.

T2-2-8
SYSTEM / Control System

Engine Intake Air Temperature Sensor

Crank Speed Sensor

Fuel Injector

Intake Manifold

ECM

ENG.

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

MC

P6 P4 P2

P5 P3 P1

Pilot Pump Power Increase Power Decrease


Solenoid Valve Solenoid Valve T18L-02-02-001

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

Function: Controls the pump flow rate according to


variations in engine speed to efficiently
utilize engine output.

Operation:
1. The engine speed sensor convert the engine
speed into electrical signal, and send this signal
to MC.
2. When the engine speed is between 1800 to 2156
-1
min and MC receives lever control signal
(front/swing or travel) from ELU, MC sends elec-
trical signal to the power increase solenoid valve
in proportion to the engine speed.
3. The power increase solenoid valve deliver pilot
pressure oil in response to this signal to the main
pump regulator, thus increasing the pump driving
power.
4. Accordingly, the pump flow rate and hydraulic
actuator speed increase. (Refer to COMPONENT
OPERATION/Pump Device group.)
5. As the pump driving power increase, the engine
load increase, so that the engine speed decrease.
This regulator operation continues until the en-
-1
gine speed decrease to 1800 min .

T2-2-10
SYSTEM / Control System

EHC Valve
(For Main Pump Control)

Power Increase
Solenoid Valve

ELU

Lever Control Signal


(Front / Swing) Lever Control Signal
(Travel)

MC

Pilot
Power Increase Pump
Solenoid Valve

Engine Speed Engine


Sensor

T18L-02-02-002

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

Function: Reduces the main pump driving power


when the engine speed is 1650 min-1 or
slower to protect the engine from being
overloaded.

Operation:
1. The engine speed sensor convert the engine
speed into electrical signal and send the signal to
MC.
-1
2. When the engine speed is less than 1650 min or,
MC receive lever neutral signal (front/swing or
travel) from ELU, MC send signal to the power
decrease solenoid valve to change over the
power decrease solenoid valve.
3. As the power decrease solenoid valve is changed
over, pilot pressure oil from the pilot pump is de-
livered to the main pump regulator, thus de-
creasing the pump driving power. (Refer to
COMPONENT OPERATION/Pump Device group.)
4. As the pump driving power decrease, the engine
load is reduced, thus increasing the engine speed.
Thereby, the engine is protected from being
overloaded.
-1
5. After the engine speed increase 1750 min or
higher, MC stop signal to the power decrease
solenoid valve, so that normal operation resume.

T2-2-12
SYSTEM / Control System

EHC Valve
(For Main Pump Control)

Power Decrease
Solenoid Valve

ELU

Lever Neutral Signal Lever Neutral Signal


(Front / Swing) (Travel)

MC

Pilot
Power Decrease Pump
Solenoid Valve

Engine Speed Engine


Sensor

T18L-02-02-002

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

Function: Always activates the power decrease


control system when control levers are in
neutral to prevent the initial decrease in
engine speed caused by shifting the con-
trol levers.

Operation:
1. When the control levers are in neutral, lever con-
trol signals (front/swing and travel) from ELU to
MC become zero. At the lapse of 0.5 second, MC
send signal to the power decrease solenoid valve
to change over the solenoid valve.
2. When the power decrease solenoid valve is
changed over, pilot pressure oil is delivered to the
main pump regulator, thus decreasing the pump
drive power. (Refer to COMPONENT OPERA-
TION/Pump Device group.)
In this control, the power increase solenoid valve
is deactivated, so that power increase control is
not carried out.
3. When the control levers are shifted, MC receives
lever control signals (front/swing or travel) from
ELU. At the lapse of 0.5 second, MC gradually
turns OFF the power decrease solenoid valve,
thus stopping power decrease control.
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 de-
-1
activated, and the engine speed is 1800 min or
higher, the power increase solenoid valve is acti-
vated, thus carrying out power increase control.

T2-2-14
SYSTEM / Control System

EHC Valve
(For Main Pump Control)

Power Decrease
Solenoid Valve

ELU

Lever Neutral Signal Lever Neutral Signal


(Front / Swing) (Travel)

MC

Pilot
Power Decrease Pump
Solenoid Valve

Engine Speed Engine


Sensor

T18L-02-02-002

T2-2-15
SYSTEM / Control System
FAST-FILLING PANEL LOWER CONTROL

Function: Prevents the Fast-Filling panel from low-


ering for safety while the pilot control
shut-off lever is UNLOCK position.
When the Fast-Filling panel is lowered,
swing is inoperative. Refer to Swing Stop
Control group.

Operation:
• Pilot control shut-off lever: LOCK position • Pilot control shut-off lever: UNLOCK position
1. When the pilot control shut-off lever limit switch 1. When the pilot control shut-off lever limit switch
opens, MC makes connection to the ground cir- closes, MC causes the ground circuit of the
cuit for Fast-Filling relay. Fast-Filling relay to shut off.
2. Under this condition, when the Fast-Filling switch 2. Even if the Fast-Filling switch is turned ON under
is ON, electric current from MC excites the this condition, the Fast-Filling relay is not excited,
Fast-Filling relay. thus preventing the Fast-Filling panel from low-
3. Electric current from the battery flows to the ering.
Fast-Filling solenoid valve via the Fast-Filling re-
lay, activating the Fast-Filling solenoid valve. IMPORTANT: Even if the pilot control shut-off limit
4. Pilot pressure oil from the Fast-Filling solenoid switch is closed while the
valve flows to the lift cylinder bottom end to lower Fast-Filling panel is lowering or
the Fast-Filling panel. when lowered fully, MC causes the
5. When the Fast-Filling panel is lowered out of the Fast-Filling solenoid valve to oper-
detection range of the detection switch, MC ate continuously.
causes the alarm LED to light red, and sends At the same time, MC sends signals
signals to IDU through CAN to indicate the warn- to IDU through CAN to sound buzz-
ing on the display. er.
6. At the same time, MC stops voltage signal to ELU,
deactivating swing. (Refer to Swing Stop Control
group.)

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


Lever Limit Switch
Power Source for 24V
ON (Lever Control Available) D/I
OFF (Lever Control Unavailable)
D/I (24V)
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 group.)

Alarm LED Red D/O (24V)


(Max. 1.6A for SOL
and LAMP)
IDU (Information Display Controller)
CAN
(Output)
Lift Cylinder y Fast-Filling Panel Position Signal
y Buzzer Signal
T18L-02-02-004

T2-2-17
SYSTEM / Control System
SLIDING FOLD-IN LADDER CONTROL

Purpose: Controls not to operate the sliding fold-in


ladder when the pilot shut-off lever is turned
UNLOCK position (the control lever can be
operated) for safety.
In addition, before the sliding fold-in ladder
cylinder reaches the stroke end, operating
speed decreases in order to protect the
sliding fold-in ladder.

Operation:
• Extending Sliding Fold-In Ladder
1. When the pilot shut-off switch is OFF and the ex-
tend switch is pushed, the ground circuits in slid-
ing fold-in ladder relays 2 and 3 are connected.
2. As sliding fold-in ladder relays 2 and 3 are excited,
sliding fold-in ladder motors 1 and 2 are also ex-
cited and the battery power operates sliding
fold-in ladder pump units 1 and 2.
3. At the same time, Sol. b in sliding fold-in ladder
solenoid valve 1 is excited and the spool is
switched.
NOTE: Although current flows to Sol. a, as the
ground is not connected (electric potential
difference: 0), Sol. a is not excited.

4. When pressure oil from sliding fold-in ladder


pump units 1 and 2 flows to the rod side of sliding
fold-in ladder cylinder through orifice A and sliding
fold-in ladder solenoid valve 3, the sliding fold-in
ladder is extended.
5. When the sliding fold-in ladder is extended half-
way, limit switch 2 for extend stroke end control is
turned ON and sliding fold-in ladder solenoid
valve 3 is connected to the ground circuit.
6. Therefore, as sliding fold-in ladder solenoid valve
3 is excited and the spool moves, the hydraulic
circuit is blocked.
7. As pressure oil from sliding fold-in ladder pump
units 1 and 2 flows to the sliding fold-in ladder
cylinder through only orifice A, sliding fold-in lad-
der cylinder speed becomes slow.

T2-2-18
SYSTEM / Control System

From Battery

Sliding Fold-In
Ladder Cylinder
Sliding Fold-In
Ladder Relay 1

Sliding Fold-In Sliding Fold-In Holding Valve


Ladder Relay 2 Ladder Relay 3 Sliding Fold-In Holding
Ladder Relay 4 Valve

Storage Switch
Extend
Switch
Sliding Fold-In
Sliding Fold-In Ladder Solenoid
Ladder Pump Valve 1
Unit 2

Sol. b
Orifice A
Sliding Fold-In
Ladder Pump
Unit 1 Sol. a

Limit Switch 1 Limit Switch 2


(For Expansion (For Expansion
Detection) Slowdown Control)

Limit Switch 3
Limit Switch 3
(For Storage (For Storage
Slowdown Control) Detection)
Sliding Fold-In
Ladder Solenoid
Valve 3 Stop Valve
(Normally Closed)
Sliding Fold-In
Limit Switch 5
Ladder Solenoid
(For Pilot Shut-Off
Valve 2
Lever) Pilot
Pump
MC 76-58
76-19

Pilot Control Shut-Off


Limit Switch

From Battery

ELU
76-58 76-59
T18L-02-02-006

T2-2-19
SYSTEM / Control System
Storage of Sliding Fold-In Ladder

1. When the pilot shut-off switch is OFF and the 10. At the same time, sliding fold-in ladder solenoid
storage switch is pushed, the ground circuits in valve 2 is also excited and the spool moves.
sliding fold-in ladder relays 2 and 3 are connect- 11. As pressure oil from the pilot pump is supplied to
ed. the bottom side of sliding fold-in ladder cylinder
2. As sliding fold-in ladder relays 2 and 3 are excited, and the pushing force of sliding fold-in ladder
sliding fold-in ladder motors 1 and 2 are also ex- cylinder increases, the sliding fold-in ladder is
cited and the battery power operates sliding stored safely.
fold-in ladder pump units 1 and 2.
3. At the same time, Sol. a in sliding fold-in ladder NOTE: While limit switch 4 for storage detection is
solenoid valve 1 is excited and the spool is turned ON, when the engine starts, sliding
switched. fold-in ladder solenoid valve 2 is excited
NOTE: Although current flows to Sol. b, as the automatically.
ground is not connected (electric potential At the same time, pressure oil from the pilot
difference: 0), Sol. b is not excited. pump is supplied to the bottom side of
sliding fold-in ladder cylinder. Although the
4. When pressure oil from sliding fold-in ladder machine moves, the sliding fold-in ladder is
pump units 1 and 2 flows to the bottom side of fixed and does not move.
sliding fold-in ladder cylinder, the sliding fold-in
ladder is stored.
5. When the sliding fold-in ladder is stored halfway,
limit switch 3 for storage stroke end control is
turned ON and Sol. a in sliding fold-in ladder so-
lenoid valve 1 is demagnetized.
6. Therefore, as sliding fold-in ladder solenoid valve
1 is neutral, the hydraulic circuit is blocked.
7. As pressure oil from only sliding fold-in ladder
pump unit 2 flows to the sliding fold-in ladder cyl-
inder, sliding fold-in ladder cylinder speed be-
comes slow.
8. When the sliding fold-in ladder is stored com-
pletely and limit switch 5 for manual lock detection
is turned ON, current flows to two terminals in
ELU.
9. Therefore, ELU releases the swing operation
lock.

T2-2-20
SYSTEM / Control System

From Battery

Sliding Fold-In
Ladder Cylinder
Sliding Fold-In
Ladder Relay 1

Sliding Fold-In Sliding Fold-In Holding Valve


Ladder Relay 2 Ladder Relay 3 Sliding Fold-In Holding
Ladder Relay 4 Valve

Storage Switch
Extend
Switch
Sliding Fold-In
Sliding Fold-In Ladder Solenoid
Ladder Pump Valve 1
Unit 2

Sol. b
Orifice A
Sliding Fold-In
Ladder Pump
Unit 1 Sol. a

Limit Switch 1 Limit Switch 2


(For Expansion (For Expansion
Detection) Slowdown Control)

Limit Switch 3
Limit Switch 3
(For Storage (For Storage
Slowdown Control) Detection)
Sliding Fold-In
Ladder Solenoid
Valve 3 Stop Valve
(Normally Closed)
Sliding Fold-In
Limit Switch 5
Ladder Solenoid
(For Pilot Shut-Off
Valve 2
Lever) Pilot
Pump
MC 76-58
76-19

Pilot Control Shut-Off


Limit Switch

From Battery

ELU
76-58 76-59
T18L-02-02-006

T2-2-21
SYSTEM / Control System
AUTO LUBRICATION CONTROL

Function: To automatically grease the front attach-


ment 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 so that
MC recognizes that the auto lubrication switch is
in the AUTO position.
2. Current from terminal 48-18 on MC flows to the
auto lubrication solenoid valve 1 at intervals pre-
set by the auto lubrication interval switch in order
to activate the auto lubrication solenoid valve 1.
3. Pressure oil from the pilot pump is routed to the
vent valve and grease pump drive motor via the
reducing valve to activate the grease pump.
4. As pilot pressure oil enters the vent valve, the
vent valve is closed to block the return circuit from
the grease pump to the grease tank.
As a result, grease is delivered to the front at-
tachment lubrication circuit.
5. Grease pressure in the front attachment lubrica-
tion circuit is routed to the pressure switch 1.
When grease pressure in the front attachment
lubrication circuit increases up to the set pressure
(17.7 MPa) or higher by the pressure switch 1, the
pressure switch 1 is turned ON, grounding the
terminal 48-38 on MC via the pressure switch 1.
Thereby, MC detects the increase in grease
pressure in the front attachment lubrication circuit.
6. MC turns ON the warning LED red, and sends
signals to IDU through CAN to indicate the warn-
ing on the display.
7. Also, MC activates the auto lubrication solenoid
valve for 150 seconds at the preset intervals for
intermittent lubrication.

T2-2-22
SYSTEM / Control System

Auto Lubrication
Switch
MC

Pressure Switch 1 76-13


(For Auto Lubrication)

48-38

76-26

Warning LED Red


Pressure Switch 2
(For Manual Lubrication)

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)

Engine Speed Sensor 48-30


48-42

Pilot
Pump

Center Joint, Swing Bearing


Lubrication Circuits

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

Grease Tank Reducing Auto Lubrication


Valve Solenoid Valve T18M-02-02-005

T2-2-23
SYSTEM / Control System
• Manual Lubrication
1. When the auto lubrication switch is set to the
MANUAL position, MC maintains the auto lubrica-
tion solenoid valve 1 and 2 ON. This causes the
grease pump to discharges grease, allowing the
use of a grease gun.
2. The pressure switch 3 checks if manual lubrica-
tion is made normally. When lubrication circuit
pressure increases up to 23.5 MPa or higher, the
pressure switch 3 is turned ON.
3. Current from the terminal #48-38 of MC is
grounded through the pressure switch 3 to allow
MC to detect abnormality.
4. Current from the terminal #48-18 of MC is shut off
to turn OFF the auto lubrication solenoid valve 1
and to stop the grease pump.

NOTE: In manual lubrication mode, the warning


LED (red) is kept ON, and the warning is
indicated on the display at all times.
When a grease gun is not used, the grease
pump does not work as pressure in the lu-
brication circuit increases.

T2-2-24
SYSTEM / Control System

Auto Lubrication
Switch
MC

Pressure Switch 1 76-13


(For Auto Lubrication)

48-38

76-26

Warning LED Red


Pressure Switch 2
(For Manual Lubrication)

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
(Fuse #15) 76-71

Engine Speed Sensor 48-30


48-42

Pilot
Pump

Center Joint, Swing Bearing


Lubrication Circuits

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

Grease Tank Reducing Auto Lubrication


Valve Solenoid Valve T18M-02-02-005

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

Function: Controls the oil cooler fan motor speed at Oil Cooler Fan Motor Speed Vs. Hydraulic Oil Temperature
four steps to maintain the hydraulic oil
Hydraulic Oil Pilot Oil Pressure from Oil Cooler Fan
temperature in the proper temperature
Temperature Solenoid Valve Motor Speed
range.
(°C) (Current: From MC) (min-1)
Operation: 59 °C (120 °F) 0 MPa 200
1. The hydraulic oil sensor (oil cooler fan motor or Lower (0 kgf/cm2)
speed control) sends signals to MC depending on [50 mA]
oil temperature, 60 to 69 °C 1.8 MPa 850
2. MC controls the oil cooler fan motor speed control (122 to 156 °F) (18.4 kgf/cm2)
solenoid valve in response to the received signals [280 mA]
to deliver pilot pressure oil to the oil cooler fan 70 to 79 °C 2.22 MPa 1150
drive pump regulator. (Refer to COMPONENT (158 to 207 °F) (22.6 kgf/cm2)
OPERATION/Pump Device group.) [310 mA]
3. As a result, the delivery flow rate from the oil 80 °C (176 °F) 3.51 MPa 1370
cooler fan drive pump is controlled, adjusting the or Higher (35.8 kgf/cm2)
oil cooler fan motor speed. [400 mA]
4. The detection data from the hydraulic oil temper-
ature sensor is sent to IDU through CAN. NOTE: The listed oil cooler fan motor speeds are
those at the rated engine speed (1800
min-1).

T2-2-26
SYSTEM / Control System

Oil Cooler Fan Motor EHC Valve Oil Cooler Fan


(For Main Pump Control) Control
Solenoid Valve

Oil Cooler Fan


Drive Pump

Oil Cooler Fan


Control
Solenoid Valve
Pump Transmission

Engine

Hydraulic Oil
Temperature Sensor

MC
IDU

CAN T18L-02-02-003

T2-2-27
SYSTEM / Control System
WIPER CONTROL

Intermittent Operation Fast Speed Operation

Function: Operates the wiper at intervals set by the Function: Operates the wipers at fast speed.
wiper intermittent switch.
Operation:
Operation: 1. When the wiper switch is set to the HIGH position,
1. The wiper intermittent switch sends electric sig- MC receives electrical signals.
nals to MC at the set intervals. 2. MC sends current from the terminal #48-16 to turn
2. When the wiper switch is set to the INT. position, ON the wiper relay 3.
MC receives electrical signals. 3. As the wiper relay 3 is turned ON, current from
3. MC sends current from the terminal #48-4 of MC fuse #76 flows, activating the wiper motor at fast
to turn ON the wiper relay 1 for about one second speed.
at intervals set by the interval switch.
4. As the wiper relay 1 is turned ON, current from
fuse #75 causes the wiper motor to run one turn Washer Operation
at slow speed.
Function: Starts the washer, and operates the wiper
at slow speed.
Slow Speed Operation
Operation:
Function: Operates the wiper at slow speed. 1. When the washer switch is pressed, the washer
motor relay is turned ON and electrical signals
Operation: from the terminal #48-40 of MC are grounded.
1. When the wiper switch is set to the LOW position, 2. When the washer motor relay is turned ON, cur-
MC receives electrical signals. rent from fuse #77 causes the washer motor to
2. MC sends current from the terminal #48-4 of MC run, thus spraying washer fluid.
to turn ON the wiper relay 1. At the same time, the wiper relay 1 is turned ON
3. As the wiper relay 1 is turned ON, current from to operate the wiper motor at slow speed.
fuse #75 flows, activating the wiper motor at slow 3. The wiper motor runs continuously for five sec-
speed. onds at slow speed after releasing the washer
switch.

T2-2-28
SYSTEM / Control System

Figure A

(Serial No.1088 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
・OFF Wiper Relay 1
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.1087)
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.1088 and up).
Refer to Figure B for the machine (Up to serial No.1087).

T2-2-29
SYSTEM / Control System
TRAVEL MODE CONTROL

Function: Selects fast or slow travel speed by ad- Travel Mode


justing the travel motor displacement an- Switch
gle with the travel mode switch.

Travel Mode Switch Circuit

• Slow Mode
1. When the travel mode switch is OFF (slow), cur-
rent from fuse #22 does not flow to the travel LED Power
mode relay, causing the relay to contact the ter- Source
minal #4.
2. At this time, IDU indicates the slow travel mode
Key Switch
mark on the display. ON Signal

• Fast Mode Fuse #22


1. When the travel mode switch is ON (fast), current
from fuse #21 is grounded via the travel mode
switch, causing the relay to contact the terminal
Travel Mode
#5. Relay
2. As the travel mode solenoid valve circuit is IDU
grounded, the travel mode solenoid valve is acti- Fuse #44
vated.
At the same time, IDU indicates the fast travel From Battery
mode mark on the display.

Indicate Fast
Travel Mode

Travel Mode
Solenoid
From Pilot Pump Valve

To Travel Mode
Switch 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, the system pressure oil from the
travel mode solenoid valve is deactivated. control valve is routed to the slow tilt piston side,
2. Then, the pilot pressure acts on the spool ends in maximizing the travel motor displacement angle
the travel mode switch valve after being reduced so that travel speed becomes slow.
by the reducing valve to the reducing valve set 5. The pilot pressure is also routed to the parking
pressure. brake to release the brake. (Refer to the COM-
3. However, the spool in the travel mode switch PONENT OPERATION / Travel Device group.)
valve does not move as the travel mode switch
valve set pressure is higher than the reduced pilot
oil 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, the system pressure oil from the
travel mode solenoid valve is activated so that the control valve is routed to the fast tilt piston side,
pilot pressure is routed to the spring side in the minimizing the travel motor displacement angle
reducing valve. so that travel speed becomes fast.
2. Then, the pilot pressure acts on the spool ends in 5. The pilot pressure is also routed to the parking
the travel mode switch valve without being re- brake, releasing the brake.
duced by the reducing valve.
3. As the pilot pressure is not reduced, the spool in
the travel mode switch valve is shifted.

Reducing Valve
Travel Mode
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 signals from


the control lever, sensors and switches. ELU makes
arithmetic operation to control pumps and control cir-
cuits by activating solenoid valves and relays.

Input Output Control


Pilot Control Shut-Off Lever Limit Pilot Control Shut-Off Lever Solenoid Pilot Control Shut-Off Con-
Switch Valve trol
Control Lever Signal Main Pump Displacement Control Sole- Positive Control
noid Valve (For No.1 to 6 Main Pump)
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 Regulation Control
Main Pump Displacement Control Solenoid
Valve (For No.1 to 6 Main Pump)
Control Lever Signal (Swing) Swing Solenoid Value (Left/Right) Swing Stop Control
Sliding Fold-In Ladder Storage
Detection Limit Switch
Fast Filling Panel Position Detection
Switch

T2-3-1
SYSTEM / ELU System
PILOT CONTROL SHUT-OFF CONTROL
Function: Activates the pilot control shut-off solenoid
valve with the pilot control shut-off lever limit
Ke-CAN
switch to deliver pressure oil from the pilot
pump to the pilot circuit.
ELU IDU
Operation:
1. With the key switch in ON position, when the pilot
control shut-off limit switch is turned ON, electric Pilot Pressure Sensor
current from the key switch terminal M flows to
ELU and MC through fuse #20 in the fuse box
To Pilot Circuit
(cab) and pilot control shut-off lever limit switch to
excites the pilot control shut-off relay at the same Pilot Control
time. Shut-Off Relay
2. ELU and MC recognize pilot control shut-off re-
lease signals respectively, and send them to IDU
through CAN. Pilot Control
Shut-Off Solenoid
3. When ELU recognizes pilot control shut-off re- Valve
lease signal, ELU outputs voltage signal.
4. The voltage signal from ELU goes to the pilot
control shut-off solenoid valve through the pilot
control shut-off relay.
5. As a result, the pilot control shut-off solenoid
valve is activated, delivering pressure oil from the
pilot pump to the pilot circuit.
Pilot Pump

Pilot Control
Shut-Off Lever
Limit Switch

Fuse #20 in
Fuse Box (Cab)

Key Switch T18K-02-03-001

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

T2-3-3
SYSTEM / ELU System
PUMP CONTROL

Positive Control

Function: Adjusts pump delivery flow according to


control lever stroke for efficient use of en-
gine horsepower.

Operation:
1. When operating the control lever, ELU receives
signal according to control lever stroke.
2. ELU sends electric signal current to EHC valves
(SE) and (SI) (main pump displacement control
solenoid valve) according to control lever stroke.
3. EHC valves (SE) and (SI) delivers pilot pressure
oil to the main pump regulator according to con-
trol lever stroke to control the pump flow rate.
4. As a result, delivery flow from each pump is
regulated to 100 to 425 L/min.
5. ELU detects pilot pressure from EHC valves (SE)
and (SI) to the pump regulator, and sends the
detected value to IDU through Ke-CAN.

Maximum flow rate of main pumps 1 to 6 when operating the control lever:
Max. Flow Rate (L/min)
Operation
MP1 MP2 MP3 MP4 MP5 MP6
Travel Right 375 375 - - - -
Travel Left - - 375 375 - -
Swing - - - - 425 425
Boom Raise 375 375 375 375 425 425
Boom Lower - - 375 375 425 425
LD: Arm Retract LD: 100
375 375 375 425 425
BH: Arm Roll-In BH: 375
LD: Arm Retract LD: - LD: -
375 375 100 375
BH: Arm Roll-Out BH: 100 BH: 100
Bucket Roll-In 375 375 375 375 425 425
LD: - LD: - LD: 375 LD: 425 LD: 425
Bucket Roll-Out 375
BH: 375 BH: 375 BH: 100 BH: 100 BH: 100
Bucket Open/Close
375 375 - - - -
(LD Only)

NOTE: LD: Loading Shovel


BH: Backhoe

T2-3-4
SYSTEM / ELU System

EHC Valve
(For Main Pump Control)
Main Pump
Displacement
Control Sole-
noid Valve (For
No.1, 2, 4 Main
Pump)

Main Pump Displacement Front Travel


Control Solenoid Valve
(For No.3, 5, 6 Main Pump)

IDU ELU

Ke-CAN

Pilot Pump
Pilot Pressure
Sensor
Pilot
Pressure
Main Pump Dis- Sensor
placement Control Main Pump
Solenoid Valve Displacement
(For No.3, 5, 6 Control Solenoid
Main Pump) Valve (For No.1,
2, 4 Main Pump)

Regulator
P6 P4 P2

P5 P3 P1

Pump Transmission

Engine

T18L-02-03-001

T2-3-5
SYSTEM / ELU System
CUSHION CYLINDER END TRAVEL
REGULATION CONTROL
Function: Protects track links and shoes from ab-
normal tension and shocks due to earth
and stone caught during travel.

Operation: Travel Regulation Control


1. When the cushion cylinder approaches its stroke As cushion cylinder rod
Travel regulation
end during traveling forward, ELU receives signal approaches stoke end
from the cushion cylinder end pressure sensor. Left forward¯ Right forward ¯
1 Forward (↑↑)
2. ELU stops electric signal current to the travel Left reverse{ Right reverse {
forward solenoid valve, EHC valves (SE) and (SI), Left forward¯ Right forward {
but delivers electric signal current to only the 2 Spin right (↑↓)
Left reverse{ Right reverse ¯
corresponding travel reverse solenoid valve. In Left forward{ Right forward ¯
addition, ELC sends the detected value from the 3 Spin left (↓↑)
Left reverse¯ Right reverse {
cushion cylinder end pressure sensor through Left forward{ Right forward {
Ke-CAN. 4 Reverse (↓↓)
Left reverse¯ Right reverse {
3. As a result, the travel forward solenoid valve and Left forward{ Right forward {
DQR valve, stop, and the travel spool in the con- 5 Turn left (↓↓)
Left reverse¯ Right reverse {
trol valve returns into the neutral position to stop Left forward¯ Right forward {
positive control. 6 Turn right (↓↓)
Left reverse{ Right reverse {
4. For traveling reverse, ELU sends electric signal Left forward{ Right forward {
current to the travel reverse solenoid valve, so 7 Turn right (↓↓)
Left reverse{ Right reverse ¯
that the travel reverse solenoid valve is activated Left forward{ Right forward ¯
to deliver pilot pressure oil to DQR valve 1 to ac- 8 Turn left (↓↑)
Left reverse{ Right reverse {
tivate it.
↑: Forward {: Control enabled
5. DQR valve 1 delivers pilot pressure oil to the
↓: Reverse ¯: Control disabled
control valve to move the spool into the travel
reverse position.
6. During traveling reverse, when the cushion cyl-
inder rod leaves from the stroke end, ELU does
not receive signal from the cushion cylinder end
pressure sensor. So, travel control, positive con-
trol resume.

T2-3-6
SYSTEM / ELU System

Ke-CAN IDU
ELU
Left Travel Lever

Right Travel Lever

DQR Valve 1
DQR Valve 2

Cushion Cylinder End


Pressure Sensor

Travel Forward
(Left)
Travel Reverse
(Left)
Travel Forward
(Right)
Travel Reverse Travel Reverse Travel Forward Travel Reverse Travel Forward
(Right) Solenoid Valve Solenoid Valve Solenoid Valve Solenoid Valve
(Right) (Right) (Left) (Left)

Main Pump Dis- Main Pump Dis-


placement Control placement Control
Solenoid Valve Solenoid Valve
(For No.1, 2, 4 (For No.3, 5, 6
Main Pump) Main Pump)

Regulator
P6 P4 P2

P5 P3 P1

Pump Transmission

Engine

T18L-02-03-002

T2-3-7
SYSTEM / ELU System
SWING STOP CONTROL
Function: Stops swing operation when the fast-filling
panel or sliding fold-in ladder is lowered fro
protection against damage.

Operation:
1. With the fast-filling panel or sliding fold-in ladder
lowered, ELU receives voltage signal (0 v) from
the fast-filling panel position detection switch or
storage detection limit switch.
2. Under this condition, when attempting to make
swing operation, ELU judges that signal from the
control lever is inactive, disabling swing operation.
At the same time, swing stop signal is sent to IDU
through Ke-CAN.
3. When the fast-filling panel and sliding fold-in
ladder are stored, ELU receives 24 V voltage
signals from the fast-filling panel position detec-
tion switch and storage detection limit switch,
enabling swing operation.

T2-3-8
SYSTEM / ELU System

Swing

MC
IDU

Ke-CAN

ELU Folding Stairway Ladder Storage Detection Limit Switch

Fast-Filling Panel Position Detection Switch

T18L-02-03-003

Swing Swing
(Left) (Right)

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

T2-3-10
SYSTEM / Hydraulic System
OUTLINE

The hydraulic system is roughly classified into the pi-


lot circuit, the main circuit, the pump transmission oil
cooling circuit, the oil cooler fan motor circuit, the
compressor motor circuit, and the travel shock damp-
er / travel stop circuit.

• Pilot Circuit
Supplies the pressure oil from the pilot pump to
the operation control circuit, the travel mode con-
trol circuit, the pump control circuit, the fan motor
speed control circuit, the auto-lubrication circuit,
and the swing parking brake release circuit.

• Main Circuit
Controls the pressure oil from the main pump at
the control valve to drive the hydraulic actuators
such as the cylinders and the motors.

• Pump Transmission Oil Cooling Circuit


Sends the transmission oil from the pump trans-
mission oil pump to the oil cooler to circulate and
cool the oil.

• Oil Cooler Fan Motor Circuit


Drives the oil cooler fan motor using the pressure
oil from the oil cooler fan motor drive pump.

• Compressor Motor Circuit


Drives the compressor motor using the pressure
oil from the compressor motor drive pump.

• Travel Shock Damper / Travel Stop Circuit


Damps shock loads applied to the front idlers and
stops traveling if excessive loads are applied.

T2-4-1
SYSTEM / Hydraulic System
PILOT CIRCUIT

Pressure oil from pilot pump is used for the following


circuits:

• Operation Control Circuit


• Pump and Oil Cooler Fan Motor Control Circuits
(Refer to SYSTEM / Control System group.)
• Travel Mode Control Circuit (Refer to the SYS-
TEM / Control System and COMPONENT OP-
ERATION / Travel Device group.)
• Travel Parking Brake Release Circuit (Refer to
COMPONENT OPERATION / Travel Device
group.)
• Swing Parking Brake Release Circuit (Refer to
COMPONENT OPERATION / Swing Device
group.)
• Fast-Filling Panel Control Circuit (Refer to SYS-
TEM / Control System group.)
• Auto Lubrication Circuit (Refer to SYSTEM /
Control System group.)

Three accumulator units are installed in the pilot cir-


cuit so that hydraulic oil is supplied in the pilot circuit
for a period of time after the engine has been stopped.
The pilot pressure in the pilot circuit is constantly
maintained to the set-pressure of 3.9 MPa (40 kgf/cm2,
568 psi) by the pilot relief valve.

T2-4-2
SYSTEM / Hydraulic System

DQR Valve (Left Side) DQR Valve (Center Side)

Operation Control Circuit

EHC Valve
(For Electric Lever
Control) (Right)

Accumulator
Pilot Control
EHC Valve
Shut-Off Lever Swing Parking Brake Release Circuit
(For Electric Lever
Solenoid Valve
Control) (Left)

Auto Lubrication Circuit

Pump/Oil Cooler Fan Motor


Control Circuit
EHC Valve
(For Main Pump
Control) Travel Parking Brake
Release Circuit

Pilot Relief
Valve

Pilot Fil-
ter Fast-Filling Panel Travel Mode
Control Circuit Control Circuit
Pilot
Pump
MP6

MP5
T18L-02-04-001

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

The operation control circuit consists of two lines as


described below.
Pressure oil from the left and right pilot pumps is de-
livered to the control solenoid valve via pilot check
valve and pilot control shutoff lever solenoid valve.
When moving the control lever, the control solenoid
valve is activated, and pressure oil from the pilot
pump serves as signal pressure to DQR valve. (Re-
fer to SYSTEM/Control System group.)

DQR Valve Line:


Pressure oil from the pilot pump is delivered to DQR
valve.
When DQR valve is operated by signal pressure
from the control solenoid valve, pressure oil from the
pilot pump is routed to the spool end in the control
valve to operate the control valve.

T2-4-4
SYSTEM / Hydraulic System

Control Lever
Travel Travel Bucket Bucket
Arm Swing Bucket Boom (Left) (Right) Open Close

ELU

Control Signal to the each


Solenoid Valve of the EHC
DQR Valve (Left) Valve (For Electric Lever DQR Valve (Center)
Control)

To Control Valve
Spools
To Control Valve
Spools

Control
Signal from
ELU

EHC Valve (For Electric Lever Control) (Left)

EHC Valve (For Electric Lever Control) (Center)

Pilot Control Shut-Off Lever


Solenoid Valve

Pilot Check
Valve

Pilot Pump

T18M-02-04-003

T2-4-5
SYSTEM / Hydraulic System
1. When moving the control lever, ELU receives
signals according to the control lever stroke.
2. ELU activates the solenoid valve of the EHC
valve in response to these signals, generating
hydraulic pressure. This hydraulic pressure is
routed to DQR valve to move its spool.
3. When the DQR spool is moved, hydraulic pres-
sure is generated according to the DQR spool
movement (stroke). The hydraulic pressure is
rooted to the spool in the control valve, moving
the spool until the hydraulic pressure is balanced
with spring force.
Accordingly, the control valve spool is controlled
by pilot pressure oil through DQR valve, not by
pilot pressure oil through the control solenoid
valve.
4. When the control valve spool is moved, main
pressure oil from the control valve is delivered to
respective motors and/or cylinders to activate
them.
5. Return oil from the control valve is routed to the
hydraulic oil tank via the other oil port in the DQR
valve.
(Refer to COMPONENT OPERATION / DQR
Valve group.)

T2-4-6
SYSTEM / Hydraulic System

Hydraulic Lines

Control Lever

DQR Valve

Spool

Port T

ELU
Port P

Pilot
Pump
From Pilot Control Actuator
Shut-Off Lever
Solenoid Valve

Control Valve
Spring

Solenoid Valve of
the EHC Valve

Spool Main
Hydraulic Oil
Pump
Tank

T18G-02-02-002

T2-4-7
SYSTEM / Hydraulic System
MAIN CIRCUIT

Loading Shovel:
• Pressure oil from main pumps MP1 and MP2
Actuates each function of the right travel, boom
raise / bucket tilt, bucket open / close, and arm
after being controlled by the center control valve.
• Pressure oil from main pumps MP3 and MP4
Actuates each function of the left travel, arm,
boom, and bucket after being controlled by the
left control valve.
• Pressure oil from main pumps MP5 and MP6
Actuates each function of the swing, arm extend,
boom, and bucket after being controlled by the
right control valve.

Backhoe:
• Pressure oil from main pumps MP1 and MP2
Actuates each function of the right travel, boom,
bucket, and arm after being controlled by the
center control valve.
• Pressure oil from main pumps MP3 and MP4
Actuates each function of the left travel, arm,
boom, and bucket after being controlled by the
left control valve.
• Pressure oil from main pumps MP5 and MP6
Actuates each function of the swing, arm, boom,
and bucket after being controlled by the right
control valve.

T2-4-8
SYSTEM / Hydraulic System

Boom Bucket Arm Dump Dump Level Bucket Boom


Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder

Left Travel Motor Right Travel Motor

Swing Motor

Bucket
Bucket Arm
Bucket Boom Arm
Left Travel
Arm
Tilt-In/ Right Swing
Extend
Bucket Boom Oil
Open/
Boom Travel Cooler
Close
Raise

Left Control Valve Center Control Valve Right Control Valve

Hydraulic Oil Tank

MP3 MP4
MP1 MP3
MP2 MP4
Engine

MP1 MP2 MP5


MP6

Pump Layout Viewed from the Front


MP5 MP6
T141-02-02-001

NOTE: The above diagram shows the loading


shovel main hydraulic circuit. When refer-
ring to this diagram for the backhoe exca-
vator, replace three control valve sections
as follows:
Loading Shovel Backhoe
Bucket Open / Close Bucket
Boom Raise / Bucket Tilt Boom
Arm Extend Arm

T2-4-9
SYSTEM / Hydraulic System
Single Operation

Loading Shovel: Backhoe:


• Boom • Boom
Pressure oil is supplied to two boom cylinders via Pressure oil is supplied to two boom cylinders via
the center, right, and left control valves to raise or the center, right, and left control valves to raise or
lower the boom. The center control valve is used lower the boom.
only when raising the boom. • Arm
• Arm Pressure oil is supplied to two arm cylinders via
Pressure oil is supplied to the arm cylinder via the center, right, and left control valves to roll in
the center, right, and left control valves to extend or out the arm.
or retract the arm. The right control valve is used • Bucket
only when extending the arm. Pressure oil is supplied to two bucket cylinders
• Bucket Tilt via the center, right, and left control valves to roll
Pressure oil is supplied to two bucket cylinders in or out the bucket.
via the center, right, and left control valves to tilt • Swing
in or out the bucket. The center control valve is Pressure oil is supplied to two swing motors via
used only when tilting in the bucket. the right control valve to swing the upperstructure
• Bucket Open/Close in both directions.
Pressure oil is supplied to the dump cylinders via • Travel
the center control valve to open or close the Pressure oil is supplied to each side of the travel
bucket. motors via the left or center control valve when
• Swing driving the left or right track respectively.
Pressure oil is supplied to two swing motors via
the right control valve to swing the upperstructure
in both directions.
• Travel
Pressure oil is supplied to each side of the travel
motors via the left or center control valve when
driving the left or right track respectively.

T2-4-10
SYSTEM / Hydraulic System
Boom Bucket Arm Dump Dump Level Bucket Boom
Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder

Left Travel Motor Right Travel Motor

Swing Motor

Bucket
Left Bucket Arm Ex-
Tilt-In/ Right
Bucket Boom Arm Arm
Open/
Swing
tend
Bucket Boom Oil
Travel Boom Travel
Close
Cooler
Raise

Left Control Valve Right Control Valve


Center Control Valve

Hydraulic Oil Tank

MP3 MP4
MP1 MP3
MP2 MP4
Engine

MP1 MP2
MP5
MP6

MP5 MP6 Pump Layout Viewed from the Front


T141-02-02-001

NOTE: The above diagram shows the loading


shovel main hydraulic circuit. When refer-
ring to this diagram for the backhoe exca-
vator, replace three control valve sections
as follows:
Loading Shovel Backhoe
Bucket Open / Close Bucket
Boom Raise / Bucket Tilt Boom
Arm Extend Arm

T2-4-11
SYSTEM / Hydraulic System
Combined Operation
Left Control Valve
NOTE: As illustrated to the right, each control
valve has both tandem and parallel circuits
so that various combined operations can
Bucket
be achieved.

• Travel and Front Attachment or Swing Combined


Operation Boom
When the travel and the front attachment or the
swing are operated at the same time, pressure oil
is supplied to the right and left travel motors via Arm
the right and center control valves respectively.
The travel spools are located in front of the other
spools in the left and center control valves, or- Left Trav-
ganizing a tandem circuit to give priority to the el
travel function over other functions. Therefore,
pressure oil is not routed to the front attachment
spools located behind the travel spools. Accord- T141-02-02-007

ingly, pressure oil is supplied to the front attach- Center Control Valve
ment and the swing functions via the right control
valve so that the combined operation of the travel
and the front attachment or the swing is Arm
achieved.

NOTE: The bucket open/close and the arm retract


Bucket
functions are not operable together with Open/Close
the travel function on the loading shovel.
NOTE: The left and center control valves are ar-
Boom Raise /
ranged to give priority to the travel function. Bucket Tilt-In
The right control valve is arranged to give
priority to the swing function, Accordingly,
when the travel, the swing, and the front Right
Travel
attachment functions are operated simul-
taneously, the front attachment is inopera-
ble.
T141-02-02-008

Right Control Valve

Swing

Arm Extend

NOTE: The right figures show the control valve on


the loading shovel. When referring to this
Bucket
figures for the backhoe excavator, replace
three control valve sections as follows:

Loading Shovel Backhoe Boom


Bucket Open / Close Bucket
Boom Raise / Bucket Tilt Boom
Arm Extend Arm
T141-02-02-009

T2-4-12
SYSTEM / Hydraulic System
Boom Bucket Arm Dump Dump Level Bucket Boom
Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder

Left Travel Motor Right Travel Motor

Swing Motor

Bucket
Left Bucket Arm Ex-
Tilt-In/ Right
Bucket Boom Arm Arm
Open/
Swing
tend
Bucket Boom Oil
Travel Boom Travel
Close
Cooler
Raise

Left Control Valve Right Control Valve


Center Control Valve

Hydraulic Oil Tank

MP3 MP4
MP1 MP3
MP2 MP4
Engine

MP1 MP2
MP5
MP6

Pump Layout Viewed from the Front


MP5 MP6
T141-02-02-001

NOTE: The above diagram shows the loading


shovel main hydraulic circuit. When refer-
ring to this diagram for the backhoe exca-
vator, replace three control valve sections
as follows:
Loading Shovel Backhoe
Bucket Open / Close Bucket
Boom Raise / Bucket Tilt Boom
Arm Extend Arm

T2-4-13
SYSTEM / Hydraulic System
PUMP TRANSMISSION OIL COOLING
CIRCUIT

The pump transmission oil pump draws oil from the


pump transmission and delivers it to the oil cooler. Af-
ter the oil is cooled at the oil cooler, the oil is returned
to the pump transmission.

Oil COOLER FAN MOTOR CIRCUIT

Pressure oil from the oil cooler fan motor drive pump
drives the oil cooler fan motor.

COMPRESSOR MOTOR CIRCUIT

Pressure oil from the compressor motor drive pump


drives the air conditioner compressor motor.

Compressor Motor

Oil Cooler Fan Motor

Hydraulic
Oil Tank

Pump
Engine Trans-
mission
Oil Cooler

T141-02-02-005

Oil Cooler Fan Motor Compressor Motor Pump Transmission


Drive Pump Drive Pump Oil Pump

T2-4-14
SYSTEM / Hydraulic System
TRAVEL SHOCK ABSORBING / TRAVEL
STOP CIRCUIT

Purposes Operation
Protects the front idlers from shocks. • When subjected to ordinary shocks:
Depending on shocks to the front idlers, the travel 1. When moving the travel lever, ELU activates the
shock absorbing/travel stop circuit functions as fol- EHC valve. (Refer to Operation Circuit.)
lows. 2. Pilot pressure is routed to DQR valve via the
• When subjected to ordinary shocks: EHC valve.
The accumulators works to absorb shocks. 3. Thereby, pilot pressure oil from the pilot pump is
• When subjected to excessive shocks routed to the travel spool in the control valve via
Refer to Cushion Cylinder End Travel Limit Con- DQR valve, thus moving the travel spool to open
trol in SYSTEM / ELU System group. the travel port.
4. Then, pressure oil from the main circuit is deliv-
ered to left and right travel motors, causing the
machine to travel.
5. At the same time, pressure oil from the main cir-
cuit is pressure reduced by the pressure reducing
valve, and is delivered to the cushion cylinder.
6. When the front idler is subjected to shocks, the
cushion piston is pushed to deliver hydraulic oil
from behind the cushion piston into accumula-
tors.
7. Then, bladders in accumulators are contracted to
absorb shocks.

Cushion Piston

Travel Stop Valve


Cushion Cylinder
Relief Valve

Pressure-Reducing
Cushion Cylinder End Valve
Pressure Sensor

Pilot Pump

Travel Spool in
Control Valve Center Joint Pilot Pressure
Select Valve T18M-02-04-005

T2-4-15
SYSTEM / Hydraulic System
(Blank)

T2-4-16
SYSTEM / Electrical System
OUTLINE
The electrical system roughly falls into three sections:
main circuit, control circuit, and monitor circuit.

• Main Circuit
Engine and accessory circuit

• Control Circuit
Machine operation control circuit
(Refer to the SYSTEM section.)

• Monitor Circuit
Machine operation status indication circuit
(Refer to electrical circuit diagrams.)

Functions and construction of the main circuits will be


explained below.

• Main Circuits

• Power Source Circuit: Supplies electric power to


all electrical systems on the machine.

• Accessory Circuit: Operates with the key switch in


the ACC position.

• Engine Start Circuit: Cranks the starter to start the


engine.

• Charging Circuit: Recharges batteries, and sup-


plies current, generated by the alternator, to op-
erate all the electrical components.

• Engine Stop Circuit Using Emergency Engine


Stop Switch, Limit Switch and Engine Stop Switch:
Stops the engine, and prevents the engine from
restarting.

• Surge Voltage Prevention Circuit: Protects elec-


trical equipment from surge voltage developed at
stops of the engine.

T2-5-1
SYSTEM / Electrical System
POWER SOURCE CIRCUIT
(Key Switch: OFF)
Negative terminal (−) of battery is connected to the
machine. With the key switch OFF, electric current
flows as follows.

Battery relays (1, 2, 3) terminal A

Fusible link #1 → Fuse box 1


Battery → Fuse box 3
Fusible link 9 → ECM power connector terminal A, C, D
Fusible link 10 → Sliding fold-in ladder relay (2) terminal #3
Sliding fold-in ladder relay (3) terminal #3
Fusible link (250 A) → Sliding fold-in ladder motor (2)
Fusible link (250 A) → Sliding fold-in ladder motor (1)

Fuse #1 → MC (Main power source)


Fuse #2 → Delayed power off relay terminals #1 and #3
Fuse box 1 → Fuse #4 → MMS communication unit (Main power source)(optional)
Fuse #5 → HMU (Main power source)
Fuse #6 → Air horn compressor relay (L1) terminal #3
Fuse #7 → Air horn compressor relay (R1) terminal #3
Fuse #8 → Sliding fold-in ladder relay (1) terminal #3
Sliding fold-in ladder alarm/flash light (1) terminal #12
Fuse #9 → Limit switch (box light switch) (electrical equipment box door inside)
Fuse #10 → Fuse box (cab)
Fuse #11 → C/U main power 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 #5 → Radio (Backup power source)

Fuse box 3 → Fuse #55 → ECM (Data link)

NOTE: The fluorescent light in the electrical


equipment box is enabled even when
the engine is OFF.

T2-5-2
SYSTEM / Electrical System
Limit Switch Fuse Box
LED (Cab)
(Box light switch)

To MC Delayed Power OFF


Relay Terminals Sliding Fold-In Ladder To ELU
#1 and #3 Relay (1) Terminal #3 To IDU
To MMS
Communication Sliding Fold-In Ladder Relay To DLU
Unit Alarm Flash Light (1) #12 ORBCOMM
To HUM Air Horn Compressor C/U Main Power Source Terminal #2 (Optional)
Relay (L1) Terminal #3 Terminal #1 (Optional)
Air Horn Compressor To Radio
Relay (R1) Terminal #3
C/U (Ke-CAN)
Terminal #1
(Optional)

Fuse Box 1 Key Switch


ECM
(Data Link)

Fuse Box 3

Sliding Fold-In Ladder Relay (2)

Sliding Fold-In Ladder Relay (3)


Fusible Link #9
Fusible Link 1
Fusible Link #10

Fusible Link (250A)

Fusible Link (250A)

Battery Relay 1

Battery Relay 2

Battery Relay 3

Battery
Sliding Fold-In Sliding Fold-In
Ladder Motor 1 Ladder Motor 2

T18M-02-05-001

T2-5-3
SYSTEM / Electrical System
ACCESSORY CIRCUIT
(Key Switch: ACC)
1. When key switch is set to ACC position, terminal
B in key switch connects to ACC terminal.
2. Current from ACC terminal flows to fuses #13,
#14, #15 and #16 in fuse box (cab).
3. Current through fuse #13 flows to radio to power.
4. Current through fuse #14 excites air horn com-
pressor relays L2 and R2, and horn relay.
5. At the same time, current flows through air horn
compressor relays L2 and R2 to excite them.
6. Current from each relay powers the horn and horn
compressor.
7. Current through fuse #15 flows to cigarette lighter
to power.
8. Current through fuse #16 flows to terminal (1) to
power.

T2-5-4
SYSTEM / Electrical System

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

Air Horn Key Switch


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

Cigarette Lighter

Fusible Link 1

Power Source
Terminal (1)

Air Horn Air Horn


Compressor Relay (R2) Compressor Relay (R1)

Horn Relay

Horn Switch

Horn (R) Horn (L)

Air Horn
Compressor (R1) Air Horn
Compressor (L1)

Battery

Horn Pressure
Horn Pressure Switch (L1)
Switch (R1)
Horn Pressure
Horn Pressure Switch (L2)
Switch (R2)
T18M-02-05-002

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

1. When key switch is turned ON, current from key


switch terminal M excites battery relays 1 to 3
through fuse #11 in fuse box (cab) and fuse #26 in
fuse box 2.
2. With battery relays 1 to 3 excited, current from
battery flows to terminal B of starter via battery
relays 1 to 3.
3. In addition, current from terminal M through fuse
#12 in the fuse box (cab), emergency switches 1
to 5, valve limit switches (return (1), return (2))
flows to the engine start switch through the valve
limit switch (suction).
4. In addition, current from valve limit switch (suc-
tion) flows to ECM through the engine start switch.
Therefore, the fuel injection pump can be con-
trolled by the governor and the engine can start.

T2-5-6
SYSTEM / Electrical System

Air Bleeding
Solenoid Valve
ECM
Emergency Switch 1 to 5

Engine Stop Valve Limit Valve Limit Valve Limit


Switch Switch Switch
Switch
(Suction ) (Return (2)) (Return (1))

Alternator

Prelube
Starter (1) Timer Relay
(Upper)
Engine Start
Switch

Starter (2) Fuse Box 3


(Lower) Fuse #47

Fusible Link 4 Fuse Box 2


Fuse #26
Battery Relay 1

Circuit Breaker
(250A) Battery Relay 2

Battery Relay 3

Fuse Box
(Cab)

From Battery
Key Switch
T18L-02-05-001

T2-5-7
SYSTEM / Electrical System
Starting Engine

• Engine Prelube Circuit


1. When the engine start switch is pushed, current Display
from terminal M in the key switch flows to terminal
#3 in the prelube timer through the engine start
switch and operates the prelube timer.
2. Current from terminal #6 in the prelube timer ex-
cites the prelube relay.
3. As the prelube relay is excited, current from the
battery flows to the prelube motor and IDU
through battery relays (1, 2) and the prelube relay.
4. The prelube motor rotates and the engine oil
pressure increases.
5. At the same time, IDU lights PRELUB on the dis-
play.
6. When the engine oil pressure increases, the pre-
lube pressure switch is turned OFF. Consequently, T18L-02-05-005

current from terminal #4 in the prelube timer relay


is blocked and the prelube timer relay stops
flowing current from terminal #6 to the prelube
relay.
7. When current from terminal #6 in the prelube
timer relay stops, the excited current to the pre-
lube relay is cut and the prelube relay is turned
OFF. Consequently, current from the battery is Prelube T18N-02-05-018

blocked and the prelube motor is stopped.


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

T2-5-8
SYSTEM / Electrical System

From Key Switch


Engine Start Terminal M
Switch
Prelube Timer
Relay

Prelube Pressure
Switch

To IDU

Prelube
Relay
From
Battery

Prelube
Motor

Starter Relay (Upper)

Starter Relay (Lower)

T18M-02-05-004

To Starter
Relay 2

T2-5-9
SYSTEM / Electrical System
• Engine Start Circuit
After the prelube operation, the prelube timer relay
flows the excited current to the starter relay and
starts the engine in the followings.

1. Voltage from the batter has already been applied 9. As the engine oil reserve pump unit relay is ex-
to terminals B in starters (1) (upper) and (2) cited, current from fusible link 4 to the engine oil
(lower). Therefore, when current flows to termi- reserve pump unit is blocked. Therefore, the en-
nals S in starters (1) (upper) and (2) (lower), gine oil reserve pump unit is turned OFF.
-1
starters (1) (upper) and (2) (lower) can rotate right 10. When the engine speed becomes 500 min or
away. more, the crank speed sensor sends the signal to
2. When the prelube operation, current from terminal ECM.
#5 in the prelube timer flows and excites starter 11. ECM excites the starter relay 2.
relays (upper) and (lower) at the same time. 12. As the starter relay 2 is excited, the ground cir-
3. Current from the battery flows to terminals S in cuits in starter relays (upper) and (lower) are
starters (1) (upper) and (2) (lower) through battery blocked. Therefore, current exciting starter relays
relays (1, 2) and starter relays (upper) and (lower) (upper) and (lower) is blocked.
respectively. 13. Therefore, as current to terminals S in starters (1)
4. Current to terminals S in starters (1) (upper) and (upper) and (2) (lower) excites is cut, starters (1)
(2) (lower) excites the starter coil connects ter- (upper) and (2) (lower) are stopped.
minal B to terminal M. Consequently, when the
starter rotates, the pinion gear meshes with the
ring gear in the engine while rotating in order to
start the engine.
5. When the engine starts, the alternator starts gen-
erating.
6. Current from terminal AC in the alternator excites
the alternator relay.
7. As the alternator relay is excited, the ground cir-
cuit between charge SIG relay and engine oil re-
serve pump unit relay is connected. Therefore,
charge SIG relay and engine oil reserve pump
unit relay are excited.
8. As the charge SIG relay is excited, current from
terminal M in the key switch to MC is blocked.
Therefore, MC detects that the engine starts.

T2-5-10
SYSTEM / Electrical System

From Key Switch


Engine Start Terminal M
Switch

Prelube Timer

Charge SIG Relay

Starter Relay (Upper)

Engine Oil Reserve


Fuse Box 3 Pump Unit Relay
Starter Relay (Lower)
Fuse #59

Alternator Relay Engine Oil Reserve


Starter Relay 2 Pump Unit Switch
From
EHU
Fusible
Link 4 Fuse Box 2
Fuse #40

Alternator ECM Fuse Box 2


Battery Relay (1)
Fuse #26

Battery Relay (2)

Battery Relay (3)

Crank Speed
Sensor
Fuse Box
(Cab)

Starter (1)
(Upper) From Battery
Key Switch
Starter (2)
(Lower)

T18M-02-05-006

T2-5-11
SYSTEM / Electrical System
CHARGING CIRCUIT
(KEY SWITCH AT ON POSITION)
1. When key switch is at ON position, terminal B 5. At the same time, current from terminal (sub) is
connects to ACC and terminal M in the key routed to each circuit via fusible link, fuse boxes 1
switch. to 4, and fuse box (cab).
2. Current from key switch terminal M is routed to
battery relays 1 to 3 via fuse #11 in fuse box (cab)
and fuse #26 in fuse box 2, thus keeping battery
relay ON.
3. When engine starts, alternator starts rotating,
generating electricity.
4. Current from alternator terminal B is routed to
battery via circuit breaker (200A), terminal (sub),
battery relays (1) and (2), and terminal (main),
thus charging battery.

Terminal Connected to Remarks


Terminal (main) Fusible link 1 -
Fusible link 9 ECM
Sliding fold-in ladder relay (2) Folding stairway circuit ground sig-
nal
Sliding fold-in ladder motor 1 Power source
Sliding fold-in ladder motor 2 Power source
Terminal (Sub) Fusible link 2 -
Fusible link 3 -
Fusible link 4 -
Fusible link 5 -
Fusible link 6 -

T2-5-12
SYSTEM / Electrical System

To T2-5-15, 17, 19, 21


Fusible Link
Terminal (Main)

Fusible Link 9

Terminal
(Sub)

Circuit Breaker
(200A)

Battery Relay 1

Battery Relay 2

Battery Relay 3

From Alterna-
tor Terminal B
From Key Switch
Terminal M

Sliding Fold-In
Ladder Relay (2)

Sliding Fold-In
Ladder Relay (3)
ECM
Battery

Sliding Fold-In Sliding Fold-In


Ladder Motor 2 Ladder Motor 1

T18M-02-05-008

T2-5-13
SYSTEM / Electrical System

Fusible link Fuse box Connected to Remarks


#1 Fuse box 1 #1 MC terminals #76-55 Main power source
#2 Delayed power off terminal #1 Ground circuit
#4 MMS communication unit (optional) terminal B Main power source
#5 HMU terminals #76-55 Main power source
#6 Air horn compressor relay (L1) terminal #3 Power source
#7 Air horn compressor relay (R1) terminal #3 Power source
#8 Sliding fold-in ladder relay (1) terminal #3 Power source
Sliding fold-in ladder 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 #55 ECM Data link

Input to Fuse 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, #76-77 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

T2-5-14
SYSTEM / Electrical System

Fuse Box (Cab)

Key Switch

To Horn Circuit
Cigarette Lighter

Power Source
Terminal (1)
See T2-5-21
Fuse Box 3
See T2-5-19
See T2-5-17 Fuse Box 1

To T2-5-13

T18M-02-05-009

T2-5-15
SYSTEM / Electrical System

Fusible link 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 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

T2-5-16
SYSTEM / Electrical System
Fuse Box 2

Fuse Box 3

Fuse Box 4

See
T2-5-19

See
T2-5-21 See
T2-5-15

To T2-5-13

T18M-02-05-010

T2-5-17
SYSTEM / Electrical System

Fusible link 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 speed switch relay terminal #3 Power source
#45 Sliding fold-in ladder relay 4 terminal #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
#59 Engine oil reserve pump unit relay terminal #1,3 Power source
#60 Oil pump Power source
Fuse box 4 #67 Maintenance light relay 1 terminal #1,3 Power source
#68 Maintenance light relay 2 terminal #3 Power source
#77 Washer motor relay terminal 3 Power source
#78 Centralized lubrication system relay terminal #3 Power source
#79 CSU terminal #9 Main power source

T2-5-18
SYSTEM / Electrical System

Fuse Box 2

Fuse Box 3

Fuse Box 4

See See
T2-5-21 T2-5-17 See
T2-5-15

To T2-5-13

T18M-02-05-011

T2-5-19
SYSTEM / Electrical System

Fusible link 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 #75 Wiper motor circuit breaker 1 (10A) / motor (L) Power source
#76 Wiper motor circuit breaker 2 (20A) / motor (H) Power source

T2-5-20
SYSTEM / Electrical System

Fuse Box 3

Fuse Box 4

See
T2-5-19

See T2-5-17
See T2-5-15

T18M-02-05-012
To T2-5-13

T2-5-21
SYSTEM / Electrical System
ENGINE STOP CIRCUIT
Engine Stopping with Emergency Switch

1. When emergency switches 1 to 5 which provided


at several location on the machine are set to the
emergency stop position, current from terminal M
in the key switch to ECM is blocked.
2. ECM controls the electronic governor in the en-
gine and stop supplying fuel.
3. Therefore, the engine stops.
4. Simultaneously, current to engine start switch is
shut-off, disabling the engine.
5. Only when emergency switch 1 in cab is set to the
emergency stop position, air release solenoid
valve on the hydraulic oil tank work to release the
pressure inside the tank.

NOTE: Figure in T2-5-23 shows the status when


the emergency switch 1 is set to the
emergency stop position.

T2-5-22
SYSTEM / Electrical System

Air Bleeding
Solenoid Valve
ECM
Emergency Switch 2 to 5 Emergency
Switch 1 (Cab)

Engine Stop Valve Valve Limit


Switch Limit Switch Switch (Re-
(Suction) turn (1))

Valve
Limit Switch
(Return (2))

Alternator

Starter (1)
(Upper)
Prelube Timer Engine
Start Switch

Starter (2)
(Lower)
Fuse Box 3
Fuse #47

Fusible Link 4 Fuse Box 2


Fuse #26
Battery Relay 1

Circuit Breaker
(200A) Battery Relay 2

Battery Relay 3

Fuse Box
(Cab)

From Battery
Key Switch
T18L-02-05-002

T2-5-23
SYSTEM / Electrical System
Engine Stopping with Valve Limit Switch

1. The valve limit switch is provided to the butterfly


valves in suction pipe and return pipe. When the
butterfly valves is closed, as the valve limit switch
is turned OFF, current from terminal M in the key
switch to ECM is blocked.
2. ECM controls the electronic governor in the en-
gine and stop supplying fuel.
3. Therefore, the engine stops.
4. At the same time, current to the engine start
switch is shut-off, disabling the starter motor.
Therefore, the engine cannot start.

NOTE: Figure in T2-5-25 shows the status when


the valve limit switch (return (1)) is OFF.

T2-5-24
SYSTEM / Electrical System

Air Bleeding
Solenoid Valve
ECM
Emergency Switch 2 to 5 Emergency
Switch 1 (Cab)

Engine Stop Valve Valve Limit


Switch Limit Switch Switch (Re-
(Suction) turn (1))

Valve
Limit Switch
(Return (2))

Alternator

Starter (1)
(Upper)
Engine
Prelube Timer
Start Switch

Starter (2)
(Lower)
Fuse Box 3
Fuse #47

Fusible Link 4 Fuse Box 2


Fuse #26
Battery Relay 1

Circuit Breaker
(200A) Battery Relay 2

Battery Relay 3

Fuse Box
(Cab)

From Battery
Key Switch
T18L-02-05-003

T2-5-25
SYSTEM / Electrical System
Engine Stopping with Engine Stop Switch

1. When the engine stop switch is pushed, current


from terminal M in the key switch to ECM is
blocked.
2. ECM controls the electronic governor in the en-
gine and stop supplying fuel.
3. Therefore, the engine stops.

NOTE: Figure in T2-5-27 shows the status when


the engine stop switch is pressed.

T2-5-26
SYSTEM / Electrical System

Air Bleeding
Solenoid Valve
ECM
Emergency Switch 2 to 5 Emergency
Switch 1 (Cab)

Engine Stop Valve Valve Limit


Switch Limit Switch Switch (Re-
(Suction) turn (1))

Valve
Limit Switch
(Return (2))

Alternator

Starter (1)
(Upper)
Engine
Prelube Timer
Start Switch

Starter (2)
(Lower)
Fuse Box 3
Fuse #47

Fusible Link 4 Fuse Box 2


Fuse #26
Battery Relay 1

Circuit Breaker
(200A) Battery Relay 2

Battery Relay 3

Fuse Box
(Cab)

From Battery
Key Switch
T18L-02-05-004

T2-5-27
SYSTEM / Electrical System
SURGE VOLTAGE PROTECTION CIRCUIT
When stopping the engine by turning key switch OFF,
current from key switch terminal M to battery relay
terminal S is shut-off, causing battery relay to turn OFF.
When key switch is turned OFF, the engine still coasts
for a while, causing the alternator to generate electric-
ity. In this case, with the battery relay OFF, the gener-
ated current from alternator terminal B does not flow to
battery via battery relay terminal B, thus developing
surge voltage (voltage buildup) in the circuit. To protect
electric equipment, such as MC, from surge voltage,
the surge voltage protection circuit is provided.

1. Current from battery flows normally to delayed


power off relay terminals #1 and #3. When key
switch is at ON position, current from key switch
terminal M flows to fuses #15 and #26.
2. Current from fuse #26 flows to battery relay ter-
minal S. Current from fuse #15 flows to MC. MC
recognizes it as power-on.
3. When current flows to MC, MC grounds the cur-
rent flowing from delayed power off relay terminal
#2 to MC terminal #48-9, thus turning ON delayed
power off relay.
4. Current from delayed power off relay terminal #5
flows to battery relay terminal S. When battery
relay is turned ON, current from alternators ter-
minal B is charged in the battery.
5. When key switch is set to ACC or OFF position,
current from fuse #15 to MC is shut-off. As a re-
sult, about 180 seconds later, MC turns delayed
power off relay OFF (shutting off ground circuit).
6. After key switch is turned OFF, delayed power off
relay is kept ON for about 60 seconds so that
current from fuse #2 keeps battery relay ON.
Consequently, the generated current from alter-
nators terminal B flows to battery to prevent the
occurrence of surge voltage in the circuit.

T2-5-28
SYSTEM / Electrical System

Fuse Box (Cab)

Fuse #11

Fuse #1

Key Switch

Fuse Box 1

Fuse #2

Delayed Power Off


Relay Fuse Box 2 Fuse #15
Fuse #26 Fuse #10

MC Fusible Link 1

Battery Relay 1

Battery Relay 2

Battery Relay 3

Alternator

Battery

T18M-02-05-016

T2-5-29
SYSTEM / Electrical System
(Blank)

T2-5-30
MEMO

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MEMO

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SECTION 3
COMPONENT OPERATION

CONTENTS
Group 1 Pump Device Group 5 DQR Valve
Outline .....................................................T3-1-1 Outline .....................................................T3-5-1
Main Pump ...............................................T3-1-2 Port Layout ...............................................T3-5-2
Regulator .................................................T3-1-4 Construction .............................................T3-5-3
4-Unit Pump ...........................................T3-1-30 Operation .................................................T3-5-4

Group 2 Swing Device Group 6 Travel Device


Outline .....................................................T3-2-1 Outline .....................................................T3-6-1
Swing Motor .............................................T3-2-2 Travel Motor .............................................T3-6-2
Swing Parking Brake ................................T3-2-4 Travel Mode Control .................................T3-6-4
Swing Reduction Gear..............................T3-2-5 Brake Valve ..............................................T3-6-6
Valve Unit .................................................T3-2-6 Parking Brake...........................................T3-6-8
Travel Reduction Gear..............................T3-6-9
Group 3 Control Valve
Outline .....................................................T3-3-1 Group 7 Others (Upperstructure)
Pilot Port Location ....................................T3-3-2 Fast-Filling System ...................................T3-7-1
Hydraulic Circuit .......................................T3-3-4 Air Conditioner .........................................T3-7-3
Main Relief Valve and Auto-Lubrication System...........................T3-7-6
Overload Relief Valve .............................T3-3-6 Oil Cooler Fan Motor ................................T3-7-7
Make-Up Valve .........................................T3-3-6 EHC Valve (For Main Pump Control) ........T3-7-8
Accumulator ...........................................T3-7-10
Group 4 Control Equipment
Outline .....................................................T3-4-1 Group 8 Others (Undercarriage)
Electric Lever ...........................................T3-4-2 Swing Bearing ..........................................T3-8-1
EHC Valve (For Electric Lever Control).....T3-4-6 Accumulator .............................................T3-8-2
Adjuster Cylinder ......................................T3-8-3
Center Joint..............................................T3-8-6

18LT-3-1
(Blank)

18LT-3-2
COMPONENT OPERATION / Pump Device
OUTLINE
The pump device consists of the pump transmission, The 4-unit pump consists of four pumps of various
main pumps (3-units) and a 4-unit pump. Power from types. From the transmission side. The first pump is a
the engine is transmitted to each pump through the swash plate type variable displacement plunger pump,
transmission. The main pump is a swash plate type driving the oil cooler fan motor. The 2nd pump is a gear
variable displacement 2-tandem plunger pump, sup- pump to supply pressure oil to the pilot circuit. The 3rd
plying the high pressure hydraulic oil to the main cir- pump is also a gear pump to drive the air conditioner
cuits. compressor. The 4th pump, farthest away from the
transmission, is used to circulate the pump transmis-
sion oil.

Main Pump 3
(Toward Transmission)
Main Pump 4
(Away from Transmission)

Main Pump 5
(Toward Transmission)
Main Pump 6
(Away from Transmission)

Main Pump 1 (Toward Transmission)


Main Pump 2 (Away from Transmission)
4-Unit Pump
T117-02-01-001

Pump Transmission

T3-1-1
COMPONENT OPERATION / Pump Device
MAIN PUMP
The main pump is a swash plate type 2-tandem NOTE: Main pumps 1 to 6 are identical in con-
plunger pump. The two shafts are connected with a struction but different in displacement.
coupling. The same type pump is mounted on each
(Refer to the GENERAL / Component
shaft. A cylinder block, in which plungers are installed,
Specification group.)
is splined onto the shaft. Engine rotation is transmitted
to the shaft via the pump transmission. As the shaft is
rotated, the plungers rotate along with the cylinder
block. The plungers slide along the surface of the shoe
plate so that the plungers reciprocate in the cylinder
block bores as the swash plate is positioned at an an-
gle toward the plungers. This plunger reciprocation
functions to draw and discharge the hydraulic oil.

Main Pumps 1, 3, and 5 Main Pumps 2, 4, and 6

Shaft Servo Piston Servo Piston

Swash Plate Plunger Cylinder Valve Plate Coupling Valve Plate Cylinder Plunger Swash Plate
Block Block
T117-02-01-002

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

The flow rate of the pump is varied by changing the


angle of the swash plate, which changes the stroke of
the plunger. The servo piston is moved by the pres-
sure oil routed from the regulator. As the swash plate
is connected to the servo piston, the swash plate an-
gle is changed in accordance with the movement of
the servo piston, so that the pump flow rate is
changed.

Servo Piston

Shaft

Valve Plate

Cylinder Block

Plunger T117-02-01-003

Swash Plate

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

Regulator Operation
• Torque Constant Control • Power Reducing Control (Main pump only)
-1
Controls the pump flow rate depending on the When the engine speed is reduced to 1650 min
pump delivery pressure (P) in order to maximize or slower, power reducing control pressure Pf
utilization of the engine horsepower. This control from the EHC valve (SF) is routed to decrease the
includes the following two operations. pump swash angle so that the pump output is
(1) Overload Prevention Operation reduced.
When pump delivery pressure (P) increases, • Power Increasing Control (Main pump only)
-1
the pump swash angle is reduced to reduce When the engine speed increases to 1850 min
the pump flow rate. or faster, power increasing control pressure Pz
(2) Flow Rate Recover Operation from the EHC valve (SD) is routed to increase the
When pump delivery pressure (P) decreases, pump swash angle so that the pump output is in-
the pump swash angle is increased to in- creased.
crease the pump flow rate. • Minimum Flow Rate Signal Priority Control
• Flow Rate Control When more than two control signals are delivered
Regulator for Main Pump: When a control lever is to the regulator at the same time, the regulator is
operated, flow rate control pilot pressure Pi from controlled by the minimum flow rate signal.
EHC valve is routed to change the pump swash
angle so that the pump flow rate is controlled. NOTE: The regulator port symbols correspond to
Regulator for Oil Cooler Fan Motor Drive Pump: the symbols used on the hydraulic circuit
MC drives EHC valve (SC) (oil cooler fan control diagram as follows.
solenoid valve) according to the hydraulic oil
temperature. Flow rate control pilot pressure Pi Symbol on Hydraulic
from EHC valve (SC) changes the pump swash Regulator Port Symbol
Circuit Diagram
angle. Pi i1 to i7
Pf j1, j3, j5
Pz k1 to k6
Psv p1 to p7

T3-1-4
COMPONENT OPERATION / Pump Device

Pi Pf Psv Pz

T141-04-04-004

Pz Psv Pi

P- Pump Delivery Pressure Pf- Power Reducing Control Pressure


(EHC Valve (SF))
Psv- Pump Servo Assist Pressure Pz- Power Increasing Control Pressure
(from Pilot Pump) (EHC Valve (SD))
Pi- Flow Rate Control Pressure
(EHC Valve (SE), (SI))

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

A
B

T141-03-01-005
A B

Cross Section A-A


1 2 3 4 5 6 7 8 9 10 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
Cross Section B-B
15 16 17 18 19 20 21 22 23
Pz

Pf

24

T117-02-01-007

15 - Piston 17 - Lever 2 19 - Hole 23 - Outer Spring


16 - Compensating Piston 18 - Pin 20 - Compensating Rod 24 - Inner Spring

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

A
B

T146-03-01-004
A B

Cross 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
Cross 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 Regulator)

Movement of pilot piston (10) is transmitted to lever Accordingly, when lever 1 (7) or lever 2 (17) rotates,
1(7) via pin (9), rotating lever 1 (7) around pin (4) held pin (5) comes in contact with the hole inside on the
in the supporting plug. Movement of compensating rod rotated lever, causing feedback lever (12) to rotate
(20) is transmitted to lever 2 (17) via pin (24), rotating around pin (13) on servo piston (14). On the other
lever 2 (17) around pin (18) held in the casing. Pin (5) hand, when servo piston (14) is moved, feed back
is installed into feedback lever (12) and both ends of lever (12) is moved via pin (13). Since lever 1 (7) and
pin (5) are inserted into the holes on lever 1 (7) and lever 2 (17) do not move at this time, feedback lever
lever 2 (17). (12) rotates around pin (5), moving spool (3).

NOTE: :Decreasing displacement angle


18 :Increasing displacement angle
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
Link Mechanism
(Fan Motor Drive Pump Regulator)

Movement of pilot piston (10) is transmitted to lever Accordingly, when lever 1 (7) or lever 2 (17) rotates,
1(7) via pin (9), rotating lever 1 (7) around pin (25) held pin (5) comes in contact with the hole inside on the
in the supporting plug. Movement of compensating rod rotated lever, causing feedback lever (12) to rotate
(20) is transmitted to lever 2 (17) via pin (24), rotating around pin (13) on servo piston (14).
lever 2 (17) around pin (18) held in the casing. Pin (5) On the other hand, when servo piston (14) is moved,
is installed into feedback lever (12) and both ends of feed back lever (12) is moved via pin (13). Since lever
pin (5) are inserted into the holes on lever 1 (7) and 1 (7) and lever 2 (17) do not move at this time, feed-
lever 2 (17). back lever (12) rotates around pin (5), moving spool
(3).

NOTE: :Decreasing displacement angle


18 :Increasing displacement angle
24
Housing
17
19

12
20
6
5
7
8
25
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 and Fan Motor Drive Pump)

NOTE: The constant torque control has the two 5. According to servo piston (14) moving, the pump
following functions. swash angle is reduced so that the pump flow rate
・ Overload Prevention Operation is reduced.
As load (pressure) increases, the pump
delivery flow rate is reduced so that the 6. As servo piston (14) moves, feedback lever (12)
engine is not overloaded. is moved via pin (13). Since compensating rod
・ Flow Rate Recover Operation (20) and lever 2 (17) do not move, feedback lever
As load (pressure) decreases, the pump (12) is rotated around pin (5) counterclockwise,
delivery flow rate is increased so that the moving spool (3) to the left. Then, when the
engine output can be effectively utilized. notches on spool (3) and sleeve (2) close. Thor-
oughly the oil pressure isn’t routed into the large
• Overload Prevention Operation chamber of servo piston (14), then servo piston
(14) stops moving.
1. When pump delivery oil pressure (P) increases
from P1 to P2, compensating piston (16) pushes 7. Consequently, the pump flow rate decreases from
compensating rod (20) to the right until the oil Q1 to Q2, reducing the pump loads.
pressure force balance 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, moving spool (3) to the right.

4. When spool (3) is moved, pump delivery pressure


oil is routed into the large chamber of servo piston
(14) through spool (3). Although the same pres- Delivery Oil Pressure T141-03-01-001

sure oil is routed into the small chamber, servo


piston (14) moves to the right due to the differ-
ence 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
17
Housing 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 Recover Operation

1. When pump delivery oil pressure (P) decreases


from P2 to P1, compensating piston (16) returns
along with compensation rod (20) 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 (2)
(17) counterclockwise, moving spool (3) to the
left.

4. When spool (3) is moved, the large chamber of


servo piston (14) is connected to the hydraulic oil
Delivery
tank through spool (3). Since the pump delivery Flow
oil pressure (P) is routed into the small chamber, Rate
servo piston (14) moves to the left.

5. According to servo piston (14) moving, the pump


swash angle increases so that the pump flow rate
Delivery Oil Pressure
increases. T141-03-01-001

6. As servo piston (14) moves, feedback lever (12)


is moved via pin (13). Since compensating rod
(20) and lever 2 (17) do not move, feedback lever
(12) is rotated around pin (5) clockwise, moving
spool (3) to the right. Then, when the notches on
spool (3) and sleeve (2) close thoroughly, the
large chamber of servo piston (14) isn’t connected
to the hydraulic oil tank.

7. Consequently, the pump flow rate increases 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)

The flow rate control increases or decreases the


pump flow rate. MC drives EHC valves (SE) and (SI)
in proportion to the control lever stroke. (Refer to the
SYSTEM / Control System group.)
Pressure oil from the pilot pump flows to the pump
regulator through EHC valves (SE) and (SI). Thereby,
the pump regulator detects the control lever
conditions so that the regulator controls the pump
swash angle.

• Flow Rate Increase Operation

1. When a control lever is operated, flow rate control


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


inserted into hole (8) on lever 1 (7), feedback lever
(12) is rotated around pin (13) by lever 1 (7)
counterclockwise, moving spool (3) to the left.
Delivery
4. When spool (3) is moved, the large chamber of Flow
servo piston (14) is connected to the hydraulic oil Rate
tank through spool (3). Since the pump delivery oil
pressure (P) is routed into the small chamber,
servo piston (14) moves to the left.

5. According to servo piston (14) moving, the pump Flow Rate Control
Pressure
swash angle increases so that the pump flow rate T141-03-01-002

increases.

6. As servo piston (14) moves, feedback lever (12) is


moved via pin (13). Since pilot piston (10) and
lever 1 (7) do not move, feedback lever (12) is
rotated around pin (5) clockwise, moving spool (3)
to the right. Then, 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, then servo piston (14) stops
moving.

7. Consequently, the pump flow rate increases in


proportion to the control lever stroke (Pi pressure
increase).

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 Decrease Operation

1. When a control lever is returned to neutral and


flow rate control pressure Pi is reduced, pilot
piston (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


inserted into hole (8) on lever 1 (7), feedback
lever (12) is rotated around pin (13) by lever 1 (7)
clockwise, moving spool (3) to the right.

4. When spool (3) is moved, pump delivery oil


pressure (P) is routed into the large chamber of
servo piston (14) through spool (3). Although the
same oil pressure (P) is routed into the small
Delivery
chamber, servo piston (14) moves to the right due Flow
to the difference in the pressure receiving areas Rate
between the servo piston ends.

5. According to servo piston (14) moving, the pump


swash angle is reduced so that the pump flow rate
is reduced. Flow Rate Control
Pressure
T141-03-01-002

6. As servo piston (14) moves, feedback lever (12)


is moved via pin (13). Since pilot piston (10) and
lever 1 (7) do not move, feedback lever (12) is
rotated around pin (5) counterclockwise, moving
spool (3) to the left. Then, when the notches on
spool (3) and sleeve (2) close thoroughly, the
pump delivery oil pressure (P) isn’t routed into the
large chamber of the servo piston (14), then servo
piston (14) stops moving.

7. Consequently, the pump flow rate decreases in


proportion to the control lever stroke (Pi pressure
decrease).

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
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
Flow Rate Control (Fan Motor Drive Pump)

The flow rate control increases or decreases the


pump flow rate. Flow rate control pressure Pi from
EHC valve (SC) is routed to the pump regulator.
Thereby, the regulator controls the pump swash
angle.

Note: Refer to the Pilot Circuit and the Oil Cooler


Fan Motor Circuit in the SYSTEM / Hydraulic
System group.

• Flow Rate Decrease Operation (Fan Motor Slow


Speed)

1. Flow rate control pressure Pi acts on pilot piston 5. According to servo piston (14) moving, the pump
(10). As pressure Pi increases, pilot piston (10) is swash angle is reduced so that the pump flow rate
moved to the right until pilot piston (10) balances is reduced.
with spring (11).
6. As servo piston (14) moves, feedback lever (12)
2. Pilot piston (10) moves lever 1 (7) via pin (9). is moved via pin (13). Since pilot piston (10) and
Lever 1 (7) rotates around pin (25) (secured in the lever 1 (7) do not move, feedback lever (12) is
supporting plug) counterclockwise. rotated around pin (5) counterclockwise, moving
spool (3) to the left. Then, when the notches on
3. As pin (5) installed in feedback lever (12) is spool (3) and sleeve (2) close thoroughly, the
inserted into hole (8) on lever 1 (7), feedback pump delivery oil pressure (P) isn’t routed into the
lever (12) is rotated around pin (13) by lever 1 (7) large chamber of the servo piston (14), then servo
clockwise, moving spool (3) to the right. piston (14) stops moving.

4. When spool (3) is moved, pump delivery oil 7. Consequently, when pump flow rate control
pressure (P) is routed into the large chamber of pressure Pi from the reducing valve increases,
servo piston (14) through spool (3). Although the the pump flow rate decreases.
same oil pressure (P) is routed into the small
chamber, servo piston (14) moves to the right due
to the difference in the pressure receiving areas
between the servo piston ends.

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
3 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

T3-1-21
COMPONENT OPERATION / Pump Device
• Flow Rate Increase Operation
(Fan Motor Fast Speed)

1. Flow rate control pressure Pi from the reducing


valve acts on pilot piston (10). As pressure Pi
decreases, pilot piston (10) is returned 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 (25) (secured in the
supporting plug) clockwise.

3. As pin (5) installed in feedback lever (12) is


inserted into hole (8) on lever 1 (7), feedback
lever (12) is rotated around pin (13) by lever 1 (7)
counterclockwise, moving spool (3) 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). Since pump delivery oil
pressure (P) is routed into the small chamber,
servo piston (14) moves to the left.

5. According to servo piston (14) moving, the pump


swash angle increases so that the pump flow rate
increases.

6. As servo piston (14) moves, feedback lever (12)


is moved via pin (13). Since pilot piston (10) and
lever 1 (7) do not move, feedback lever (12) is
rotated around pin (5) clockwise, moving spool (3)
to the right. Then, when the notches on spool (3)
and sleeve (2) closes thoroughly, the large
chamber of servo piston (14) isn’t connected to
the hydraulic oil tank, then servo piston (14) stops
moving.

7. Consequently, the pump flow rate increases as


flow rate control pressure Pi from the EHC valve
decreases.

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
Horsepower Reducing Control (Main Pump Only)

Horsepower reducing control acts on main pump (1),


(3) and (5). When the engine speed is reduced to less
-1
than 1650 min , power decrease control pressure Pf
from the power reducing solenoid valve is routed to the
pump regulator (main pumps 1, 3, and 3) so that the
pump swash angle is minimized, reducing the pump
drive power.

1. Power decrease control pressure (Pf) acts on


piston (15). Then, piston (15), compensating
piston (16), and compensating rod (20) move to
the right until they balance with outer spring (21)
and inner spring (22).

2. Compensating rod (20) moves lever 2 (17) via pin


(24). Lever 2 (17) is rotated around pin (18)
(secured in the housing) counterclockwise.

3. As pin (5) installed in feedback lever (12) is


inserted into hole (19) on lever 2 (17), feedback
lever (12) is rotated around pin (13) by lever 2
(17) clockwise, moving spool (3) to the right.
Delivery
Flow
4. When spool (3) is moved, pump delivery oil Rate
pressure (P) is routed into the large chamber of
servo piston (14) through spool (3). Although the
same oil pressure (P) is routed into the small
chamber, servo piston (14) moves to the right due
to the difference in pressure receiving area Delivery Oil Pressure
between the servo piston ends. T141-03-01-004

5. According to servo piston (14) moving, the pump


swash angle is reduced so that the pump flow rate
is reduced.

6. As servo piston (14) moves feedback lever (12) is


moved via pin (13). Since compensating rod (20)
and lever 2 (17) do not move, feedback lever (12)
is rotated around pin (5) counterclockwise,
moving spool (3) to the left. Then, when the
notches on spool (3) and sleeve (2) close
thoroughly, the pump delivery oil pressure (P) isn’t
routed into the servo piston (14), then servo
piston (14) stops moving.

7. Consequently, when power decrease control


pressure (Pf) is routed, the pump flow rate and
pressure curve (P-Q curve) varies as illustrated
below. Therefore, torque constant control
(overload prevention operation and flow rate
recover operation) is performed in conformity with
the varied P-Q curve.

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

T117-02-01-014

2- Sleeve 13 - Pin 17 - Lever 2 21 - Outer Spring


3- Spool 14 - Servo Piston 18 - Pin 22 - Inner Spring
5- Pin 15 - Piston 19 - Hole 24 - Pin
12 - Feedback Lever 16 - Compensating Piston 20 - Compensating Rod

T3-1-25
COMPONENT OPERATION / Pump Device
Horsepower Increasing Control (Main Pump
Only)

When the engine speed increases to more than 1800


-1
min , power increase control pressure Pz from the
EHC valve is routed to the pump regulator so that the
pump swash angle is increased, increasing the pump
drive power.

1. When power increase control pressure (Pz)


increases, piston (23) moves compensating rod
(20) to the left until they balance with pump
delivery oil pressure (P) acting on compensating
piston (16).

2. Compensating rod (20) moves lever 2 (17) via pin


(24). Lever 2 (17) is rotated around pin (18)
(secured in the housing) clockwise.

3. As pin (5) installed in feedback lever (12) is


inserted into hole (19) on lever 2 (17), feedback
lever (12) is rotated around pin (13) by lever 2
(17) counterclockwise, moving spool (3) to the Delivery
left. Flow Rate

4. When spool (3) is moved, the large chamber of


servo piston (14) is connected to the hydraulic oil
tank through spool (3). As pump delivery oil
pressure (P) is routed into the small chamber,
servo piston (14) moves to the left. Delivery Oil Pressure
T141-03-01-004

5. According to servo piston (14) moving, the pump


swash angle increases so that the pump flow rate
increases.

6. As servo piston (14) moves, feedback lever (12)


is moved via pin (13). Since compensating rod
(20) and lever 2 (17) do not move, feedback lever
(12) is rotated around pin (5) clockwise, moving
spool (3) to the right. Then, when the notches on
spool (3) and sleeve (2) close thoroughly, the
large chamber of servo piston (14) isn’t connected
to the hydraulic oil tank, then servo piston (14)
stops moving.

7. Consequently, when power increase control


pressure (Pz) is routed, the pump flow rate and
pressure curve (P-Q curve) varies as illustrated
below. Therefore, torque constant control
(overload prevention operation and flow rate
recover operation) is performed conforming with
the varied P-Q curve.

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
Smaller Swash Angle Smaller (Flow Rate) Signal
Priority Control

When both pump flow rate increase and decrease


signals arrive at the same time, this regulator
operates so that the priority is given to the flow rate
decrease signal.

The flow rate and the horse power decreasing /


increasing control signal pilot pressure are
transmitted to feedback lever (12) and spool (3) via
hole (8 or 19) on lever 1 (7) or lever 2 (17), and pin
(5).
(Refer to the descriptions in the flow rate control and
the horse power decreasing / increasing control
operation.)

Pin (5) comes in contact with the flow rate decrease


side 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

3 7 5 8

Pi

12
T117-02-01-013

3 17 5 19

Pz

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
The engine power is transmitted to the shaft via the The pilot pump, the air conditioner compressor motor
transmission. When the shaft is rotated, the four unit drive pump, and the pump transmission oil pump are
pumps are driven at the same time. The oil cooler fan gear type pumps. When the shaft rotates, the drive
motor drive pump is a swash plate type variable gear is rotated, driving the driven gear. The hydraulic
displacement plunger pump, the operational principle oil drawn into the pump fills the spaces enclosed by
of which is equal to that of the main pump. the gear teeth and housing, then it delivered to the
outlet as the gears rotate.

A B C D

T117-02-01-017
A - Oil Cooler Fan Motor Drive Pump C - Compressor Motor Drive Pump
(Plunger Pump) (Tandem gear pump on the top side)
B - Pilot Pump D - Pump Transmission Oil Pump
(Tandem gear pump on the transmission side) (Gear Pump)

Inlet Port

Driven Gear Drive Gear

Housing

Outlet Port

T137-02-03-005

T3-1-30
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.
The major parts of the swing motor are shaft (4),
The parking brake is a wet type multi-disc brake, con- swash plate (3), shoe (2), plunger (5), rotor (6), valve
sisting of friction plates (8) and plates (9). plate (7), housing (1), and the parking brake.
Shoe (2) is crimped on plunger (5) 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 3 - Swash Plate 5 - Plunger 7 - Valve Plate
2 - Shoe 4 - Shaft 6 - Rotor 8 - Friction Plate
9 - Plate

T3-2-2
COMPONENT OPERATION / Swing Device
Operational Principle

Swing speed varies depending on the amount of oil


delivered to the swing motor from the pump. When
the pressure oil is routed to port A, the plungers are
pushed so that the shoes slide along the swash plate,
developing rotational force. This rotational force is
transmitted to the swing reduction gear via the shaft.
The return oil from the swing motor flows back to the
hydraulic oil tank from opposite port B. If the pres-
sure oil is delivered from port B, the motor rotates in
the opposite direction.

Plunger

Shoe

T115-02-03-003

Swash Plate
Shaft

T3-2-3
COMPONENT OPERATION / Swing Device
SWING PARKING BRAKE
The swing parking brake consists of coupling (4), fric- When the pilot control shut-off lever is placed in the
tion plates (5), plates (6), piston (2), and springs(1). UNLOCK position, the brake release oil pressure is
Coupling (4) is splined to shaft (3). Plates (6) are routed into the piston chamber. Therefore, piston (2) is
splined to coupling (4). Friction plates (5) are splined raised against spring (1). Then, friction plates (5) are
to casing (7). When the pilot control shut-off lever is released from plates (6), allowing shaft (3) to rotate.
placed in the LOCK position, the brake release oil
pressure is not routed into the piston chamber. There-
fore, piston (2) is pushed by springs (1), locking fric-
tion plates (5) and plates (6) together so that shaft (3)
does not rotate.

1 2 3 4

Piston Chamber

7
Brake Release
Pressure
6 (From Pilot Shut-Off
Solenoid 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 two stage planetary gear
type. The swing motor shaft rotates first stage sun
gear (7), which is transmitted to second stage sun
gear (5) after rotation speed is reduced between first
stage planetary gear (1) and carrier (6). Rotation of
second stage sun gear (5) is transmitted to shaft (3)
after rotation speed is reduced between second stage
planetary gear (2) and 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 makeup Then, when the oil pressure at port AV (BV) in-
valves (1). creases further, the oil pressure in piston chamber
(9) moves piston (6) to the left, increasing spring (5)
Relief Valve force.
When piston (6) reaches the stroke end, spring (5)
The relief valve prevents the swing circuit oil pres- force stops increasing.
sure from increasing over the set-pressure when Then, when the oil pressure at port AV (BV) in-
starting or stopping the swing operation. creases more than spring (5) force, main poppet (4)
When the oil pressure at port AV (BV) increases, the is opened again, allowing the pressure oil to flow
oil pressure is routed into piston chamber (9) through from port AV (BV) to the hydraulic oil tank.
orifice (3) on main poppet (4) and acts on pilot piston As described above, main poppet (4) is opened in
(7). When the pressure (force) overcomes spring (8) two stages so that shock loads in the circuit are re-
force and pilot piston (7) moves to the right, the oil duced.
pressure in piston chamber (9) is reduced. The dif-
ferential pressure arises between the front and the
rear of main poppet (4). Therefore, if the pressure at Makeup Valve
the front of main poppet (4) overcomes spring (5)
force and the pressure (force) at the rear of main When the swing motor is driven by inertia force of the
poppet (4), main poppet (4) is opened, allowing the upperstructure when stopping the swing operation,
pressure oil to flow from port AV (BV) to the hydraulic the swing motor is rotated more than the stroke
oil tank. When pilot piston (7) is moved to full stroke, driven by the oil pressure from the pump, causing
the differential pressure between the front and the cavitation to develop in the swing motor. The makeup
rear of main poppet (4) disappears so that main pop- valve draws the hydraulic oil from port M (return cir-
pet (4) is closed. cuit) into the swing circuit so that occurrence of cavi-
tation is prevented.

Makeup Circuit

Port AV (BV) T117-02-02-003


To Hydraulic Oil Tank

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

Makeup Valve
10 11

Makeup Circuit

Port AV (BV) T117-02-02-005

1 - Makeup 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 controls the main hydraulic circuit oil Overload relief valve and makeup valves are provided
pressure and flow direction. Three units of the control in each section as required. All spools are operated by
valves are provided on this machine. Each unit is the hydraulic pilot pressure.
equipped with one unit of the main relief valve and
consists of four valve sections.

5 6 7 8
Overload Relief Valve
Makeup Valve

Main Relief Valve

Makeup Valve
Overload Relief Valve

T117-02-03-002
Center Control Valve

1 2 3 4 Overload Re- 9 10 11 12
Overload
lief Valve
Relief Valve
Makeup Makeup
Valve Main Relief Valve
Valve

Main Relief
Valve
Makeup Makeup
Valve Valve
Overload Overload
Relief Valve Relief Valve
T117-02-03-003 T117-02-03-001
Right Control Valve Left Control Valve

NOTE: This illustration shows the control valve lo- LD: Loading Shovel
cation viewed from the front of the loading BH: Backhoe
shovel.

1 - Boom 4 - Swing 7 - Bucket Open / Close (LD) 10 - Arm


Bucket (BH)
2 - Bucket 5 - Right Travel 8 - Arm 11 - Boom
3 - Arm Extend (LD) 6 - Boom Raise / Bucket Tilt-In 9 - Left Travel 12 - Bucket
Arm (BH) (LD)
Boom (BH)

T3-3-1
COMPONENT OPERATION / Control Valve
PILOT PORT LOCATION 9 10 11 12

16 15 14 13
T117-02-03-002
Center Control Valve 17 18 19 20
1 2 3 4

8 7 6 5 24 23 22 21

Right Control Valve Left Control Valve


T117-02-03-003 T117-02-03-001

NOTE: This illustration shows the control valve lo- LD: Loading Shovel
cation viewed from the front of the loading BH: Backhoe
shovel.

1 - Boom Raise 7 - Bucket Tilt-Out 13 - Arm Retract (LD) 19 - Boom Raise


Arm Roll-Out (BH)
2 - Bucket Tilt-In 8 - Boom Lower 14 - Bucket Close (LD) 20 - Bucket Tilt-In
Bucket Roll-Out (BH)
3 - Arm Extend (LD) 9 - Right Travel Forward 15 - Bucket Tilt-In (LD) 21 - Bucket Tilt-Out
Arm Roll-In (BH) Boom Lower (BH)
4 - Right Swing 10 - Boom raise 16 - Right Travel Reverse 22 - Boom Lower
5 - Left Swing 11 - Bucket Open (LD) 17 - Left Travel Reverse 23 - Arm Retract (LD)
Bucket Roll-In (BH) Arm Roll-Out (BH)
6 - Arm Roll-Out (BH) 12 - Arm Extend (LD) 18 - Arm Extend (LD) 24 - Left Travel Forward
Arm Roll-In (BH) Arm Roll-In (BH)

T3-3-2
COMPONENT OPERATION / Control Valve
(Blank)

T3-3-3
COMPONENT OPERATION / Control Valve
HYDRAULIC CIRCUIT
Loading Shovel
The left control valve controls the pressure oil deliv- The control circuit is a combined circuit consisting of
ered from main pumps MP3 and MP4. The spools for tandem circuits and parallel circuits. The parallel cir-
the left travel, arm, boom, and bucket are arranged cuits are provided between the arm and boom sec-
from port P in this order. The center control valve tions in the left control valve, the boom raise / bucket
controls the pressure oil delivered from main pumps tilt-in and bucket open / close sections in the center
MP1 and MP2. The spools for the right travel, boom control valve, and the arm extend, bucket, and boom
raise / bucket tilt-in, bucket open / close, and arm are sections in the right control valve, making the ma-
arranged from port P in this order. The right control chine to perform combined operations.
valve controls the pressure oil delivered from main
pumps MP5 and MP6. The spools for the swing, the
arm extend, the bucket, and the boom are arranged
from port P in this order.
Boom
Bucket Raise /
Open Bucket Right
Arm /Close Tilt-In Travel

Parallel Circuit Arm


Bucket Boom Arm Left Travel Swing Extend Bucket Boom
Center Control Valve

P P

Parallel Circuit Parallel Circuit

Left Control Valve Right Control Valve

MP 3 MP 4 MP 1 MP 2 MP 5 MP 6 T141-03-03-001

T3-3-4
COMPONENT OPERATION / Control Valve
Backhoe
The left control valve controls the pressure oil deliv- The control circuit is a combined circuit consisting of
ered from main pumps MP3 and MP4. The spools for tandem circuits and parallel circuits. The parallel cir-
the left travel, arm, boom, and bucket are arranged cuits are provided between the arm and boom sec-
from port P in this order. The center control valve tions in the left control valve, the boom and bucket
controls the pressure oil delivered from main pumps sections in the center control valve, and the arm,
MP1 and MP2. The spools for the right travel, boom, bucket, and boom sections in the right control valve,
bucket and arm are arranged from port P in this order. making the machine to perform combined opera-
The right control valve controls the pressure oil de- tions.
livered from main pumps MP5 and MP6. The spools
for the swing, arm, bucket, and boom are arranged
from port P in this order.

Right
Arm Bucket Boom Travel

Left Parallel Circuit


Bucket Boom Arm Travel Swing Arm Bucket Boom
Center Control Valve

P P

Parallel Circuit Parallel Circuit

Left Control Valve Right Control Valve

MP 3 MP 4 MP 1 MP 2 MP 5 MP 6
T141-03-03-001

T3-3-5
COMPONENT OPERATION / Control Valve
MAIN RELIEF VALVE AND OVERLOAD MAKEUP VALVE
RELIEF VALVE
The makeup valve is located between port T (tank
The main relief valve is located between port P (pump port) and the actuator port, it draws the hydraulic oil
port) and port T (tank port) to prevent the main circuit from port T when the oil pressure in the main circuit is
oil pressure from rising over the set-pressure. reduced lower than the hydraulic oil tank pressure.

1. The oil pressure in port P acts on pilot poppet (7) 1. The oil pressure in the actuator port acts on pop-
through orifice (2) in main poppet (1) and orifice pet (10).
(6) in sleeve (5). 2. Then, poppet (10) is seated onto sleeve (11) so
2. If the oil pressure increases over the set-pressure that the pressure oil cannot flow to port T.
by spring (8), the pilot poppet is opened, allowing 3. When the oil pressure in the actuator port is re-
a small amount of pressure oil to flow to port T duced lower than the hydraulic oil tank pressure,
through the clearance around the outer diameter the pressure oil in port T opens poppet (10) and
of sleeve (9). flows to the actuator port.
3. At this time, the differential pressure is developed 4. When the oil pressure in the actuator port in-
between port P and spring chamber (4) due to creases again, poppet (10) is closed by the oil
orifice (2). pressure acting on poppet (10) and spring (12)
4. Then, when the differential pressure increases force.
and the pressure pushing main poppet (1) over-
comes spring (3) force, main poppet (1) is
opened so that the pressure oil in port P flows di-
10 11 12
rectly to port T.
5. When the oil pressure in port P is reduced, main
poppet (1) is closed again by spring (3).

The overload relief valve is located between port T


(tank port) and the actuator port. It prevents the oc- Actuator
Port
currence of surge pressure in the actuator circuit due
(to external loads). Operational principle of the over-
load relief valve is the same as that of the main relief
valve.
Port T
T145-02-03-002

1 2 3 4 5 6 7 8
10 - Poppet
11 - Sleeve
12 - Spring

Port P

Port T
9
T145-02-03-001

1- Main Poppet 6- Orifice


2- Orifice 7- Pilot Poppet
3- Spring 8- Spring
4- Spring Chamber 9- Sleeve
5- Sleeve

T3-3-6
COMPONENT OPERATION / Control Equipment
OUTLINE
On the existing machines, spools in control valves are
moved by pilot pressure oil from the pilot valves, or
through quick valves.
On this machine, spools in control valves are moved by
electric lever, ELU and EHC valve (for electric lever
control).

DQR Valve
This Machine
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

Existing Machine Quick Valve

Spool

Port T

Port P
Pilot Valve
Pilot
Pump Actuator

Control Valve

Spring

Output Port

T118-03-04-002
Spool Main Pump Hydraulic Oil Tank

T3-4-1
COMPONENT OPERATION / Control Equipment
ELECTRIC LEVER
When moving the electric lever, command current is
sent from the controller to ELU according to lever
stroke.

Boom, Arm, Bucket, Swing

15 to 20° 15 to 20°
-

+
Controller
To ELU X
T18G-03-04-001

Travel, Bucket Open/Close 12.4°±1° 12.4°±1°

Controller

To ELU

T18G-03-04-002

T3-4-2
COMPONENT OPERATION / Control Equipment
Boom, Arm, Bucket, Swing

90%±2%
Short Zone
About 3°

Output Voltage Ratio


50%±1.5%

10%±2%

Center
±15° to ±20°
Mechanical Control Angle

2 (Red)

1 (Yellow) 3 (Green)
Short Zone 4 (White) Short Zone
Resistor for Calibration Resistor for Calibration
30°±5°
Electrical Turning Angle
Total Resistance 2 kΩ±15%
+ Direction on XY Axis
T18G-03-04-003

T3-4-3
COMPONENT OPERATION / Control Equipment
Travel
(Control Curve: 25±5°C)

Control Torque Output Voltage


N⋅m v
100
16.0 V OUT
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)

Control Torque Output Voltage


N⋅m 100 v
V OUT
16.0 80±7.5

Output
50±5
12.0 Voltage
Ratio
9.3±1.4 20±7.5
8.0 0
12.4±1 0 12.4±1 deg

T18M-03-04-004
4.0
3.9±0.6
Neutral Switch Voltage
0
12.4±1 0 12.4±1 deg
T18L-03-04-001

deg
T18G-03-04-006

T3-4-4
COMPONENT OPERATION / Control Equipment
(Blank)

T3-4-5
COMPONENT OPERATION / Control Equipment
EHC VALVE (FOR ELECTRIC LEVER
CONTROL)
EHC valve consists of proportional solenoid valves (8
used).

EHC Valve (Center Side) EHC Valve (Left Side)


1 2 3 4 9 10 11 12

8 7 6 5 T18L-01-02-023
16 15 14 13 T18L-01-02-022

1 - Boom Lower 5 - Auxiliary 9 - LD: Bucket Close 13 - Right Travel Reverse


BH: Auxiliary
2 - Arm Extend 6 - Arm Retract 10 - Left Travel Forward 14 - Left Swing
3 - Bucket Tilt-Out 7 - Bucket Tilt-In 11 - Left Travel Reverse 15 - Right Swing
4 - Auxiliary 8 - Boom Raise 12 - Right Travel Forward 16 - LD: Bucket Open
BH: Auxiliary

NOTE: LD: Loading Shovel


BH: Backhoe

T3-4-6
COMPONENT OPERATION / Control Equipment
Proportional Solenoid Valve
The proportional solenoid valve is excited by a cur-
rent signal from ELU and delivers pressure oil in
proportion to the current signal value.

• When in neutral:
1. Spool (1) is pushed to the right by spring (2) force
so that output port (S) is connected to hydraulic oil
tank port (T3).

• When excited:
1. Solenoid (3) pushes spool (1) to the left in pro-
portion to the current value flowing through sole-
noid (3).
2. Then the pilot pressure oil flows to output port (S)
from port (P), increasing oil pressure at output
port (S).
3. The increased oil pressure acts on stepped
flanges (a) on spool (1).
4. The right side flange has a larger diameter so that
spool (1) is pushed to the right.
5. When oil pressure force to push spool (1) to the
right overcomes solenoid (3) force pushing spool
to the left, spool (1) is moved back to the right,
closing the oil passage from port (P) to output port
(S).
6. Then, the pressure at output port (S) stops in-
creasing.

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, the control valve spools are moved by the
response characteristics of the control valve spool pressure oil routed from the pilot pump directly to the
when the control lever is operated. A large amount of control valve spool ends through the DQR valve.
the pilot pressure oil is required to move the spools in
the maximum 3 units of the control valves. Therefore,
the secondary pilot pressure oil from the EHC valve
operates the DQR valve.

Pilot Panel (Center Side)

DQR Valve

EHC Valve

T18L-01-02-009

Pilot Panel (Left Side)

DQR Valve

EHC Valve

T18L-04-05-002

T3-5-1
COMPONENT OPERATION / DQR Valve
PORT LAYOUT
Pilot Panel (Center Side)
1 2 3 4

16

15
14

13

12

11

10

9 8 7 6 5
T18L-01-02-009

Pilot Panel (Left Side)

17

32 18

31 19

30 20

29
21
28
22

27 23
26

25 24
T18L-04-05-002

1 - Bucket Tilt-Out Port 9 - Port P 17 - Bucket Close Port 25 - Port T


(From the EHC valve) (From the pilot pump) (To the control valve) (To the hydraulic oil tank)
2 - Arm Extend Port 10 - Bucket Open Port 18 - Left Travel Forward Port 26 - Right Swing Port
(From the EHC valve) (To the control valve) (To the control valve) (From the EHC valve)
3 - Boom Lower Port 11 - Arm Retract Port 19 - Left Travel Reverse Port 27 - Left Swing Port
(From the EHC valve) (To the control valve) (To the control valve) (From the EHC valve)
4 - Boom Raise Port 12 - Bucket Tilt-In Port 20 - Right Travel Forward Port 28 - Right Travel Reverse Port
(From the EHC valve) (To the control valve) (To the control valve) (From the EHC valve)
5 - Bucket Tilt-In Port 13 - Boom Raise Port 21 - Right Travel Reverse Port 29 - Right Travel Forward Port
(From the EHC valve) (To the control valve) (To the control valve) (From the EHC valve)
6 - Arm Retract Port 14 - Boom Lower Port 22 - Left Swing Port 30 - Left Travel Reverse Port
(From the EHC valve) (To the control valve) (To the control valve) (From the EHC valve)
7 - Bucket Open Port 15 - Arm Extend Port 23 - Right Swing Port 31 - Left Travel Forward Port
(From the EHC valve) (To the control valve) (To the control valve) (From the EHC valve)
8 - Port T 16 - Bucket Tilt-Out Port 24 - Port P 32 - Bucket Close Port
(To the hydraulic oil tank) (To the control valve) (From the pilot pump) (From the EHC valve)

T3-5-2
COMPONENT OPERATION / DQR Valve
CONSTRUCTION
The DQR valve consists of the 7 units of adapters, NOTE: The following figure shows the valve status
spools, and springs. when the control levers are in neutral.

A A A A A A A

A A A A A A A

Signal Port
(From the EHC Valve)
Adapter

Spool
Port T
(To the Hydraulic Oil
Output Port Tank)
(To the Control Valve
Spool Ends)
Plug

Spring
Port P
(From the Pilot Pump) Plug
Cross Section
A-A
T18M-03-05-004

T3-5-3
COMPONENT OPERATION / DQR Valve
OPERATION
In Neutral
1. The spool in the DQR valve is kept raised with the
spring so that the pressure oil passage from port
P is fully blocked.
2. As the output port is connected to port T, pressure
in the output port equals that in the hydraulic oil
tank.
3. Accordingly, the control valve spools are kept in
the neutral position.

In Operation
1. When a control lever is operated, the signal
pressure oil from the EHC valve is routed into the
DQR valve in response to the control lever
strokes, lowering the spool.
2. Therefore, a large amount of the pilot pump
pressure oil from port P passes through the notch
on the spool and flows into the output port,
increasing pressure in the output port.
3. In addition, the pressure oil in the output port is
also routed to the spring chamber via the passage
in the spool.
4. As the spool section area on which pilot pressure
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
2
which is equivalent to 0.15 MPa (1.5 kgf/cm , 21
psi) plus output port pressure] balances with the
oil pressure from the EHC valve.
5. On this account, large amount of the pilot pump
pressure oil, in response to the signal pilot
pressure from the EHC valve, is supplied to the
control valve from the DQR valve output port.
6. When the control lever is returned to neutral, the
signal pressure oil is not supplied to the DQR
valve from the EHC valve, allowing the DQR
valve spool to be raised by the spring force.
7. Then, the output port is connected to port T so
that the returning pilot pressure oil from the
control valve flows back to the hydraulic oil tank
from port T via the DQR valve spool.
8. Therefore, the control valve spools are returned to
the neutral position.

T3-5-4
COMPONENT OPERATION / DQR Valve
DQR Spool Position When Control Lever is in DQR Spool Position When Control Lever is
Neutral: Operated:

Signal Pressure Oil Port


(From the EHC Valve)

Spool
Output Port
Spool
(To the Control Valve Spool)

Port T
(To the
Hydraulic
Oil Tank)

Passage
Output Port

Port P
(From the
Port P Notch
EHC Valve)

Spring T18B-03-05-003 Spring T18B-03-05-004

Spool

Output Port

Port P

T18B-03-05-005

Spring (Set Pressure: 0.15 MPa Spring Chamber


(1.5 kgf/cm 2, 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 motor and the
travel reduction gear. The brake valve is installed
separately from the travel motor.

The travel motor is driven by the pressure oil from the The brake valve consists of the counter balance valve
pump and transmits rotation to the travel reduction and the relief valve, protecting the travel circuit from
gear. The travel reduction gear is a planetary gear type, being overloaded and prevents the machine from run-
converting the motor rotation to a slow large torque to ning away on slopes.
rotate the drive tumbler.

Forward

Brake Valve

Travel Forward
Line
Travel Reverse
Line
Travel Mode
Control Line
Drain Line

Travel Motor

Rearward
Travel Reduction Gear Travel Reduction Gear T117-03-01-001

T3-6-1
COMPONENT OPERATION / Travel Device
TRAVEL MOTOR
The travel motor is a swash-plate type variable dis-
placement axial plunger motor, equipped with the
parking brake and a travel mode control valve. The Travel Mode Control Valve
major parts of the travel motor are shaft (1),
swash-plate (2), shoes (7), plungers (4), rotor (3) valve
plate (5) and housing (6). Shoe (7) is crimped onto
plunger (4) which is inserted into the bore of rotor (3).
Rotor (3) is splined to shaft (1).

T141-003-05-002

Motor Parking Brake

2 3 4 5

7 6 T117-03-01-002

1 - Shaft 3 - Rotor 5 - Valve Plate 7 - Shoe


2 - Swash-Plate 4 - Plunger 6 - Housing

T3-6-2
COMPONENT OPERATION / Travel Device
Operational Principle
1. Travel speed varies depending on both the
amount of the oil supplied from the pump and the
swash-plate angle.
2. When the pressure oil is routed to port A on the
valve plate, the pressure oil enters one side of the
rotor, pushing the plungers.
3. Then, the plunger pushes the shoe against the
swash-plate. As the swash-plate is tilted, the shoe
slides along the plate surface, causing the rotor to
rotate.
4. This rotation is transmitted to the reduction gear
via the shaft.
5. As the rotor rotates, the plunger reaches port B,
returning the pressure oil to the hydraulic oil tank.
6. Whether the forward travel or reverse travel de-
pends on whether pressure oil is supplied to port
A or port B.

Rotor Valve Plate


Port B Port A

Shaft

Shoe Plunger

T117-03-01-003

T3-6-3
COMPONENT OPERATION / Travel Device
TRAVEL MODE CONTROL
Slow Speed Mode
1. Ports PA and PB of the travel mode control valve 4. Then, the main hydraulic oil pressure from port
are connected to the travel main hydraulic circuit. PA or PB, through the notch on the spool is
When travel operation either forward or reverse is routed to port SA, and acts on the slow speed
made, the main hydraulic pressure oil passes side tilt piston.
through port PA or PB, pushes the shuttle, and 5. Accordingly, the travel speed is changed to the
enters port P. slow speed mode, increasing the swash plate an-
2. When the travel mode switch is turned OFF (slow gle to the maximum.
mode), the reduced pilot oil pressure [2.4 MPa 6. The hydraulic oil in the fast speed side tilt piston
2
(24.6 kgf/cm , 350 psi)] is routed to port PS of the is routed to port DR via port SB through the pas-
travel mode control valve. sage in the spool and flows back to the hydraulic
3. Although the spool is pushed to the left by the pi- oil tank. (Refer to the SYSTEM / Control System
lot oil pressure in port PS, the spring force over- group.)
comes so that the spool does not move to the left.

Spring Spool Pilot Pressure


from Reducing Valve
Travel Mode Control Valve (2.4 MPa (24.6 kgf/cm 2 , 350 psi))

SA SB

PS
DR

PB
Shuttle PA

T141-03-05-007

From Port SA To Port SB


Parking Brake

Tilt Piston
Travel Mode
Control Valve

Tilt Piston Tilt Piston


(Slow Speed (Fast Speed
Side) Side)

Control Valve

T118-03-06-002 T141-03-05-003

T3-6-4
COMPONENT OPERATION / Travel Device
Fast Speed Mode
1. When the travel mode switch is turned ON (fast 4. Accordingly, the travel speed is changed to the
mode), the pilot oil pressure is routed to port PS fast speed mode.
of the travel mode control valve without being re- 5. The hydraulic oil in the slow speed side tilt piston
duced. is routed to port DR via port through the passage
2. Then, the pilot oil pressure (force) overcomes the in the spool and flows back to the hydraulic oil
spring force so that the spool is pushed to the left. tank. (Refer to the SYSTEM / Control System
3. Then, the main hydraulic oil pressure is routed group.)
from port PA or PB to port SB through the notch
on the spool and acts on the fast speed side tilt
piston, reducing the swash-plate angle to the
minimum.

Spring Spool
Pilot Pressure
Travel Mode Control Valve from Reducing Valve
(3.9 MPa (40 kgf/cm 2 , 565 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) Travel Mode
Side) Control Valve

Control Valve

T118-03-06-002

T141-03-05-006

T3-6-5
COMPONENT OPERATION / Travel Device
BRAKE VALVE
The brake valve consists of counter balance valve (10)
and relief valve (11).

When Traveling Circuit Protection


1. When the pressure oil from the control valve is 1. If the oil pressure in the circuit increases over the
routed to port AV, the pressure oil flows into port set-pressure, relief valve (11) opens to relieve
AM after passing through the clearance around high pressure to the lower pressure side, protect-
the spool (5) and opening check valve (4). ing the travel motor from being overloaded.
2. On the other hand, the return oil from port BM is 2. In addition, relief valve (11) buffers shock pres-
blocked by check valve (6) and spool (5) so that it sure developed by inertia force of the machine
cannot flow to port BV. when stopping traveling.
3. Accordingly, the oil pressure in port AV increases 3. When the travel motor draws the hydraulic oil like
gradually and is routed into chamber (1) through a pump, check valve (4 or 6) opens to prevent the
orifice (3), moving spool (5) to the right. occurrence of cavitation (makeup operation) in
4. Consequently,the return oil from port BM flows to the circuit.
port BV through the notch on spool (5), allowing
Control Valve
the travel motor to rotate.

3 7 10
When Descending Slope
1. While traveling down slope, the travel motor is 4 6
forcibly rotated by the machine weight, causing
the travel motor to draw oil like a pump.
2. When the pressure oil in port AM is drawn into the 11
travel motor, the oil pressure in port AV and
chamber (1) decreases. 11
3. Therefore, spool (5) is returned to the left, re-
stricting the oil flow from port BM so that the
travel motor is braked.
4. Once the oil flow from port BM is restricted, the oil
pressure in port AV increases again, moving
spool (5) to the right. T141-03-05-004
5. Then, the machine is prevented from running
away due to this repetition of hydraulic oil braking
operation.

T3-6-6
COMPONENT OPERATION / Travel Device

1 2 3 4 5 6 7 8 9

AV BV

10

AM BM

11 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

T3-6-7
COMPONENT OPERATION / Travel Device
PARKING BRAKE
The parking brake consists of the coupling, friction When the pilot control shut-off lever is in the UNLOCK
plates, plates, piston, and springs. The coupling is position, the pilot pressure oil is routed to port PR.
splined to the shaft. The plates are splined to the cou- Then, the pilot oil pressure pushing the piston against
pling. The friction plates are splined to the casing, and spring, freeing the friction plates and plates from each
located alternately one by one. other, allowing the shaft to rotate.
When the pilot control shut-off lever is in the LOCK
position, the pilot pressure oil is not routed to port PR.
Then, the friction plates and the plates are pushed to-
gether by the spring via the piston, preventing the
shaft from rotating.

Friction Plate Plate

Pilot Oil Pressure

PR

Shaft
Spring

Coupling

Piston

Casing
T117-03-01-004

T3-6-8
COMPONENT OPERATION / Travel Device
TRAVEL REDUCTION GEAR
The travel reduction gear consists of one stage reduc-
tion spur gear and two stage reduction planetary gear.
Motor shaft (5) rotates spur gear (7) via pinion gear (6).
After the first stage reduction takes place between pin-
ion gear (6) and spur gear (7), shaft (5) rotates first
stage sun gear (4). 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
the drive tumbler 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

T141-03-05-001

1 - Second Stage Carrier 4 - First Stage Sun Gear 6 - Pinion Gear 8 - First Stage Planetary Gear
2 - Second Stage Sun Gear 5 - Shaft 7 - Spur Gear 9 - Second Stage Planetary
Gear
3 - First Stage Carrier

T3-6-9
COMPONENT OPERATION / Travel Device
(Blank)

T3-6-10
COMPONENT OPERATION / Others (Upperstructure)
FAST-FILLING SYSTEM
Refilling coolant, hydraulic oil, fuel, and engine oil, can NOTE: Quick couplers made by Wiggins are in-
be achieved through this system. The major compo- stalled on the fast-filling panel.
nents of this system are the fast-filling switch,
fast-filling panel, fast-filling solenoid valve, lift cylinders,
and proximity switch.

Fast-Filling Panel Lift Cylinder Fast-Filling


Solenoid Valve

Proximity Switch

T18L-01-02-015

Fast-Filling Panel
1 2 3 4 5 6 7 8

16

15 9

M18L-01-012

14 13 12 11 10

1 - Engine Oil Reserve Tank 5 - Fuel Fill Indicator 9 - Grease 13 - Coolant


Fill Indicator (Radiator Outside)
2 - Engine Oil Reserve Tank 6 - Hydraulic Oil 10 - Gear Oil (Rear Side Swing 14 - Engine Oil In
Shut-Off Valve Open Indi- Device) (Reserve Tank)
cator
3 - Engine Oil Reserve Tank 7 - Gear Oil (Front Side Swing 11 - Fuel 15 - Coolant
Filling System Power Device) (Radiator Engine Side)
Switch
4 - Engine Oil Reserve Tank 8 - Pump Transmission Oil 12 - Engine Oil Out 16 - Engine Oil
Filling System Control (Reserve Tank) (Engine Oil Pan)
Switch

T3-7-1
COMPONENT OPERATION / Others (Upperstructure)
(Blank)

T3-7-2
COMPONENT OPERATION / Others (Upperstructure)
AIR CONDITIONER
The air conditioning system consists of gear pump (9), When the engine starts, compressor motor (12) is
compressor motor (12), air conditioner units (4, 5, 6), driven by the pressure oil from the gear pump (9).
condensers (1, 2, 3), receiver dryers (14, 15, 16), hot When the air conditioner switch in the cab is turned
water outlet (10), and hot water return port (11). ON, the compressor clutch is engaged to operate the
compressor, starting cooling operation.

7
8

3 9

2
A
1 View A

10

16
15

14
13
12

11

T18L-03-07-001

1 - Condenser 5 - Air Conditioner Unit (Side) 9 - Gear Pump 13 - Compressor


(Rear Air Conditioner) (Rear Air Conditioner)
2 - Condenser 6 - Air Conditioner Unit (Front) 10 - Hot Water Outlet Hose 14 - Receiver Dryer
(Side Air Conditioner) (Rear Air Conditioner)
3 - Condenser 7 - Compressor 11 - Hot Water Return Hose 15 - Receiver Dryer
(Front Air Conditioner) (Front Air Conditioner) (Side Air Conditioner)
4 - Air Conditioner Unit (Rear) 8 - Condenser 12 - Compressor Motor 16 - Receiver Dryer
(Side Air Conditioner) (Front Air Conditioner)

T3-7-3
COMPONENT OPERATION / Others (Upperstructure)
Cooling Operation Heating Operation
The cooling circuit consists of compressor (10), con- During heating operation, valve (8) is opened so that
denser (1), receiver dryer (9), expansion valve (3), high temperature engine coolant circulates through
evaporator (5), thermistor (6), thermo sensor tube (4), heater (7). Air from blower fan (2) is warmed as it
and blower fan (2). The circuit is charged with refrig- passes through heater (7) and is sent into the cab
erant. Air from the fresh and / or circulation air inlet is from the vents.
sent to evaporator (5) by blower fan (2). As evapora-
tor (5) is cool, air is cooled while passing through Dehumidifying and Heating
evaporator (5). Then, cooled air is sent into the cab During dehumidifying and heating, the cooling and
from the vents. heating systems are operated at the same time. Air
Each component functions as follows: from blower fan (2) is cooled and dehumidified at
• Compressor evaporator (5) then, air is warmed at heater (7) be-
Draws and compresses refrigerant from the low fore being sent into the cab.
pressure circuit (between the evaporator and the
compressor), then sends it to the condenser. (Re-
frigerant generates heat when compressed.)
• Condenser
Cools hot refrigerant.
• Receiver Dryer
Removes moisture from refrigerant and stores
refrigerant.
• Expansion Valve
Atomizes high pressure liquid refrigerant into low
pressure gas via an orifice.
• Evaporator
Vaporizes refrigerant to absorb heat from atmos-
phere.
• Thermo Sensor Tube
Checks air temperature after passing through the
evaporator and adjusts the orifice on the expan-
sion valve in response to air temperature change
to control the refrigerant flow.
• Thermistor
Stops the compressor if temperature on the fin
surface of evaporator falls lower than 0 °C.
• Blower Fan
Sends air from the fresh and/or circulation air inlet
to the evaporator.

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

10 9
From Hot To Hot Water
Water Outlet Return 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 SYSTEM
The auto-lubrication system automatically lubricates the The auto-lubrication mode switch has three positions:
front attachment pins, swing bearing, and center joint. Auto / Off / Manual. When the switch is in the Auto po-
The major components of this system are a grease pump, sition, greasing is automatically performed at the in-
auto-lubrication solenoid valve, vent valve, auto-lubrica- terval set by the auto-lubrication interval switch. When
tion interval switch, auto-lubrication mode switch, pres- the switch is in the OFF position, greasing is not per-
sure switch (Auto Lubrication) and pressure switch (Man- formed. When the switch is in the Manual position, the
ual Lubrication). auto-lubrication system is deactivated. However,
greasing can be performed using a grease gun.

NOTE: Refer to the SYSTEM / Control System


group for the system operation.

Lubricator Panel Grease Tank


4

1 6
3

2
5

M18L-07-015

T146-01-03-026

T18L-01-02-024

T18M-03-07-006

1 - Pressure Switch 3 - Auto-Lubrication 5 - Grease Pump 7- Auto-Lubrication


(Auto Lubrication) ON/OFF Switch Interval Switch
2 - Pressure Switch 4 - Vent Valve 6 - Auto-Lubrication
(Manual Lubrication) Solenoid Valve

T3-7-6
COMPONENT OPERATION / Others (Upperstructure)
OIL COOLER FAN MOTOR
The oil cooler fan motor and the radiator fan motor are
an inclined-shaft type, fixed displacement axial plunger
motor. The operating principle of this motor is the
same as the travel motor. (Refer to the COMPONENT
OPERATION / Travel Device group.)

Drive Disc

Rotor

W118-02-09-002

T3-7-7
COMPONENT OPERATION / Others (Upperstructure)
EHC VALVE (FOR MAIN PUMP CONTROL)
The EHC valve consists of proportional solenoid
valves (8 used).

1 2

7
3

T18L-01-02-004

1 - Main Pump Displacement Control 3 - Main Pump Displacement Control 5 - Oil Cooler Fan Control 7 - Auxiliary
(No. 3, 5, 6 Main Pump) (No. 1, 2, 4 Main Pump)
2 - Power Decrease Control 4 - Power Increase Control 6 - Auxiliary 8 - Auxiliary

T3-7-8
COMPONENT OPERATION / Others (Upperstructure)
Proportional Solenoid Valve
The proportional solenoid valve is excited by a cur-
rent signal from ELU and MC delivers pressure oil in
proportion to the current signal value.

• When in neutral: • When excited:


1. Spool (1) is pushed to the right by spring (2) force 1. Solenoid (3) pushes spool (1) to the left in propor-
so that output port (S) is connected to hydraulic tion to the current value flowing through solenoid
oil tank port (T3). (3).
2. Then the pilot pressure oil flows to output port (S)
from port (P), increasing oil pressure at output
port (S).
3. The increased oil pressure acts on stepped
flanges (a) on spool (1).
4. The right side flange has a larger diameter so that
spool (1) is pushed to the right.
5. When oil pressure force to push spool (1) to the
right overcomes solenoid (3) force pushing spool
to the left, spool (1) is moved back to the right,
closing the oil passage from port (P) to output
port (S).
6. Then, the pressure at output port (S) stops in-
creasing.

T3 S P 1 2 3

a
T107-02-07-005

1 - Spool 2 - Spring 3 - Solenoid

T3-7-9
COMPONENT OPERATION / Others (Upperstructure)
ACCUMULATOR
6
1
The accumulator is provided in the pilot circuit to
buffer fluctuations in oil pressure, and to maintain the
pilot pressure for a short time period after the engine
is stopped. Nitrogen Gas
The accumulator mainly consists of body (5), holder 5 (N2)
2
(4), bladder (2), which encloses nitrogen gas (N2), and
poppet (1). 4

• Pressure oil from the pilot pump enters into the


accumulator via port A. Pilot pressure Pilot Pressure Oil
compresses the nitrogen gas in bladder (2) until 3
they balance against each other.

• When pressure supply is stopped due to engine


stall or any other reasons, bladder (2) starts
expanding, supplying accumulated oil into the
pilot circuit via port A.
A

T105-02-10-003

1 - Poppet 4 - Holder
2 - Bladder 5 - Body
3 - Oil Port 6 - Gas Plug

T3-7-10
COMPONENT OPERATION / Others (Undercarriage)
SWING BEARING
The swing bearing supports the upperstructure on the
undercarriage and allows the upperstructure to rotate
smoothly. The swing bearing is a three-row-roller type
bearing, consisting of retaining ring (7), support ring
(8), nose ring (4), three types of rollers (1, 2, 6), and
seals (3, 5).
Retaining ring (7) and support ring (8) are bolted to the
upperstructure. Nose ring (4) is bolted to the undercar-
riage. The internal gear on the nose ring meshes with
the swing reduction gear shaft teeth.

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)
ACCUMULATOR
The accumulator consists of the shell, bladder, gas
valve, and oil port assembly. The hydraulic oil is filled
inside the shell. The high pressure nitrogen gas is en-
closed in the bladder. The bladder contracts until the
gas pressure in the bladder balances with the hydrau-
lic oil pressure routed into the accumulator through the
oil port assembly.

Oil Port Assembly Shell Bladder Gas Valve

T115-03-03-003

T3-8-2
COMPONENT OPERATION / Others (Undercarriage)
ADJUSTER CYLINDER
The adjuster cylinder consists of two single-acting The travel stop valve is located at the stroke end of
pistons. The front section is a cushion piston to absorb the cushion piston. When the cushion piston is moved
shock loads. The rear section is an adjuster piston to to the stroke end, the travel stop valve is activated,
adjust track sag. stopping the travel function. (Refer to the SYSTEM /
The cushion piston stores the pressure oil in the piston Hydraulic System for the travel shock absorption/stop
chamber connected to the accumulator. When the circuit.)
cushion piston is pushed by an external load, the
pressure oil in the piston chamber flows into the ac-
cumulator, absorbing the shock load. The adjusting
piston is moved by grease supplied into the piston
chamber to adjust track sag.

Adjuster Piston Signal Pressure Cushion Piston

Grease Hydraulic
Oil

Rear Side
Front Side
(Travel Device Side)
(Front Idler Side)

T115-03-03-002

Travel Stop Pilot Valve

T3-8-3
COMPONENT OPERATION / Others (Undercarriage)
Shock Absorbing / Travel Stop Operation
1. The main pressure oil from the right travel for- 4. If the external load increases further, relief valve
ward circuit is routed into the accumulators (3) (4) relieves and the cushion piston is moved
and both right and left cushion cylinders (6) after backward full stroke, shifting travel stop pilot
being reduced at reducing valve (2). valve (9).
2. When an external load is applied to the front idler, 5. The pressure oil from the travel stop pilot valve
the cushion piston is pushed so that pressure oil (9) changes over the pilot pressure switch valve
in the piston chamber flows into accumulators (3). (8).
3. Then, the bladder in the accumulator contracts to 6. Pressure oil from the pilot pressure switch valve
absorb the external load. (8) is converted into electrical signals through
pressure sensor, and sent to ELU. ELU receives
these signals, and stops travel. (Refer to Cushion
Cylinder End Travel Restriction Control in SYS-
TEM / ELU System.)

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 Switch Valve
2 - 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

Drain

3
From Right
Cushion Cylinder

2 Pilot Oil Pressure to


Travel Motor

4
8
5

T115-03-03-004

1 - Center Joint 4- Relief Valve 6- Cushion Cylinder 8- Pilot Pressure Switch Valve
2 - Reducing Valve 5- Stop Valve 7- Grease Fitting 9- Travel Stop Pilot Valve
3 - Accumulator

T3-8-5
COMPONENT OPERATION / Others (Undercarriage)
CENTER JOINT
The center joint is a 360 ° rotating joint. When the
upperstructure rotates, the center joint eliminates
twisting of hoses and allows the hydraulic oil to flow
the travel motors. The spindle and the body are se-
cured to the upperstructure and to the undercarriage
in the swing center on the undercarriage respectively.
The pressure oil is routed into the right and the left
travel motors through the passage oil in the spindle
and the oil ports on the body. Seals are located be-
tween the spindle and the body, preventing oil leaks
from the 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
Fax: 81-29-831-1162

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