Beruflich Dokumente
Kultur Dokumente
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
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
Example : T 1-3-5
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
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)
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
18LT-1-1
(Blank)
18LT-1-2
GENERAL / Specifications
SPECIFICATIONS
A
F
C
J I
H G
T18L-01-01-004
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
T1-2-2
GENERAL / Component Layout
Pump and Components
1 2
6 5 4 3
T18L-01-02-003
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
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
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
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)
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)
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
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)
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
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
T18L-01-02-007
B
T18L-01-02-017
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
6 8 9
T18L-01-02-026
T1-2-21
GENERAL / Component Layout
AIR CLEANER
T18L-01-02-027
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
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
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
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
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)
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
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
1
3 6
2
5
M18L-07-015
T146-01-03-026
T18L-01-02-024
T18M-03-07-006
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
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)
Output Output
(HP) (kW)
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)
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
4-Unit Pump
Model............................................................ K3V112S (Fan Motor Drive Pump)
KFP4156 (Pilot Pump / Compressor Pump /
Transmission Oil Pump)
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)
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)
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)
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)
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
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
Fuel Level Switch (For Fast Filling System Fuel Fill Indicator,
Engine Oil Reserve Tank Level Check Switch)
Type .............................................................. Capacitance type
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)
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 %
Accelerator Sensor
Resistance.................................................... 5 kΩ±20 %
Output........................................................... 0.4±0.1 V at Slow idle
4.4±0.1 V at Fast idle
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
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.
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
T2-1-2
SYSTEM / Controller
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.
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.
T2-1-4
SYSTEM / Controller
Wiper Motor
MC
Wiper Relay 2
Key Switch
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
Battery
Travel Pilot Pressure Sensor
Power Shut-Off
Delay Relay
Travel Alarm
Fuel Level Switch (Hi)
CAN
Monitor
IDU Display
T2-1-5
SYSTEM / Controller
• Alarm Judgment
MC passes the following judgment.
• 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)
To IDU, DLU
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.
T2-1-8
SYSTEM / Controller
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
T18L-02-01-002
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.
• 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
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
T18L-02-01-002
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
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)
T18L-02-01-003
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
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
ke-CAN
Engine Speed Sensor
MC
Hydraulic Temperature Sensor
ke-CAN
Fuel Level Sensor
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.
• 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.
• 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.
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.
• 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.
• 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
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 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
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.
Ke-CAN
T18M-02-02-001
T2-2-2
SYSTEM / Control System
(Blank)
T2-2-3
SYSTEM / Control System
Low Temperature Start Control
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
Ether Bottle
Ether Solenoid Valve
Ether Line
Intake Manifold
Engine Stop
Switch
Starter Motor
T18M-02-02-002
T2-2-5
SYSTEM / Control System
Auto-Idle Control
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.
T2-2-6
SYSTEM / Control System
Fuel Injector
D/0(24V) 2
Lever Control
Signal (Travel)
Auto-Idle Switch
T18M-02-02-003
T2-2-7
SYSTEM / Control System
Engine Protection Control
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
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
T2-2-9
SYSTEM / Control System
PUMP CONTROL
Power Increase Control (Speed Sensing)
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
MC
Pilot
Power Increase Pump
Solenoid Valve
T18L-02-02-002
T2-2-11
SYSTEM / Control System
Power Decrease Control
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
MC
Pilot
Power Decrease Pump
Solenoid Valve
T18L-02-02-002
T2-2-13
SYSTEM / Control System
Power Decrease Control (with Control Levers in
Neutral or at Start of Operation)
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
MC
Pilot
Power Decrease Pump
Solenoid Valve
T18L-02-02-002
T2-2-15
SYSTEM / Control System
FAST-FILLING PANEL LOWER CONTROL
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
D/O (O/C)
(Max.100mA)
T2-2-17
SYSTEM / Control System
SLIDING FOLD-IN LADDER CONTROL
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.
T2-2-18
SYSTEM / Control System
From Battery
Sliding Fold-In
Ladder Cylinder
Sliding Fold-In
Ladder Relay 1
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 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
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
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 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
From Battery
ELU
76-58 76-59
T18L-02-02-006
T2-2-21
SYSTEM / Control System
AUTO LUBRICATION CONTROL
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
48-38
76-26
CAN IDU
Auto Lubrication
Interval Switch
76-57 48-18
3 Min.
5 Min.
10 Min.
15 Min.
76-6
76-18
76-5
Key Switch ON Signal 76-71
(Fuse #15)
Pilot
Pump
Front Attachment
Lubrication Circuit
Grease Pump
Hose Reel Circuit
(Manual Lubrication)
Vent Valve
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.
T2-2-24
SYSTEM / Control System
Auto Lubrication
Switch
MC
48-38
76-26
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
Pilot
Pump
Front Attachment
Lubrication Circuit
Grease Pump
Hose Reel Circuit
(Manual Lubrication)
Vent Valve
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
Engine
Hydraulic Oil
Temperature Sensor
MC
IDU
CAN T18L-02-02-003
T2-2-27
SYSTEM / Control System
WIPER CONTROL
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
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
• 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
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
Reducing Valve
Travel Mode
Solenoid
Travel Mode
Valve
Switch
Center Joint
Pilot
Pump
Tilt Piston
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
Tilt Piston
T2-2-33
SYSTEM / Control System
(Blank)
T2-2-34
SYSTEM / ELU System
OUTLINE
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)
T2-3-2
SYSTEM / ELU System
(Blank)
T2-3-3
SYSTEM / ELU System
PUMP CONTROL
Positive Control
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)
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)
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.
T2-3-6
SYSTEM / ELU System
Ke-CAN IDU
ELU
Left Travel Lever
DQR Valve 1
DQR Valve 2
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)
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
T18L-02-03-003
Swing Swing
(Left) (Right)
T2-3-9
SYSTEM / ELU System
(Blank)
T2-3-10
SYSTEM / Hydraulic System
OUTLINE
• 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.
T2-4-1
SYSTEM / Hydraulic System
PILOT CIRCUIT
T2-4-2
SYSTEM / Hydraulic System
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)
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
T2-4-4
SYSTEM / Hydraulic System
Control Lever
Travel Travel Bucket Bucket
Arm Swing Bucket Boom (Left) (Right) Open Close
ELU
To Control Valve
Spools
To Control Valve
Spools
Control
Signal from
ELU
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
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
MP3 MP4
MP1 MP3
MP2 MP4
Engine
T2-4-9
SYSTEM / Hydraulic System
Single Operation
T2-4-10
SYSTEM / Hydraulic System
Boom Bucket Arm Dump Dump Level Bucket Boom
Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder
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
MP3 MP4
MP1 MP3
MP2 MP4
Engine
MP1 MP2
MP5
MP6
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.
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.
Swing
Arm Extend
T2-4-12
SYSTEM / Hydraulic System
Boom Bucket Arm Dump Dump Level Bucket Boom
Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder
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
MP3 MP4
MP1 MP3
MP2 MP4
Engine
MP1 MP2
MP5
MP6
T2-4-13
SYSTEM / Hydraulic System
PUMP TRANSMISSION OIL COOLING
CIRCUIT
Pressure oil from the oil cooler fan motor drive pump
drives the oil cooler fan motor.
Compressor Motor
Hydraulic
Oil Tank
Pump
Engine Trans-
mission
Oil Cooler
T141-02-02-005
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
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.)
• Main Circuits
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.
T2-5-2
SYSTEM / Electrical System
Limit Switch Fuse Box
LED (Cab)
(Box light switch)
Fuse Box 3
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
Cigarette Lighter
Fusible Link 1
Power Source
Terminal (1)
Horn Relay
Horn Switch
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
T2-5-6
SYSTEM / Electrical System
Air Bleeding
Solenoid Valve
ECM
Emergency Switch 1 to 5
Alternator
Prelube
Starter (1) Timer Relay
(Upper)
Engine Start
Switch
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
T2-5-8
SYSTEM / Electrical System
Prelube Pressure
Switch
To IDU
Prelube
Relay
From
Battery
Prelube
Motor
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
Prelube Timer
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.
T2-5-12
SYSTEM / Electrical System
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
T18M-02-05-008
T2-5-13
SYSTEM / Electrical System
T2-5-14
SYSTEM / Electrical System
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
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
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
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
T2-5-22
SYSTEM / Electrical System
Air Bleeding
Solenoid Valve
ECM
Emergency Switch 2 to 5 Emergency
Switch 1 (Cab)
Valve
Limit Switch
(Return (2))
Alternator
Starter (1)
(Upper)
Prelube Timer Engine
Start Switch
Starter (2)
(Lower)
Fuse Box 3
Fuse #47
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
T2-5-24
SYSTEM / Electrical System
Air Bleeding
Solenoid Valve
ECM
Emergency Switch 2 to 5 Emergency
Switch 1 (Cab)
Valve
Limit Switch
(Return (2))
Alternator
Starter (1)
(Upper)
Engine
Prelube Timer
Start Switch
Starter (2)
(Lower)
Fuse Box 3
Fuse #47
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
T2-5-26
SYSTEM / Electrical System
Air Bleeding
Solenoid Valve
ECM
Emergency Switch 2 to 5 Emergency
Switch 1 (Cab)
Valve
Limit Switch
(Return (2))
Alternator
Starter (1)
(Upper)
Engine
Prelube Timer
Start Switch
Starter (2)
(Lower)
Fuse Box 3
Fuse #47
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.
T2-5-28
SYSTEM / Electrical System
Fuse #11
Fuse #1
Key Switch
Fuse Box 1
Fuse #2
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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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
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)
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.
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
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
T3-1-5
COMPONENT OPERATION / Pump Device
Cross Section (Main Pump Regulator)
A
B
T141-03-01-005
A B
Pi
14 13 12
T117-02-01-006
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
T3-1-7
COMPONENT OPERATION / Pump Device
Cross Section (Fan Motor Drive Pump Regulator)
A
B
T146-03-01-004
A B
Pi
14 13 12
T146-03-01-008
T3-1-8
COMPONENT OPERATION / Pump Device
Cross Section B-B
15 16 17 18 19 20 21 22
24
T146-03-01-005
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).
12
20
6
5
7
8
4
9
Supporting
3 Plug
13
10
14
T117-02-01-009
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).
12
20
6
5
7
8
25
4
9
Supporting
3 Plug
13
10
14 T142-02-01-005
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).
T3-1-12
COMPONENT OPERATION / Pump Device
1 2 16 3 17 18 5 19 20 21 22
Pz
Pf
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
T3-1-14
COMPONENT OPERATION / Pump Device
2 16 3 17 18 19 5 20 21 22 Pz
Pf
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)
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.
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
T3-1-17
COMPONENT OPERATION / Pump Device
• Flow Rate Decrease Operation
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
T3-1-19
COMPONENT OPERATION / Pump Device
Flow Rate Control (Fan Motor Drive Pump)
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)
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)
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
T3-1-25
COMPONENT OPERATION / Pump Device
Horsepower Increasing Control (Main Pump
Only)
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
T3-1-27
COMPONENT OPERATION / Pump Device
Smaller Swash Angle Smaller (Flow Rate) Signal
Priority 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
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
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
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
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
T3-2-6
COMPONENT OPERATION / Swing Device
Relief Valve
3 4 5 6 7 8
Port AV (BV)
Makeup Valve
10 11
Makeup Circuit
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
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.
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
NOTE: This illustration shows the control valve lo- LD: Loading Shovel
cation viewed from the front of the loading BH: Backhoe
shovel.
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
P P
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
P P
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).
1 2 3 4 5 6 7 8
10 - Poppet
11 - Sleeve
12 - Spring
Port P
Port T
9
T145-02-03-001
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
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.
15 to 20° 15 to 20°
-
+
Controller
To ELU X
T18G-03-04-001
Controller
To ELU
T18G-03-04-002
T3-4-2
COMPONENT OPERATION / Control Equipment
Boom, Arm, Bucket, Swing
90%±2%
Short Zone
About 3°
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)
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
deg
T18G-03-04-006
Bucket Open/Close
(Control Curve: 25±5°C)
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).
8 7 6 5 T18L-01-02-023
16 15 14 13 T18L-01-02-022
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
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.
DQR Valve
EHC Valve
T18L-01-02-009
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
17
32 18
31 19
30 20
29
21
28
22
27 23
26
25 24
T18L-04-05-002
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:
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)
Spool
Output Port
Port P
T18B-03-05-005
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
2 3 4 5
7 6 T117-03-01-002
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.
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.
SA SB
PS
DR
PB
Shuttle PA
T141-03-05-007
Tilt Piston
Travel Mode
Control Valve
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
Tilt Piston
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).
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
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.
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.
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
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
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
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.
1 6
3
2
5
M18L-07-015
T146-01-03-026
T18L-01-02-024
T18M-03-07-006
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.
T3 S P 1 2 3
a
T107-02-07-005
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
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
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.
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.
Grease Hydraulic
Oil
Rear Side
Front Side
(Travel Device Side)
(Front Idler Side)
T115-03-03-002
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.)
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
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
REPLY: