Professional Documents
Culture Documents
Ec210b Ec290b Prime Step1 Public en
Ec210b Ec290b Prime Step1 Public en
MENU
Picture text:
Overview(EC210B PRIME)
1. New Engine
- D6E EAE3(Tier 3): Serial number starts from 80001(CHW Production)
- D6E EAE2(Tier 2): Serial number starts from 70001(CHW Production) and 35001(SHA Production)
I-EGR is not used in D6E EAE2 engine
2. Remote installation of filters
- Engine oil filter, fuel filter, water separater, Drain filter and pilot filter are installed in pump room
3. Work mode refining
- Pump input power of H & G mode are increased by 5%
4. E-ECU(EMS2)
- EMS-2 is used for both Tier 3 and Tier 2 engine
5. Electric box & Battery connection
- Safety start relay removed
- Master switch removed
6. Fabricated counterweight
Picture text:
Overview(EC240B PRIME)
1. New Engine
- D7E EBE2(Tier 2): Serial number starts from 15001(CHW Production) and 35001(SHA Production)
2. Remote installation of filters
- Engine oil filter, fuel filter, water separater, Drain filter and pilot filter are installed in pump room
3. Work mode refining
- Pump input power of H & G mode are increased by 5%
4. E-ECU(EMS2)
- EMS2 is used for D7E EBE2 engine
5. Electric box & Battery connection
- Safety start relay removed
- Master switch removed
6. Fabricated counterweight
Picture text:
Overview(EC290B PRIME)
1. New Engine
- D7E EAE3(Tier 3): Serial number starts from 85001(CHW Production)
- D7E EAE2(Tier 2): Serial number starts from 17001(CHW Production) and 35001(SHA Production)
I-EGR is not used in D7E EAE2 engine
2. Remote installation of filters
- Engine oil filter, fuel filter, water separater, Drain filter and pilot filter are installed in pump room
3. Work mode refining
- Pump input power of H & G mode are increased by 5%
4. E-ECU(EMS2)
- EMS2 is used for both Tier3 and Tier2 engine
5. Electric box & Battery connection
- Safety start relay removed
- Master switch removed
6. Fabricated counterweight
Picture text:
Overview(Main component)
- Comparison of specification with old machine
Picture text:
Picture text:
Picture text:
Picture text:
Picture text:
Picture text:
Picture text:
Engine specification
EC210B PRIME(KOR)
EC210B PRIME
: D6EEAE3(Tier3)
: D6EEAE2(Tier2)
Picture text:
Main components
1.The most advanced Volvo engine controller, EMS2, will be utilized to provide the highest level of
electronic features and to enhance reliability.
2.The IEGR(Jacobs system) creates a small second exhaust valve lift. This extra lift feeds exhaust gases
back into the cylinder during the inlet stroke to reduce NOx.
3. Common Rail
Whereas in conventional diesel engines injection pressure is generated for each injector individually, a
common rail engine stores the fuel under high pressure in a central container (common rail) and delivers it
to the individual injectors on demand. Benefits of common rail injection are reduced noise levels, stronger
performance, improved emission control and greater efficiency.
4.The new high-pressure solenoid diesel fuel injector.(BOSCH-CRIN 2nd Generation Injector)
Picture text:
External view(1)
1. Cam speed sensor
2. Coolant temp. sensor
3. Solenoid(IEGR)
4. Boost press. & temp. sensor
5. Waste gate actuator
6. Preheat unit
7. Injector
8. Rail pressure sensor
9. Engine oil press. sensor
10. Fuel Control Unit (PWM valve)-FCU
11. Fuel pressure sensor
12. PTO
Picture text:
External view(2)
1.
2.
3.
4.
5.
6.
7.
8.
Picture text:
Electric circuit(EMS2)
Picture text:
Picture text:
Fuel line
In conventional diesel engines injection pressure is generated for each injector individually. A direct
injection engine based on the common rail principle separates the two functions pressure generation and
injection by first storing the fuel under high pressure in a central container ("common rail") and delivering
it to the individual injection valves (injectors) only on demand. This way an injection pressure of up to
1,600 bar (23,200 psi) is available at all times, even at low engine speeds. The high pressure produces a
very fine atomisation of the fuel leading to better and cleaner combustion. Moreover, the fuel supply is
not dependent on the engine revolutions but can be optimised independently. The time and duration of
injection is not fixed (as in older conventional engines) but can be chosen independently for every
operation point in order to optimise combustion and emissions.
Benefits of the common rail principle compared to conventional engines are lower engine noise levels,
stronger performance and greater combustion efficiency leading to lower emissions and enhanced fuel
economy. Push "check result" button to see the actual measuring data on the machine for reference only.
Picture text: 1: Manual feed pump
2: Pre filter & water separator
3: Fuel feed pump 4: Fuel filter
5: Fuel pressure sensor(low)
6: Fuel control unit (PWM)
7: High pressure pump
8: Rail
9: Rail pressure sensor
10: Max. pressure limit valve
11: Injector
12: Thermostat valve
Water seperator
1:
2:
3:
4:
5:
6:
7:
8:
Picture text:
Injector
The main injector components are:
Hole-type nozzle(c), hydraulic servo-system(b), solenoid valve(a).
The forces required to open and close the nozzle needle cannot be generated by the solenoid valve on its
own. The nozzle needle is therefore indirectly triggered via a hydraulic force-amplification system.
1. Injector closed
With the solenoid valve closed, the complete chamber volume and the rail are at the same pressure. The
nozzle needle is forced against its seat by a spring.
2-1. Solenoid ON
When the solenoid valve opens, fuel flows from the valve control cavity and into the fuel return.The feed
throttle prevents complete pressure equalization, and the pressure in the cavity drops.
2-2. Start of injection
Hydraulic servo spool move up side and the excess pressure in the chamber volume overcomes the spring
force and lifts the needle so that injection can start.
Picture text:
Rail
1. High pressure storage of injection system
2. Rail contains pressure relieve valve(a) and rail pressure sensor(b).
3. Pressure relief valve
- Pressure relieve valve is a mechaninical safety device, which opens at 1950 (-100) bar / 28,275 psi (
-1,450 psi) and protects the system concerning over pressure caused by any malfunction.
-If opened the rail pressure remains in the range of 650 - 850 bar (9,425~12,325 psi) (dependend on
speed and load). The engine keeps running but if necessary with decreased performance (limp home
mode)
-Under usual conditions the relief valve will not open during engine operation.
4. Rail pressure sensor
- Output signal goes to ECU and ECU controls FCU by using this signal.
- If any malfunction is detected, the ECU may force the pressure relief valve to open by putting over
pressure onto the system.
Picture text:
Picture text:
IEGR(Jacobs system)
NOx reduction solution is provided by Internal Exhaust Gas Recirculation (IEGR) which is altering engine
valve lift. Jacobs IEGR reduces peak combustion temperatures and, therefore, reduces the formation of
Nitrogen Oxides (NOx) to levels acceptable to meet upcoming emissions standards.
Picture text: A: IEGR Solenoid
B: Control valve
C: Slave piston
D: Master piston
E: Connection passage
F: Bleed hole(1 mm, 0.04 in)
IEGR operation
1. IEGR consists of a solenoid valve, control valve, and master and slave pistons. These components are
assembled into a housing.
2.When the solenoid is de-energized, the control valves move down and the high-pressure oil is released
through the tops of the control valve bores.
3. When the IEGR is activated, the solenoid allows oil to pass to the control valve. The control valve moves
up and the check ball in the control valve is unseated, allowing oil to fill the master/slave piston circuit.
4.The oil pushes the master piston out, and when rocker motion pushes the master piston back, high
pressure is created which seats the check ball in the control valve.
5.Continued rocker motion causes the high-pressure oil to move the slave piston. The slave piston motion
causes the exhaust valves to open. As the rocker moves back down, the master piston follows, and the
slave piston moves up, allowing the valves to close again, ready for the next cycle. These cycles continue
as long as the brake solenoid is energized.
Picture text: 1: IEGR Solenoid
2: Bleed hole: 1 mm (0.04 in)
3: Slave piston
4: Master piston
5: Intake rocker arm
6: Exhaust rocker arm
7: Control valve
8: Oil supply line: 2~5 bar (29~73 psi)
Picture text:
Picture text:
Picture text:
Picture text:
Engine specification
Common Rail Direct Injection type
------------------------------------EC240B PRIME
: D7E EBE2(Tier2)
EC290B PRIME(KOR)
EC290B PRIME
: D7E EAE3(Tier3)
: D7E EAE2(Tier2)
Picture text:
Main components
1.The most advanced Volvo engine controller, EMS2, will be utilized to provide the highest level of
electronic features and to enhance reliability.
2.The IEGR creates a small second exhaust valve lift. This extra lift feeds exhaust gas back into the
cylinder during the inlet stroke to reduce NOx.
3. Common Rail
Whereas in conventional diesel engines injection pressure is generated for each injector individually, a
common rail engine stores the fuel under high pressure in a central container (common rail) and delivers it
to the individual injectors on demand. Benefits of common rail injection are reduced noise levels, stronger
performance, improved emission control and greater efficiency.
4.The new high-pressure solenoid diesel fuel injector.
Picture text:
External view(1)
1. Cam speed sensor
2. Coolant temp. sensor
3. IEGR solenoid
4. Boost press. & temp. sensor
5. Waste gate actuator
6. Preheater unit
7. Injector
8. Rail pressure sensor
9. Engine oil pressure sensor
10. Fuel control unit
11. Fuel feed pressure sensor
12. PTO
13. Blowby gas control valve
14. Rail unit
15. Alternator
16. Oil cooler
Picture text:
External view(2)
1.
2.
3.
4.
5.
6.
7.
8.
Picture text:
Electric circuit(EMS2)
Picture text:
Picture text:
Picture text:
Picture text:
Electric system
EC210B/240B/290B Prime
Picture text:
Picture text:
Alternator
B+
BDFM
BS
15
L
W
:
:
:
:
:
:
:
Connection to Battery
Ground
None
Output check
Ignition
Charge warning Lamp control
None
Picture text:
Electric Box
Picture text:
Fuse box
-Fuse1~Fuse30
Picture text:
Picture text:
RPM Control SW
Input voltage is 24v and output voltage is 0.5~4.5V.
They have a shield ground to prevent noise at signal line.
Picture text:
Sensors(VECU)
1. Pilot pressure switch
-SE9111: Attachment
-SE9140: Travel
-SE9112: X1
-SE9140: Boom float
2. Fuel level sender
Picture text:
Picture text:
Picture text:
VECU
Picture text:
Picture text:
Picture text:
Picture text:
Boost control
When the boost solenoid is activated, the limit of system pressure will be increased by 10%.
1. Travel only case
2. F-mode(Slow but strong)
3. One touch power boost for 1-button joystick
- RH joystick button=ON
4. One touch power boost for 3-button joystick
- Lower button=ON
Picture text:
Conflux cutoff
1. F-mode (slow but strong)
- EC210B/240B Prime : Boom-up, Arm-In and Arm-Out use only 1-pump flow.
- EC290B Prime: Boom-up, Arm-In and Arm-Out use only 1-pump flow.
Picture text:
3. Safe stop
- Key ON --> OFF
- VECU send stop command to EECU
- EECU supply max. current to FCU to stop the fuel supply
- EECU Check rpm to recognize whether engine is stop or not.
- If engine stop, EECU transfer the operating data.
- EECU send message to VECU that VECU can cutoff power supply to EECU.
- VECU deenergize the battery relay(RE3101)
** Too much quick stop & start again without data saving time can cause serious damage to the
computer.
Picture text:
Emergency control
1. Emergency low
- Auto/Manual SW is in AUTO.
- IVS(Idle Validation SW) is off
- Communication error between VECU & EECU
- Engine speed fix in emergency low(I2)
- VECU supply I2 mode control current
2. Emergency high
- Auto/Manual SW is in AUTO.
- IVS(Idle Validation SW) is ON
- Communication error between VECU & EECU
- Engine speed fix in emergency high(H)
- VECU supply emergency current
3. Emergency stop
- IVS(Idle Validation SW) is in STOP position.
- EECU lose electric power.
- Engine stop.
Picture text:
VECU in Manual
SW9103 is in Manual position.
IECU
- VECU status signal is off.
- Auto position signal is off .
- IECU recognize current situation with combination of above two signals.
- IECU do not produce corresponding error code.
EECU
- EECU goes to emergency mode because of no communication within VECU.
Pump control
- By using the resistance on the Elec. BOX, Power shift valve use constant current.
Travel speed in manual mode
- In manual mode, can change speed of travel.
Picture text:
Starter lock
(EC210B/EC240B/290B Prime)
1. Starter lock relay
- Key OFF --> ON
- Safety lever=Down
- If there is code-lock option, PIN conde shoud be matched.
- When key is in start position, RE3301 will be ON.
From now on, power can goes to the magnet of starter(MO3301).
2. Magnet on the starter will be off by EECU,
- When Engine is running.(RPM > 650)
- During 6 seconds after EECU checked engine running.(to prevent overunning of starter)
- During 2 seconds after EECU checked engine stop.(Confrimation of engine stop after starting failure)
- During 1 seconds after key position changed from START --> ON. ( To prevent an quick retry after
starting failure)
Picture text:
Picture text:
P-mode parameter
In the old version, Dataset2 was different according to the region machine used.
From this machine, VECU will have only 1 Dataset2 which has two specification. VECU can select one of
the specification according to the parameter setting.
Picture text:
Picture text:
X1 (1-switch + Pedal)
PAR(BFJ: X1 Flow contriol)=ON
** Before turn on above parameter, PWM9109 shoud be installed.
- X1 flow rate setting on IECU
- Control lock-out lever up, RE9106=ON
1. 1-Switch only
1-way (Hammer selection)
- When joystick- button=ON, MA9103=ON.
This option only can use hammer.
MA9117 & MA9118 are not installed.
2. 1-Switch+Pedal
1-way (Hammer selection)
- When joystick- button=ON, MA9103=ON.
-X1 Pedal forward
2-way(Shear selection)
- X1 Pedal forward
- X1 Peal reward
Joystick button can not be used for Shear
- X1 Conflux
- When SW9112=ON, MA9116=ON.
Picture text:
X1 (2-switch only)
PAR(BFJ: X1 Flow contriol)=ON
** Before turn on above parameter, PWM9109 shoud be installed.
- X1 flow rate setting on IECU
- Control lock-out lever up, RE9106=ON
- If 1-way (Hammer selection)
- When joystick- upper RH button=ON, MA9103=ON.
- When joystick- upper LH button=ON, MA9104=OFF.
- If 2-way (Shear selection)
- When joystick- upper RH button=ON, MA9103=ON.
- When joystick- upper LH button=ON, MA9104=ON.
- X1 Conflux
- When SW9112=ON, MA9116=ON.
Picture text:
I ECU
1) Layout
A : Central warning lamp
B : Coolant temp. & fuel Gauge
C : Warning indicator
D : MCD(Message Center Display)
E : Key button
2) Key OFF condition
3) Key ON (Booting operation)
Central warning lamp(2 times), gauge(all segment ON),all indicator lamp ON
4) Key OFF (Shutdown operation)
Picture text:
Picture text:
MCD Operation
(1)
(2)
(3)
(4)
:
:
:
:
Normal condition
Anti-theft(Code-lock) condition
X1 condition
Error display
Picture text:
Picture text:
Pop-up indicator
This is not a warning but just indication of activation.
Picture text:
X1 flow setting
You can select any number from 30 to 500 at flow setting screen.
But if you select number that is larger than actual maximum flow, the set value will not be changed as you
select.
For example, if you select 240 at EC210B, the set value will be changed to 200.
Picture text:
Wiper
Picture text:
Picture text:
Care Track(Telematics)
The VCE telematics solution will contain three main services; Mapping and Tracking, Operational
Management, and Service Management. Within Mapping and Tracking services such as mapping of
machines, geo fence and location report will be included. Operational Management will contain
performance and utilization reports. Under Service Management service for the different machines
can be planned and followed up. Different alarms and error codes will be handled under service
management.
Service
- Machine position
- Instantaneous Machine data
- Geographical fence
- Location report
- Sanil Trail
- Machine Utilization Report
- Event Report
- Performance/Productivity Report
- Immobilizer
- Alarms & Warnings
- Error Codes
- Service Report
- Logged Machine Data, Complete Download
- Logged Machine Data, Partial Download
- Sleep Mode
- Work Shift
- Over the Air Programming
China GPS
Shut down request from V-ECU
-Power line cut: 60 (Duty ratio output by GPS-ECU)
-GSM cable cut or GPS cable cut: 70
-Open ECU cover: 80
-Stop request from web: 90
-GPS ECU failure: 100
-GPS ECU theft: 0
Engine running condition
-Normal condition: 40 (Duty ratio output by GPS-ECU)
-ECU normal but no GPS signal: 20 (Machine can be moved in tunnel)
-ECU normal but no GSM signal: 30 (Machine can be moved in tunnel)
-Reserved: 50
Applied machine Serial no.;
-SHI Products
EC210B Prime: 35109~
EC240B Prime: 31175~
EC290B Prime: 35001~
EC360B: 35279~
-CHW Products
EC210B Prime: 70417~
EC240B: 14147~
EC290B Prime: 17043~
EC330B: 15013~
EC360B: 15098~
EC460B: 14342~
EC700B: 10539~
EW145B: 15540~
Picture text: 1. GPS ECU
Picture text:
Power transmission
-
Swing motor
Travel motor
Turning joint
Swing Ring gear
Picture text:
Picture text:
External view
Compare the circuit & port on the motor.
Picture text:
Sectional view
Rotary group consists of cylinder block and 9 piston assemblies located in the cylinder. Both ends of
cylinder block are supported by bearings. Piston assemblies are guided by return plate and spring so they
slide smoothly on the swash plate. Valve plate is pressed against the cylinder block surface by the
mechanical pressure of spring and hydraulic pressure working on the bushing.
Between the outer diameter of the cylinder block and housing a mechanical brake for parking is mounted.
The cover section has a relief valve for cushioning and an anti-cavitation valve to prevent cavitation and
rebound damping valve for smooth stoping.
Picture text:
Picture text:
Closing position
Low pressure relief
Relief pressure increase by moving of piston
Final stage of relief
Picture text:
Picture text:
Picture text:
Travel Motor
(EC210B PRIME)
- Travel motors
- Gear box
Picture text:
External view
*Circuit animation for travel motor
-
Gear box
- Gear ratio: 50.5
Picture text:
Sectional view
When you click the component on the circuit diagram, you can see the location of correspondent
component.
1.
2.
3.
4.
5.
6.
7.
8.
Picture text:
Picture text:
Picture text:
Speed changeover
1. When the pilot pressure at port P is disconnected, the spool moves upward by the spring force &
hydraulic force which is applied to the differential area between red section and yellow section. The oil in
chamber of swash piston flows to the drain line, and the swash plate moves to increase swash angle, so
the motor rotates at low speed.
2. When the pilot pressure at port P is connected, spool moves downward by the pressure at Pi. The
supply oil through check ball folws to the swash piston. Swash pisto pushs the swash plate and decrease
swash angle, so the motor rotates at high speed.
3. In this picture, the force by P port pressure acts against the force by supply pressure which is applied
on the differential area and spring. When the supply pressure reach to specified value, the force by supply
pressure and spring overcomes the force by Pi pressure. So the spool moves upward.
The oil in chamber of swash piston flows to the drain line, and the swash plate moves to increase swash
angle, so the motor rotates at low speed and high torque.
Picture text:
Swing motor
Travel motor
Turning joint
Swing Ring gear
Picture text:
Swing System
-
Swing motor
Gear box
Pinion
Turning joint
Swing Ring gear
Picture text:
External view
**Compare the circuit & port on the motor.
Gearbox
- Gear ratio : 24.487
- Oil : SAE NO. 90 (6.1 liter)
A,B : Main
M
: Anti-cavitation
Dr
: Case drain
PG : Brake releasing
SH : Brake pilot
PA,PB: Pressure checking
GI,L : Gear oil filling & Oil level checking
GO : Gear oil outlet
Picture text:
Sectional view(1)
Rotary group consists of cylinder block and 9 piston assemblies located in the cylinder. Both ends of
cylinder block are supported by bearings. Piston assemblies are guided by return plate and spring so they
slide smoothly on the swash plate. Valve plate is pressed against the cylinder block surface by the
mechanical pressure of spring and hydraulic pressure working on the bushing.
Between the outer diameter of the cylinder block and housing a mechanical brake for parking is mounted.
The cover section has a relief valve for cushioning and an anti-cavitation valve to prevent cavitation and
rebound damping valve for smooth stoping.
Picture text:
Sectional view(2)
Gear box reduce the speed and increase torque using planetary gear.
Picture text:
Picture text:
Picture text:
External view
*Circuit animation for travel motor
- Model name : EM140V
- Displacement(cc/rev): 82.4/140.5
Picture text:
Sectional view(1)
When you click the component on the circuit diagram, you can see the location of correspondent
component.
1.
2.
3.
4.
5.
6.
7.
8.
Picture text:
Sectional view(2)
Gear box reduce the speed and increase torque using planetary gear.
Picture text:
Picture text:
External view
*Circuit animation for travel motor
Travel motors
- Displacement: 104.6/166.3 cc/rev
- Relief pressure: 370 kgf/cm^2 (36.3 MPa)
- Speed changeover pressure: 265Kgf/cm^2(26.0 MPa)
- Brake release pressure: 8 kgf/cm^2(0.83MPa)
Gear box
- Gear ratio: 59.889
- Oil : SAE#90 Gear oil(6.2 liter)
Picture text:
Sectional view(1)
1.
2.
3.
4.
5.
6.
7.
Picture text:
Sectional view(2)
Gear box reduce the speed and increase torque using planetary gear.
Picture text:
Picture text:
Picture text:
Speed changeover
1. When the pilot pressure at port Pi is disconnected, the spool moves upward by the spring force &
hydraulic force which is applied to the differential area between red section and yellow section. The oil in
chamber of swash piston flows to the drain line, and the swash plate moves to increase swash angle, so
the motor rotates at low speed.
2. When the pilot pressure at port Pi is connected, spool moves downward by the pressure at Pi. The
supply oil through check ball folws to the swash piston. Swash pisto pushs the swash plate and decrease
swash angle, so the motor rotates at high speed.
3. In this picture, the force by Pi port pressure acts against the force by supply pressure which is applied
on the differential area and spring. When the supply pressure reach to specified value, the force by supply
pressure and spring overcomes the force by Pi pressure. So the spool moves upward.
The oil in chamber of swash piston flows to the drain line, and the swash plate moves to increase swash
angle, so the motor rotates at low speed and high torque.
Picture text:
Brake system
Picture text:
Steering system
Picture text:
Picture text:
Upper frame
1.
2.
3.
4.
5.
6.
Center frame
Cabin mouting position
Engine mounting position
Swing motor mounting position
Turning joint mounting position
Counterweight mounting position
Picture text:
Lower frame
1. Lower frame
2. Idler & Track tensioner
There is high pressure grease in track adjuster cylinder. Do not remove grease fitting or nut and valve
assembly to release grease.
To decrease track sag, add multi-purpose grease to track adjuster cylinder through grease nipple(A) using
a grease gun with a maximum capacity 690 bar (10000 psi). To increase track sag, loosen valve assembly
(B) one turn so that grease in the track adjuster cylinder can be drained through rod hole (C). Tighten the
valve assembly when track sag is correct.
3.
4.
5.
6.
7.
8.
Picture text:
Track Link
1. Link LH
2. Link RH
3. PIN-Regular
4. PIN-Master
5. Bushing-Regular
6. Bushing-Master
7. Seal
8. Spacer
9. Greasing area
10. Greasing area
11. Do not apply grease here.
**EP2 Grease
Picture text:
Picture text:
Picture text:
Picture text:
Aircon unit
Receiver drier
Condensor
Compressor
Coolant connection on Engine
Controller & Heating unit for diesel heater(Option)
Fuel pump for Diesel heater
Diesel heater timer
Picture text:
Picture text:
Picture text:
Picture text:
Error code
Picture text:
Picture text:
Picture text:
1. Actuator - RH foot
2. Connection point - Refrigerant
3. Actuator - LH foot
4. Connection point - Coolant
5. Actuator - Mix door
6. Actuator - Face door
7. Filter - Main
8. Blower fan
9. Heater core
10. Evaporator
11. Duct temp. sensor
12. Expansion valve
13. Filter - Ambient
Picture text:
Sensors
Duct temperature sensor is installed at the core of evaporator.
If sensor is failed, compressor clutch will be disabled.
1.
2.
3.
4.
Picture text:
Actuator
1. Mix door actuator(MO8707)
- Inside of mix-door actuator, there is a position sensor. This informs the real-position to controller for
precise positioning.(Feedback control)
2. Foot, Face door acutator(MO8704-6)
- Opeating angle= 90 degree
3. Intake door acutator(MO8703)
- Operating angle= 120 degree
Picture text:
Picture text:
Compressor
Refrigerant : R-134a
Displacement : 154.9 cc/rev
Oil : SP-10 or equivalent
Oil charge : 240cc
Picture text:
Expansion valve
This is a kind of feedback system.
From output temperature from evaporator, System decides the amount of refrigerant.
Output temp. high ---> More flow
Output temp. low ---> Less flow
Picture text:
Receive dryer
Receive dryer
- Is a kind of reservoir to store excess liquid refrigerant in the system.
- Is a strainer or filter to remove particles from the system.
- Has desiccant to absorb moisture from the refrigerant.
- Has a built in pressure switch to protect system from excessive high or low pressure.
1. Desiccant
2. Filter
3. Baffle plate
4. Inner tube
5. Outlet port
6. Inlet port
7. Pressure switch
- Low pressure OFF : 2.0 +/- 0.2 kgf/cm^2
- High pressure OFF : 32 +/- 2 kgf/cm^2
Picture text:
1. Timer
The timer controls the diesel heater, and displays the operating status. The display shows current date,
current time and operating time.
2. Controller & Heating unit
The heating unit raises the temperature of the coolant using the fuel combustion unit, consists of the glow
plug, the thermostats, the flame sensor, the controller, the electric motor and the fuse. The case of the
unit has the fuel supplying port, the coolant inlet/outlet port, the air inlet port and the exhaust port.
3. Fuel pump
The fuel pump supplies the diesel heater with the fuel from the tank.
4. Water pump
The water pump is located between the diesel heater and the engine block, and supplies the diesel heater
with the coolant from the engine block.
a: Water flow
b: Fuel
c: Fresh air
d: Exhaust gas
Picture text:
Picture text:
Picture text:
Option
- X1
- X3
- Quick fit
Picture text:
Picture text:
Brief circuit-1
Brief circuit for main line.
How to read this circuit diagram.
In the circuit diagram, every component has unique number and there are many parentheses.
For example FR(1-Pi2), This means that the port FR is connected to the port Pi2 of the component 1. This
is the way how to read our circuit diagram.
Picture text:
Brief circuit-2
Brief circuit for pilot system
Picture text:
Circuit animation
This animation can be used when you explain or study the hydraulic circuit. By pressing the lines,
character or spool with mouse, you can change the colour of lines and spool position.
Picture text:
Hydraulic Pump
Piston pump
- Model : K3V112DT-1XJR-9N2D-V
- Displacement(cc/rev) : 114 X 2
- Max. flow rate @ 1800rpm (LPM) : 200 X 2
Gear pump
- Model : ZX10LGRZ1-07A-V
- Displacement(cc/rev) : 10
- Max. flow rate @ 1800rpm (LPM) : 18
Picture text:
External veiw
Picture text:
Sectional view
This pump assembly consists of two pumps connected by spline coupling.
The suction and delivery ports are integrated at the connecting section of the two pumps: The common
suction port serves both the front and rear pumps.
The pump consists of rotary group, swash plate group and valve block group.
The rotary group consists of front drive shaft, cylinder block, piston and shoe, set plate, spherical bushing,
and cylinder spring. The drive shaft is supported by bearings. The shoe is caulked to the piston to form a
spherical coupling. It has a pocket to relieve thrust force generated by loading pressures and create a
hydraulic balance so that it slides lightly over shoe plate.
The sub group composed of a piston and a shoe is pressed against the shoe plate by the action of the
cylinder spring through the set plate and spherical bushing. Similarly, the cylinder block is pressed against
valve plate by the action of the cylinder spring.
The swash plate group consists of swash plate, shoe plate, swash plate support, tilting bushing, tilting pin
and servo piston.The servo piston moves to the right and the left as hydraulic oil controlled by the
regulator flows to a hydraulic chamber located on both sides of the servo piston. The force exerted on the
tilting pin by the servo piston causes the swash plate to slide on support to change the tilting angle.
The valve block group consists of valve block, valve plate and valve plate pin. The valve plate which has
two crescent ports is attached to the valve block to feed oil to and collect oil from the cylinder block. The
oil discharged via the valve plate is routed to an external pipe line by way of the valve block.
Section A-A: Horsepower & Power shift control section
Section B-B: Negative control section
Picture text:
Picture text:
Regulator animation
Picture text:
P-Q curve
Test condition
- P1=P2
Picture text:
Picture text:
Picture text:
MCV Animation
Push the component in the circuit diagram with mouse then you can see the location of that components
and other information.
Picture text:
1. Neutral condition( Central passage fully open -> High Pi -> Minimum flow)
2. Half stroke( Central passage partially open -> Medium Pi -> Medium flow)
3. Full stroke( Central passage fully close -> the lowest Pi -> Maximum flow)
Picture text:
Picture text:
Picture text:
Picture text:
Picture text:
Picture text:
Boom up operation
1. Neutral
- Center passage open
- Holding valve closed
2. Joystick signal on(BU)
- Spool move to upword
- Center passge close & pressurize
3. Open load check
4. Holding valve open
5. Logic valve internal spool move
6. Logic valve open
7. Logic valve close when PL side pressure is lower than boom side.
eg. Boom up + Swing at light load
8. Logic valve close when Arm In(AI) signal is strong.
Picture text:
Picture text:
Arm-IN operation
1. Neutral
- Holding condition
2. Joystick Arm-IN(AI) ON
- Center passage block and pressurized
- The other pump side also pressurized due to center bypass valve movement.
3. Load check open and return line blocked by holding valve.
- 4pi pressure move valve and meke oil inside of holding valve free.
4. Holding valve open and return line restricted by arm regeneration valve when supplying pressure is low.
- Internal check open and return line is connecting to supply line.
5. When supplying pressure is high, arm regeneration valve make wide hole for return line to reduce back
pressure.
6. Swing priority
- Port-Pa has pilot signal and make restriction at the return side to supply more oil to swing side.
Picture text:
Straight travel
1. All spools are in neutral condition.
- 40 bar enters in port-Pg1 which has two orifice.
- oil from one orifice pass through two travel spool and go to the return line.
- Oil from the other orifice pass through arm, option, swing, boom, bucket and go to the return line.
2. Travel Right
- Spool movement block the line from orifice and bulid up pressure.
- Travel pilot pressure switch ON
3. Travel Left
4. Both supply line for TR & TL is waiting in the front of the straight travel spool but don't have connection
with each other.
5. Swing operation
- Swing spool movement block the line from the other orifice and build up pressure and this pressure
moves the straight travel valve. Now TR & TL is connected with each other.
Picture text:
Picture text:
21.
22.
23.
24.
29.
Return check 3k
Return check 4.5k
Hyd oil cooler
Hyd oil tank
Tank breather
Picture text:
Option hydraulics
Picture text:
X1 circuit
X1 option is mainly used for hammer & shear.
Main line change
Hammer(Single acting)
- MCV --> Hammer, Hammer --> Hyd. Tank.
Shear(Double acting)
- Both lines are connected to tank.
** Selection is made by Hammer & Shear select sol.(35) and 3-way valve(41).
2-stage port relief valve
- Hammer (210 kgf/cm^2)
- Shear(365 kgf/cm^2)
**2-step port relief valve always maintains high pressure except hammer use.
Flow control function
- According to IECU setting, The amount of flow can be adjusted by proportional valve(43).
- 2-pump flow option for X1(99)
Various RCV selection
- X1 1way switch(a)
- X1 2way switch(b) with sloenoid(38)
- X1 1way switch(c) with boom floating option
- X1 pedal(d)
Picture text:
X1 components
12. X1 1-switch control solenoid
34. X1 pedal
35. Hammer shear select sol.
38. X1 2-switch control solenoid
99. X1 2-pump flow solenoid
37. Shuttle valve block
39. Valve 2-pump flow
40. Variable orifice
41. 3-way select valve
42. Hammer return filter
43. Flow control PWM valve
46. Connector with orifice
47. Connector with check valve
X. X1 Pressure switch
Picture text:
X3 Rotator
30.
31.
32.
33.
Picture text:
Quick fit
Locking condition
- Pilot pressure is always ON at the large chamber to make quick fit lolcked position.
Releasing condition
- Pilot pressure enter the small chamber and pilot check valve open. If the pressure is lower to release
quick fit, main pressure can go to small chamber to release quick fit.
Picture text:
U-Quick fit
X: Quick fit solenoid valve
Y: Quick fit cylinder
Picture text:
Picture text:
Picture text:
Option
- X1
- X3
- Quick fit
Picture text:
Picture text:
Brief circuit-1
Brief circuit for main line.
How to read this circuit diagram.
In the circuit diagram, every component has unique number and there are many parentheses.
For example FR(1-Pi2), This means that the port FR is connected to the port Pi2 of the component 1. This
is the way how to read our circuit diagram.
Picture text:
Brief circuit-2
Brief circuit for pilot system
Picture text:
Circuit animation
This animation can be used when you explain or study the hydraulic circuit. By pressing the lines,
character or spool with mouse, you can change the colour of lines and spool position.
Picture text:
Hydraulic Pump
Piston pump
- Model : K3V112DT-1XDR-9N2A
- Displacement(cc/rev) : 115 X 2
- Max. flow rate @ 2000rpm (LPM) : 230 X 2
Gear pump
- Model : ZX10LGRZ1-07A-V
- Displacement(cc/rev) : 10
- Max. flow rate @ 2000rpm (LPM) : 20
Picture text:
External veiw
Picture text:
Sectional view
This pump assembly consists of two pumps connected by spline coupling.
The suction and delivery ports are integrated at the connecting section of the two pumps: The common
suction port serves both the front and rear pumps.
The pump consists of rotary group, swash plate group and valve block group.
The rotary group consists of front drive shaft, cylinder block, piston and shoe, set plate, spherical bushing,
and cylinder spring. The drive shaft is supported by bearings. The shoe is caulked to the piston to form a
spherical coupling. It has a pocket to relieve thrust force generated by loading pressures and create a
hydraulic balance so that it slides lightly over shoe plate.
The sub group composed of a piston and a shoe is pressed against the shoe plate by the action of the
cylinder spring through the set plate and spherical bushing. Similarly, the cylinder block is pressed against
valve plate by the action of the cylinder spring.
The swash plate group consists of swash plate, shoe plate, swash plate support, tilting bushing, tilting pin
and servo piston.The servo piston moves to the right and the left as hydraulic oil controlled by the
regulator flows to a hydraulic chamber located on both sides of the servo piston. The force exerted on the
tilting pin by the servo piston causes the swash plate to slide on support to change the tilting angle.
The valve block group consists of valve block, valve plate and valve plate pin. The valve plate which has
two crescent ports is attached to the valve block to feed oil to and collect oil from the cylinder block. The
oil discharged via the valve plate is routed to an external pipe line by way of the valve block.
Section A-A: Horsepower & Power shift control section
Section B-B: Negative control section
Picture text:
P-Q curve
Test condition
- P1=P2
Picture text:
Option hydraulics
Picture text:
X1 circuit
X1 option is mainly used for hammer & shear.
Main line change
Hammer(Single acting)
- MCV --> Hammer, Hammer --> Hyd. Tank.
Shear(Double acting)
- Both lines are connected to tank.
** Selection is made by Hammer & Shear select sol.(44) and 3-way valve(46).
2-stage port relief valve
- Hammer (210 kgf/cm^2)
- Shear(365 kgf/cm^2)
**2-step port relief valve always maintains high pressure except hammer use.
Flow control function
- According to IECU setting, The amount of flow can be adjusted by proportional valve(53).
- 2-pump flow option for X1(48)
Various RCV selection
- X1 1way switch(a)
- X1 2way switch(b) with sloenoid(42)
- X1 1way switch(c) with Boom floating option
- X1 pedal(d)
Picture text:
X1 components
12. X1 1-switch control solenoid
41. X1 pedal
44. Hammer shear select sol.
42. X1 2-switch control solenoid
48. X1 2-pump flow solenoid
43. Shuttle valve block
49. Valve 2-pump flow
50. Variable orifice
46. 3-way select valve
47. Hammer return filter
53. Flow control PWM valve
51. Connector with orifice
52. Connector with check valve
X. X1 Pressure switch
Picture text:
X3 Rotator
37.
38.
39.
40.
Picture text:
Quick fit
Locking condition
- Pilot pressure is always ON at the large chamber to make quick fit lolcked position.
Releasing condition
- Pilot pressure enter the small chamber and pilot check valve open. If the pressure is lower to release
quick fit, main pressure can go to small chamber to release quick fit.
Picture text:
Picture text:
Picture text:
Picture text:
Picture text:
Brief circuit-1
Brief circuit for main line.
How to read this circuit diagram.
In the circuit diagram, every component has unique number and there are many parentheses.
For example FR(1-Pi2), This means that the port FR is connected to the port Pi2 of the component 1. This
is the way how to read our circuit diagram.
Picture text:
Brief circuit-2
Brief circuit for pilot
Picture text:
Circuit animation
This animation can be used when you explain or study the hydraulic circuit. By pressing the lines,
character or spool with mouse, you can change the colour of lines and spool position.
Picture text:
Hydraulic Pump
**External view & sectional view is almost same with EC240B Prime pump.
Piston pump
- Model : K3V140DT-151R-9NE9-HV
- Displacement(cc/rev) : 139 X 2
- Max. flow rate @ 1800rpm (LPM) : 250 X 2
Gear pump
- Model : ZX10LGRZ1-07A-V
- Displacement(cc/rev) : 10
- Max. flow rate @ 1800rpm (LPM) : 18
Picture text:
P-Q curve
Test condition
- P1=P2
Picture text:
Picture text:
MCV Animation
Push the component in the circuit diagram with mouse then you can see the location of that components
and other information.
Picture text:
Boom up operation
1. Neutral
- Center passage open
- Holding valve closed
2. Joystick signal on(BU)
- Spool move to upword
- Center passge close & pressurize
3. Open load check
4. Holding valve open
5. Logic valve internal spool move
6. Logic valve open
7. Logic valve close when PL side pressure is lower than boom side.
eg. Boom up + Swing at light load
8. Logic valve close when Arm In(AI) signal is strong.
Picture text:
Picture text:
Arm-IN operation
1. Neutral
- Holding condition
2. Joystick Arm-IN(AI) ON
- Center passage block and pressurized
- The other pump side also pressurized due to center bypass valve movement.
3. Load check open and return line is blocked by holding valve.
4. 4pi pressure move valve and meke oil inside of holding valve free.
5. Holding valve open.
6. Return line is restricted by arm regeneration valve when supplying pressure is low.
- Internal check open and return line is connecting to supply line.
7. When supplying pressure is high, arm regeneration valve make wide hole for return line to reduce back
pressure.
8. Swing priority
- Port-Pa has pilot signal and make restriction at the return side to supply more oil to swing side.
Picture text:
Straight travel
1. All spools are in neutral condition.
- 40 bar enters in port-Pg1 which has two orifice.
- oil from one orifice pass through two travel spool and go to the return line.
- Oil from the other orifice pass through bucket, boom, swing, option, arm and then go to the return line.
2. Travel (RH & LH)
- Spool movement block the line from orifice and bulid up pressure.
- Travel pilot pressure switch ON
- Both supply line for TR & TL is waiting in the front of the straight travel spool but don't have connection
with each other.
3. Swing operation
- Swing spool movement block the line from the other orifice and build up pressure and this pressure
moves the straight travel valve. Now TR & TL is connected with each other.
Picture text:
Picture text:
Picture text:
Option hydraulics
Picture text:
X1 circuit
X1 option is mainly used for hammer & shear.
Main line change
Hammer(Single acting)
- MCV --> Hammer, Hammer --> Hyd. Tank.
Shear(Double acting)
- Both lines are connected to tank.
** Selection is made by Hammer & Shear select sol.(40) and 3-way valve(41).
2-stage port relief valve
- Hammer (210 kgf/cm^2)
- Shear(365 kgf/cm^2)
**2-step port relief valve always maintains high pressure except hammer use.
Flow control function
- According to IECU setting, The amount of flow can be adjusted by proportional valve(43).
- 2-pump flow option for X1(48)
Various RCV selection
- X1 1way switch(a)
- X1 2way switch(b) with sloenoid(37)
- X1 1way switch(c) with Boom floating option
- X1 pedal(d)
Picture text:
X1 components
11. X1 1-switch control solenoid
36. X1 pedal
40. Hammer shear select sol.
37. X1 2-switch control solenoid
48. X1 2-pump flow solenoid
38. Shuttle valve block
41. 3-way select valve
42. Hammer return filter
43. Flow control PWM valve
X. X1 Pressure switch
Picture text:
X3 Rotator
32.
33.
34.
35.
Picture text:
Quick fit
Locking condition
- Pilot pressure is always ON at the large chamber to make quick fit lolcked position.
Releasing condition
- Pilot pressure enter the small chamber and pilot check valve open. If the pressure is lower to release
quick fit, main pressure can go to small chamber to release quick fit.
Picture text:
U-Quick fit
X: Quick fit solenoid valve
Y: Quick fit cylinder
Picture text:
Hydraulic System(COMMON)
Picture text:
Cylinder
1.
2.
3.
4.
5.
6.
Piston
Tube
Rod
Gland
Cushion ring
Cushion plunger
a. Dust wiper
b. Rod packing
c. Buffer ring
d. Dry bearing
e. Contamination seal
f. Wear ring
g. Piston packing
Picture text:
Cushion operation
Picture text:
Joystick
The remote control valve is a kind of the reducing valve and has four reducing valves controlling the
secondary pressure in one valve casing. Its secondary pressure is controlled by adjusting the tilting angle
of the handle. And the electric switches are equipped inside of joystick for various option.
Picture text:
Travel pedal
Basic function is almost same with joystick and this pedal has damping function to prevent oscilation when
releasing the lever.
Picture text:
Option pedal
The component itself is almost same between X1 & X2 pedal but the characteristic curve is a little bit
different.
Picture text:
Picture text:
Picture text:
Machine Overview(2-Way)
Applied machine serial no.: 70001~
1.Boom cylinder guard
2.Arm cylinder protector guard
3.Bucket cylinder protector gurad
4.Cover for swing ring gear(Bolted with 4-pieces)
5.Track guard
6.Side impact protector
7.Counterweight work light
8.Front protector guard
9.Swing room guard
10.Side work light
11.Front work lights
12.Upper protector guard
13.Extra work lights
14.Additional fuse box
15.Water tank for operator convenience
**Bucket cylinder is available.
Picture text:
Overview(2-Way)
The 2-way hydraulic circuit is almost same with EC210B Prime which has X1 2-switch control and 2 pump
flow option. The machine will be usually used for log loader and road construction machine. Bucket is used
and Harvester is available in Hammer selection mode.
1. Log loader
2. Harvester
Picture text:
Machine Overview(1-Way)
Applied machine serial no.: 70001~
1.Filter for X1 return
2.Filter for X1 supply
3.Filter for X1 drain
4.Adaptor stick
-Adaptor stick upward with oil tank
-Adaptor stick straight with oil tank
-Adaptor stick downward HD type
5.Boom cylinder guard
6.Cover for swing ring gear(Bolted with 4-pieces)
7.Water tank for operator convenience
8.Additional fuse box
9.Track guard
10.Extra work lights
11.Upper protector guard
12.Swing room guard
13.Front protector guard
14.Arm cylinder protection
15.Front work lights
16.Side work lights
17.Counterweights work lights
18.Side impact protector
**No bucket cylinder
Picture text:
Overview(1-Way)
This machine will be used for harvester head or processing.
** Some of PWM valves and solenoid valves will be controlled by harvester ECU.
The machine will be possible to supply 2-pump oil using bucket side control. That means BKT side is
controlled by harvester ECU. In this case, BKT pilot signal can be used for X3.
Picture text:
Electric System(EC210BF)
Picture text:
X1 Forest(2-way)
PAR(BFJ: X1 Flow contriol)=ON
** Before turn on above parameter, PWM9109 must be installed.
- X1 flow rate setting on IECU
- Control lock-out lever up, RE9106(R4)=ON
1. If Hammer selection(Harvester)
- When SW9107, hammer selection button=ON, MA9117=ON.
- When joystick- upper RH button=ON, MA9103=ON.
- When joystick- upper LH button=ON, MA9104=OFF.
If additional ECU for forestry attachemnt is installed, hammer can be controlled by PWM valve(PWM-A2)
Picture text:
X1 forest (1-way)
** MA9103 & MA9103A are connected to SW9107 from factory in the begining.
But these connection will be cutoff from SW9107 and will be connected to the Harvester ECU. Customer
can select on-off control by the solenoid valves or proportional control by PWM Valve
And also the joystick will be changed by header precessor supplier.
**Bucket pilot signal from joystick can be used for X3.
PAR(BFJ: X1 Flow contriol)=ON
** Before turn on above parameter, PWM9109 must be installed.
- X1 flow rate setting on IECU
1. Hammer selection(Harvester)
- Control lock-out lever up, RE9106(R4)=ON
- When SW9107 Hammer selection button=ON, MA9117=ON.
- MA9117 supplies primary pilot pressure to MA9103, MA9103A & PWM Valve
2. High speed
- For sawing or log feeding
- HECU activates MA9103(PWM A-2) & MA9103A(PWM A-1)
- P1 & P2 pump oil are supplied to the harvester for high speed
3. Low speed
- For other operation
- HECU activates MA9103(PWM A-2)
- Only P1 pump oil is supplied to the harvester for low speed
4. Current to PWM9109
- X1 Pressure switch(SE9112)=ON
- VECU supplies control current according to the set flow on the IECU
Picture text:
Picture text:
Picture text:
Picture text:
Light Circuit
Picture text:
Hydraulic System(EC210BF)
Picture text:
X1 Circuit animation(2-way)
The 2-way hydraulic circuit is almost same with EC210B Prime which has X1 2-switch control and 2 pump
flow option. The machine will be usually used for log loader and road construction machine. Bucket is used
and harvester operation is available in Hammer selection.
If additional ECU for forestry attachemnt is installed, hammer & Shear can be controlled by PWM
valve(PWM-A1, PWM-A2)
During travel operation, the X1 Conflux is deactivated by the travel pilot pressure switch operation.
2 step port relief valve setting
-High pressure: 365 kgf/cm^2
-Low pressure: 210 kgf/cm^2
Picture text:
X1 Components(2-way)
14.
51.
53.
67.
50.
59.
46.
49.
45.
44.
43.
42.
Picture text:
X1 Circuit animation(1-Way)
This machine will be used for harvester head or processing.
** Some of PWM valves and solenoid valves will be controlled by harvester ECU.
The machine will be possible to supply 2-pump oil using bucket side control. That means BKT side is
controlled by harvester ECU. In this case, BKT pilot signal can be used for X3.
-1-Switch control(From the factory in the begging)
By pressuring the joystick button, both P1 and P2 pump flow are supplied to harvester simultaneously.
-Harvester ECU
-1 Pump flow: Selectable and controlled by Harvester ECU
-2 Pump flow: Selectable and controlled by Harvester ECU
Picture text:
X1 Components location(1-way)
14.
38.
59.
54.
47.
24.
42.
43.
46.
25.
26.
Picture text: