7.

HYDRAULIC COMPONENTS

7-1 Hydraulic pump

1. Appearance

Bolt for Back-up (M8)

a3 Dr PNl a8 PSV2 PH2 a6

i
A3
./a

3
a5
7 PHl PSVl a9 PN
Bolt for Back-up (M8)

PSVl a9

uLAEIp
T
a5

a5
a.
a9

/
PH2

&



i;

1

@ PN 2

K PNl

a6

*

@
#

a
* A3
/

&
*
W

Bl
Dr3
al a2

103 7-1
2. Hydraulicdiagram of main pump

(FRONT) PSV2 (REAR)

a5 PNl PSrla.A.
A2a2
pN2a6
.I-T--

r;tn 1
L
I-J I

a8 a9
]
l
_J ._+

PNl PN2

+ _ + +
a4
ll

a3
1

l
J ____J r I -

t[i _
t
l

l
---
a7
._L
L

Dr BI B3 Dr3 A3

unitMode] SK200-6 SK230-6 SK320-6

Mainpump K3Vl12DT-1RAP-9TIL K3Vl12DT-1RAP-9TOL K3Vl12DT-1RAP-9TOS

Model
Gearpump ZXIOLGRZ2-06D

1052/10 1152/10
Displacementcc/rev (Gearpump) (Gearpump)

Ratedspeed 2,200(2,200) 2,100(2,100) 2,200(2,200)

(C]ockwiseviewed
(Rotationdirection)min-1(rpm)
fromshaftend)
Highid]ingmin-1(rpm) 2,220(2,220)orlovv 2,300(2,300)orJovv 2,385(2,385)orlow
Mainpump 34.3(350)
I

Ratedpressure
MPa(kgf/cm2) Gearpump 4.9(50)
ATTboostpress.MPa(kgf/cm2) 37.8(385)

rax8.flogT/rcaX)L/min
2102/20(G.P) 2382/21(G.P) 2502/22(G.P)

106.6(145)(incude 129(175)(include 177(240)(include

Max.inputpowerkW(PS) 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)
!inmnie.r.P.rceaSsSiunrgeMPa(kgf/cm2)
SurgeO.39(4)
OilquantityincasingL 2.8 -

Controlcharacteristic Nega-Con/Total
powershiftcontro]
Mainpump 125 126 I

Weightkg
Gearpump 1.6 +J

Note : G.P is Gearpump.

104 7-2
3. Structure

1) Mainpump
901 954 1? 151 1S2 211
? B9 ?32 532 214 548 531 534 724 8CB
53S

953 A

I
BB8

261

4C6

ILL-:_-:_ 10
74
U
113
111

r`

127 it
).,
J _
-__

I+
123 l

_-
I
10

251

981 141 211 401

?17 153 1S6 1S? 3 3 488 312 114 12 886 88S 314
212 49O

546

l I

rl
I l

VW A
325 ?2S

Code Name Q'ty Code Name Q'ty Code Name Q'ty

111 Shaft(Front) 1 313 Valveplate(Front) 1 725 0-ring(JJSB240l-Pll) 7

113 Shaft(Rear) 1 314 Valveplate(Rear) 1 728 0-ring(JISB240l-P24) 4

114 Sp]inejoint 1 325 Cover 1 732 0-ring 2

I

123 Rol[erbearlng 2 401 Socketbot(M20210) 8 774 Oi[sea] 1

I

124 Needlebeanng 2 406 Socketbolt(M820) 4

Back-upnng
789 2
3 (J]SB2407-P18)
I

127 BearlngSPaCer 4 407 Socketbolt(M630)

141 Cy)inderb[ock 2 466 VPplug(PFl/4) 2

Back-upr]ng
792 2
151 Piston 18 468 VPp]ug(PF3/4) 4 (J[SB2407-G35)

152 Shoe 18 490 P)ug(Meek) 20 806 Nut(M16) 2

11i3 Retainer
I

2 531 Tiltingpln 2 808 Nut(M20) 2

156 Sphericalbushing 2 532 Servopiston 2 824 Snaprlng 2

157 Cylinderspnng 18 534 Stopper(Large) 2 885 Pin(812L) 2

11
Ill

Shoep[ate 2 535 Stopper(Smal)) 2 886 SprlngPln 4

212 Swashplate 2 546 Spacer 2 901 Eyebolt(M10) 2

I

214 Tiltingbushing 2 548 Feedbackp]n 2 953 Setscrew 2

I

251 Support 2 702 0Ing 2 954 Setscrew 2

261 Sealcover 1 710 0-ring(JISB2401-G95) 1 981 Nameplate 1

271 Pumpcaslng 2 717 0-ring(JISB2401-G145) 4 983 Rivet 2

312 Valveblock 1 724 0-ring(JISB2401-P8) 16

105 7-3
2) Regulator

Structure of reguator 734

755 858
85 836 652 601 624 629 6) 628
855 654 851
B9?

612 B 653

614

12 81

801
615 81

925
813

A 831

LB 811 627

898 l

e:.'3
l

:;

Lal
732

56

?32

625 626 887 763

?33

496 418 Section AA

VALVE ASSY. SOLENOID

YN35VOOO18F2)

646

4&

438

92

l
801
-

I I

643 00 644 645 7 8

Section BB
View C

Bot for back-up II

Jr-

E
(Regular
position)
_J

a3
Bolt for back-u
PNl
(1n back-up condition)

Section DD P2

l
1

545
1
+ +
543

Section EE
Hydrauic diagram

7-4
Code Name Q'ty Code Name Q'ty

412 scketbott(M850) 2 730 0-ring(JISB2401-P22) 1

413 Socketbolt(M870) 2 732 0-ring(JISB2401-P16) 2

418 Socketbo]t(M512) 2 733 0-ring(J[SB2401-P20) 2

436 Socketbolt(M650) 5 734 0-ring(JISB240l-G25) 1

438 Socketbo[t(M620) 4 753 0-ring(JJSB2401-P9) 1

439 Socketbolt(M640) 4 755 0-ring(JISB2401-Pll) 6

466 VPplug(PFl/4) 3 756 0-ring(J[SB2401-P26) 2

467 Plug(PF3/8M8) 1 763 0-ring(JISB2401-G35) 1

496 PIug 18 801 Locknut(M8) 3

541 Seat 2 814 Snapring(JISB2804SR-15) 1

543 Stopperl 2 836 Snaprmg 1

545 BalI 2 858 Lockingring(J[SB2804RR-15) 2
I

60l Caslng 1 874 Pin(411.7L) 1

611 Feedback[ever 1 875 Pin(48L) 4

612 Lever(l) 1 887 Pin 1

613 Lever(2) 1 897 Pin(419L) l

614 FulcrampTug 1 898 Pin(6.59L) 1

615 Adjustplug 1 924 Setscrew 1

621 Compensatingpiston 1 925 Setscrew(Ql) 1

I

622 Pistoncas[ng 1

623 Compensatingrod 1 079 So)enoidvalve 1

624 Springseat(C) 1
I

625 Outersplng 1

626 lnnersprlng 1

627 PIunger(C) 1

628 Adjustscrew(C) 1

629 Cover(C) 1
630 Locknut 1

63l Pfsleeve 1
641 PiLotcover 1

642 Rod 1

643 Pilotpiston 1

644 Springseat(Q) 1

645 PIunger(Q) 1

646 Pilotsprlng 1

651 Seeve 1

Tightemng torque
652 Spoo) 1
Torque
I

Code Size
653 SprlngSeat 1 Nm(kgfm)
4
I

Returnspnng 1 412,413 M8

29.4(3)
655 Setsprlng 1
436,438,439 M6 ll.8(1.2)
656 Portplate 1
466 PFl/4 36.3(3.7)
708 0-ring(JISB2401-G75) 1

722 0-ring(JISB2401-P6) 2 467 PF3/8 73.5(7.5)

724 0-ring(JISB2401-P8) 12
496 NPTFl/16 8.8(0.9)
725 0-ring(JJSB2401-Plo) 1
630 M301.5 156.8(16)
727 0-ring(JJSB2401-P14) 1

728 0-ring(JISB2401-P18) 1 801 M8 15.7(1.6)

107 7-5
 Operation of regulator

COMP[NSTING LEVER NEGATVE CONTROL LEVER

r`
HORSE POWER CONTROL PART



/
,A l


:@

/

I
l
I
I

OIL FLOW
CONTROPART

F[D BACK LEVER

SERVO PISTON
.+

+

NGATIVE
COMPENSAT(NG PISTON COMPENSATING ROD
CONTROSPOO SPOOL

l
r

l

I

l
I

/ l
J


/

+ /

-
-r
I
L=@ 1 1


i
l

i !-+
1
I

I +

+ ...._.
J 1
FEED BACK LEVER
l

i)cT
+

SERVO PISTON

pin attaching
1. Feed back lever is connected with 3 pins, spool attaching Tilting to
pin.
servo
piston, and pin reaching to large holes of negative control lever, and control lever.

2. The negative control lever is connected with 2 pins, a

pinfij(ed on
casing , and pin in

contact with negative control spool groove part.

3. The compensating lever is connected with 2 pins, a

pin fixed on
casing , and a
pin in

contact with compensating rod groove part.

 @ Conceptual diagram for pump operation

Flow r8t8 uP F)ow rate down

Left Right

Large diameter Side

small diameter side

selfpressure

C Servo piston
Self-pressure

T8nk

Swash pJate
Cylinder block

1 This is the mechanism to vary the incation resulting from movmg servo

piston right and
left.

2 That is the right movement of servo

piston the swsh plate vertical slightly reducing

makes
the flow rate, and the left movement makes the incation of swash plate larger increaslng
the flow rate.

3. The diameters of servo

piston on
right and left sides differ, and are
referred to as the "small
diameter side and "large diameter side for explanation.

4. On the small diameter side, the self-pressure is always given.

5. Now, the self-pressure is given to the large diameter sidelike the small diameter As a
side.
result, the servo
piston moves
rightward due to the difference of area
reduclng the flow

rate.

6. By connecting the large diameter side to tank, the servo

piston moves leftward due to the

difference of pressure increasmg the flow rate.

7. The pump havmg these actions is caued a

variable displacement pump.

109 7-7
 Regulator operation

SMALL DIAMETER

532 SERVO-PISTON
@531 T[LJtNG PIN

LARGE DIAMFrER

613 LEVERl 625 OUTER SPRJNG

611 FEEDBACK LEVER
i(E)
LEVER 1 1NNER SPRING

874 PIN
T

Cl

Pl
651 SLEEV /

654 RETURN SPRJNG I

/

652 SPOOL

)

646 PJLOT SPRING

621 COMPENSATING
()
P)STON 897 P

'
/ 875 PJN
643 P[LOT PJSTON

B98 PJN
()

T)LT[NG P(N
@531
548 FEED BACK PIN
647 STOPPER

623 COMPENSATING ROD

110 7-8
 @ Conceptual diagram of regulator operation ([n case of negative flow rate control)

l Negative control fever
Selfpressure
A

@

/

Sleeve l

e)

Spool

Sprin
C)

Self- reSSur
=
/ +/

Servo I diamete
J

piston Smal

Negative contro
spooJ

Feedback ever
Negative control
pressure
Large di8mete Swash plate

The regulator can be controlled by taking the balance for the hydraulic force sprlng force.
and
Each is connected

regulator with plnS.

1. The negative control lever is joined by pin securing the casing and pin in contact

with a groove of the negative control spool .

2. The feedback lever is joined by , tilting the
pin attaching spool pin attached on

servo
piston and pin through up to the large hole part on the negative control lever

compensating lever.

3 While the operation lever is setinneutral, the negative control pressure rises pressing the

spring , and moves the negative control spool rightward.

4. The control lever moves the the casing to ful-

negative rightward making pin securing
Crum.

5. Then, the feedback lever moves

rightward making the tilting to fulcrum.
pin
6. Therefore, the spool moves rightward.

7. The movement of spool enables the self-pressure to reach to the large hole side of servo

piston , and moves the servo

piston rightward due to the difference of area.

8 The tilting angle of swsh plate is very close to vertical the flow rate.

reducing

9 Besides, by moving the servo

piston rightward, the feedback lever moves
making the
pin to fulcrum mog the pin 1eftward Therefore, its movement stops at the angle
corresponding to the negative control pressure.

111 7-9
 compensation control (1)

COMPENSATING SPRING
COMP[NSrlNG ROD (

COMPENSATING SPRING
PI CL - -
I--

I

I

i__

COMPENSTING
PI TON
-

+
+-

-

FOMIpL,puMP P,(P,) PUMP
DELIVERY PRESSURE

Pl : Delivery pressure, P2 : Companion pump pressure

1. The delivery pressure (Pl) and companion pump pressure- (P2) actuates compensating

piston.

2. And, try to move the piston to right by turnmg the compensating rod.

3. However, asthe spring force of compensating spring is stronger than that of piston, the
flow in maximum is delivered.

LJl

-J
L

l
....1..l

+ +
]T-
_1_

112 7-10
 compensation control (2)

COMPENSATINGVER
SPOOL
COMPENSANG ROD
RETURN SPRING
COMPENSNG SPRING
PI CL
COMPNSNG SPRING @

P 2

COMPNSnNG
P!ST N

FEED BACKEVR

SMALL DIAMETER
LARGE = CHAMBER
DIAMETER
CHAMBER
L37.R= PISTON

9
`


f--. SWASH PLATE
Pl

Pl : Deivery pressure, P2 : Companion pump pressure

Small diameter chamber ; Always actuated by self-pressure (Pl).

1. As the delivery (Pl) and companion pump pressure (P2) is higher the force of compensat-
ing spring .

2. The compensating rod moves to right, and,

3. pin at compensating rod groove part also moves to right.

4. Then, compensating lever is moved to fulcrum the fixed for casing.

right pin
5. Pin also moves to right. (Feed back lever is
moved.)

6. Pin is connected with the feed back lever, so the spool is also moved to right.

7. Pl (Delivery)CL -
Large diameter chamber.

8. Delivery pressure Pl actuates both faces (large diameter, diameter). then the
smau servo

piston moves to right due to the difference area.

9. Servo is directly tilting plate, and the swash

piston connected with plate will be closer and
closer perpendicular to the piston.

10. The delivery flow is reduced.

113 7-ll
 Compensation contro (3) (At steady condition)

RTURN SPRING SPOOL COMPENSATING LEVER

COMPNSANG SPRING
PI CL r-

1

COMPENSATING SPRING

L_

P2 Pl

T-
_

..

SERVO PJSTON

L ----

FEED BACKEVER



J:

WASH PLATE

1. As soon as the servo

piston moves to right, the feed back lever connected with pin also
moves to right.

2. Pin moves to left fulcrum the pin . (Spool moves to left.)

3. (Pl) and (CL) ports areclosed.

4. Then, the tilting plate win be steady on the angle corresponding plate to the summed pres-
sure
of delivery pressure (Pl) and companion pressure (P2).

114 7-12
 @ Compensation controf (4) (Oj[ f]ow increasing)

COMPENSJING LEVER

COMPENSATING SPRJNG
RTURN SPRING SPOOL

Pl COMPNSATING SPRING

6;

P2 Pl
E

COMPENSATING
R D

FEED BACK LEVR

L..
a

- l-

--. .-1

Pl

1. When the summed pressure of delivery (Pl) and the companion pump pressure (P2) become
low pressure.

2. The spring power of compensating spring and is stronger than the summed pressure,

the compensating rod is moved to left.

3. Pin also moves to left.

4. Then, the compensating lever moves to left fulcrum the fixed pin for casing.

5. And, spool is moved to left by return sprmg.

6. Large diameter chamber

-
CL -
T (Tank).

7. Servo piston moves to left.

8. The swash plate angle becomes large.

9. The delivery flow is increased.

115 7-13
 Power shift control

Pl CL - `


I I

PIN

t>
Pf _

P2 Pl

L.. -

(

P,

Pf : Powershift pressure (M
A
B)

1. Controller recognizes au digging modes.

2. However, the power from the solenoid is fixed.

shift pressure coming valve

3. The pressure corresponding to the engine horse (power shift pressure)

power is conducted
to Pl by actuating of engine speed sensing. (Mechatronics E.S.S)

4. Compensating to
right throughpin.
moves
piston

5. Therefore, engine horse power pump horse power fixed.

and wbe

116 7-14
 Negative flow control

SPOOL

NGAVE CONTROL LVER

SLVE

PI CL r-TI,I _
tl l

RETURN SPRING

I
NEGA
I
J CONTR SPRING
l
Pi

=>
/ I _
I

NEGATIVE

CONTROL SPOOL

I L

FEED BACK[VR
T--

LARGEJ
DIAMETER
I
SRVO PISTON
1' SMA
CHAMBER
ETER

CHAMBER

'
_
+..


Pl
SWASH PLATE

Pi : Negative control pressure, Small bore : One pump PI pressure acts on it constantly

1. The negative control pressure rises.

2. The negative control spool moves

rightward.

3. Pin on the negative control spool groove section moves

rightward.

4. Then, the negative control lever moves taking to the casing

rightward securing pin as a

support.

5. Pin moves rightward.

6. Because pin is connected to the feedback lever, the spool also moves
rightward.

7. Pl (Self pressure)CL -
Large bore.

8 One pump pressure Pl acts on both faces of servo

piston, and the servo moves

piston righ
ward.

9 Because the servo is directly the swash

piston connected with plate, the swash plate
approaches verticauy.

10. The delivery flow rate reduces.

And, the feedback lever connected with pin moves rightward concurrently the movement
with
of servo
piston in ltem 8, and the spool moves leftward taking as a support.
pin
To close the Pl and CL ports.

Therefore it is held at the angle of swsh to the

plate corresponding negative control pressure.

117 7-15
 Regulator operation
Comparison when controlling pump propor-
tional 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 a8
side, and is closed in A chamber with rod PN1
(642).
@ Negative control pressure (PN1) enters 1 ) Pump propo. valve
from right side, and is closed in B controlled
chamber with rod (642).
Therefore, the pump delivery flow rate is
643
varied by the negative control/compensating
pressure which is calculated by deducting
back pressure (Tn2) from negative control
pressure (PN1).
PSV
2 ) Buck-up control function
@ When CPU mechatro controller fails, re-
laxes rod (642) (See Figure), and the
function changes into hydraulic pressure C' 642' TOpiiot piston
control. 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 pres-
sure P1 and other pump delivery pressure,
the pump delivery flow rate is reduced 2 ) When controlling
automatically, and controls the input back-up function
torque constant.
(When the number of rotation is constant,
the input power becomes constant.) 643
@ Pilot pressure (PSV) enters from the left
P I : Self press.
side, and is led from A and C chambers
into pin (898), and acts on compensating P2 : Other press.
piston (623), and finally the power is con- PSV: Pilot press.
trolled to the constant power. PN1: Nega-Con press.
Therefore, the pump delivery flow rate is Pi : Secondary press, of propo. valve
controlled by acting pilot pressure (PSV) 623 : Compensating piston
and negative control pressure (PNl), and 642 : Rod (Screw)
one pump pressure (PI) and other pump 643 : Pilot piston
pressure (P2) on the compensating piston 898 : Pin
(623) and pilot piston (643).
 3 ) Gear pump (Forpi[ot control)

1 0 7 354 351 435 433

Suction port : PF3/4

Delivery port
- -

- ----

PF 3/8

434
//
l

//
ltl
//
/

/I;

7,/

=

//

312 //
//
//

(:@ -

311

32

)9

435 361 353 310 307 )8 355 4& 850 66 725 28 67

Drain ort : PF3/8

Note:

Oppositeside Sideof 1. After assembly of gear pump, check that

ofcauJkingcaulking thedrivegear rotates smoothly at 0.1 N.m
(1.Okgfm) oess.
2 After assemb)y of gear pump, apply oil
Det ailoffiJter
sufficient(y on the sliding section.
3 Bringtheoppositesideofcaulking
Code Name Q'ty of the
fi[tershown in the left figure into contact
307 Poppet l

wjth the insert end face, paylng attention

308 Seat 1

to the installing direction.
309 Spnngseat l
A3

310 Sprlng 1
31l

312
Adjustscrew
Locknut
1
l

1
I
351 Gearcase 1
,_..!
I

I
l

Dr4
l

353 Drivegear 1 a3 I
l

354 Drivengear 1 Il
1
I

355 Filter 1
361 Frontcase 1
!,,I
433
434

435
SocketboJt(M840)
Socketbolt(M855)
Socketbolt(M820)
2

2
4
L__TlJ B3
466 Plug(PFl/4) 1 Hydraulic circuit
467 Adapter(PFl/2-PF3/8) 1
Tightening torque
Squarenng
I

700 1
Torque
710 0-ring(JJSB2401-G95) 1 Code Threadsize
Nm(kgfm)
725 0-ring(JISB240l-Pll) 1 312 M141.5 29.4(3.0)
728 0-ring(JISB2401-P18) 1 433,434
M8 16.7(1.7)
732 0-ring(JJSB2401-P16) 1 435
850 Lockingring(JJSB28041RR-18) 1 466 PFl/4 15.7(1.6)

119 7-17