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7.

7-1

HYDRAULIC
Hydraulic
pump

COMPONENTS

1. Appearance Bolt for Back-up a3


Dr

(M8)
a6

PNl

a8

PSV2

PH2

./a

A3

7
a5

3
PHl PSVl a9 PN Bolt for Back-up

(M8)

PSVl

a9

a5

i;

uLAEIp T
a.

a5 a9

PH2

PN 2

* @

# *

&

PNl

a6

/
A3

al

Bl

a2

Dr3

&

103

7-1

2.

Hydraulicdiagram

of main

pump

(FRONT)
a5
tn r;
.I-T--

PNl

PSrla.A. A2a2

PSV2

(REAR)

pN2a6

1 L
._+

a8 PNl

I-J

l _J

a9

PN2

+
ll

+
1 ____J
l r

a3

a4
I -

t[i
Dr

l
t

BI

._L

l --L

a7

B3

Dr3

A3

unitMode] Mainpump Model Gearpump

SK200-6 K3Vl12DT-1RAP-9TIL ZXIOLGRZ2-06D

SK230-6 K3Vl12DT-1RAP-9TOL

SK320-6 K3Vl12DT-1RAP-9TOS

Displacementcc/rev
Ratedspeed

1052/10 (Gearpump) 2,200(2,200) (C]ockwiseviewed fromshaftend) 2,220(2,220)orlovv


Mainpump Gearpump

1152/10 (Gearpump) 2,100(2,100) 2,200(2,200)

(Rotationdirection)min-1(rpm) Highid]ingmin-1(rpm)
Ratedpressure

2,300(2,300)orJovv

2,385(2,385)orlow
I

34.3(350) 4.9(50) 37.8(385) 2382/21(G.P)

MPa(kgf/cm2)

ATTboostpress.MPa(kgf/cm2)

2102/20(G.P) rax8.flogT/rcaX)L/min Max.inputpowerkW(PS)

2502/22(G.P)

106.6(145)(incude 129(175)(include 177(240)(include gearpumpinputtorque)gearpumpinputtorque) gearpumpinputtorque) /3.4(4.6)(gearpump) /3.4(4.6)(gearpump) /3.4(4.6)(gearpump) 509.6(52)(include 588.4(60)(incJude 735.3(75)(include gearpumpinputtorque) gearpumpinputtorque) gearpumpinputtorque) /14.7(1.5)(gearpump)/14.7(1.5)(gearpump) /14.7(1.5)(gearpump)

.T?qxlnputNm(kgfm) AverageO.1(1)
OilquantityincasingL Controlcharacteristic Mainpump Weightkg Gearpump 1.6 2.8

!inmnie.r.P.rceaSsSiunrgeMPa(kgf/cm2) SurgeO.39(4)
-

Nega-Con/Total
powershiftcontro] 125
+J

126

Note

G.P

is Gearpump.

104

7-2

3.

Structure Mainpump
53S
? B9 ?32

1)

532

214

548

531

534

724

8CB

901

954

1?

151

1S2

211

953

I
BB8

261 4C6

ILL-:_-:_
74 111

1 0
U
113

r`

127

it
J
l

).,
_ -__

I+ 123
10

_-

251

212

49O

?17

153

1S6

1S?

981

488

312

114

12

886

88S

314

141

211

401

546

l I

rl
I

325

?2S

VW

Code 111 113 114 123 124 127 141 151 152

Name

Q'ty 1 1 1
I

Code 313 314 325 401 406 407 466 468 490 531 532 534 535 546 548 702 710 717 724

Name

Q'ty 1 1 1 8 4 3 2 4 20 2 2 2 2 2
I

Code 725 728 732 774 789

Name

Q'ty 7 4 2 1

Shaft(Front) Shaft(Rear)

Valveplate(Front) Valveplate(Rear)
Cover

0-ring(JJSB240l-Pll) 0-ring(JISB240l-P24)
0-ring Oi[sea] Back-upnng

Sp]inejoint
Rol[erbearlng Needlebeanng BearlngSPaCer Cy)inderb[ock Piston Shoe
I I

2 2 4 2 18 18 2 2 18 2 2 2 2 1

Socketbot(M20210) Socketbolt(M820) Socketbolt(M630) VPplug(PFl/4) VPp]ug(PF3/4) P)ug(Meek)


I

(J]SB2407-P18)
Back-upr]ng

792 806 808 824 885 886 901 953 954 981 983

(J[SB2407-G35) Nut(M16) Nut(M20)


Snaprlng

2 2 2 2 4 2 2 2 1
2

11i3 Retainer
156 157 Sphericalbushing Cylinderspnng

Tiltingpln Servopiston

Stopper(Large) Stopper(Smal))
Spacer Feedbackp]n 0Ing
I

Pin(812L)
SprlngPln
Ill

11 Shoep[ate
212 214 251 261 271 312 Swashplate Tiltingbushing Support Sealcover

Eyebolt(M10)
Setscrew Setscrew Nameplate Rivet

2 2 1 4 16

0-ring(JISB2401-G95) 0-ring(JISB2401-G145) 0-ring(JISB2401-P8)

Pumpcaslng Valveblock

2 1

105

7-3

2)

Regulator Structure of reguator

734

85 B9?

755

858 855 654

836

851

652

601

624

629

6)

628

612

B
614

653

12

81
801 615 81

813

925

LB

831

811
898
l

627
1
l

e:.'3
:;

Lal
?32 ?33

732


625

56

626 887 763

496

418

Section
VALVE ASSY. SOLENOID

AA

YN35VOOO18F2)

646

4&

438

92

801
- -

I I

643

00

644

645

Section

BB View C

Bot for back-up


E

II Jr-

(Regular

position)
a3 PNl

_J

Bolt for back-u

(1n back-up condition)


DD

Section

P2

l
1

545

1 +

+
Hydrauic diagram

543

Section EE

7-4

Code 412 413 418 436 438 439 466 467 496 541 543 545 60l 611 612 613 614 615 621 622 623 624 625 626 627 628 629 630 63l 641 642 643 644 645 646 651 652 653

Name

Q'ty 2 2 2 5 4 4 3 1 18 2 2 2

Code 730 732 733 734 753 755 756 763 801 814 836 858 874 875 887 897 898 924 925

Name

Q'ty 1 2 2 1 1 6 2 1 3 1 1 2 1 4 1 l 1 1 1

scketbott(M850)
Socketbolt(M870) Socketbo]t(M512) Socketbolt(M650) Socketbo[t(M620) Socketbolt(M640) VPplug(PFl/4) Plug(PF3/8M8)
PIug Seat Stopperl BalI
I

0-ring(JISB2401-P22)

0-ring(JISB2401-P16)
0-ring(J[SB2401-P20) 0-ring(JISB240l-G25) 0-ring(JJSB2401-P9) 0-ring(JISB2401-Pll) 0-ring(J[SB2401-P26) 0-ring(JISB2401-G35) Locknut(M8) Snapring(JISB2804SR-15)
Snaprmg

Lockingring(J[SB2804RR-15) Pin(411.7L) Pin(48L)


Pin

Caslng Feedback[ever

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
I

Lever(l) Lever(2)
FulcrampTug

Pin(419L) Pin(6.59L)
Setscrew

Adjustplug
Compensatingpiston Pistoncas[ng
I

Setscrew(Ql)
So)enoidvalve

Compensatingrod

079

Springseat(C)
I

Outersplng lnnersprlng

PIunger(C)

Adjustscrew(C)
Cover(C)
Locknut Pfsleeve PiLotcover Rod Pilotpiston

Springseat(Q) PIunger(Q)
Pilotsprlng Seeve Spoo) SprlngSeat Returnspnng Setsprlng Portplate
I

Tightemng

torque Size M8 M6 Torque

Code 412,413 436,438,439 466 467 496 630 801

Nm(kgfm) 29.4(3) ll.8(1.2) 36.3(3.7) 73.5(7.5) 8.8(0.9) 156.8(16) 15.7(1.6)

4
655 656 708 722 724 725 727 728

1 1 1 1 2 12 1 1 1

0-ring(JISB2401-G75) 0-ring(JISB2401-P6) 0-ring(JISB2401-P8) 0-ring(JJSB2401-Plo) 0-ring(JJSB2401-P14) 0-ring(JISB2401-P18)

PFl/4 PF3/8 NPTFl/16


M301.5 M8

107

7-5

Operation

of regulator

COMP[NSTING

LEVER

NEGATVE

CONTROL

LEVER

HORSE

POWER

CONTROL

PART

r`

,A

:@

I l
I

OIL FLOW CONTROPART

F[D

BACK

LEVER

SERVO

PISTON

NGATIVE

.+

CONTROSPOO

SPOOL

COMPENSAT(NG

PISTON

COMPENSATING

ROD

l I l I I

/
/
l J


-r

I I

J
+
...._.

FEED

1
BACK

I
l

L=@ 1 1 !-+
l

LEVER

i)cT
+

SERVO

PISTON

attaching

1.

Feed
servo

back

lever is connected and pin

with

3 pins, spool to large

pin.

Tilting

piston, negative with

reaching

holes

of negative
a

control
on

to pin attaching lever, and control lever.

2.

The

control negative

lever is connected control spool

with

2 pins, part.

pinfij(ed

casing

and

pin

in

contact

groove

3.

The

compensating with

lever is connected rod


groove

with

2 pins,

pin fixed

on

casing

, and

pin

in

contact

compensating

part.

Conceptual

diagram

for pump

operation

Flow

r8t8

uP

F)ow

rate Right

down

Left Large diameter Side

small selfpressure

diameter

side

C
T8nk

Servo

piston

Self-pressure

Swash

pJate

Cylinder

block

This left.

is the mechanism

to vary

the incation

resulting

from

movmg

servo

piston

right

and

That

is the right movement


rate, rate.

of

servo

piston makes

makes

the flow the flow

and

the left movement

the swsh plate vertical slightly reducing the incation of swash plate larger increaslng

3.

The

diameters

of

servo

piston "large

on

right and

left sides differ, and

are

referred

to

as

the

"small

diameter 4. 5. On Now,

side and diameter

diameter

side for explanation. is always diameter due


to

the small

side, the self-pressure is given


moves

given. the small of


area

the self-pressure
servo

to the large

sidelike

diameter reduclng

side. the

As

result, the
rate.

piston

rightward

the

difference

flow

6.

By

connecting

the large

diameter increasmg actions

side to tank, the flow is caued


a

the

servo

piston

moves

leftward

due

to

the

difference 7. The
pump

of pressure havmg these

rate.

variable

displacement

pump.

109

7-7

Regulator

operation

SMALL

DIAMETER

532 SERVO-PISTON

@531

T[LJtNG

PIN

LARGE

DIAMFrER

613 611

LEVERl

625

OUTER
1NNER

SPRJNG

FEEDBACK
1

LEVER

i(E)
SPRING

LEVER

874 T Cl Pl 651 654 RETURN

PIN

SLEEV
/
I

SPRJNG

652

SPOOL

646

PJLOT

SPRING

621

COMPENSATING P)STON

()

897

P P[LOT

'

875
PJN

643

PJSTON

B98

PJN

()

@531
647 STOPPER 623
COMPENSATING ROD

T)LT[NG FEED

P(N BACK PIN

548

110

7-8

Conceptual

diagram

of regulator

operation

([n

case

of negative

flow

rate

control)

Negative

control

fever

Selfpressure

Sleeve

/ l

Spool

e)
=
+/

Sprin

C)
SelfreSSur

I
J

Servo

piston

Smal

I diamete


Negative Large di8mete Swash control pressure plate

Negative spooJ

contro

Feedback

ever

The Each 1.

regulator regulator The with

can

be controlled with lever

by taking

the balance

for the hydraulic

force

and

sprlng

force.

is connected control

plnS.

negative
a

is

joined

by

pin

groove

of the negative lever

control by pin
up

spool

securing

the casing

and

pin

in contact

2.

The
servo

feedback piston

is

joined

to

attaching the large

spool hole

, tilting
part
on

pin

attached control

on

the lever

and

pin

through

the

negative

compensating

lever. lever is setinneutral, the negative lever control the negative spool control
pressure

While spring

the operation

rises

pressing

the

, and

moves

rightward. the

4.

The
Crum.

negative

control

moves

rightward

making

pin

securing

the casing

to ful-

5.

Then,

the feedback the spool

lever

moves

rightward

making

the tilting

pin

to fulcrum.

6.
7.

Therefore, The
movement

moves

the

rightward. enables the self-pressure


to reach to the

of spool and
moves

large

hole of

side of

servo

piston 8 9

servo

piston is very

rightward

due

to

the difference the flow lever

area.

The

tilting angle by

of swsh
servo

plate

close

to vertical

reducing

rate.

Besides, pin

the moving to fulcrum mog


to the

piston

rightward,
1eftward
pressure.

the feedback

moves

making
at

the

the pin

Therefore,

its movement

stops

the angle

corresponding

negative

control

111

7-9

compensation

control

(1)

COMP[NSrlNG

ROD

COMPENSATING

SPRING

(
SPRING

PI

CL
I- -

COMPENSATING

I I I

i__

COMPENSTING PI TON

L
+
FOMIpL,puMP

P,(P,)
DELIVERY PUMP PRESSURE

+-

P2
:

Pl

Delivery

pressure,

Companion

pump

pressure

1.

The

delivery

pressure

(Pl)

and

companion

pump

pressure-

(P2)

actuates

compensating

piston. 2. 3. And,
try to
move

the piston

to right

by

turnmg

the compensating spring

rod. than that of piston, the

However, flow

the spring force of compensating is delivered. in maximum


as

is stronger

LJl
-J
....1..l

L
+

_1_

]T-

112

7-10

compensation

control

(2)

COMPENSATINGVER SPOOL COMPENSANG RETURN SPRING COMPENSNG


PI

ROD SPRING

SPRING

CL

COMPNSNG

L P 2

COMPNSnNG N P!ST FEED BACKEVR SMALL CHAMBER DIAMETER

LARGE DIAMETER CHAMBER

L3 7.R=

PISTON

PLATE
Pl

f--.
SWASH

Pl

Deivery

pressure,

P2

Companion

pump

pressure

Small 1. As

diameter

chamber

Always

actuated
pump

by

self-pressure
pressure

(Pl).
is higher the force of compensat-

the delivery

(Pl)

and

companion

(P2)

ing spring 2. The pin

.
rod
moves

compensating

to right, groove part to

and, also
moves

3.
4. 5.

at

compensating

rod

to right.

Then, Pin Pin Pl

compensating

lever is moved
to right.

right

fulcrum

the fixed

pin

for casing.

also

moves

(Feed

back back

lever is lever,
so

moved.)
the spool is also moved
to right.

6.
7. 8.

is connected

with
-

the feed Large

(Delivery)CL
pressure
moves

diameter both faces

chamber.

Delivery piston

Pl actuates due

(large
area.

diameter,

smau

diameter).

then

the

servo

to right

to the

difference with

9.

Servo closer

piston

is directly

connected

tilting plate, and

the swash

plate

will be closer

and

perpendicular flow

to the piston.

10.

The

delivery

is reduced.

113

7-ll

Compensation

contro

(3) (At

steady

condition)

RTURN

SPRING

SPOOL

COMPENSATING

LEVER COMPNSANG SPRING

SPRING

PI

CL
r-

COMPENSATING

L_

P2

Pl

T
SERVO PJSTON
_

..
----


J:

FEED

BACKEVER

back

WASH

PLATE

1.

As
moves

soon

as

the

servo

piston

moves

to right,

the feed

lever

connected

with

pin

also

to right.

2. 3. 4.

Pin

moves

to left fulcrum

the pin

. (Spool

moves

to

left.)

(Pl)
Then,
sure

and

(CL)

ports

areclosed. be steady
on

the tilting plate win of delivery


pressure

the angle

corresponding

plate

to the

summed

pres-

(Pl)

and

companion

pressure

(P2).

114

7-12

Compensation

controf

(4) (Oj[ f]ow

increasing)

COMPENSJING SPOOL

LEVER COMPENSATING SPRJNG

RTURN

SPRING

Pl

6;

COMPNSATING

SPRING

P2

Pl

COMPENSATING
R D

FEED

BACK

LEVR

L..

/
l-

--.

.-1

pump pressure

Pl

1.

When low

the summed
pressure.

pressure

of delivery

(Pl)

and

the companion

(P2)

become

2.

The

spring

power

of compensating rod is moved

spring
to left.

and

is stronger

than

the summed

pressure,

the compensating

3.
4. 5. 6. 7. 8. 9.

Pin
Then, And, Large Servo The The

also

moves

to left.

the compensating spool is moved

lever
to left by

moves

to left fulcrum

the fixed

pin

for casing.

return
-

sprmg.

diameter piston swash delivery


moves

chamber
to

CL

(Tank).

left. becomes large.

plate flow

angle

is increased.

115

7-13

Power

shift control

Pl

CL

PIN

t>
Pf _

P2

Pl

L..

P,

Pf

Powershift

pressure

(M

B)

1. 2. 3.

Controller However, The


to pressure

recognizes the power

au

digging

modes. coming from horse the solenoid


power

shift pressure

valve

is fixed. is conducted

corresponding of

to the engine

Pl

by

actuating

engine
moves

speed
to

sensing.

(power shift pressure) (Mechatronics E.S.S)

4. 5.

Compensating Therefore,

piston engine

right throughpin.
and
pump

horse

power

horse

power

wbe

fixed.

116

7-14

Negative

flow

control

SPOOL SLVE NGAVE CONTROL


LVER

PI

CL

r-TI,I

RETURN

SPRING

tl

I J l

NEGA CONTR

SPRING

Pi

=>

EGATIVE CONTROL

SPOOL

I
LARGEJ
DIAMETER CHAMBER

T-L I

I
SRVO

PISTON

1'
+..

FEED

BACK[VR SMA CHAMBER ETER

'

SWASH

PLATE Pl

Pi

Negative

control

pressure,

Small

bore

One

pump

PI pressure

acts

on

it constantly

1. 2.

The The Pin Then,

negative negative

control control

pressure

rises.
moves

spool

rightward. spool
moves

3.
4.

on

the negative

control lever

groove

section

moves

rightward. securing pin

the negative

control

rightward

taking

to

the casing

as

support.

5. 6. 7. 8

Pin

moves
pin

rightward.

Because Pl One ward.

is connected
-

to the

feedback bore. faces of

lever, the spool

also

moves

rightward.

(Self pressure)CL
pump pressure

Large
on

Pl

acts

both

servo

piston,

and

the

servo

piston

moves

righ

Because approaches

the

servo

piston

is directly

connected

with

the swash

plate, the swash

plate

verticauy. flow
rate

10.

The

delivery

reduces.

And, of To
servo

the feedback piston the Pl

lever connected in ltem and CL


8, and ports.

with

pin
moves

moves

rightward taking

concurrently pin

with
support.

the movement

the spool

leftward

as

close

Therefore

it is held

at the angle

of swsh

plate corresponding

to the

negative

control

pressure.

117

7-15

Regulator operation Comparison when controlling pump proportional valve and back-up operation

1 ) Pump proportional valve control @ This is loaded flow rate control (negative control) type that the delivery flow rate reduces when secondary pressure (Pi) of pump proportional valve rises.

@ Under the condition where the rod (642) is


tightened, (See Figure), pump proportional valve secondary pressure (Pi) is led in pilot piston (643) and controls the pump delivery flow rate.

@ Pilot pressure (PSV) enters from the left


side, and is closed in A chamber with rod (642).

a8 PN1

@ Negative control pressure (PN1) enters


from right side, and is closed in B chamber with rod (642). Therefore, the pump delivery flow rate is varied by the negative control/compensating pressure which is calculated by deducting back pressure (Tn2) from negative control pressure (PN1).
PSV

1 ) Pump propo. valve controlled

643

2 ) Buck-up control function

@ When CPU mechatro controller fails, relaxes rod (642) (See Figure), and the function changes into hydraulic pressure control.
C' 642' TOpiiot piston at propo. valve control led

@ The secondary pressure (Pi) circuit of the


pump proportional valve closes due to the movement of rod (642).

@ With the rises of one pump delivery pressure P1 and other pump delivery pressure, the pump delivery flow rate is reduced automatically, and controls the input torque constant. (When the number of rotation is constant, the input power becomes constant.)

2 ) When controlling back-up function

643

@ Pilot pressure (PSV) enters from the left


side, and is led from A and C chambers into pin (898), and acts on compensating piston (623), and finally the power is controlled to the constant power. Therefore, the pump delivery flow rate is controlled by acting pilot pressure (PSV) and negative control pressure (PNl), and one pump pressure (PI) and other pump pressure (P2) on the compensating piston (623) and pilot piston (643).

P I : Self press. P2 : Other press. PSV: Pilot press. PN1: Nega-Con press. Pi : Secondary press, of propo. valve 623 : Compensating piston 642 : Rod (Screw) 643 : Pilot piston 898 : Pin

Gear

pump
7

(Forpi[ot control)
354 351

1 0

435

433

Suction

port

PF3/4
Delivery
--- -

port

PF 3/8

434

//
//

// /

312

// // // //

7,/

l ltl

(:@
-

/I;

311

32

)9

435

361

353

310

307

)8

355

4&

850

66

725

28

67

Drain

ort

PF3/8
Note: Sideof 1. After that check at 0.1 N.m

Oppositeside ofcauJkingcaulking

assembly thedrivegear

of gear
rotates

pump,

smoothly

(1.Okgfm)
2 Det ailoffiJter Code 307 308 309 310 31l 312 351 353 354 355 361 433 434 435 466 467 700 710 725 728 732 850
Poppet

oess. of gear the sliding pump, apply oil

After

assemb)y
on

sufficient(y Q'ty l 1 3

section. of the into contact

Name

Bringtheoppositesideofcaulking fi[tershown wjth the in the left figure

Seat Spnngseat Sprlng


to the

insert end face, paylng installing direction. A3

attention

l 1 1 1 1 1 1 1 1 2 2 4 1 1 1 1 1 1 1 1 312 433,434 435 466 M8 Code Threadsize M141.5 Torque Tightening a3


I

Adjustscrew
Locknut Gearcase Drivegear Drivengear Filter Frontcase

I
I l l l

,_..!
I
l

Dr4

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l

1
I

!,,I

SocketboJt(M840) Socketbolt(M855) Socketbolt(M820) Plug(PFl/4) Adapter(PFl/2-PF3/8)


Squarenng
I

L__TlJ
B3 Hydraulic torque circuit

0-ring(JJSB2401-G95) 0-ring(JISB240l-Pll) 0-ring(JISB2401-P18) 0-ring(JJSB2401-P16) Lockingring(JJSB28041RR-18)

Nm(kgfm) 29.4(3.0) 16.7(1.7) 15.7(1.6)

PFl/4

119

7-17