Hydraulic Ver (Eng) Yoshida Kaizo

Title
Hydraulics
SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 1

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Agenda
Summary of Today
Hydraulics equipments review
with interchangeability
Hydraulics diagram review
1 New feature; Straight Travel
2 New feature; Swing Speed limit
3 New feature; Swing Relief Cut Off
4 New feature; Swing Parking
5 New feature; Bucket Regeneration
6 New feature; Nega-Con Power Save
7 New feature; HYD HP Boost - Arm in
8 New feature; HYD HP Boost - Travel
9 New feature; Cushon valve
10 New feature; Auto Press Boost
11 New feature; Option line
Maintenance Procedure
New Return Filter
Machine Walking Around
Q and ?
Close
-
Title Comp. review
Hyd. Component Review
Major Hydraulic Components

Review

Section;Data P.4
Interchangeability

-
Pump
Hydraulic pump
Position Part name SH200-3 Interchangeability SH200-5 Remarks
KRJ6199 KRJ10290
J Hydraulic pump <-- X --> Spec. changed
KAWASAKI KAWASAKI
Basic system & structure are similar to -3.
Difference
5 % Increase
-3 Hydraulic pump Max. Flow
・Increased Expelling volume 2 X 201 L/min ( H mode ) (-3 Model)
103cc/rev → 117cc/rev >>>2 X 211 L/min ( H mode ) (-5 Model) for pump flow
・New HP setting
・P1 Solenoid valve, and shuttle valve
For Swing speed limit, Swing relief cut off,
Option line flow control, and Power save system
・P2 Shuttle valve
For Power save system
・New valve plate, New pump housing
Low noise 2db reduction
・Clearance improve of regulator piston 2 % Improvement
Decrease internal leakage for fuel consumption
Section;Hydraulics P.116
Hydraulic pump
Diagram difference
210-5
P1 P2
Shuttle Shuttle
valve valve
P1 Solenoid valve ( Proportional Solenoid Valve )

Hydraulic pump Inverse Proportional Solenoid Valve
Diagram difference
I min >>> Give Pressure
210-5
I max >>> No Pressure
N1; Negative Control

Pilot
P1 Proportional Solenoid Valve

I min >>> No Pressure
I max >>> Give Pressure
-
Hydraulic pump
Outward difference Shuttle valve
P1 solenoid valve port
200-3 210-5
New housing

Hydraulic pump
Outward difference

Hydraulic pump
Outward difference
2) Accumulator
3) Pilot filter
1) Hydraulic Pump
4) 5 pcs Solenoid valve

Hydraulic pump
Outward difference
6) P2 Sensor
5) N1 Sensor
7) P1 Sensor
4) 5 pcs Solenoid valve
8) Pilot Pump

Hydraulic pump
Outward difference
9) N2 Sensor
11) Hyd Temp Sensor

10) Proportional Solenoid V

Section;Hydraulics P.112/117
Hydraulic pump
Internal difference
210-5

Section;Hydraulics P.120 to 138
Travel unit
Travel unit
KRA10120 KRA10150
A Travel motor <-- X --> Drive force increased
KAYABA KAYABA
Difference
Hyd oil displacement change
Displacement 162.2 / 95.0 cc /rev (-3 Model)
>>> 168.9 / 100.3 cc /rev (-5 Model) 4 % Increase

for Travel Drive Force
Same travel speed with –3 (5.6/3.4 km/hr)
Compact Reduction

Travel unit
210-5

Swing unit
Swing unit
KRC0226 KRC10010
C Swing motor assy <-- X --> Spec. changed
TOSHIBA TOSHIBA
LJ01076 LJ014440
C Swing motor <-- X -->
TOSHIBA TOSHIBA
LN00111 LN001820
C Swing reduction <-- X -->
TOSHIBA TOSHIBA
Difference
Working pressure change
29.4 MPa (210-5) <<< 27.9 MPa (210-3)
On 240, the same between -3 and -5
By pass valve less
240-5 has the valve
New gear oil level gauge
240-5, new reduction but similar spec. to -5
Drain port layout change
Swing unit
200-3 210-5

Swing unit
200-3 210-5

Swing unit
Effectiveness measurement
Brake Reverse Brake Reverse

pressure pressure pressure pressure
210-5 200-3
However, the anti-drift valve is installed on SH240-5

same as SH240-3.

Swing unit 210-5
200-3

Swing unit
KBC0110 KBC10010
C Swing motor assy <-- X --> Spec. changed
KAWASAKI HITACHI
KBC0108 KBC10020
C Swing motor <-- X -->
KAWASAKI KAWASAKI
KBC0127 KBC10030
C Swing reduction <-- X -->
KAWSAKI HITACHI

-
Free Swing
Swing unit
210-5
Free Swing

Control valve
Control valve
KRJ10420 KRJ10310
J Control valve <-- X --> Spec. changed
KAYABA KAYABA

Difference
New Straight Travel Pilot Line
Bucket Close Regeneration Circuit
Add-on Valves for Option Line

Control valve
210-5

Control valve
210-5
New Straight Travel Pilot Port

Control valve
210-5
Arm Close
Boom Up
Bucket Open
Arm Open
Boom Down
Bucket Close
Main
For Boost For Standard

Rem ote C V
Remote control valve
Remote control valve KRJ5804 KHJ13270
J <-- X --> Spec. changed
(Operating machine) KAWASAKI KAWASAKI

Difference
Spring strength
By Length of Joystick change
Housing shape
By Airtight cab

Remote control valve
210-5

-
Attach cylinder
Attachment Cylinders
KRV2952 KRV11130
V Boom cylinder KRV2953 <-- X --> KRV11140 Spec. changed
KAYABA KAYABA
KRV2954 KRV11150
V Arm cylinder <-- X --> Spec. changed
KAYABA KAYABA
KRV2955 KRV11160
V Bucket cylinder <-- X --> Spec. changed
KAYABA KAYABA

Difference
Bigger Bore of cylinders
For Real Maneuverability

-
Bucket Cylinder on 210
-3: Cylinder bore φ115 / Rod bore φ80
>>> -5: Cylinder bore φ120 / Rod bore φ85
Arm Cylinder on 210


-
Boom Cylinder on 240

Hydraulic diagram
Title Diagram review
Hyd. diagram Review
Hydraulic Diagram
Review

-
Title Cir. review
Hyd. Circuit Review
New Hydraulic Circuits

Review

List Cir. review
Hyd. Circuit Review

Straight Travel
Hyd. Circuit Review
Straight Travel
Advantage;
Reduce shock by attachment operation during traveling.
Background;
At steep slope in a mountain area,

operators dislike the shock for their logging application.

-
Hyd. Circuit Review
Straight Travel
210-3
Switched by 1st pressure.

Switched Press. ; 4MPa.
Travel --->Sharp spool shift

Travel
Straight Travel Pilot

Valve
Upper
Press Sensor
Travel
Press Sensor Pilot pump
Hyd. Circuit Review
Straight Travel
210-5
New orifice diameter.
--->Reduce shifting shock
Travel
Switched by 2ndary Pressure.
Proportionate movement.
--->Linear spool shift

Travel Press Sensor Upper Press Sensor
Hyd. Circuit Review
Straight Travel
4
SH210-5
3
ZX200-3
km/hr 2 PC200-8
SK200-8
1
CAT320D
0
single 1st speed Boom up + 1st
Travel speed Travel
SH210-5 3.4 2.99
ZX200-3 3.5 2.09
PC200-8 2.9 1.91
SK200-8 3.57 1.97
CAT320D 3.6 2.82

Hyd. Circuit Review
Straight Travel
8
SH210-5
6
ZX200-3
km/hr 4 PC200-8
SK200-8
2
CAT320D
0
single 2nd speed Boom up + 2nd
Travel speed Travel
SH210-5 5.7 4.62
ZX200-3 5.3 3.1
PC200-8 5.6 2.44
SK200-8 5.96 3.09
CAT320D 5.9 4.63

Swing speed limit
Hyd. Circuit Review
Swing Speed Limit
Purpose;
Swing Drift Reduction
( To be same drift amount of -3 model)
For optimum swing speed (Same speed with –3)
Background;
Hydraulic flow of -5 is increased,
but speed up of swing speed makes longer swing drift.
>>> For Real Maneuverability, and safety

Hyd. Circuit Review
Swing Speed Limit Max. Pump flow
Swing motor 210-5: 211 L/min >>> 200 L/min SP mode
240-5: 234 L/min >>> 214 L/min SP mode
Nega-Con Signal
240-5: 222 L/min >>> 203 L/min H mode
Steer pilot pressure into negative control

port through electrify into front side
proportional valve.
Then flow will be decreased.
Condition of swing speed limit

・Only Swing operation
Cut out condition of swing speed limit

・When operate other attachment
→Release gradually
P1 （shock reduction）
Solenoid Valve ・When operate travel
→Release immediately
350mA
（meandering prevention）
Hyd. Circuit Review
Swing Relief Cut Off
Advantage;
2 % Improvement
Economize energy for fuel consumption
Background;
When start to swing,
High pressure for swing motor is needed,
but hydraulic oil flow is not needed so much.

Hyd. Circuit Review
210-5 At Swing Start When quick swing operation and
swing with load on bucket.
P1 Pump flow is decreased by P1-
Solenoid works.
Only
Quick Swing and Boom Down.
P1 Solenoid Valve
Computer 740 mA inputted,
Flow DOWN Min Pump Flow of P1
P1 Solenoid Valve
Hyd. Circuit Review
210-5 During Swinging During Swinging,
P1 Pump flow is increased by P1-
Solenoid works.
P1 Solenoid Valve
Computer
Down to 350mA,
Flow UP Pump Flow of P1 UP

P1 Solenoid Valve
-
Hyd. Circuit Review
Save Energy
210-3 210-5
Flow
Pressure
Nega-Con
Press
Time Time
740mA
mA for P1 Solenoid valve >>>
350mA

Swing parking
Hyd. Circuit Review
Swing Parking
Changed points;
A) Time to engage swing parking brake after using arm functio
5 sec ( -3 model) >>> 1 sec (-5 model)
Time to engage Swing Parking after swinging
is same. ( 5 sec)
B) Hydraulic Lock of Swing Spool in Control valve
Background;
a) Drift prevention at slope during no equipment operation.
b) By removing Swing Parking button

Arm in Regeneration
Hyd. Circuit Review
Arm-In Regeneration
Advantage;
Optimum flow for quicker cylinder movement.
>>>Regenerated flow is increased
about 10 % from 210-3.
Background;
4.0
3.0
Arm in
sec
2.0
Arm out
1.0
0.0
SH210-3 SH210-5
Arm in 3.2 2.9
Arm out 2.5 2.6

Hyd. Circuit Review
Arm-In Regeneration
210-5
Check valve
for Regeneration
Narrow Orifice
Wide Orifice

Bucket close Regeneration
Hyd. Circuit Review
Bucket-Close Regeneration
Advantage;
Optimum flow for quicker cylinder movement.
>>> Speed of Bucket Close is increased
about 24 % from 210-3.
( Approx. 20% of return flow from rod side)
Background;
6.0
4.0
sec
Bucket close
2.0 Bucket open
0.0
SH210-3 SH210-5
Bucket 4.0 2.8
close
Bucket 2.3 2.2
open

Hyd. Circuit Review
Bucket-Close Regeneration
210-5 Check valve
for Regeneration
Orifice

Power save
Hyd. Circuit Review
Power save
Advantage;
1 % Improvement
Economize energy for fuel consumption
Background;
By studying of machine history record of 210-3,
30% to 34% of total hours were idling.
Previous Negative control system saves energy also,

but hydraulic flow to make 3MPa of Nega-Con pressure
are needed.

Hyd. Circuit Review
Power save
Nega-Con
210-3 Pressure : 3MPa
Servo Piston
Reduce
flow
Hyd. Circuit Review
Power save
210-5
Condition to work;
No signal from Nega-Con Pressure;
Travel, Upper, and Swing Pilot
3 MPa >>> 1 MPa
Pressure Sensors for 1 second.
740 mA--->
Servo Piston
Reduce
flow
Hyd HP Boost -Arm in
Hyd. Circuit Review
Hydraulic HP Boost -Arm In-
Advantage;
Smooth Arm cylinder speed down from low load to high load.
Reduced Speed Ratio: 7% Improved.
Background;
Operator feels “ No power” by speed reduction,

not pressure.

Sales text
Hyd. Circuit Review
Hydraulic HP Boost -Arm In-
Reduced Speed Ratio:
1150
7% Improved.
Arm Cylinder Speed
1050
950
850 SH210-5
-29.5%
SH210-3
750
-36.5%
650
mm/sec
Low load High load

Hyd HP Boost -Travel
Hyd. Circuit Review
Hydraulic HP Boost -Travel-
Advantage;
Smooth travel speed down from flat ground to slope.
Background;
Operator feels “ No power” by speed reduction,

not pressure.

Cushion valve
Hyd. Circuit Review
New Cushion Valve
Advantage;
Faster heating Joystick valve up
>>> Approx. 30% faster warming up
Background;
Warming up speed of Joystick heating circuit on 210-3
is slower than our expectation.

-
Hyd. Circuit Review
New Cushion Valve
From Oil Cooler Line
210-3
By this orifice,
Warmed oil from oil
cooler line goes to
Tank.

-
Cushion valve
Hyd. Circuit Review
New Cushion Valve
From
210-5 Control valve T8
By this orifice,
Warmed oil from T8
port goes to Joystick
valve.

Auto power boost
Hyd. Circuit Review
Auto Power Boost
Advantage;
Main relief valve setting is shifted 34.3 MPa to 36.8 MPa
for 8 seconds automatically
depending on working situation
under SP, H and A mode(position 3).
Under A mode(position 4 to 15), always 36.8 MPa.
Judgment term becomes faster. (Approx. 0.1 sec)
Background;
On 210-3 system,
1 second is needed to work Auto power boost.

Option
Hyd. Circuit Review
Option Line
Advantage;
Stress free during Breaker operation
by Engine rpm dropping.
Selectable hydraulic flow for option line in the CAB.
Background;
Some operators dislike Engine rpm dropping during Breaker
operation.
Only 1 setting can be memorized in 210-3 system.

Hyd. Circuit Review
Option Line
Many attachment with many

setting flow for 20 ton class.
-3 system;
Breaker SW ; ON
Foot pedal ; ON
>>> Drop Eng rpm to a setting.
(-_-)1: Eng drop sound makes discomfort.
(-_-)2: Flow can adjust only for breaker.
(-_-)3: Only one setting can be memorized.

Hyd. Circuit Review
Option Line
(^_^)1: No Eng rpm drop for Breaker

(^_^)2: Adjustable flow for breaker and crusher
(^_^)3: 5 setting can be memorized from 10 default
System works condition;

Foot pedal ;On
All Pilot Press Sensors ;Off
Once operate Attachment, Travel, or Swing,

*Breaker mode; Under breaker setting.
*Crusher mode; Exit from this program.

Hyd. Circuit Review
Option Line
Engine rev (rpm) Flow (L/min) Pressure (MPa)
1000 140.2 0.40
1100 151.0 0.46
1200 162.7 0.51
1300 170.5 0.56
1400 198.1 0.72
1500 206.3 0.78
1600 213.5 0.83
1750 232.2 0.97
1800 236.3 0.99
Braker mode 1 pump
1.20
1.00
Pressure MPa
0.80
0.60
0.40
0.20
0.00
140.2 151.0 162.7 170.5 198.1 206.3 213.5 232.2 236.3
L/min

Hyd. Circuit Review
Option Line
Max. 1 pump flow

Active setting for Option line
Max. 2 pumps flow

P1 Main Pump Pressure
Section;Electrics P.155/ 156

Hyd. Circuit Review
Option Line

Option -Multi B-
Hyd. Circuit Review
Option Line -Multi <Breaker>-
Neutral Cut Valve Breaker
Breaker Mode Direction Valve
Switch to Breaker Mode
予備ライン
Mode切替えSW
Select SW
Computer A
MOM MOM
C/V
OP
3POSITION
3 positions
Middle; Normal or Sum Option
予備ラインSelect
切替え
Solenoid Valve
SOL
Choose BREAKER,
Solenoid becomes ON

Option -Multi C-
Hyd. Circuit Review
Option Line -Multi <Crusher>-
Neutral Cut Valve Crusher
Crusher Mode Direction Valve
Switch to Crusher MODE
予備Mode
ライン切替えSW
Select SW
Computer A
MOM MOM
C/V
OP
3POSITION
3 positions
Middle; Normal or Sum Option
予備ラインSelect
切替え
Solenoid Valve
SOL
Select CRUSHER,
Solenoid becomes OFF

2nd Option
Hyd. Circuit Review
Second Option Line
Advantage;
Save space
Increased hydraulic flow
Background;
Second option control valve is located in the Tool Box
on 210-3.

-
Title New filter
New Return Filter
New Return Filter

Review

-
New Return Filter
210-3
Paper
Return Filter
＋
NEPHRON
Full Flow FILTER
KRJ3836
By pass

-
New Return Filter
Catch dust
Fiber Dia. = 20 to 40 micron

Paper material
Superior to Flow
Speed
Hold dust
Glass Fiber material Fiber Dia. = 0.1 to 10 micron

-
New Return Filter
10000
Quantity of contamination over 5 micron
1000
100
Paper Filter
10
Paper Filter +
Nephron
New Filter
1
0
Time

New Return Filter
Beta value=dust number ratio of filter inlet to filter outlet (filtration ratio)
Outlet Test Inlet

sampling filter sampling Inlet outlet
port port 3 10 3 5 3 5 10 3
5
Test dust 10 3
5 10 3 3 5
3 5
１０μmのダスト＝１個
Number of 10micro meter Number of 10micrometer
Number of 10micrometer ５μmのダスト＝２個
=3No dust = 3Nos
dust = 3Nos ３μmのダスト＝３個
５μmのダスト＝４個 Number of 5micrometer
Number of 5micrometer
３μmのダスト＝５個 dust = 4Nos
dust = 4Nos
dust = 5Nos
dust = 5Nos
Number of 3micrometer and above dust at inlet 5+4+3 12

βBeta
＝ 33==
Beta
３ = = =2
Number of 3micrometer and above dust at outlet 3+2+1 6
Number of 5micrometer and above dust at inlet 4+3

7
Beta 5 = =
２個+１個
=
3
= 2.33
Number of 5micrometer and above dust at outlet 2+1
Number of 10micrometer and above dust at inlet
3
βBeta
１０＝ 10 = = =3
Number of 10micrometer and above dust at outlet 1

New Return Filter
10micro
meter
Beta10 Beta 10
1.4 and above 8 and above
Special paper filter Synthetic fiber filter
Filter media: Special paper Filter media: Synthetic fiber

10μcontamination catch ratio/flow : 28.6%. 10μcontamination catch ratio/flow : 87.5%.

Section; General Difference from -3 P4
New Return Filter

-
New Return Filter
210-5
High-Performance
Return Filter
Faster and same
Full Flow
filtering ability without
KRJ15830 NEPHRON

-
Maintenance
Maintenance
Maintenance Section
Review
If we have time…

Hydraulic Ver (Eng) Yoshida Kaizo

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Hydraulic Ver (Eng) Yoshida Kaizo

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Title

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 1

Major Hydraulic Components

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 3

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 4

P1 Solenoid valve ( Proportional Solenoid Valve )

N1; Negative Control

P1 Proportional Solenoid Valve

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 8

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 9

4) 5 pcs Solenoid valve

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 10

4) 5 pcs Solenoid valve

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 11

11) Hyd Temp Sensor

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 12

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 13

>>> 168.9 / 100.3 cc /rev (-5 Model) 4 % Increase

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 14

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 15

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 17

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 18

Brake Reverse Brake Reverse

However, the anti-drift valve is installed on SH240-5

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 19

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 20

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 21

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 22

Basic system & structure are similar to -3.

Bucket Close Regeneration Circuit

Add-on Valves for Option Line

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 23

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 24

New Straight Travel Pilot Port

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 25

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 26

Basic system & structure are similar to -3.

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 27

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 28

Basic system & structure are similar to -3.

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 29

>>> -5: Cylinder bore φ120 / Rod bore φ85

Arm Cylinder on 210

>>> -5: Cylinder bore φ140 / Rod bore φ100

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 30

>>> -5: Cylinder bore φ130 / Rod bore φ90

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 31

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 32

New Hydraulic Circuits

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 33

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 34

At steep slope in a mountain area,

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 35

Switched by 1st pressure.

Travel --->Sharp spool shift

Straight Travel Pilot

New orifice diameter.

--->Reduce shifting shock

--->Linear spool shift

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 38

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 39

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD 40

Steer pilot pressure into negative control