EEBMOO0505 SOW IM LAINNO AIL KOMATSU PC210, 210LC-ck PC240, 240LC, PC240NLC-ck MACHINE MODEL SERIAL NUMBER PC210, 210LC-6K K30001 and up PC240, 240LC, 240NLC-6K 30001 and up This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. PC210, 210LC-6 mount the S6D102L-1 engine; PC240, 240LC-6 mount the SA6D102L-1 engine. For details of the engine, see the 102 Service Engine Shop Manual. ©1997 MOMATSU All Rights Reserved Printed in Belgium 02-97‘The affected pages are indicated by the use of the following marks. It is requested that necessary ac- Merk | indication Action required tions be taken to these pages according to the table below. Page to be newly added ane [Page to be replaced | Replace (_ ) [Page tobe deleted | Discard Pages having no marks are those previously revised or made addons. LIST OF REVISED PAGES wa Pace eT wane Page Tl wan rage Th] man Pape 770] wan page Tat © 004 ® 10-13 fo} 10-48 oO 10-82 @ 10-115 © vo uO oO ros} one © 2 021 © 10-45, @ 10-50 oO 10-84 oO wn7 © 0-2-2 ® 10-16 oO 10-51 oO 10-85, oO 10-118 @ © 023 © 10-17 oO 10-52 o 10-86 @Q 18119 @ 00-3 10418 fo} 10-53 ® 10-87 o 10-120 @ vo 0 wo oO wont os io} 1080 oe 0 foi 0 toe ne oe oO wows o7 woe} wor oO wom toe ioe 10880 oe 8 ious 0 009 10-25 oO 10-59 oO 10-93 ® 10-126 OD coro oO oo wo 0 won? oo wor 8 or ios om 0 0012 10-28 @ 10-62 oO 10-96 oO 10-129 00-13 10-29 oO 10-63, @® 10-97 ® 10-130 © 00-14 10-30 oO 10-64 oO 10-98 oO 10-131 @ wos sr | ees 8 mo woe cos be 6 08 8 om ois @ oo sO eer 8 wor wore ne we 3 joi 0 ious sO we 3 wom 0 wore tos ioe} om foie foie1 @ we 8 woe won 0 ions 0 o1ee @ 10-3, oO 10-39 oO 10-72 oO 10-106 = @ 10-1363 @ 104 @ 10-40 fo 10-73 oO 10107 © 10-136-4 @ sO io tom 0 iow ones 10-6 oO 10-42 ® 10-76 OQ 10109 @ 10-1366 @ 10-7 oO 10-43 ® 10-77 ® 10-110 @ 10-138 sO tou on 0 foi 0 owe 0 sO ios om O wore © iouo 10-10 oO 10-46 @O 10-80 ® 10113 © 10-141 fo} 10-12 ® 10-47 Oo 10-61 ® 10-114 @ 10142 @ 00-2-1Mark Page Foreon| Mat Page iugol| Mark Page TM! mark Pago TIMES! wark Page Time of 1143 @ 2019 20-69 2osa8 zo-te tore @ 20-14 20-70 20-128 20-182 co) © 2015 2071 2os27 20-188 (oan © 20-16 zor 20-128 20-108 (10-148) © 2017 20-73 20-120 20-185, 10-149 2018 2074 20-190 20-108 10-180 © 2020 2075 20-31 20-187 10181 2021 2076 20-132 20-188, 1012 © 2022 2078 204138 20-189 10153 © 2023 2079 20134 20-190 10158 2024 2080 20-135 20-101 10-155 2025 2081 20-136 20-192 10-158 2028 2082 20197 20-183 10157 2027 2089 20-138 20-196 10-158 20.28 20-84 20-139 20-195 1189 © 2029 20.85 2-140 zows tote 20-0 20.88 zoe ow wis © 2031 20.87 20-42 20-198 wie 202 20-88 2osa3 20.199 118s © 2003 20-89 2014s tore 20-94 20-00 20-48, 20201 118s © 2095 2001 20-46 20202 1016 © 2036 20-82 2oca7 20208, 10167 © 2087 2093 20-48 20.204 1018 2038 2094 20-49 20.205 10-168 2030 2095 20150 20206, 10170 20.40 2098 20st 20207 171 2041 2007 20153 20.208 1017 20.42 2098 20154 20209 10.173 © 2043 2090 20455, 20210 10178 20.48 20-100 20-156 zo2ti 10175 20.45 20:01 20187 20212 10.178 20.48 zo-102 204158, 20213 10.177 2047 20-108 201859 20216 10.178 20.48 20-104 20-160 20215 10.179 20-49 20-105 zoe 20216 10-180 © 2080 20-108 2oss2 20217 worse 2051 20007 204183, 20-218 118s 2053 20-108 20-68 20219 10-188 20-54 20-100 20-165 20-200 2055 20-110 204186 20-221 2058 2011 20467 20222 201 2087 zone 20-168 20-205 22 20.58 20-113 20-169 2022 208 2059 20-18 2070 20225 204 200 20-16 zor 20205, 205 2081 20-116 zoare * 227 © 206 2062 20118 20.173 20208 207 20-63 2-119 2oara 20220 ns @ 2064 20-120 2075 2021 209 2065, 20-121 20.176 20282 20-10 20-66 20-122 zea? 20283 zon 2067 20-123 20-78 20235, 202 2068 20-124 20-180 20236 00-2-2Mark Page [ircon| Mark Page (yrgcl| Mark Page T¢Ol Mak Page TIME! wark Page Timeot 202007 3027 30-82 oO 20-298 3028 30-89 ow 0 20-299 2029 20-04 21 O 20-240 30.90 20-85 «2 © 20281 3031 20-86 42 ® 20242 m0 2087 4022 20.248 90.33 30-88 4023 2024 3034 2089 4024 20245 w025 20-90 4025 20.246 3096 2001 4028 20247 3037 30-92 4027 20248 2098 2009 4028 20-240 2099 3084 doz 20-250 2040 30-95 40:30 20251 aot 20-06 4031 20-252 9042 3097 4032 20-259 3043 30-08 4033 20254 20-44 20-09 404 20255 2045 230-100 4035 ® 20.256 2046 30-101 40-96 20-257 30-47 30-102 40-37 @ 20258 2048 20103 4038 20.250 209 so-108 402 «@ 20-260 20-50 30108 faa) 20261 2st 20-106 40st 20-262 20-82 3007 20263 3053 30-108 3054 20-109 90-55 30-110 4 30-56 sont 02 2057 sone 203 2058 oo-119 204 2089 0-114 205. 3060 0-115 206 2061 0-116 27 2062 30-117 8 2009 209 20-64 20-10 3065 404 won 20-86 402 w0-12 2067 403 20-19 20-68 404 woe 20-89 405 18 30-70 406 2047 oo-72 407 20418 90-73 408 a9 2074 09 3020 30-75 40-10 2021 2076 wont 2022 2077 40-12 3023 3078 40-19 3028 2079 404 2025 30-80 40-18 3026 3081 4018 00-2-3a)20506 10 STRUCTURE AND FUNCTION Engine related parts nn 10-2 Radiator « oil cooler « aftercooler wo 10-3. Powertrain nnn eee 0) Final dfive sesnmnnnnnnnnnnnnnnnnn 102 5) Swing circle 10 6 Swing machindery smn W028 Track frame recoil spring 10- 9 Hydraulic piping drawing sno W001 Hydraulic circuit diagram 10- 12 Hydraulic tank. 10-14 Hydraulic PUMP wnnnnnnmnnnnnnnne 10° 15 Control valve... 40- 38 ciss 10- 47 SWING MOF ensmnmnesennnnnnnnnsnnn 10° 92 Center swivel joint so snes 10> 96 Travel motor... 40-105 Work equipment « swing PPC valve 10-108 Travel PPC valve se 0-110 Service PPC valve osnnneesnnnee WANG Safety lock valve 10-117 PPC accumulator 10-117 PPC shuttle « travel junction Valve nnn 10-118, EPC * solenoid ValVE wnrnnnnnnnennnnnees 10425, Hydraulic cylinder 10-130 Additional ft for breaker 10-131 Overload warning device svnnnees 10-432 Hose burst protection valve snnnees 10-136, 2nd Boom Holding valve sow 10-136-3 Work equipment... 10-136-6 Electrical control system 10-138 Electrical wiring diagram 10-143 Engine control SySteM w.rnnnnnnnnnnne 10-149) Electronic control system 10-154 Machine monitor system on 10179, 10-1STRUCTURE AND FUNCTION ENGINE RELATED PARTS ENGINE RELATED PARTS Be cc ce 1. Drive plate OUTLINE . Torsion spring + The damper assembly is a wet type. . Stopper pin Oil capacity: 0.752 2 3 4, Friction plate 5. Damper assembly 6. Air cleaner 7. Intake connector & Muffler 9. Rear engine mount }0. Front engine mount 10-2 @STRUCTURE AND FUNCTION 2ND BOOM HOLDING VALVE pooe Port T (to tank) Port Pi (from boom LOWER PPC valve) Port Cy (to boom cylinder bottom) Port V (from boom control valve) osena 2ND BOOM HOLDING VALVE . Safety-suction valve Pilot spring . Pilot spool Poppet spring Poppet 10-136-3STRUCTURE AND FUNCTION 2ND BOOM HOLDING VALVE Operation 1) 2) At boom EXTEND When the second boom is extended, the main pressure from the control valve pushes poppet (6) up in the direction of the arrow. Because of this, the main pressure from the control valve passes through the valve and flows to the bottom end of the boom adjust cylinder. f Seat FF een a Tren # exten OF Premen, Boom pedal at NEUTRAL When the second boom is raised and the control lever is returned to NEUTRAL, the cir- cuit for the holding pressure at the bottom end of the boom adjust cylinder is closed by poppet (6) and at the same time, the oil flowing into poppet (5) through orfice a of poppet (5) is closed by pilot spool (3). Asa result, the second boom is held in position. concros econo Contras valve 10-136-4 @STRUCTURE AND FUNCTION 2ND BOOM HOLDING VALVE 3) Atboom RETRACT When teh second boom is retracted, the pilot pressure from the PPC valve pushes pilot spool (3) and the pressurised oil in chamber b inside the poppet is drained, ‘When the pressure at port Cy rises because of the pressurised oil from the bottem end of the adjust cylinder, the difference in pressure bet- ween the oil surrounding the lower end of pop- pet (5) and the oil in chamber b allows the pop- pet tot rise allowing to flow from port Cy to port V which then flows to the control valve. If anny abnormal pressure is generated in the circuit at the bottom end of the boom adjust cylinder, safaty valve (1) is actuated contro! Seas! secona 10-136-5 ®STRUCTURE AND FUNCTION 2ND BOOM HOLDING VALVE 208608129 Arm Bucket cylinder . Arm cylinder Boom Boom cylinder Bucket Parons 10-136-6EEBM000502 DIOP 1M WANINAOANILy KOMATSU PC210,210LC-6k PC240 240LC, PC240NLC-6K MACHINE MODEL SERIAL NUMBER PC210, 210LC-6K K30001 and up PC240, 240LC, 240NLC-6K 30001 and up + This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. PC210, 210LC-6 mount the $6D102L-1 engine; PC240, 240LC-6 mount the SA6D102L-1 engine. For details of the engine, see the 102 Service Engine Shop Manual, © 1995 KOMATSU All Rights Reserved. Printed in Belgium 10-95.05002.SP01 00-110 20 30 40 00-2 CONTENTS No. of page STRUCTURE AND FUNCTION weve 10-1 TESTING AND ADJUSTING... DISASSEMBLY AND ASSEMBLY MAINTENANCE STANDARD..............c:ss:scssessesssssssesesseeneeees 40-1 2050620506 ‘The affected pages are indicated by the use of the following marks. It is requested that necessary actions must be taken to these pages according to the list oe Indication eeecae below. © | Page to be newly added | Add # | Page 0 be replaced Replace (1 | Page to be deleted Discard Pages having no marks are not revised at this time LIST OF REVISED PAGES. Mork Pages Revo” Tarark Pages ReViiON | ntark Pages PESO | ear Pages FEB | Mark Pages Revlon © 00-1 @ 10-23 @ 10-64 @® 10-105 @ © 10-143 @® 00. 2 wa oO 10-65 1-106 O | + wm @ © 00-21 @ 10-25 @ 10-66 10-107 @ (10-146) @ © 00-22 @ 10-26 @ 10-67 © 10-108 @ (10-147) @ © 0-23 @ 10-27 @ 10-68 @D 10-109 @® (10-148) @ 00- 3 10-28 @ 10-69 D 10-110 OD 10-149 © 00- 4 10-29 OD 10-70 @ 0-111 @ 10-150 O 00- 5 10-30 @ 0-71 @ 10-112, @ 10-151 © 00. 6 031 wn @ 10.113 © 1182 00-7 10-32 oO 10-73 OD 10-114 D 10-153 @ 00-8 033 074 @ 10-115 10-154 00-8 1038 @ 0-76 018 10-185 00-10 1035 077 0117 10-155 © 00-11 1036 10-78 OD 10-118 OD 10-157 @ 00-12 10-38 10-79 OD 10-119 10-158 @ 00-13 1033 10-80 OD 10-120 OD 10-159 © oo-t4 1040 wer o w121 10-160 00-15 10-41 ® 10-82 © 10-122, D 10-161 @® 00-16 02 © wes © 10-123 toi 00-17 10-43 10-84 © 10-124 OD 10-168 OD +01 @ wu 085 © 0-125 @ tose 02 O 45 wo8 0-126 10185 03 @ 1048 © wa 0127 @ 10-188 04 O 47 we @ 10-128 10.167 05 © 1048 © 10-89 OD 10-129 OD 10-168 10-6 fo} 10-49 @ 10-90 © 10-130 © 10-169 OD 07 © |e 00 © war © | o wim @ 0.170 08 @ 1031 © we © | o wim @ win 10-9 oO 10-52 @ 10-93 © © 10133 @ 10-172, 10-10 @ 10-63 ® 10-94 ® o 10134 @ 10-173 wn @ 1054 @ ws © | o 15 @ wim 02 O 055 © wos © | o 16 @ 10.175 0-14 O 1056 10-97 © © 10-1361 @ 10-176 OD 10-15 oO 10-57 @ 10-98 © o 10-1362 @ 10-177 © 10.18 1058 wo © | o w1363 @ 104178 10-17 oO 10-59 fo} 10-100 ® 10-138 @ 10-179 ® 0-18 OD 10-60 @ 10-101 © 10-139 @ 10-180 © 10-19 oO 10-61 @ 10-102 @® 10-140 @ 10-181 © 10-20 ®Q 10-62 ® 10-103 @ 10-141 O 10-182 O 10-22, 10-63 @ 10-104 10-142, 10-183 00-2-1Mark Pages FOC” | mark Pages REWsiOn | mark ages Fevition | rar Pages ROMSIO" | mare Pages Revision 10-184 20- 64 20-110 20-167 20-225 10-185 © 20- 85 20.111 20-168 20-226 10-188 O 20- 56 20-112 20-169 20-227 20- 87 20-113 20-170 20.228 20-1 20- 58 20-114 204171 20-229 20. 2 20. 59 20-115 20-172 20.231 20-3 20- 60 20-116 20-173 20-232 20- 4 20- 61 20-118 20-174 20-233 20-5 20- 62 20-19 20-175 20-238 20- 6 20- 63 20-120 20-176 20-236 20-7 20-64 @ 204121 20-17 20-237 20- 8 20-65 20-122 20-178 20-238 20- 9 20-66 20-123 20-180 20-239 20- 10 20-67 @ 20-124 20-181 20-240 20-11 20- 68 20-125 20-182 20-241 20- 12 20- 69 20-126 20-183 20-242 20.13 20: 70 20-127 20-184 20-243 20. 14 20-71 20-128 20-185 20-244 20-15 20-72 20-129 20-186 20-245, 20-16 20-73 20-130 20-187 20-246 20-17 20-74 20-131 20-188 20.287 20-18 20-75 20-132 20-189 20-248 20-19 20-76 20-133 20-190 20-249 20- 20 20-77 20-134 20-191 20-280 20-21 20-78 20-135 20-192 20-251 20- 22 20-79 20-136 20-193 20.252 20- 23 20- 80 20-137 20-194 20.253 20- 24 20- a2 20-138 20-195 20.254 20- 28 20- €8 20-138 20-196 20.255 20- 26 20- 84 20-140 20-197 20-256 20-27 20- 86 20-141 20-198 20-257 20- 28 20- 86 20-142 20-199 20-258 20- 29 20- 87 20-143 20-201 20-259 20- 30 20- 88 20-144 20-202 20-260 20- 32 20- 89 20-145 20-203 20.261 20- 33 20- 90 20-48 20-204 20-262 20- 34 20-91 20-47 20-205 20-263 20-35 20- 92 20-48 20-208 20- 36 20- 93 20-149 20-208, 304 20-37 20- 94 20-150 20-209 30-2 20-38, 20- 95 20-151 20-210 30-3 20-39 20- 96 20-153 20211 30-4 20- 40 20. 97 20-154 20-212 30-5 20-41 20- 98 20-155 20-213 30-6 20-42 20- 99 20-156 20-214 30-7 20- 43 20-100 20-157 20-215 30 8 20- 44 20-101 20-158 20-216 30-9 20- 45 20-102 20-159 20.217 30-10 20- 46 20-103 20-160 20.218 30-11 20-47 20-104 20-161 20219 30-12 20- 48 20-108 20-162 20-220 30-13 20- 49 20-108 20-163 20-221 30-14 20- 60 20-107 20-164 20-222 30-16 20- 51 20-108 20185, 20-223 30-17 20. 53 20-109 20-168 20-224 30-18 00-2-2 2050620506 Mark Pages Revlon | hark Pages ROMO | ark Pages FEMSOM | ark pages REVIOM | mark Pages Reiton 30-19 30-75 OD 40-12 30-20 30-76 40-13 30-21 30-7 40-14 30-22 30- 78 40-15 30-23 30-79 40-17 oO 30-24 30- 80 40-18 30-25 30- 81 40-19 30-26 30- 82 40-20 @ 30-27 30- 83 40-21 30-28 30- 84 40-22 30-29 30- 85, 40-23 30-20 30. 86 40.24 30-31 30- 87 40-25 30-32 30- 88 40.28 30-33 30- 89 4027 30-34 30- 90 40-28 30-35 30-91 40-29 30-36 30: 92 40-30 20.37 30. 99 aoa 30-38 30- 94 40-32 30-39 30- 95, 40-34 30-40 30- 96 40-35 30-41 30- 97 40-36 30-42 30- 98 40.37 30-43 30- 99 40-38 30-44 30-100 40-39 30-45 30-101 40-40 30-46 30-102 40-41 30-47 30-103 3048 30-104 3049 30-108 30-50 30-106 30-51 30-107 30-52 30-108 30-53 30-109 30-54 30-110 30-55 30.117 30-56 30-112 30-57 30-113 30-58 30118 30-59 30-115, 30-60 30-116 30-61 30-117 30-62 30-63 4 30-64 40- 2 30-65 40- 3 30-668 wo 4 30-67 40- 5 30-68 00. 6 30-69 @ 40- 7 30-70 40- 8 30-72 “0 9 30-73 oO 40- 10 30-74 @ 40-11 00-2-3k20506 10 STRUCTURE AND FUNCTION Engine related parts Radiator « oll cooler + aftercooler. 3 Power train .. 4 Final drive .. 5 Swing CifCle «von 6 Swing machinery 10-7 Track frame + recoil spring... 10-8 Track shoe Hydraulic piping drawing .. Hydraulic circuit diagram .. Hydraulic tank. Hydraulic pump Control valve .. CLSS.... Swing motor... Center swivel joint Travel motor Valve control... Work equipment « swing PPC valve .. Travel PPC valve Service PPC valve ... Safety lock valve .... PPC accumulator... PPC shuttle + travel junction valve EPC + solenoid valve Hydraulic cylinder Additional filter for breaker... Overload warning device .. Hose burst protection valve . Work equipment: Electrical control system Electrical wiring diagram Engine control system Electronic control system .. Machine monitor system 10-1 ®STRUCTURE AND FUNCTION ENGINE RELATED PARTS ENGINE RELATED PARTS 20506 on 88 ce DD |. Drive plate OUTLINE Torsion spring + The damper assembly is a wet type. . Stopper pin Oil capacity: 0.758 . Friction plate . Damper assembly . Air cleaner . Intake connector Muffler . Rear engine mount . Front engine mount Seerogsens 10-2k20506 STRUCTURE AND FUNCTION 2). Pressure compensation ciss A valve (pressure compensation valve) is installed to the outlet port side of the control valve to balance the load. When there is compound operation of the actuators, this valve acts to make pressure difference AP constant for the upstream flow (inlet port) and downstream flow (outlet port) of the spool of each valve. In this way, the flow of oil from the pump is divided in proportion to area of opening $1 and $2 of each valve. Load oe Actuator Load w g ft oe R [Pressure Pressure ese et »| TS Lf le ” WU um LT 202F06081 10-49 ©STRUCTURE AND FUNCTION OPERATION FOR EACH FUNCTION OF CLSS Hydraulic cirouit diagram for system fee 10-50 2050620506 STRUCTURE AND FUNCTION ADDITIONAL FILTER FOR BREAKER ADDITIONAL FILTER FOR BREAKER * FOR MACHINE EQUIPPED WITH BREAKER 20505096 1. Head cover SPECIFICATIONS 2. Element Rated pressure : 6.86 MPa (70 kg/cm?) 3. Case Flow :107¢/min 4. Drain plug Relief valve cracking pressure: 0.34 + 0.049 MPa 5. Valve (3.5 £ 0.5 kg/om’) 6. Spring Filter mesh size: 6 um 7. Spring set plug Filtering area: 3160 em? 10-131 ®‘STRUCTURE AND FUNCTION OVERLOAD WARNING DEVICE 1 OUTLINE Buzzer Oil pressure switch / /- Boom control 7 “ / 800m eylindor aaa ae FUNCTION + This device is installed to warn the operator when the machine is close to tipping over when it lifts an excessive weight while be- ing used as a crane. STRUCTURE + When an excessive weight is lifted, the oil pressure goes up at the bottom side of the boom cylinders. When this happens, the pressure switch senses the rising pressure, turns the pressure switch on, and lights the monitor lamp to warm the operator. When the monitor lamp lights, immediately lower the weight to the ground or bring the arm closer in to the operator to prevent the ma- chine from tipping over. 10-132 OVERLOAD WARNING DEVICE FO20E346C20506 STRUCTURE AND FUNCTION OVERLOAD WARNING DEVICE Control panel Overload warning pilot lamp (Monitor, 10-133STRUCTURE AND FUNCTION OPERATION + Hose (2) directs the oil pressure from the bottom side of the boom cylinders to pressure switch (3). When the boom is in the lowest position + When boom (5) is in the lowest po: tion, lever (4) takes position A in Fig. 1 and the pressure to activate its switch (closed and open) becomes 60 kg/cm*. . When the boom is in the highest position + When the boom is in the highest posi tion, lever (4) takes position B in Fig. 1 and the pressure to activate the switch becomes 360 kg/cm, When the boom is in an arbitrary position + When the boom is in a position any- where between the lowest and the high- est points, the operating pressure of switch (3) will be somewhere between 60 kg/cm? and 360 kg/cm’, based on the boom position: For instance, when the boom is in a cer- tain position between the lowest and the highest points, lever (4) takes a position which corresponds to that boom posi tion. OVERLOAD WARNING DEVICE If lever (4) is in the position to make the operating pressure of the pressure switch 10 kg/cm? (which is the same pressure as the bottom side of the boom cylin- der), the pressure switch will turn on when excessive weight is lifted by the boom and the oil pressure of the bot- tom of the boom cylinders exceeds 150 kgfor. When the machine is performing any kind of operation other than lifting loads, fasten the pressure switch lever (4) with the bolt (6) to prolong the life at the pressure switch. k2050620506 ‘STRUCTURE AND FUNCTION OVERLOAD WARNING DEVICE 3. ADJUSTING PRESSURE OF THE OIL PRESSURE SWITCH + Screw D: Pressure range adjustment screw To make an adjustment so that the oil pressure switch acts normally when checking the operation of the overload warn- ing device. Turning to the left makes the pressure range wider. + Screw E: Zero point adjustment screw Turning to the right one com- plete turn raises the pressure by 57 kg/cm’. Each complete turn to the left lowers the pressure by 57 kg/ cm? a 1. Body AiWren an adjustments required, contact 2, Bouldon tube your Komatsu distributor and have 3. Eocontie make the adjustment. 4, Microswitch 5. é 1 Lever and roller Adjustment screw (E) Adjustment screw (D) 0206361 10-135 ©STRUCTURE AND FUNCTION HOSE BURST PROTECTION VALVE (BOOM) HOSE BURST PROTECTION VALVE (BOOM) High pressure from 1) @D contrel valve w'por At signal ipod —_ Overond cation signal yp YZ, TEA < ‘ ao Ly vy 3 1. Body 2. Spool 3. Relief valve 4, Check valve pone 210-1008 FUNCTION This valve prevents sudden uncontrolled lowering of the boom, when lifting, due to the burst of a hose in the boom cylinder line. In such a condition this valve will hold the load until operator lowers the boom in a controlled way using the normal wrist control. 10-136 2050620506 STRUCTURE AND FUNCTION When hose burst occurs (Operation to lower safety) The sudden loss of pressure at port V will cause check valve (4) to re-seat and so the valve is locked. + The boom can be lowered in a controlled way by operating the wrist control in the normal way. HOSE BURST PROTECTION VALVE (BOOM) V port Ec To tank cylinder [| Be0m control |L_L contot ever i 10-136-1 ®STRUCTURE AND FUNCTION HOSE BURST PROTECTION VALVE (BOOM) OPERATION BOOM RAISE During boom raising the pilot signal from wrist control operates control valve spool to direct high pressure oil to port V of hose burst valve. + This pressure lifts check valve (4) from seat & high pressure oil flows in the bottom of the cylinder raising the boom. V port ED To tank aon Boom control L\ control lever BOOM LOWER During boom lowering the pilot signal re- == verses the front through the control valve spool. High pressure oil flows to the head side of the cylinder. Oil in the bottom side of the cylinder flows through the port Cy of the valve but cannot flow past the check valve. The pilot signal also opens the spool (2) of the hose burst valve and allows oil to flow back to tank. Tpont ep To tank p | 10-136-2 20506k20506 STRUCTURE AND FUNCTION WORK EQUIPMENT WORK EQUIPMENT easeNe 2osroei2a Arm Bucket cylinder Arm cylinder Boom Boom cylinder Bucket 10-136-3 ®EEBM000501 EOP IMUAINTO ANIL KOMATSU PC210,210LC-6k PC240, 240LC, PC240NLC-6K MACHINE MODEL SERIAL NUMBER PC210, 210LC-6K K30001 and up PC240, 240LC, 240NLC-6K K30001 and up This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. + PC210, 210LC-6 mount the S6D102L-1 en; PC240, 240LC-6 mount the SA6D102L-1 1 For details of the engine, see the 102 Service Engine Shop Manual, © 1995 KOMATSU Al Rights Reserved Printed in Belgium 05-95.05002.SP01 00-110 20 30 40 00-2 CONTENTS No. of page STRUCTURE AND FUNCTION.. 10-1 TESTING AND ADJUSTING DISASSEMBLY AND ASSEMBLY . MAINTENANCE STANDARD................04 2050620506 ‘The affected pages are indicated by the use of the following marks. It is requested that necessary actions ‘must be taken to these pages according to thelist below. Mark Indication ‘Action required © | Page to be newly added add © | Page tobe reptaced Replace (1 | Page to be deleted Discard Pages having no marks are not revised at this time. LIST OF REVISED PAGES 00-1 00-2 00- 2-1 00- 2-2 00- 2-3 00-3 00-4 00-5 00-6 00-7 00-8 00-9 00-10 00-11 00-12 00-13 00-14 00-15 00-16 00-17 10-1 10-2 10-3 10-4 10-5 10-6 10-7 10-8 10-9 10-10 10-11 10-12 10-14 10-15 10-16 ‘number lInegee90008880090 ark Page REVO” Iwack Page Revition Intark Page Revition |mark Pape Revition © 1018 @ | o1s8 © | o 10987 @ | 0 10195 © 10-19 D 210-659 OD °o 10-98 @ © 10-136 @ © 10-20 @ 210-60 O o 10-99 @ © 10-138 @ o 02 @ | ows © | o 1100 @ | © 10139 © © 10-23 @O © 10-62 Oo 10-101 © o 10-140 @ 0 1024 @ | o16s @ | 0 10102 © | © 1044 © 0 1028 @ | ot06s @ | > 10103 @ | 0 10-142 © © 10-26 @ 010-65 @ oO 10-104 © © 10-1438 OD 0 1027 @ | ot06 @ | o 10105 @ | 0 10-144 © ° 10-28 «@ 010-67 @ © 10-106 O oO 10-146 OD ° 10-29 @ 010-68 = @ o 10-107 O o 10-147 © © 10-30 «@ 010-69 @ o 10-108 @O o 10-148 @ © 10-31 @ 010-70 © o. 10-109 O o 10-149 @ o 1032 @ | ot071 @ | o 10110 @ | 0 10-150 © o 133 @ | o1072 @ |o 10111 @ | o 10151 © ° 10-34 @ 010-73 O o 10-112 @ © 10-152 @ 01035 © | o174 @ | o 0-113 @ | 0 10453 @ o 103 @ | 01076 © | o 10-118 © | 0 10154 © © 10-38 «@ 010-77 @ oo 10-115 @O © 10-155 @ o 10-39 ® 010-78 @ © 10-1146 O o 10-156 @ o 10-40 @ 010-79 O ° 10-117 @ o 10-157 @ 0 10-41 @ | ot080 © | ° 118 © | o 10158 © 0 10-42 @ 010-81 © °o 10-119 © 10-159 O co 10-43 @ 01082 © ° 10-120 @ o 10-160 @ o 10-44 @ | oto @ | o 10121 © | 0 10161 © 0 10-45 0° 10-84 @ o 10-122 o 10-162 © 0 10-46 010-85 @ o 10-123 @ o 10-163 O 0 10-47 @ 010-86 «OD ° 10-124 @ o 10-164 OD 01048 @ | os © | o 12 © | o W185 © oss @ | oss © | o 112 @ | o 10-168 © 010-50 © | otoss @ | o 10127 @ | o 10-4167 © © 10-51 oO 010-90 @ oO 10-128 © o 10-168 OD 01052 @ 010-91 @ o 10-129 @ o. 10-169 @ 01053) 010-92 © o 10-130 O o 10-170 © 01054 0 10-93 O o 10-171 © 01055 @ 01094 @O o 10-172 O 010-56 DO 010-95 OD o 10173 © 01057) @O 010-96 =O o 10-174 © 00-2-1— Mark Page Revition Tiark Page Revision [er roe Tomer [Mark Page SEO" Intark Page Revision ° 10-175 20-47 20-95 20-148 20-208 © 10-176 @ 20-42 20-98 20-149 20-204 ° 10.177 20-43 20-97 20-150 20-205 © 10-178 @ 20-44 20-98 20-151 20-206 © 10-179 @ 20-45 20-99 20-153 20-208 © 10-180 © 20-46 20-100 20-154 20-209 © 10-181 © 20-47 20-101 20-185 20-210 © 10-182 @ 20-48 20-102 20-156 20-211 ° 10-183 @ 20-49 20-103 20-187 20-212 © 10-184 @ 20-50 20-104 20-158 20-213 o 10-185 @ 20-51 20-105 20-159 20-214 0 10-186 ® 20-53 20-108 20-160 20-215 20-54 20-107 20-161 20-216 20-1 20-55 20-108 20-162 20-217 20-2 20-56 20-109 20-163, 20-218 20-3 20-57 20-110 20-164 20-219 20-4 20-58 20-111 20-165 20-220 20-5 20-59 20-112 20-166 20-221 20-6 20-60 20-113 20-167 20-222 20-7 20-61 20-114 20-168 20-223 20-8 20-62 20-115 20-169 20-224 20-9 20-63 20-116 20-170 20-228 20-10 ° 2066 © 20-118 20-171 20-228 20-11 © 2065 © 20-119 20-172 20-227 20-12 206 © 20-120 20-173 20-228 20-13 © 20-67 ® 20-121 20-174 20-228 20-14 20-68 20-122 20-175 20-231 20-18 20-68 20-123, 20-176 20-232 20-16 20-70 20-124 20-177 20-233 20-17 20-71 20-128 20-178 20-235 20-18 20-72 20-126 20-180 20-236 20-19 20-73 20-127 20-181 20-237 20-20 20-74 20-128 20-182 20-238 20-21 20:75 20-129 20-183 20-239 20-22 20-76 20-130 20-184 20-240 20-23 20-77 20-131 20-185 20-281 20-24 20-78 20-132 20-186 20-242 20-25 20-79 20-133 20-187 20-243 20-26 20-80 20-134 20-188 20-244 20-27 20-82 20-135 20-189 20-245 20-28 20-83 20-136 20-190 20-246 20-29 20-84 20-137 20-191 20-247 20-30 20-85, 20-138 20-192 20-248 20-32 20-86 20-139 20-193 20-249 20-33, 20-87 20-140 20-194 20-250 20-34 20-88 20-141 20-195 20-251 20-35 20-89 20-142 20-196 20-252 20-36 20-90 20-143 20-197 20-253 20-37 20-91 20-148 20-198 20-254 20-38 20-92 20-145 20-199 20-255 20-39 20-93 20-146 20-201 20-256 20-40 20-147 20-287 pr 00-2-2 ® 2050620506 — via poe Retort rane ter [nn rane enter [an row een Juan row tor 70.358 aoa 30-700 7038 20.250 30-48 30-101 to? 20.260 30-49 30-102 40-38 20.261 30.80 30.108 40.39 20.262 30.81 30-104 toto 20.283 30.52 30.108 tout 30.53 30-108 a0 30-54 30-107 302 ae 30-108 303 20-56 30-109 a0 30-87 actin 308 30-58 sont 30-6 30-59 30.112 307 30-60 30.113 308 sot gota 30.9 30-62 30-115 30-10 30-63 30-116 30-11 30-68 son? 30.12 30-65 30.13 30-66 won acta ° 3087 toe 30-16 30-88 oa 30-17 © 3069 @ 40-4 30-18 30.70 tos 30.19 30.72 toe 30-20 o 30-73 @ ‘40-7 30-21 oo 30-74 @ 40-8 30.22 3 3075 tos 30.23 3 3078 nD 30-24 30-77 40-11 30-25 30.78 atte 30.26 30.79 tors 30-27 30-80 40-14 aad 3081 oe 30.29 30-82 on oO 30.30 30-83 oon 8 3031 30-88 ote} 30.32 30-85 Cite 8 30.33 30.86 oe 30-38 30.87 oa 30-35 30-88 tos 30.36 30-88 too 30.37 30-90 woe 30.38 30.81 aa 30.39 30.82 eae 30-40 30-93 too 30.41 30-98 fos 30.42 30-95, fo30 3043 30.96 os 30-44 3097 tose 30-45 30-98 tose 30.46 30-88 woos a 0-2-31020506 10 STRUCTURE AND FUNCTION Engine related parts... et Radiator « oil cooler + aftercooler Power train Final drive ‘Swing circle ‘Swing machinery . Track frame + recoil spring Track shoe : Hydraulic piping drawing .. Hydraulic circuit diagram Hydraulic tank. Hydraulic pump Control valve 2 3 4 5 6 7 8 9 n 2 4 6 38 a7 cis... ‘Swing motor... 0- 92 Center swivel j -10- 95 Travel motor 10- 96 Valve control... ‘Work equipment + swing PPC valve ... Travel PPC valve Service PPC valve Safety lock valve PPC accumulator PPC shuttle « travel junction valve EPC - solenoid valve... Hydraulic cylinder Additional filter for breaker... Overload warning device Work equipment. Electrical wiring diagram Electrical control system ... Engine control system Electronic control system Machine monitor system.. 10-105 10-106 1. 10-110 10-114 10-117 10-117 10-118 . 10-125 10-130 10-131 10-132 10-136 - 10-138, 10-145 10-149 - 10-154 10-179STRUCTURE AND FUNCTION ENGINE RELATED PARTS ENGINE RELATED PARTS BB cc DD 1. Drive plate OUTLINE 2. Torsion spring + The damper assembly is a wet type. 3. Stopper pin Oil capacity: 0.75¢ 4. Friction plate 5. Damper assembly 6. Air cleaner 7. Intake connector & Muffler 9. Rear engine mount 10. Front engine mount 10-2 2050620506 STRUCTURE AND FUNCTION RADIATOR «+ OIL COOLER + 1 2 3 4 PEN OMReNe AFTERCOOLER 5 6 Reservoir tank il cooler Radiator Fan Radiator inlet hose Radiator outlet hose Radiator cap Net Shroud RADIATOR - COOLER + AFTERCOOLER SPECIFICATIONS Radiator: CWX-4 Oil cooler: SF-3 10-3STRUCTURE AND FUNCTION POWER TRAIN POWER TRAIN 1. Idler 2. Center swivel joint 3. Control valve 4, Final drive 5. Travel motor 6. Hydraulic pump 10-4 ® 7. Engine 8, Travel speed solenoid vaive ‘9. Swing brake solenoid valve 10. Swing motor 11. Swing machinery 12. Swing circle 20506k20506 STRUCTURE AND FUNCTION FINAL DRIVE 3 rT) Fr] 12 FINAL DRIVE |. Level plug . Drain plug . No. 2 sun gear (No. of teeth: 12) . No. 1 sun gear (No. of teeth: 21) . No. 1 platetary carrier . Cover . No. 2 planetary carrier . Sprocket . Floating seal ). Travel motor |. Hub . No. 2 planetary gear (No. of teeth: 36) . Ring gear (No. of teeth: 84) . No. 1 planetary gear (No. of teeth: 31) ‘SPECIFICATIONS. Reduction ratio: — CE) x CS) + 1 = 39.000 20sca06012 10-5STRUCTURE AND FUNCTION SWING CIRCLE 1. Swing circle inner race (No. of teeth: 110) 2. Ball 3. Swing circle outer race a. Inner race soft zone position b. Outer race soft zone S position 10-6 2oscaosor SPECIFICATIONS Reduction ratio: 110 . 7.333 Amount of grease: 21¢ (G2-LI) SWING CIRCLE k2050620506 STRUCTURE AND FUNCTION SWING MACHINERY " 12 13 }—4 15 16 7 20sFosooe ‘SWING MACHINERY 1. Swing pinion (No. of teeth: 15) 2. Cover 3. Case 4. No, 2 of planetary carrier 5. No. 2 sun gear (No. of teeth: 15) 6. No. 2 ring gear (No. of teeth: 72) 7. Case 8. No. 1 ring gear (No. of teeth: 72) 9. No. 1 sun gear (No. of teeth: 21) 10. Swing motor I level gauge 12. Cover 13. No. 1 planetary gear (No. of teeth: 25) 14, No. 1 planetary carrier 15. Coupling 16. No. 2 planetary gear (No. of teeth: 28) 17. Drain plug SPECIFICATIONS Reduction ratio: 21472 ,, 15472 21 15 5.686 10-7‘STRUCTURE AND FUNCTION TRACK FRAME - RECOIL SPRING ‘* The diagram shows the PC210-6K. ‘TRACK FRAME + RECOIL SPRING Idler Track frame Carrier roller Final drive Track roller Track shoe Center guard Recoil spring Front guard PON OMPONS 10-8 ® 205cA06015| The dimensions and number of track rollers may differ according to the model, but the. basic structure is the same. No. of track rollers Model PC210-6K PC210LC-6K PC240-6K PC240LC-6K PC240NLC-6K No. of rollers (each side) 7 9 8 10 9 2050620506 STRUCTURE AND FUNCTION ‘TRACK SHOE TRACK SHOE ‘STANDARD SHOE Item Model! pczi0-6k_| PC2t0LC-6k | PC240-6K_| PC240LC-6K |PC240NLC-6K Shoe width (triple shoe) | 600mm | 700mm | 600mm | 700mm | 600mm Link pitch 190 mm 1gomm_ | 190mm | 190mm | 190mm No. of rollers (each side) 45 49 47 51 49 ‘SELECTION OF TRACK SHOE + Select the most suitable track shoe from the following table. PCHIO-GK POZTOLC-OK PozaoeK PCROLESK PORONLC-OK Mots! [Epeareaton] SES [Seciteton, GBR [Specticnion] GE [Soectcwion] SE% [Soectenion] SH standord | su" [ a | Oem | a | Same | | mm | a | RP Tw Option mam [ 8 | Mme |e | am | oe | Ome | Aw | Om | 8 Option me | c | Mmm | c = — | mr [ ic | Mme [ic ‘Option a = = = — | ar |e Option — [-- - e a e - Option =| = J-|] = [-7 - [-[ - [- Option -~| - [-[ = [-[T - [-T = [=STRUCTURE AND FUNCTION TRACK SHOE Precautions when using Travel in Lo speed when traveling on rough ground obstacles such as large boulders and fallen trees. Cannot be used on rough ground where there are large obstacles such as boulders and fallen trees. Travel in Hi speed only on flat ground, and when i impossible to avoid traveling obstacles, lower the travel speed to approx. half of Lo speed. Category Use ‘a | Rocky ground, normal river soil B | Normal soil, soft land | Extremely soft ground {swampy ground) Use only for ground where “A" and “B” sink and are impossible to use. Cannot be used on rough ground where there are large obstacles such as boulders and fallen trees. Travel in Hi speed only on flat ground, and when it is impossible to avoid traveling over obstacles, lower the travel speed to approx. half of Lo speed. * Categories “B" and “C” are wide shoes, so there are restrictions on their use. There- fore, before using, check the restrictions and consider carefully the conditions of use be- fore recommending a suitable shoe width. * When selecting the shoe width, select the narrowest shoe possible within the range that will give no problem with flotation and ground pressure. Ifa wider shoe than necessary is used, there if ;cessary, give the customer guidance in their use. 10-10 will be a large load on the shoe, and this may lead to bending of the shoe, cracking of the links, breakage of the pins, loosening of the shoe bolts, or other problems. 20506STRUCTURE AND FUNCTION HYDRAULIC TANK HYDRAULIC TANK Hydraulic tank Bypass valve Oil fitter cap Sight gauge Hydraulic oil level sensor Suction strainer Filter element NOOPOND 10-14 7 Pce10-Kost SPECIFICATIONS Tank capacity: 2300 Amount of oil inside tank: 166 Pressure valve Relief cracking pressure: 0.017 + 0.004 MPa (0.17 + 0.04 kg/cm’) Suction cracking pressure: 0 ~ 0.0005 MPa (0 - 0.005 kg/cm’) Bypass valve set pressure: 0.103 + 0.02 MPa (1.05 + 0.2 kg/cm’) 2050620506 STRUCTURE AND FUNCTION HYDRAULIC PUMP Pump drain port PDF Front delivery port PAF Rear delivery port PAR Control pump suction port PGS Control pump delivery port PGA Front LS pressure port PLSF ar LS pressure port PLSR control EPC pressure port PSIGR i, Main pump suction port PS j. LS control EPC pressure port PSIGF e@seacge PRaeNe HYDRAULIC PUMP |. Front main pump . Rear main pump Control relief valve Rear TVC-LS valve 3. Front TVC+LS valve Control pump 10-15STRUCTURE AND FUNCTION 1. MAIN PUMP (HPV95+95) Pump drain port PDF Front delivery port PAF Rear delivery port PAR Front control pressure PENF Rear delivery pressure port PAR Front delivery pressure port PAZF Rear delivery pressure port PAIR Rear control pressure port PENR Suction port PS Front delivery pressure port PAIF vrpesseege 10-16 oO HYDRAULIC PUMP 208F 05006 20506,20506 STRUCTURE AND FUNCTION HYDRAULIC PUMP OPERATION 1. Operation of pump 1) Cylinder block (7) rotates together with shaft (1), and shoe (5) slides on flat sur- \ face A. \ When this happens, rocker cam (4) moves along cylindrical surface B, so angle « between center line X of rocker = cam (4) and the axial direction of cylin- 7 der block (7) changes. (Angle «is called the swash plate angle.) 2) Center line X of rocker cam (4) mai tains swash plate angle « in relation to the axial direction of cylinder block (7), 8 205F06009 and flat surface A moves as a cam in relation to shoe (5). In this way, piston (6) slides on the in- side of cylinder block (7), so a differ- ence between volume E and Fis created inside cylinder block (7). The suction and discharge is carried out by this differ- ence F-E. In other words, when cylinder block (7) rotates and the volume of chamber E becomes smaller, the oil is discharged during that stroke. On the other hand, the volume of chamber F becomes larger, and as the volume becomes big- ger, the oil is sucked in, 3) If center line X of rocker cam (4) is in 205F06010 line with the axial direction of cylinder block (7) (swash plate angle = 0), the ifference between volumes E’ and F” inside cylinder block (7) becomes 0, so ‘the pump does not carry out any suc- tion or discharge of oil. (In actual fact, the swash plate angle never becomes 0) _208F06011 10-17, ®STRUCTURE AND FUNCTION 2. Control of discharge amount + If swash plate angle a becomes larger, the difference in volumes E and F becomes larger and discharge volume Q increases. + Swash plate angle o: is changed by servo piston (12), + Servo piston (12) moves in a reciprocal movement (c+) according to the command from the TVC*LS vaive. + This straight line movement is transmitted through rod (13) to rocker cam (4), and rocker cam (4), which is supported by the cylindri- cal surface to cradle (2), moves in a swing- ing movement on the cylindrical surface in (Cdirection) 10-18 HYDRAULIC PUMP 205F06012 With servo piston (12), the area receiving the pressure is different on the left and right, so main pump discharge pressure (self-pres- sure) PP is always connected to the cham- ber receiving the pressure on the small di- ameter piston side (the self-pressure is brought in). Output pressure PEN of the LS valve is brought to the chamber receiving the pres- sure at the large diameter piston end. The relationship in the size of self-pressure PP and the pressure at the small diameter piston end, and the ratio between the area receiving the pressure of the small diameter piston and the large diameter piston con- trols the movement of servo piston (12). 2050620506 STRUCTURE AND FUNCTION HYDRAULIC PUMP 20806007 7. Cylinder block 8. Valve plate 9. End cap 10. Rear shaft 11. Rear case 6. Piston 12. Servo piston 10-19 ®STRUCTURE AND FUNCTION HYDRAULIC PUMP oS = é Ey Ee) ae Sarees la a Spline A 2 Spline 20506008 FUNCTION + The engine rotation and torque transmitted to the pump shaft is converted into hydrau- lic energy, and pressurized oil is discharged according to the load. + It is possible to change the delivery amount by changing the swash plate angle. ‘STRUCTURE + Cylinder block (7) is supported to shaft (1) by a spline, and shaft (1) is supported by the front and rear bearings. + The tip of piston (6) is a concave ball, and shoe (5) is caulked to it to form one unit. Piston (6) and shoe (5) form a spherical bear- ing. + Rocker cam (4) has flat surface A, and shoe (5) is always pressed against this surface while sliding in a circular movement. + Rocker cam (4) brings high pressure oil at cylindrical surface B with cradle (2), which is secured to the case, and forms a static pres- sure bearing when it slides. 10-20 ® Piston (6) carries out relative movement in the axial direction inside each cylinder cham- ber of cylinder block (7). The cylinder block seals the pressure oil to valve plate (8) and carries out relative rota- tion. This surface is designed so that the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cyl- Inder block (7) is sucked in and discharged through valve plate (8). K20506STRUCTURE AND FUNCTION 2. TVC+LS VALVE HYDRAULIC PUMP. a. Port PA2 (Pump delivery pressure inlet port) b, Port PEN (TVC:LS valve signal pressure outlet port) ¢, Port PA1 (Pump delivery pressure inlet port) 10-22 |. Port PLS (Control valve LS pressure inlet port) Port PSIG (LS control EPC valve pressure inlet port) 2050620506 ‘STRUCTURE AND FUNCTION HYDRAULIC PUMP LS VALVE ‘TVC VALVE 1. Locknut 8. Solenoid 2. Plug 9. Piston 3. Spring 10. 4. Spool 1 5. Sleeve 2 6. Piston 8. 7. Plug 14. 15. Valve body 10-23STRUCTURE AND FUNCTION FUNCTION 1 LS VALVE The LS valve detects the load and controls the discharge amount. This valve controls main pump discharge amount Q according to tial pressure 4 PLS (= PP - PLS) (the difference between main pump pressure PP and control valve outlet port pressure PLS) (called the LS dif- ferential pressure). Main pump pressure PP, pressure PLS (called the LS pressure) coming from the control valve output, and pressure PSIG (called the LS selection pressure) from the proportional solenoid valve enter this valve. The relation- ship between discharge amount Q and dif- ferential pressure A PLS, (the difference be- tween main pump pressure PP and LS. pres- sure PLS) (= PP - PLS) changes as shown in the diagram on the right according to LS selector pressure PSIG. When PSIG changes between 0 and 2.94 MPa (0 and 30 kg/cm*), the spool load changes according to this, and the selector point for the pump discharge amount changes at the rated central value between 0.64 and 2.11 MPa (6.5 and 21.5 kg/cm’). ‘TVC VALVE When the pump discharge pressure PP1 (self- pressure) and PP2 (other pump pressure) are high, the TVC valve controls the pump so that no more oil than the constant flow (in accordance with the discharge pressure) flows even if the stroke of the control valve becomes larger. In this way it carries out ‘equal horsepower control so that the horse- power absorbed by the pump does not ex- ceed the engine horsepower. In other words, if the load during the opera- tion becomes larger and the pump discharge pressure rises, it reduces the discharge amount from the pump; and if the pump discharge pressure drops, it increases the discharge amount from the pump. The rela- tionship between the average of the front and rear pump discharge pressures (PP1 + PP2)/2 and pump discharge amount Q is shown on the right, with the current given to the TVC valve solenoid shown as a pa- rameter. However, in the heavy-duty opera- tion mode, there are cases where it is given the function of sensing the actual speed of the engine, and if the speed drops because 10-24 o HYDRAULIC PUMP. PSIG ~ 2.96 MPa (20 kglem*) PSIG = 0 MPa (0 kglem) Pump discharge amount @ DEES) 217 BTS) MPa glee) LS differential pressure PLS 18a 4A 7a Pump discharge amount Q Pump discharge pressure PP z05F06018 of an increase in the load, it reduces the pump discharge amount to allow the speed to recover. In other words, when the load increases and the engine drops below the set value, the command to the TVC valve solenoid from: the controller increases ac- cording to the drop in the engine speed to reduce the pump swash plate angle, k2050620506 STRUCTURE AND FUNCTION HYDRAULIC PUMP OPERATION eae a a PSIG : : ; Li ; ry CTT if =p = 44 a) ‘Small ciameter end 8 (Direction of minimum dischergel + The LS valve is a three-way selector valve, with pressure PLS (LS pressure) from the outlet port of the control valve brought to spring chamber “% charge pressure of plug (6). The "and main pump brought to chamber *j e of this LS pressure PLS + force F of spring (3) and the main pump pressure (self- pressure) PP determines the position of spool (4). However, the size of the output pressure PSIG (the LS selection pressure) of the EPC valve for the LS valve entering port "e" also changes the position of spool (4). (The set pressure of the spring changes.) + Before the engine is started, servo piston (1) is pushed to the right by spring (7) installed to rod (2). (See the fiagram on the right) + When the engine is started and the control lever is at the neutral position, LS pressure PLS is 0 MPa (0 kg/cm’). (It is interconnected with the drain circuit through the contro! valve spool.) Large diameter end 205F06019 -208F06020 At this point, spool! (4) is pushed to the left, and port “d” and port “e” are connected. Pump pressure PP enters the large diameter end of the piston from port “h”, and the same pump pressure PP also enters the small diameter end of the piston, so the swash plate is moved to the minimum angle by the difference in area of piston (1). 10-25STRUCTURE AND FUNCTION 2) Operation in maximum discharge amount HYDRAULIC PUMP. TWe valve (from outlet port of (from LS controt ai control valve) EPC valve) PLS PSIG = PP iS 4 » e tal 7 a f éild cq 20506 [ol tT yz malt diameter end ff \y Large diameter end (Direction of maximum discharge) + When the difference between main pump + pressure PP and LS pressure PLS, in other words, LS differential pressure APLS, be- ‘comes smaller (for example, when the area of opening of the control valve becomes larger and pump pressure PP drops), spool (4) is pushed to the right by the combined force of LS pressure PLS and the force of spring (3). . + When spool (4) moves, port “b” and port “¢" are joined and connected to the TVC valve. When this happens, the TVC valve is Connected to the drain port, so circuit “e” - “h" becomes drain pressure PT. (The opera- tion of the TVC valve is explained later.) 10-26 @ 205F06021 For this reason, the pressure at the large piston diameter end of servo piston (1) be- ‘comes drain pressure PT, and pump pres- sure PP enters the small diameter end, so ‘servo piston (1) is pushed to the right. There- fore, rod (2) moves to the right and moves the swash plate in the direction to make the discharge amount larger. If the output pressure PSIG of the EPC valve for the LS valve enters port “e”, this pres- sure creates a force to move piston (5) to the left. If piston (5) is pushed to the left, it acts to make the set pressure of spring (3) ‘weaker, and the difference between PLS and PP changes when ports “b” and “e” of spool (4) are connected.20506 STRUCTURE AND FUNCTION HYDRAULIC PUMP 3) Operation in minimum direction for pump discharge amount trom outlet port of from LS control control valve) EPC valve! Te valve 9 ‘Small diameter end Lerge diameter end {Direction of minimum discharge) The following explains the situation if servo piston (1) moves to the left {the discharge amount becomes smaller). When LS differ- ential pressure A PLS becomes larger (for example, when the area of opening of the control valve becomes smaller and pump pressure PP rises), pump pressure PP pushes spool (4) to the left. When spool (4) moves, main pump pressure PP flows from port "d" to port "e", and from port “h', it enters the large piston diameter end. 20806022 ‘Main pump pressure PP also enters the small piston diameter end, but because of the dif ference in area between the large piston di ameter end of servo piston (1) and the small piston diameter end, servo piston (1) is pushed to the left. As a result, rod (2) moves in the direction to make the swash plate angle smaller. IFLS selection pressure PSIG enters port "e", it acts to make the set pressure of spring (3) weaker. 10-27STRUCTURE AND FUNCTION 4) When servo piston balanced (from outer port of control valve) EPC valve) ee Psi HYDRAULIC PUMP (from LS control TVC vaive [ Orr Pon eee |e oe | Area receiving pressure At PEN EA wea [UY si 2 + Let us take the area receiving the pressure at the large piston diameter end as At, the area receiving the pressure at the small di- ameter end as AQ, and the pressure flowing into the large piston diameter end as PEN. If the main pump pressure PP of the LS valve and the combined force of force F of spring (3) and LS pressure PLS are balanced, and the relationship is AO x PP = A1 x PEN, servo piston (1) will stop in that position, and the swash plate will be kept at an intermediate position. (It will stop at a position where the ‘opening of the throttle from port "b" to port “c" and from port “d to port “c” of spool (4) is approximately the same. At this point, the pressure of port “e" is approx. 1/2 pump pres- sure PP.) 10-28 Largo diameter ond 20sF06023 At this point, the relationship between the area receiving the pressure at both ends of piston (1) is AO:A1 = 1:2, so the pressure applied to both ends of the piston when it is balanced becomes PP:PEN # 2:1. The posi- jon where spool (4) is balanced and stopped is the standard center, and the force of spring (3) is adjusted so that it is determined when PP — PLS = 2.11 MPa (21.5 kg/cm’), However, if PSIG (the output pressure of 0 - 2.94 MPa {0 - 30 kg/cm’) of the EPC valve of the LS valve) is applied to port “e*, the balance stop position will change in proportion to pres- sure PSIG between PP - PLS = 2.11 ~ 0.64 MPa (21.5 - 6.5 kg/cm’). k2050620506 STRUCTURE AND FUNCTION ‘TVC VALVE When pump controller is normal HYDRAULIC PUMP PPI PP2 MH i PT iS valve . a : - | ’ 1 So co 6 5 0 347 10 21 Ty all dametes endl 8 Of Ul Lage ciomete ona eoseeacen irction of maximum dschrga eM) Pump controler TVC prolix Ee a * Other pump pressure t atry [I This is the pressure of 2ase06024 on the pump at the oppo- When the load on the actuator is small and pump pressures PP1 and PP2 are low + Movement of solenoid (1) ‘Command current X from the pump control- ler flows to solenoid (1). This command cur- rent changes the internal force pushing so- lenoid push pin (11). On the opposite side to the force pushing this solenoid push pin (11) is the spring set pressure of springs (3) and (4) and pump Pressure PP1 and other pump (see *) pres- sure PP2. Piston (2) stops at a position where the combined force pushing piston (2) is balanced, and the pressure (pressure of port “¢") output from the TVC valve changes ac- cording to this position. sites end. For the Front pump, it is the Rear pump pressure. For the Rear pump, it is the Front pump pressure. The size of command current X is deter- mined by the nature of the operation (lever operation), the selection of the working mode, and the set value and actual value for the engine speed. 10-29STRUCTURE AND FUNCTION (2) Movement of spring + The spring load springs (3) and (4) in the TVC valve is determined by the swash plate position + When servo piston (9) moves, cam (7), which is connected to rod (8), also moves. When this happens, lever (6) is rotated by the angle of cam (7), and piston (5) moves to the right and left. + If piston (5) moves to the right, spring (3) is compressed, and if it moves further to the right, spring (4) contacts seat (10), so both spring (3) and spring (4) function. In other words, the spring load is changed by piston () extending or contracting springs (3) and @. + lf command current X input to solenoid (1) ‘changes further, the force pushing solenoid push pin (11) changes, and the spring load of springs (3) and (4) also changes accord- ing to the value of the solenoid command current. + Port “c" of the TVC valve is connected to port “e” of the LS valve (see 1. LS valve). Self pressure PP1 enters port “b” and the small piston diameter end of servo piston (9), and the other pump pressure enters port ta", + When pump pressures PP1 and PP2 are ‘small, piston (2) is on the right. At this point, port “c” and port “d" are connected, and the pressure entering the LS valve becomes drain pressure PT. If port “h” and port “e” of the LS valve are connected (see 1. LS valve), the pressure entering the large pis- ton diameter end from port “f” becomes drain pressure PT, and servo piston (9) moves to the right. In this way, the pump discharge amount moves in the direction of increase. 10-30 @ HYDRAULIC PUMP As servo piston (9) moves further, piston (5) is moved to the left by rod (8), cam (7), and lever (6). Springs (3) and (4) expand and the spring force becomes weaker. When the spring force becomes weake, piston (2) ‘moves to the left, so the connection between port “e” and port “d” is cut, and the pump discharge pressure is connected to port “b”. As a result, the pressure at port “c” rises, and the pressure at the large piston diam- eter end also rises, so the movement of pis- ton (9) to the right is stopped. In other words, the stop position for piston (9) (= pump dis- charge amount) is deceded at the point where the force of springs (3) and (4) and the pushing force from the solenoid and the pushing force created by pressure PP1 and PP2 acting on piston (2) are in balance. 2050620506 STRUCTURE AND FUNCTION PPI PP2, HYDRAULIC PUMP 1s vave co 6 5 pf [4a fo 2 TF KN Ismail diameter endl 3 pert re ws —P b, When load on actuator is small and pump discharge pressure is high + When the load is large and pump discharge pressures PP1 and PP2 are high, the force pushing piston (2) to the left becomes larger and piston (2) moves to the position shown in the diagram above. + When this happens, as shown in the die- ‘gram above, part of the pressurized oil form Port "b" flows out to port "d” and the pres- surized oil flowing from port “c" to the LS valve becomes approximately half of main pump pressure PP1. When port "h' and port "e" of the LS valve are connected (see 1. LS valve), the pres- sure from port “f" enters the large piston diameter end of servo piston (9), and servo piston (9) stops. ff main pump pressures PP1 and PP2 in- crease further and piston (2) moves further to the left, main pump pressure PP1 flows to port "e" and acts to make the discharge amount the minimum. When piston (9) moves to the left, piston (5) is moved to the right by cam (7) and lever (6). For this reason, springs (3) and (4) are ‘compressed and push back piston (2). Be- cause of this force, piston (2) cuts off the connection from port “b" to port “e', and port “e' and port “d* are connected. As a result, the pressure at port "c" (= "") drops, and piston (9) stops moving to the left. The position in which piston (9) stops when this happens is further to the left than the posi- tion when pump pressures PP1 and PP2 are low. 10-31 ®STRUCTURE AND FUNCTION HYDRAULIC PUMP. + The relation of pump pressures PP1 + PP2 and the position of servo piston (9) forms a bent line because of the double-spring ef- fect of springs (3) and (4). The relationship between pump pressures PP1 + PP2 and pump discharge amount Q is shown in the figure on the right. + if command voltage x sent to solenoid (1) increase further, the relationship between pump pressures PP1 and PP2, and pump discharge amount Q is proportional to the pushing force of the solenoid and moves in parallel. In other words, if the pushing force of solenoid (1) is added to the force pushing to the left because of the pump pressure applied to the piston (2), the relationship between PP and Q moves from A to B in accordance with the increase in x 10-32 PP1+PP2 ‘208F06027 B be large) 20srosoze 2050620506 STRUCTURE AND FUNCTION HYDRAULIC PUMP 2) When pump controller is abnormal and TVC prolix switch is ON 6 $0347] [fo 2a small diameter ena] 9 Bon 8 Ff (Direction of maximum discharged fH Battery _205F06029 esisor ‘a, When load on main pump is light + If there is a failure in the pump controller, turn TVC prolix switch ON to switch to the resistor side. In this case, the power source is taken directly from the battery. But if the current is used as itis, itis too large, so use the resistor to control the current flowing to solenoid (1), + When this is done, the current becomes con- stant, so the force pushing solenoid push pin (11) is also constant. + If main pump pressures PP1 and PP2 are low, the combined force of the pump_pres- sure and the force of solenoid (1) is weaker than the spring set force, so piston (2) is balanced at a position to the right. Large diameter end Pump controller TVC prox OFF switen ‘At this point, port “e" is connected to the drain pressure of port "d", and the large pis- ton diameter end of servo piston (9) also becomes the drain pressure PT through the LS valve. When this happens, the pressure at the small piston diameter end is large, so servo piston (9) moves in the direction to make the discharge amount larger. 10-33STRUCTURE AND FUNCTION PPt PP2) mM eT Swale | » ‘ 1 5 os Fart 43 fo 201 (Deecton of minimum sscharse) Pump conolr TVG poli Ore witch ip ea fon Taito esto b. When main pump load is heavy Q\ + In the same way as in the previous item, when the TVC prolix switch is ON, the com- mand current X sent to solenoid (1) becomes constant. For this reason, the force of sole- noid push pin (11) pushing piston (2) is con- stant. + If main pump pressures PP1 and PP2 in- crease, piston (2) moves further to the left than when the main pump load is light, and is balanced at a position towards the left. + Inthis case, the pressure from port “b” flows to port “e”, so servo piston (9) moves to the left (to make the discharge amount smaller) by the same mechanism as explained in Item 2.1)-b. In other words, even when the TVC prolix switch is ON, the curve for the pump pressure P and discharge amount Q is de- termined es shown in the diagram for the 10-34 ® HYDRAULIC PUMP. zosrosozs _-A (when controlier is ormal, x email value of the current sent to the solenoid through the resistor. The curve when the TVC prolix switch is ON is curve B, which is to the left of curve A for when the pump controller is normal. 2050620506 STRUCTURE AND FUNCTION 3. CONTROL PUMP (BAR-016) HYDRAULIC PUMP. Ga oO a Ks b cr 2osrocora 1. Body ‘SPECIFICATIONS 2. Driven gear Type: BAR- 016 3. Housing Theoretical delivery: 16.0 cc/rev 4. Drive gear Max. delivery pressure: 3.23 MPa (33 kg/cm?) 5. Relief valve 6. Filter a. Suction port b. Delivery port 10-35‘STRUCTURE AND FUNCTION RELIEF VALVE \ 2 y \ 5 8 \ \ | ~ oo = Sous: ee FUNCTION ‘The relief valve is assembled in the body of the control pump, and when the PPC valve is at neutral, the oil sent from the pump is relieved through this valve. (It sets the maximum. pres- sure in the circuit during operations.) OPERATION + Chamber A is the pump circuit and chamber Cis the drain circuit. The oil passes through the orifice in the main valve and fills cham- ber B. +f any abnormal pressure is generated, and the differential p ressure [n/4(D2 - d2) x pres- sure of chamber A] created by the differ- ence in the area of “d” and diameter D reaches the pressure set by the main valve spring, the main valve opens, and the oil in chamber A is released to chamber C. This suppresses the rise in the pressure in cham- ber A. 10-36 rn HYDRAULIC PUMP Adjustment screw Locknut Sleeve valve spring Pilot piston Main valve oaPeNe Set pressure: 3.33 MPa (34 kg/cm®) (at 33 g/min) oaiKris2 20506STRUCTURE AND FUNCTION CONTROL VALVE CONTROL VALVE 9-SPOOL VALVE (STANDARD + 3 SERVICE VALVE) 8 uu + @), ee f/f VV \ VA pb pd ff pf ph 99 pj pl pn PP pr 10-38 k2050620506 STRUCTURE AND FUNCTION 6-spool valve Cover 1 Cover 2 Pump merge-divider valve ‘Arm counterbalance valve No. 1 Service valve No. 2 Service valve No. 3 Service valve PASM ERONa Port PP1 (from rear main pump) Port PP2 (from front main pump) Port A6 (to arm cylinder head) Port BG (to arm cylinder bottom) Port AB (to LH. travel motor) Port B5 (to LH. travel motor) Port Aé (to swing motor) Port B4 (to swing motor) Port A3 {to boom cylinder bottom) Port B3 (to boom cylinder head) Port A2 (to RH, travel motor) Port B2 (to R.H. travel motor) Port A1 (to bucket cylinder head) Port B1 (to bucket cylinder bottom) Port A-1 (to attachment) Port B-1 (to attachment) Port A-2 (to attachment) Port B-2 (to attachment) Port A-3 (to attachment) Port B-3 (to attachment) Port T (to tank) Port T1 (to travel junction valve) Port T2 (to travel junction valve) Port T3 (to travel junction valve) Port Té (to travel junction valve) pose one prepopgrarcse xgser CONTROL VALVE OUTLINE This control valve consists of the 6-spool valve (an integrated composition) and 3 serv- ice valves. The pump merge-divider valve and arm counterbalance valve are installed to this. Each vaive forms one unit with the connec- tion bolt, and the passages are internally connected, so the structure is compact and is very easy to service. This control valve consists of one spool for one item of the work equipment, so it has @ simple structure. . Port PLS1 (to rear pump control) Port PLS2 (to front pump control) 9. Port TS (to tank) Port PS (from solenoid valve) |. Port BP (from solenoid valve) . Port PX (from solenoid valve) . Port P12 (from arm PPC/EPC valve) Port P11 (from arm PPC/EPC valve) . Port P10 (from L.H. travel PPC valve) . Port P9 (from LH. travel PPC valve) . Port PB (from swing PPC/EPC valve) f. Port P7 (from swing PPC/EPC valve) . Port P6 (from boom PPC/EPC valve) . Port PS (from boom PPC/EPC valve) Port P4 (from R.H. travel PPC valve) . Port P3 (from R.H. travel PPC valve) . Port P2 (from bucket PPC/EPC valve) |. Port P1 (from bucket PPC/EPC valve) pm Port P-2 (from service PPC valve) pn. . Port P-4 (from service PPC valve) Pp. Pa. po. pr. ff. 99. hh. kk. Port P-1 (from service PPC valve) Port P-3 (from service PPC valve) Port P-6 (from service PPC valve) Port P-5 (from service PPC valve) Port SA (pressure sensor mount port) Port SB (pressure sensor mount port) Port BP3 (from travel PPC) Port BP2 (from arm PPC) 10-39 @STRUCTURE AND FUNCTION MAIN STRUCTURE KK 4 1. Spool (arm) 2. Spool (LH. travel) 3. Spool (swing) 4. Spool (boom) 5, Spool (RH. travel) 6. Spool (bucket) 7. Spool (service 1) 8. Spool (service 2) 10-40 CONTROL VALVE 13 ew ot in 10. nN. 12. 13. 14. 15. . Spool (service 3) Spool return spring Main unload « LS relief valve Main relief valve (bucket end group) ‘Sub-unload valve (bucket end group) Main relief valve (arm end group) Sub-unload valve (arm end group) 2050620506 STRUCTURE AND FUNCTION CONTROL VALVE Mem, |. LS shuttle valve LS select valve 1 2 3. Pump merge-divider valve (for main) 4, Return spring 5. Pump merge-divider valve (for LS) 6. Return spring 7. LS bypass valve 10-41STRUCTURE AND FUNCTION Pressure compensation valve Safety-suction valve Check valve for arm regeneration circuit ‘Arm counterbalance vaive Suction valve Check valve for boom regeneration cir ogrens 10-42 CONTROL VALVE 2050620506 STRUCTURE AND FUNCTION CONTROL VALVE 6-SPOOL VALVE (STANDARD) For details of the names of the ports and the main structure, see 9-SPOOL VALVE. 10-43 ®oSTRUCTURE AND FUNCTION CONTROL VALVE 7-SPOOL VALVE (STANDARD + 1 SERVICE VALVE) For details of the names of the ports and the main structure, see 9-SPOOL VALVE. 1 i q 10-44 2050620506 STRUCTURE AND FUNCTION CONTROL VALVE 8-SPOOL VALVE (STANDARD + 2 SERVICE VALVE) For details of the names of the ports and the main structure, see 9-SPOOL VALVE. f VL \\N pb pd pf ff 4 99 PNpiPe pm PP y x / bb. 10-45‘STRUCTURE AND FUNCTION SAFETY-SUCTION VALVE FOR SERVICE VALVE CONTROL VALVE |. Suction valve 1 2. 3. 4. 5. Poppet 6. Poppet spring 7 8. 9. 0. f = p . Suction valve spring i = b , Sleeve Y ry . Adjustment screw ; 10. Locknut osro6ose Part No. Set Pressure Use 709-70-74600 24.5 MPa (250 kglem) at & &/min For crusher (Okada) 10-46 @ 2050620506 STRUCTURE AND FUNCTION cLSS OUTLINE OF CLSS cuss Contr valve 1] rv vatve ' ' ' ' ' ' ' ' 1 ' ' T ' t t 1 u Ls valve b}-—— A t 1 i 1 1 1 L Iservo pistor} Features v 2) 3) 4) CLSS stands for Closed center Load Sens- ing System, and has the following features. Fine control not influenced by load Control enabling digging even with fine con- trol Ease of compound operation ensured by flow divider function using area of opening of spool during compound operations. Energy saving using variable pump control 20sr06o39 Structure The CLSS consists of a main pump (2 pumps), control valve, and actuators for the work equipment. ‘The main pump body consists of the pump itself, the TVC valve and LS valve. 10-47STRUCTURE AND FUNCTION cuss BASIC PRINCIPLE 1) Control of pump swash plate angle The pump swash plate angle (pump discharge amount) is controlled so that LS differential pressure APLS is constant. LS differential pressure APLS, which is the differential pressure between pump discharge pressure PP and LS pressure PLS (actuator load pressure) at the outlet port of the control valve (LS differential pressure APLS = Pump discharge pressure PP — LS pressure PLS) + IFLS differential pressure APLS becomes lower than the set differential pressure of the LS valve, the pump swash plate angle becomes greater, and if it becomes higher, the pump swash plate angle becomes smaller. Actuator Max. ° ee : a 4 3 in é Pump passoge—~ | 1! Ls passage 202rosoeo Max 1 ‘ I Servo ' paon ty 4 ans tt 4 " 1S valve i \ ad] Dirt err sant Diterenil pressure U1 Smal tow) IVC valve oy ‘small caren Ty tarae current Gio 2o2r060s9 10-48 2050620506 STRUCTURE AND FUNCTION 2 Pressure compensation ciss A valve (pressure compensatin valve) is installed to the outlet port side of the control valve to balance the load. ‘When there is compound operation of the actuators, this valve acts to make pressure difference AP constant for the upstream flow (inlet port) and downstream flow (outlet port) of the spool of each valve. In this way, the flow of oil from the pump is divided in proportion to area of opening S1 and $2 of each valve. Load w ‘Actuator ‘Actuator Pressure compensa. Pressure compensa tion waive oP 20206061 10-49STRUCTURE AND FUNCTION OPERATION FOR EACH FUNCTION OF CLSS. Hydraulic circuit diagram for system 10-50 ® k2050620506 STRUCTURE AND FUNCTION 1. Main unload valve 2. LS relief valve 3A. Main relief valve (group at bucket end) 3B. Main relief valve (group at arm end) 4A. Sub-unload valve (group at bucket end) 48. Sub-unload valve (group at arm end) 5, Bucket spool 6. Pressure compensation valve 7. Safety-suction valve 8, LS shuttle valve 9. RH. travel spool 10. Suction valve 11. Boom spool 12. Check vaive (for boom regeneration circuit) 13. Swing spool 14. LH. travel spool 15, Arm spool 16. Arm counterbalance valve 17. Check valve (for arm regeneration circuit) 18. LS select valve 19. Pump merge-divider valve To bucket cylinder To RH. travel motor To boom cylinder To swing motor To LH. travel motor To arm cylinder To travel junction valve To travel junction valve ZOMMOOwD> ciss 10-51 @oSTRUCTURE AND FUNCTION ciss SYSTEM DIAGRAM * This shows actuator (6A) and the stroke end relief in the merge mode. 1A Main pump 18. Main pump 2A. Main relief valve (for power max.) 2B. Main relief valve (for power max.) 3A. Sub unload valve 3B. Sub unload valve 4. Pump merge-divider valve 5A. Control valve 5B. Control valve 10-52 ® 6A. Actuator 6B. Actuator 7A. Check valve 7B. Check valve 8, Pump passage 9. LS circuit 10. Tank passage 11. Valve 12. Spring 2osFoso43 13, Piston 14. Clearance filter 15. Poppet 16. Spring 17. Piston 18. Piston 19. Piston 20. LS bypass valve 2050620506 STRUCTURE AND FUNCTION cuss 1. Main unload valve + LS relief valve 1), When main unload valve is actuated \ 10 . i > 1 a 18 as o AL /, “f L \ 15 da ds PXY PAR PAF 2osFosota Function Operation + When all the control valves are at neutral, the oil discharged when the pump is at the minimum swash plate angle is drained. When this happens, the pump pressure be- comes a pressure that matches the set load of spring (12) inside the vaive (P1 pressure): The LS pressure is drained from LS bypass valve (20), so LS pressure = tank pressure = 0 MPa (0 kg/cm’). + When operated (for operations in the dis- charge range for the minimum swash plate angle), the discharge pressure of the oil dis- charged with the pump at the minimum swash plate angle is LS pressure + P1 pres- sure. In other words, the LS control differen- tial pressure (APLS) of the oil discharged at the minimum swash plate angle is the P1 pressure. The pressure in pump passage (8) is received by area di at the end face of the valve and area d2 at the end face of piston (13). The pressure in LS circuit (9) is drained to the tank from LS bypass vaive (20), so LS pres- sure 0 MPa (0 kg/cm?) There is no way for the pressurized oil dis- charged by the pump to escape, so the pre: sure in pump passage (8) rises. This pres- sure acts on surface differential portion At between area d1 at the end face of the vale and area d2 at the end face of piston (13), and this is received by force F1 of spring (12) (condition: d1 > d2). Therefore, if pas- sage pressure P1 x area difference Al > spring force F1, the valve is pushed to the right, and the pressurized oil flows from the valve to tank passage (10). The LS differential pressure (pump discharge pressure ~ LS circuit pressure) is greater than the pump LS control pressure at the time of the unload operation, so a signal is sent to move the pump swash plate in the direction of the minimum angle. 10-53 ®STRUCTURE AND FUNCTION cLss 2) At LS relief (standard mode relief, cut-off control) 20 0 D zi zi = — 16 a aon ns | : im t \ ‘ A d@ Bg m4 6 ds f5 da dS XY 7m” 78 PAR PAF ose0e04s Function + When the control valve is actuated, the maxi- mum pressure in LS circut (9) is controlled to the specified pressure (the specified maxi- mum pressure for the pump circuit). That is, the cut-off control is carried out. Operation (1) When the control vale is operated, the LS pressure passes through throttle $1 of spool (GA) and is sent to LS circuit (9). This LS Pressure goes from clearance filter (14) through orifice B to spring chamber (12). Part also goes through orifices C and D, and the poppet end portion d3, and is sent to end portion d4 of piston (17). Piston (19) acts as a stopper for piston (17). Therefore, the LS pressure is applied to area difference ‘A2 between area d3 at the end of the poppet and area dé at the end of the piston, and this is received by force F2 of spring (16) (condition: d3 > d4). (2) When LS pressure rises, and the condition becomes LS pressure x area difference A2 > force F2 of spring (16), the poppet moves to the right and seat E opens. As a result the 10-54 o pressurized oil in LS circuit (9) passes through the notched groove in the outside circumference of poppet (15) and flows to tank passage (10). * Clearance filter (14) is set to diameter clear- ance < orifice diameter, and prevents the entry of dirt which might block the orifice. Pump circuit pressure (3) When the pressurized oil in LS circuit (9) flows to tank passage (10) in operation (2) above, the pressure difference from the Pump passage becomes greater because of the pressure loss in the LS circuit. (4) When the pressure difference becomes P1 Pressure as explained in item 1) "When main unload valve is actuated", the valve moves to the right, and the pressurized oil dis- charged from the pump flows to tank pas- sage (10). In this way, the maximum pressur of the pump passage is controlled. (5) When this unload operation is carried out, pump discharged pressure - LS circuit pres- sure is greater than the pump LS control pressure, so a signal is sent to set the pump swash plate to the minimum angle. 2050620506 STRUCTURE AND FUNCTION 3) When power max. function is actuated PAR PAF When the pilot pressure is applied to port PX1, piston (18) and piston (18) move to the left, and poppet (15) and piston (17) are brought into close contact, so poppet (15) cannot move and the LS control pressure rises. ciss 2osF 06045 10-55 oOSTRUCTURE AND FUNCTION 2. Sub-unload valve Function + When the pump flow is divided and the con- trol vaive group on one side is actuated (with the remaining control valve group at neu- tral), the sub-unload vaive drains the pump flow to the group that is at neutral. Operation + The pressure in pump passage (1) is received at the end portion of valve (4). The control valve is at neutral, so the pressure of LS circuit (2) is 0 MPa (0 kg/cm?) + The pressurized oil in pump passage (1) is. stopped by valve (4) and cannot escape, so the pressure rises, When this pressure be- comes larger than the force of spring (5), valve (4) moves to the left, ports B and C are interconnected, and the pump pressure flows to tank passage (3). In addition, the pressu- rized oil in LS circuit (2) passes from orifice A through port C and is drained to tank pas- sage (3). Therefore, in this operation, LS pres- sure = tank pressure. + In this unload operation, pump discharge pressure ~ LS circuit pressure is greater than the pump LS control pressure, so a signal is sent to set the pump swash plate to the minimum angle. 10-56 @ ciss 208F06047 2osFo604e 20506k20506 STRUCTURE AND FUNCTION ciss 3. Introduction of LS pressure * The diagram shows the condition for arm IN. Upstream pressure of pressure compensation valve {for spoot meters downstream) A D 6 => 3 1 2osFoe049 1. Main pump Function 2. Main spool + The upstream pressure (= spool meter-in 3. Pressure compensation valve downstream pressure) of pressure compen- 4. Valve sation valve (3) is introduced and goes to 5. Ball valve shuttle valve (7) as the LS pressure. When 6. LS shuttle valve this happens, it is connected to port B of the actuator through valve (4), and LS pressure ;ctuator load pressure. Introduction hole a inside the spool has a small diameter, so it also acts as a throttle. Operation + When spool (2) is operated, the pump pres- sure passes through introduction hole a, enters port C, and is taken to the LS circuit. ‘When the purnp pressure rises and reaches the load pressure of port B, ball valve (5) opens. 10-57 @‘STRUCTURE AND FUNCTION 4. LS bypass valve ciss Main pump Main spool Pressure compensation valve LS shuttle valve LS bypass valve LS circuit 10-58 20506050 Function + The residual pressure in LS circuit (6) is re- leased from orifices a and b. + This reduces the speed of the rise in the LS pressure, and prevents any sudden change in the oil pressure. Furthermore, a pressure loss is generated by the circuit resistance between LS shuttle valve (4) and throttle ‘of main spool (2) according to the bypass flow from LS bypass vale (5), As a result, the effective LS differential pressure drops, and the dynamic stability of the actuator is increased. k2050620506 STRUCTURE AND FUNCTION 5. Pressure compensation valve 3 2 4 —— eE—fo 5—— Ty ciss oaeeNe Main pump Valve Shuttle valve Piston Spring LS shuttle valve 208F060s1 Function 1) During independent operation and at max mum load pressure (during compound op- erations, when load pressure is higher than other work equipment) + The pressure compensation valve acts as @ load check valve. Operation + If the pump pressure (LS pressure) is lower than the load pressure at port C, shuttle valve (3) inside pressure compensation valve pis- ton (4) moves to interconnect spring cham- ber E and port C. From this condition, the force of spring (5) acts to move piston (4) and valve (2) in the direction of closing. 10-59STRUCTURE AND FUNCTION ciss 6 8 ; Upocoom pres of posure ee oorrerescrn booood5 - 1 2) When receiving compensation (during com- pound operations, when load pressure is lower than other work equipment) + The pressure compensation valve is closed by the LS pressure of port D, and the spool meter-in downstream pressure of port B be- comes the same as the maximum pressur of the other work equipment. The spool meter-in upstream pressure of port Ais the pump pressure, so spool meter-in differential pressure (upstream pressure (pressure of port A) - downstream pressure (pressure of port B)) becomes the same for all spools that are being operated. There- fore, the pump flow is divided in proportion to the area of the meter-in opening. 10-60 Operation + Spring chamber E's interconnected with port D. Piston (4) and valve (2) are actuated by the LS circuit pressure from the other work equipment at port F in the direction of clos- ing (to the right). In other words, the valve upstream pressure of port B (= spool meter- in downstream pressure) is controlled by the LS pressure. 2050620506 STRUCTURE AND FUNCTION cuss 6. Shuttle valve inside pressure compensation valve => L), 20sF06053 4. Main pump Funetion 2. Valve When holding pressure at port A > LS pressure 3. Shuttle valve inside pressure in spring chamber B compensation valve + Shuttle valve (3) is pushed to the right by 4. Piston the pressure of port A, and the circuit be- ‘tween ports A and C is shut off. In this con- dition, the holding pressure at port A is taken to spring chamber B, and pushes piston (4) to the left to prevent piston (4) and valve (2) from separating. 10-61STRUCTURE AND FUNCTION + TMi For travel, swing Travel: No holding pressure is generated at port, Ain the travel circuit, so a pressure com- pensation valve without a shuttle valve is used. ‘Swing: The holding pressure at the swing port is low, $0 a pressure compensation valve without a shuttle vaive is used. Reference: When there is no shuttle valve + If there is no shuttle valve, piston (4) and valve (2) will separate. In this condition, if another actuator is operated, the piston acts as an accumulator, so there is a time lag. 10-62 ® ciss 2osros0se LS pressure Time lag 20805055, Time Holding pressure 20sFos056 2050620506 STRUCTURE AND FUNCTION cuss Shuttle valve Al From LS eireuit | To actuator Spool meter-in downstream pressure 20506067 Surface area ratio of pressure compensation valve The condition of the flow division changes ac- cording to the ratio of the area of portion At and portion AZ of the pressure compensation valve. Area ratio = A2/A1 + When area ratio = 1: Spool meter-in downstream pressure = Max. load pressure, and oil flow is divided in pro- portion to area of opening of spool. + When ratio is more than 1: Spool meter-in downstream pressure > Max. load pressure, and oil flow is divided in a proportion less than area of opening of spool. + When ratio is less than 1 ‘Spool meter-in downstream pressure < Max. load pressure, and oil flow is divided in a proportion more than area of opening of spool. 10-63 oOSTRUCTURE AND FUNCTION cLss 7. Boom regeneration circuit -—- © nase Lowel > ab ah 1 aosrososs 1 2. Main spool 3A. Pressure compensation valve 3B. Pressure compensation valve 4A, Safety-suction valve 4B. Suction valve 5. Check valve 6. LS shuttle valve 7. Drain circuit 8. Regeneration circuit 10-64 Function 1) Cylinder head pressure < cylinder bottom pressure (free fall, etc.) + A return flow circuit is provided from the ‘cylinder bottom to the cylinder head so that when the boom is lowered, the return flow can be used to increase the flow of oil from the pump to the cylinder bottom. Operation + When the cylinder head pressure < cylinder bottom pressure, part of the pressurized oil from the cylinder bottom passes through the Notch in spool (2), goes through port B, and enters drain circuit (7). The rest of the oil goes from port C, enters regeneration cir- cuit (8), opens check valve (6), and passes through ports G and D to flow back to the cylinder head, 2050620506 STRUCTURE AND FUNCTION ciss > RAISE LOWER © 208F06059 2) Cylinder head pressure > Cylinder bottom pressure (digging operations, etc.) + Check valve (5) in regeneration circuit (8) acts to shut off the flow from the cylinder head to the cylinder bottom. 10-65STRUCTURE AND FUNCTION 8, Arm regeneration circuit ciss Main pump Main spool . Pressure compensation valve . Pressure compensation valve . Safety valve 3. Safety valve Arm counterbalance valve Piston Spool Check valve . LS shuttle valve . Drain circuit |. Regeneration circuit BSBSya SSeeroge 10-66 205F06060 Function 1) Cylinder head pressure > cylinder bottom pressure + A return flow circuit is provided from the cylinder head to the cylinder bottom so that when the arm is moved in, the flow of oil to the cylinder becomes the pump discharge amount + the return flow, and this increases the cylinder speed. Operation + When the cylinder head pressure > cylinder bottom pressure, the pressurized oil from the cylinder head passes through the notch in spool (2), enters port € and opens check valve (8), then passes through ports D and E 10 flow back to the cylinder bottom. 2050620606 STRUCTURE AND FUNCTION ciss 2) When load is large + During arm IN operations, if the load in- creases and the cylinder bottom pressure exceeds 16.6 MPa (170 kg/cm*), counterbal- ance valve (5) is actuated to increase the meter-out opening at the cylinder head. This reduces the pressure loss between the cyl- inder head and the hydraulic tank, and en- sures the digging force. Operation + The cylinder bottom pressure enters port F and pushes piston (6) to the left. Spool (7) ‘moves fully to the left and interconnects port € of regeneration circuit (11) and tank drain circuit (10). As a result, the pressure loss in the drain circuit is reduced. 20506063, 3) Cylinder bottom pressure > Cylinder head pressure + When the cylinder bottom pressure > cylin- der head pressure, check valve (8) is closed by the cylinder bottom pressure and pre- vents any oil flowing back from the cylinder bottom to the head end. 10-67STRUCTURE AND FUNCTION 9. Arm counterbalance valve Check valve Regeneration Tank drain circuit uit ome eNe 10-68 From eylinder head ciss From eylinder bottom 4 208F06062 Operation During arm IN operations, if the actuating pressure at the arm cylinder bottom rises, the pressure at port A also rises. When the force received by piston (1) from the pres- sure at port A becomes greater than the force of spring (3), piston (1) moves to the left. Spool (2) is pushed by piston (1) and also moves to the left, so ports B and C are inter- ‘connected. When this happens, the pressu- rized oil from the cylinder head passes through ports B and C, and flows directly to drain circuit (6). (The pressure loss is re- moved when draining.) ‘When this happens, check valve (4) is closed by the pressure at port A, so it shuts off regeneration circuit (5), and prevents the oil from flowing back from the cylinder bottom to the head end. 2050620506 STRUCTURE AND FUNCTION ciss 10. Spool stroke modulation (1) Boom raise modulation rf =< Boom raise — PPC pressure Spool iston : Spool stroke a AL ._ Boom raise reres oF ae <2 PPC pressure i Sti: Spool stroke St2: Piston stroke Boom and arm simultaneous operation Function Operation ‘When boom RAISE and arm DIG are operated © 1.. When no arm operation. simultaneously, good simultaneous operation is When boom raises, spool (1) goes to left achieved by restriction of boom spool max. (@) by stroke Sto to touch piston (2) stroke. 2. When arm digs (1) Arm DIG PPC pressure goes to LH. of piston (2) from Port A, and pushes pis- ton (2) to right ( =»). (2) When boom raises, spool (1) goes to left (4=), but’spool max. stroke is restricted to Stt because piston (2) moves by Stz. 10-69 @STRUCTURE AND FUNCTION ciss (3) Arm dig modulation | Monee JF 3 z / No travel operation pressure sa 3 A sem PPC pressure > Arm and travel simultsneous operation Function Operation When machine goes up high slope and arm digs, 1. With no travel operation flow to arm cylinder is restricted by limitation of When arm digs, spool (1) goes to R.H. (=) arm spool stroke to avoid pressure drop of by stroke Sto to touch piston (2). pump. F pump flow goes to LH. travel motor 2. With travel operation through travel junction valve. (1) Travel PPC pressure goes to R.H. of pis- ton (2) from port A, and pushes piston (2) to left. (2) When arm digs, spool (1) goes to right (#), but spool max. stroke is restricted to Sti because piston (2) moves by Stz. 10-70 2050620506 ‘STRUCTURE AND FUNCTION ciss Pee refaure s ve PL lr from erm dig U7 P, PPC valve 2 Function In simultaneous operation of boom and arm, such as finishing, arm spool speed is delayed to prevent sudden speed change of arm and ma: chine operates smoothly. 8. Movement of arm timing valve a pressure Operation When arm digs and boom raises simultaneously, spool is delayed because PPC circuit is reduce by arm timing vaive and pressure which forces spool (1) is reduced. 2 pressure + t Time of delay Ye During simul Function Reduce arm PPC pressure to M/V for simultane: ‘ous operation of arm dig and boom up. Operation 1. Simple operation of arm dig PPC pressure goes to P1 port and pushes spool (1) to right against spring (2) and P1 port through P2 port via B. taneous operation 2. Simultaneous operation of arm dig and boom up {i) When boom raises, PPC pressure goes to P3 port and pushes spool (1) to left. When levers are fully stroked towards arm dig and boom raise simultaneously, spool (1) is pushed to left by force ac- cording to following formula. P1 pressure < P2 pressure + spring force (P1 pressure = P2 pressure) Then B is.intercepted and PPC pressure of arm dig goes to P2 port from P1 port via orifice A. iy 10-71 oOSTRUCTURE AND FUNCTION 11. Pump merge-divider valve Ps rors To control valve Main spool Spring LS spool Spring LS circuit (bucket end) LS circuit (arm end) LS circuit (arm end) LS circuit (bucket end) PaO PEN Function + This acts to merge or divide (send to its own control valve group) oil flows P1 and P2 of pressurized oil discharged from the two pumps. + Atthe same time, it also carries out merging ividing of the LS circuit pressure. ciss P2 Pt 205F06063 Operation v When merging pump flow (when pressure PS is OFF) Pilot pressure PS is OFF, so main spool (1) is pushed to the left by spring (2), and ports E and F are interconnected. Therefore, pressurized oil P1 and P2 dis- charged from the two pumps is merged at ports E and F, and is sent to the control valve that demands the oil. In the same way, LS spool (3) is also pushed to the left by spring (4), so the ports are connected as follows. Connected ports: A < D, B <> C Therefore, the LS pressure supplied from the spools of each control valve to LS circuits (6), (6), (7), and (8) is all sent to the pressure compensation valve and other valves. 2050620506 STRUCTURE AND FUNCTION cLss 5 A 8 D 7 5 =aNE z EEL ~ — 8 I Ps TON, »> E F 2 To bucket control vaive end To arm contol valve end P2 Pt 205F0s064 2) When dividing pump flow (when pilot pressure PS is ON) + When pilot pressure PS is ON, main spool (1) is moved to the right by the PS pressure, and ports E and F are disconnected. Therefore, the pressurized oil discharged from each pump is sent to its own control valve group. Pressure P1: To bucket, RH. travel, boom group Pressure P2: To swing, LH. travel, arm group + Inthe same way, LS spool (3) is also moved to the right by the PS pressure, and the prots are connected as follows. Connected ports: B © D, others are not connected. Therefore, LS circuits (5), (6), (7) and (8) are all sent to their own control valve group, 10-73 ®‘STRUCTURE AND FUNCTION ciss 12. LS select valve * The diagram shows the situation when the swing and left travel are operated at the same time. (BP pressure ON) Valve Spring Piston Piston ‘Swing spool LH. travel spool ‘Arm spool LH. shuttle valve LS circuit OorOnEENe 205F0s06s Function + This valve is used to increase the ease of operating the work equipment. It prevents high pressure from being generated when the swing is operated, It also prevents the high LS pressure from the swing circuit from flowing into any other LS circuit when the BP ‘swing is operated together with the work ‘OFF 4 equipment. Operation 1), When pilot pressure BP is OFF Pilot pressure BP is OFF, so piston (3) is To LS shuttle vake Pushed to the left by spring (2). if the swing is then operated, swing LS pressure P1 2osFo60ss passes through swing spool (6) and enters port A. It pushes valve (1) to the left and 4 3 2 el ‘connects ports A and B. Therefore, swing LS | / a pressure P1 flows to LS shutttle valve (8). 2) When pilot pressure BP is ON + When pilot pressure BP is ON, piston (3) is moved to the right against spring (2) by the > >) aad BP pressure. It pushes valve (1) to the right BP and closes the circuit between ports A and "O's B. As a result, swing LS pressure P1 stops flowing to LS shuttle valve (8), and even if swing LS pressure P1 rises to a high pres- sure, it does not influence any other LS cir- To LS shuttle valve cuit. 20806067 10-74 ® 2050620506 STRUCTURE AND FUNCTION Operation 1) When the arm and boom are operated multaneously, the swash plate angle for both pumps becomes the maximum. When this happens, the load pressure at the boom RAISE side is higher than at the arm side, so the LS pressure passes through ports E and F of boom spool (8), enters LS shuttle valve (22) and is sent to the LS circuit. This LS pressure is transmitted to port G of arm pressure compensation valve (17), and acts to increase the set pressure of the pressure compensation valve. Because of this, the pressure between port H or arm spool (11) and port I or pressure compensation valve (17) rises, and spool meter-in LS differential pressure (pump pressure - LS pressure APLS) becomes the same as that at the boom end. 2) Because of the above operation, the oil flow is divided in proportion to the size of the opening area of boom spool (8) and the ‘opening area of arm spool (11). Meter-in LS differential pressure APLS dur- ing boom RAISE + arm IN is APLS < boom LS control pressure, so the main pump swash plate angle is set to maximum. ciss 10-91STRUCTURE AND FUNCTION SWING MOTOR SWING MOTOR Port S Port MB (from control valve) Port MA (from control valve) Port T (to tank) Port B (from swing brake solenoid valve) paege 10-92 rrosesois SPECIFICATIONS ttem —~M¢e!) pc2to-6k | Pc240-6K Type KMF90AB-2 Taporeticst 87.8 cclrev Safety valve Bah NP Set pressure (280 kglen) Rated speed | 2,298 rpm | 2,403 rpm Brake releasing 737 MPa, pressure eigen k2050620508 STRUCTURE AND FUNCTION SWING MOTOR . Brake spring . Drive shaft Cover Case Disc Plate Brake piston End cover Piston penemeeno 10. 1 2. 13. 4. 15 Faoscso16 Cylinder Valve plate Air bleed plug Center shaft Center spring . Safety valve 16. "7. Check valve Check valve spring 10-93STRUCTURE AND FUNCTION ‘SWING HOLDING BRAKE OPERATION 1) When swing brake solenoid valve is deacti- vated When the swing brake solenoid valve is de- activated, the pressurized oil from the con- trol pump is shut off and port B is con- nected to the tank circuit. Because of this, brake piston (7) is pushed down in the direction of the arrow by brake spring (1), so disc (5) and plate (6) are pushed together and the brake is applied. 2) When swing brake solenoid valve is excited When the swing solenoid valve is excited, the valve is switched, and the pressurized il from the control pump enters port B and flows to brake chamber "a". The pressurized oil entering chamber “a” ‘overcomes the force of brake spring (1), and brake piston (7) is pushed up in the direc- tion of the arrow. Because of this, disc (5) and plate (6) separate, and the brake is re- leased. 10-94 SWING MOTOR [fab i | | | ‘Swing brake solenoid vaive 20808050 ‘Swing brake solenoid valve 208F05051 2050620506 STRUCTURE AND FUNCTION CENTER SWIVEL JOINT CENTER SWIVEL JOINT 4-PORT SWIVEL —=( ene SOs e2 a—l z 1. Cover Al. From control valve port B2 2. Body A2.To R.H. travel motor port PB z0sFo0076 3. Slipper seal B1. From control valve port BS 4. O-ring B2. To LH. travel motor port PA 5. Shaft C1. From control valve port AZ C2. To RH. travel motor port PA D1. From control valve port AS D2. To LH. travel motor port PB E1. From travel speed solenoid valve E2, To LH. and R.H. travel motors port P Ti. To tank 12. From LH. and R.H. travel motors port T 10-95 ®STRUCTURE AND FUNCTION TRAVEL MOTOR TRAVEL MOTOR Port PB (from contro! valve) Port PA (from control valve) Port T (to tank) Port P (from travel speed solenoid valve) pogo 10-96 ‘TRAVEL MOTOR aostooore SPECIFICATIONS tem Model | pc210-6k | PC240-6K Type HMV160ADT-2 Rayoguen [Mie_[r0s core]ne corev "Y _|Mex. 160.8 colrev Set pressure eats, Rated Min. ity] 1-834 rpm | 1,780 rpm ’ can Max ty] 1.004 rpm | 1,048 rpm Brake releasi 78 MPs pressure "9 seer Travel speed iff aaa 1 . scune eae Skat’ 2050620506 STRUCTURE AND FUNCTION exomrens Output shaft Motor case Ball Rocker cam Piston Cylinder Valve plate End cover Regulator valve . Spring |. Brake spring . Brake piston . Plate . Disc . Regulator piston Spring TRAVEL MOTOR 17. 19. 20. 22, 20806079 . Check valve spring }. Check valve 1. Counterbalance valve . Spool return spring . Safety valve . Slow return valve 10-97‘STRUCTURE AND FUNCTION OPERATION OF MOTOR 1) Motor swash plate angle (capacity) at maxi- mum TRAVEL MOTOR valve (deactivated) 15 mW © + The solenoid valve is deactivated, so the pi- lot pressure oil from the control pump does not flow to port P. For this reason, regulator valve (9) is pushed to the right in the direction of the arrow by spring (10). + Because of pushes check valve (22), and the main pressure oil from the control valve going to end cover (8) is shut off by regulator valve (9). + Fulcrum ‘a" of rocker cam (4) is eccentric to point of force "b" of the combined force of the propulsion force of cylinder (6), so the combined force of the piston propulsion force acts as a moment to angle rocker cam (4) in the direction of the maximum swash plate angle. 10-98 ® + Atthe same time, the pressurized 2 ‘Travel contra! ‘20sF6080 lator piston (15) passes through orifice "e" in regulator valve (9) and is drained to the mo- tor case. + As a result, rocker cam (4) moves in the maximum swash plate angle direction, the motor capacity becomes maximum. k20506k20506 STRUCTURE AND FUNCTION TRAVEL MOTOR 2) Motor swash plate angle (capacity) at minimum ‘Travel speed solenoid valve (excites) + |r ‘Travel control valve 20806081 + When the solenoid valve is excited, the pilot pressure oil from the control pump flows to port P, and pushes regulator valve (9) to the left in the direction of the arrow. + Because of this, the main pressure oil from the control valve passes through passage “d” in regulator valve (9), enters regulator piston (15) at the bottom, and pushes regu- lator piston (15) to the right in the direction of the arrow. + As a result, rocker cam (4) moves in the minimum swash plate angle direction, the motor capacity becomes minimum. 10-99‘STRUCTURE AND FUNCTION OPERATION OF PARKING BRAKE 1) When starting to travel When the travel lever is operated, the pres- surized oil from the pump actuates counter- balance valve spool (19}, opens the circuit to the parking brake, and flows into chamber A of brake piston (12). If overcomes the force of spring (11), and pushes piston (12) to the right in the direc- tion of the arrow. ‘When this happens, the force pushing plate (13) and disc (14) together is lost, so plate (13) and disc (14) separate and the brake is released. 2) When stopping travel When the travel lever is placed in neutral, counterbalance valve spool (19) returns to the neutral position and the circuit to the parking brake is closed. The pressurized oil in chamber A of brake piston (12) is drained to the case from the orifice in the brake piston, and brake piston (12) is pushed to the left in the direction of the arrow by spring (11). As a result, plate (13) and disc (14) are pushed together, and the brake is applied. A time delay is provided by having the pres- surized oil pass through a throttle in slow return valve (22) when the brake piston re- turns, and this ensures that the bake still effective after the machine stops. 10-100 TRAVEL MOTOR 2o8F06082 [See ve acto 20506003, 2050620506 STRUCTURE AND FUNCTION OPERATION OF BRAKE VALVE 7 The brake valve consists of a check valve, counterbalance valve, and safety valve in a circuit as shown in the diagram on the right. (Fig. 1) The function and operation of each compo- nent is as given below. ince valve, check valve When traveling downhill, the weight of the machine makes it try to travel faster than the speed of the motor. As a result, if the machine travels with the engine at low speed, the motor will rotate without load and the machine will run away, which is extremely dangerous. To prevent this, these valves act to make the machine travel according to the engine speed (pump discharge amount) peration when pressure oil is supplied When the travel lever is operated, the pres- surized oil from the control valve is supplied to port PA. It pushes open check valve (18A) and flows from motor inlet port MA to mo- tor outlet port MB. However, the motor outlet port is closed by check valve (18B) and spool (19), so the pres- sure at the supply side rises. (Fig. 2) The pressurized oil at the supply side flows from orifice E1 in spool (19) and orifice E2 in the piston to chamber $1. When the pres- sure in chamber $1 goes above the spool switching pressure, spool (19) is pushed to the right in the direction of the arrow. As a result, port MB and PB are connected, the outlet port side of the motor is opened, and the motor starts to rotate. (Fig. 3) ‘TRAVEL MOTOR Check valve Safety valve! ae 2osrocoee [Trove ontot Pal Pe 18h H 188 e Us sit} wal MB E2 20sF0s0es (Fig. 2) 18h 5 sid 2 ig. 3) 20506086, 10-101STRUCTURE AND FUNCTION Operation of brake when traveling downhill If the machine tries to run away when traveling downhill, the motor will turn under 1no load, so the pressure at the motor inlet port will drop, and the pressure in chamber $1 through orifices E1 and E2 will also drop. When the pressure in chamber $1 drops below the spool switching pressure, spool (19) is returned to the left in the direction of the arrow by spring (20), and outlet port MB is throttled. As a result, the pressure at the outlet port side rises, resistance is generated to the ro- tation of the motor, and this prevents the machine from running away. In other words, the spool moves to a posi- tion where the pressure at outlet port MB balances the pressure at the inlet port and the force generated by the weight of the Machine. It throttles the outlet port circuit and controls the travel speed according to the amount of oil discharged from the pump. (Fig. 4) 2) Safety valve (2-way operation, 2-stage set safety valve) Function + When travel is stopped (or when traveling downhill, the circuits at the inlet and outlet ports of the motor are closed by the coun- terbalance valve, but the motor is rotated by inertia, so the pressure at the outlet port of the motor will become abnormally high and damage the motor or piping. The safety valve acts to release this abnormal pressure and send it to the inlet port side of the motor to prevent damage to the equipment. Operation in both directions 1) When pressure in chamber MB has become high (when rotating clockwise) + When the travel is stopped (or when traveling downhill), chamber MB in the outlet port circuit is closed by the check valve of the counterbalance valve, but the pressure at the outlet port rises because of inertia. (Fig. 5) + If the pressure goes above the set pressure, the force produced by the difference in area between D1 and D2 [r/4(D1? - D2") x pres- sure] overcomes the force of the spring and moves the poppet to the left, so the oil flows to chamber MA in the circuit on the oppo- site side. (Fig. 6) 10-102 ® ‘TRAVEL MOTOR ig. 9 20806087 ig.) 20506088, p2 Dt i; aio: a Poppet ig. 6) 205F06089 2050620506 STRUCTURE AND FUNCTION 2) When pressure in chamber MA has become high (when rotating counterclockwise) + When the travel is stopped (or when traveling downhill), chamber MA in the out- let port circuit is closed by the check valve of the counterbalance valve, but the pres- sure at the outlet port rises because of iner- tia. (Fig. 7) + Ifthe pressure goes above the set pressure, the force produced by the difference in area between D1 and D3 [n/4 (D3? - D1?) x pres- sure] overcomes the force of the spring and moves the poppet to the left, so the oil flows to chamber MB in the circuit on the oppo- site side. (Fig. 8) Operation of mechani sure 1) When starting travel (high pressure setting) When the travel lever is operated, the pre: surized oil from the pump actuates counter balance valve spool (19), and opens the pi lot circuit to the safety valve. The oll passes from chamber G to passage H and flows into chamber J, pushes the piston to the right in the direction of the arrow, and com- presses the spring to make the set load larger. Because of this, the set pressure of the safety valve is switched to the high pres- sure setting, and a large drawbar pull is made available. for varying set pres- TRAVEL MOTOR OO ig.) 208F06090 poppet aie ‘205F06091 Piston Spring / Mi = Ce MB fl J H G = | 4 ‘Travel control 19 (Fig. 9) 208F00082 10-103 @STRUCTURE AND FUNCTION 2) When stopping travel (low pressure setting) When the travel lever is placed at neutral, the pressure in chamber PA drops and coun- terbalance valve spool (19) returns to the neutral position. While the counterbalance valve spool is returning to the neutral posi- tion, the pressurized oil in chamber J passes through passage H, and escapes to chamber PA from chamber G. The piston moves to the left in the direction of the arrow, and the set load becomes smaller. Because of this, the set pressure of the safety valve is ‘switched to the low pressure setting in or- der to relieve the shock when reducing speed. [Set pressure of safety vaive] ‘When starting, wee aera When stopping High pressure setting | Low pressure setting ‘37.73 MPa (385 kglem’) | 27.44 MPa (280 kg/cm’) 10-104 o TRAVEL MOTOR Piston Spring LL MB ‘Travel control valve Fg. 10) 20805093 2050620506 STRUCTURE AND FUNCTION VALVE CONTROL C210, 210LC-6K PC240, 240LC, 240NLC-6K 1. Travel PPC valve 10. 2. Service PPC valve 11 3. Service pedal 12. 4. LH. travel lever 1B. ravel lever 4. |. PPC valve RH. work equipment 15. lever 16. 8. LS control EPC valve 17. 9. Hydraulic pump 18. Control valve PPC shuttle valve Accumulator Solenoid valve LH. work equipment lever Safety lock valve LH. PPC valve Safety lock lever Timing valve @8006600 Boom LOWER Bucket DUMP Bucket CURL Neutral Arm IN Arm OUT @SG8260 VALVE CONTROL ‘Swing RIGHT ‘Swing LEFT Neutral Travel REVERSE Travel FORWARD Lock FREE 10-105STRUCTURE AND FUNCTION WORK EQUIPMENT - SWING PPC VALVE WORK EQUIPMENT - SWING PPC VALVE PC210, 210LC-6K C240, 240LC, 240NLC-6K ol TT 20uF02032 a. Port P (from control pump) b. Port T {to tank) ¢. Port P2 (L.H.: Arm IN / R.H.: Boom RAISE) d. Port P4 (LH. Swing LEFT / R.H.: Bucket DUMP) fe. Port Pt (LH. Arm OUT / R.H.: Boom LOWER) Port P3 (L.H.: Swing RIGHT / R.H.: Bucket CURL) 10-106 2050620506 STRUCTURE AND FUNCTION WORK EQUIPMENT - SWING PPC VALVE — 1 i a lof hf Oo a 1— [ae O 10 a—a = be ' ml ¢ > i > 20uF02083 1. Spool 7. Joi 2. Metering spring 8. Plate 3. Centering spring 9. Retainer 4. Piston 10. Body 5. Disc 11. Filter 6. Nut (for connecting lever) 10-107STRUCTURE AND FUNCTION OPERATION 1) At neutral Ports A and B of the control vaive and ports Pr and P2 of the PPC valve are connected to drain chamber D through fine control hole “f* in spool (1). (Fig. 1) 2) During fine control (neutral — fine control) When piston (4) starts to be pushed by disc (6), retainer (9) is pushed; spool (1) is also pushed by metering spring (2), and moves down. When this happens, fine control hole "f" is shut off from drain chamber D, and at al- most the same time, it is connected to pump pressure chamber PP, so pilot pressure oil from the control_pump passes through fine contro! hole “f* and goes from port Pt to port A. When the pressure at port P1 becomes higher, spool (1) is pushed back and fine control hole “f" is shut off from pump pres- sure chamber PP. At almost the same time, it is connected to drain chamber D to release the pressure at port Pt. When this happens, spool (1) moves up or down so that the force of metering spring (2) is balanced with the pressure at port Pt. The relationship in the position of spool (1) and body (10) (fine control hole "f is at a point midway between drain hole D and pump pressure chamber PP) does not change until retainer (9) contacts spool (1). Therefore, metering spring (2) is compressed proportionally to the amount of movement Of the control lever, so the pressure at port P1 also rises in proportion to the travel of the control lever. In this way, the control valve spool moves to a position where the pressure in chamber ‘A (the same as the pressure at port P1) and the force of the control valve spool return spring are balanced. (Fig. 2) 10-108 ® WORK EQUIPMENT + SWING PPC VALVE Fig.) \ 5 4 4 cS oO to tT ® 1— Mer ASM convotvane M38)! orroroes (Fig.2) 2050620506 STRUCTURE AND FUNCTION 3) During fine control (when control lever is returned) ‘When disc (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port P1. When this happens, fine control hole “f" is connected to drain chamber D and the pres- sure oil at port Pt is released. H the pressure at port Pt drops too far, spool (1) is pushed down by metering spring (2), and fine control hole "f" is. shut off from drain chamber D. At almost the same time, it is connected to_pump pressure chamber Pp, and the pump pressure is supplied until the pressure at port Pt recovers to a pres- sure that corresponds to the lever position. When the spool of the control valve returns, oil in drain chamber D flows in from fine control hole "fin the valve on the side that is not_working, The oil passes through port P2 and enters chamber B to fill the chamber with oil. (Fig. 3) 4) At full stroke When disc (5) pushes down piston (4), and retainer (9) pushes down spool (1), fine con- trol hole *f* is shut off from drain chamber D, and is connected with pump pressure chamber Pr. Therefore, the pilot pressure oil from the control pump passes through fine control hole *f* and flows to chamber A from port P1, and pushes the control valve spool. The oil returning from chamber B passes from port P2 through fine control hole "f* and flows to drain chamber D. (Fig. 4) WORK EQUIPMENT - SWING PPC VALVE Control valve (Fig.3) Control valve rorro1087 (Fig.4) 10-109STRUCTURE AND FUNCTION ‘TRAVEL PPC VALVE TRAVEL PPC VALVE Port P (from control pump) Port T (to tank) Port P1 (LH. travel REVERSE) Port Ps (R.H. travel REVERSE) Port P2 (LH. travel FORWARD} Port P4 (R.H. travel FORWARD) se aooe 10-110 oO 2050620506 STRUCTURE AND FUNCTION TRAVEL PPC VALVE ce 208F06108 1. Piston 5. Valve 2. Plate 6. Metering spring 3. Collar 7. Centering spring 4. Body 8. Bolt 10-111STRUCTURE AND FUNCTION OPERATION 1. At neutral Ports A and B of the control valve and ports P1 and P2 of the PPC vaive are connected to drain chamber D through fine contro! hole "fin spool (1). (Fig. 1) 2. Fine control (neutral — fine contro!) When piston (4) starts to be pushed by disc (6), retainer (9) is pushed. Spool (1) is also pushed by metering spring (2) and moves down. When this happens, fine control hole "f" is shut off from drain chamber D. At almost the same time, it is connected to pump pres- sure chamber PP, and the pilot pressure of the control pump is sent from port A through fine control hole “f* to port P1. When the pressure at port P1 rises, spool (1) is pushed back. Fine control hole "fis shut off from pump pressure chamber Pr. At almost the same time, it is connected to drain chamber D, so the pressure at port P1 escapes. As a result, spool (1) moves up and down until the force of metering spool (2) is bal- anced with the pressure of port Pt. The relationship of the positions of spoo! (1) and body (10) (fine control hole “fis in the middle between drain hole D and pump pres- sure chamber Pr) does not change until re- tainer (9) contacts spool! (1) Therefore, metering spring (2) is compressed in proportion to the travel of the control le- ver, so the pressure at port Pt also rises in proportion to the travel of the control lever. In this way, the spool of the control valve moves to a position where the pressure of chamber A (same as pressure at port Pt) and the force of the return spring of the control valve spool are balanced. (Fig. 2) 10-112 ® TRAVEL PPC VALVE AM Control vaive pe 1 i jane 4 a A 4%. ru . a LJ t i sjees : 7 1 db (the a a eM conor ve 2H) 2050620506 STRUCTURE AND FUNCTION 3. 4) Fine contro! (control lever returned) When disc (6) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port P1. Because of this, fine control hole “f” is con- nected to drain chamber D, and the pressu- rized oil at port Pt is released. If the pressure at port P1 drops too much, spool (1) is pushed up by metering spring {2), so fine control hole “f" is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, so the pressure at port Pt supplies the pump pressure until the pressure recovers to a pressure equiva- lent to the position of the lever. When the control valve returns, oil in drain chamber D fiows in from fine control hole “" of the valve on the side that is not mov- ing. It passes through port P2 and goes to chamber B to charge the oil. (Fig. 3) At full stroke Disc (5) pushes down piston (4), and retainer (8) pushes down spool (1). Fine control hole “f" is shut off from drain chamber D, and is connected to pump pressure chamber PP. Therefore, the pilot pressure oil from the control pump passes through fine control hole “f” and flows to chamber A from port P1 to push the control valve spool. The re- turn oil from chamber B passes from port P2 through fine control hole “f” and flows to drain chamber D. (Fig. 4) ‘TRAVEL PPC VALVE ig. 3) 227701096 ig. 4 22F01097 10-113STRUCTURE AND FUNCTION SERVICE PPC VALVE ‘SERVICE PPC VALVE . Pin Cam . Ball Piston Cover Sleeve . Centering spring . Metering spring Spool . Body Seernogrena Port T (to tank) Port P (from control pump) Port A (to service valve P1) Port B (to service valve P2) pegs 10-114 2050620506 STRUCTURE AND FUNCTION OPERATION At neutr + The pressurized oil from the control pump ‘enters from port P and is blocked by spool (9). + Port A and B of the control valve and port “a" and “b” of the PPC valve are connected to drain port T through fine contro! hole X of spool (9). When operated + When cam (2) is moved, metering spring (8) is pushed by ball (3), piston (4), and sleeve (6), and spool (9) is also pushed down by this + As a result, fine control hole X is shut off from the drain circuit. At almost the same time, fine control portion ¥ is connected with port “a”, and the pressurized oil from port P flows from port “a” to port A of the control valve. ‘SERVICE PPC VALVE Pce10-K003 10-115 ®‘STRUCTURE AND FUNCTION + When the pressure at port “a” becomes higher, spoo! (9) is pushed back by the force acting on the end of the spool. When fine control portion ¥ closes, fine control hole X is connected to the drain circuit at almost the same time. + Asa result, spool (9) moves up and down to balance the force at_port “a” and the force at metering spring (8). + Therefore, metering spring (8) is compressed in proportion to the amount the control le- ver is moved. The spring force becomes larger, so the pressure at port “a” also i creases in proportion to the amount the con- trol lever is operated. + In this way, the control valve spool moves to a position where the pressure of port A {the same as the pressure at port “a”) is balanced with the force of the return spring of the control valve spool. 10-116 SERVICE PPC VALVE © Control valve P210-Ko0s 2050620506 STRUCTURE AND FUNCTION SAFETY LOCK VALVE Fzoscso18 PPC ACCUMULATOR ‘SAFETY LOCK VALVE PPC ACCUMULATOR Lever Body Seat Ball End cap Gas plug Shell 1 2 3. Poppet 4. 5 6 Holder . Bladder Oil port SPECIFICATIONS Gas capacity: 400 cc 10-117 oO‘STRUCTURE AND FUNCTION PPC SHUTTLE - TRAVEL JUNCTION VALVE PPC SHUTTLE + TRAVEL JUNCTION VALVE @ 2 [9 te 6-6 G A, ! ‘| . , Lt, er wo = os a 1. PPC shuttle valve OUTLINE (2. Travel junction valve + The PPC shuttle valve and travel junction valve form a combined structure. 10-118 ® 2050620506 STRUCTURE AND FUNCTION PPC SHUTTLE VALVE PPC SHUTTLE + TRAVEL JUNCTION VALVE FUNCTION This sends the PPC valve output pressure or EPC valve output pressure to the control valve and travel junction valve. It is provided with a mount port for the pressure switch for detect- ing the pilot pressure. 10-119STRUCTURE AND FUNCTION Port P11 (from swing PPC valve) Port P21 (from swing PPC valve) Port P31 (from bucket PPC valve) Port P41 (from bucket PPC valve) Port PB1 (from boom PPC valve) Port P61 (from arm PPC/EPC valve) Port PLS (to LS select valve) Port P71 (from arm PPC/EPC valve) Port P81 (from boom PPC/EPC valve) Port PA1 (from R.H. travel PPC valve) Port PB1 (from LH. travel PPC valve) Port PC1 (from LH. travel PPC valve) Port P91 (from R.H. travel PPC valve) Port P12 [to control valve (swing)] Port P22 [to control valve (swing) Port P32 [to control valve (bucket)] Port P42 [to control valve (bucket)] Port P52 [to control valve (boom)] Port P62 [to control valve (arm)] Port P72 [to control valve (arm)] Port P82 [to control valve (boom)] Port PAZ [to control vaive (R.H. travel)] w. Port PB2 [to control valve (L.H. travel)] x. Port PC2 [to control valve (L.H. travel)] y. Port P92 [to control valve (R.H. travel)] 21, Port PR (to travel junction valve) 22, Port PF (to travel junction valve) aa. Port A1 (mount port for swing oil pressure switch) ba, Port AB (mount port for bucket DUMP oil pressure switch) bb. Port A2 (mount port for bucket CURL oil pressure switch) ca, Port A4 (mount port for arm OUT oil pressure switch) cb. Port A3 (mount port for arm IN pressure switch) da. Port AS (mount port for boom RAISE pressure switch) db. Port A7 (mount port for boom LOWER oil pressure switch) ee. Port AG (mount port for travel oil pressure switch) grRT seme eoge To tank Boom contro! fi vatve Tpor =D To tank 2050620506 STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM Battery relay Battery Starting switch Fuel control dial Governor motor Starting motor Engine throttle controller Fuel injection pump PxET REND Ful ENGINE CONTROL SYSTEM INCTION The engine can be stated and stopped sim- ply by using the starting switch. A dial type engine control is used to control the engine speed. The engine throttle con- troller receives the control signal from the fuel control dial, sends a drive signal to the governor motor, and controls the angle of the governor lever in the fuel injection pump. At the same time, the engine throttle con- troller also receives signals from other con- trollers to control the engine speed. 10-149 ®STRUCTURE AND FUNCTION OPERATION OF SYSTEM Starting engine When the starting switch is turned to the START position, the starting signal flows to the starting motor, and the starting motor turns to start the engine. When this happens, the engine throttle con- troller checks the signal from the fuel con- trol dial and sets the engine speed to the speed set by the fuel control dial Engine speed contrat The fuel control dial sends a signal to the engine throttle controller according to the position of the dial. The engine throttle con- troller calculates the angle of the governor motor according to this signal, and sends a signal to drive the governor motor so that it is at that angle. When this happens, the operating angle of the governor motor is detected by the potentiometer, and feedback is sent to the engine throttle controller, so that it can ob- serve the operation of the governor motor. Stopping engine When the starting switch is placed at the OFF position, the shut off valve is closed so the supply of fuel to the engine is shut off and the engine stops. 10-150 ENGINE CONTROL SYSTEM ‘Power source fl on satpe ivenisagnateonior Fusteontat Ln [opine Erin yet cont one (Throne gnah|eonater 2050620506 ‘STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM 2, COMPONENTS OF SYSTEM 1) FUEL CONTROL DIAL a HIGH Front of machine 61 “ee A-A * we FUNCTION + The fuel control dial is installed at the bot- tom of the monitor panel. A potentiometer is installed under the knob, and when the knob is turned, it rotates the potentiometer shaft. When the shaft rotates, the resistance of the variable resistor inside the potentiometer changes, and the desired throttle signal is sent to the engine throttle controller. The shaded area in the graph on the right is the abnormality detection area and the en- gine speed is set at low idling. 1. Knob 2. Dial 3. Spring 4. Ball 5. Potentiometer 6. Connector Composition of cireut Wy 109 : 5 Lo 00.251 Characteristics of throttle voltage 46.75 5 Voltage 10-151 ®STRUCTURE AND FUNCTION 2) GOVERNOR MOTOR ENGINE CONTROL SYSTEM FUNCTION + The motor is rotated and the governor lever of the fuel injection pump is controlled by the drive signal from the engine throttle con- troller. + Astepping motor is used for the motor which provides the motive power. In addition, a potentiometer for giving feed- back is installed to allow observation of the operation of the motor. + The rotation of the motor is transmitted to the potentiometer through a gear. 10-152 oO i 8 1. Potentiometer [ | 2) Cover A | 3. Shaft 4. Dust seal 8. Bearing 3 8. Motor 7. Gear 8. Connector - — Y Aa a aosrosiae OPERATION Motor stationary + Both A phase and B phase of the motor are continuous, and a holding torque is gener- ated in the motor. Motor rotating + A pulse current is applied to the A phase and B phase from the engine throttle con- troller to give synchronous rotation with the pulse, 2050620506 STRUCTURE AND FUNCTION 3) ENGINE THROTTLE CONTROLLER ENGINE CONTROL SYSTEM Input and output signals zosrosias CN-E01 No.| Name of signal input/output No.| Name of signal Inputioutput 1 [Controller power source (24V) = 12 |Gno Input 2 | Controller power source (24V) = 13 | Battery relay drive Output 3 | Network circuit -) = 14 | Network circuit (pump +) = 4 | Auto deceleration Input 15 | Network circuit (monitor +) = 5 |Potentiometer power source (5V)|__ — 16 | Potentiometer GND = 6 | Starting switch ON signal Input 17 | signat ©” “Or Potentiometer Input 7 | Fuet contro! dial Input 18 | Model selection 2 Input Model selection 1 Input 18 | Model selection 4 Input 9 | Model selection 3 Input 20 | Governor motor drive A (+) Output 10 | Governor motor drive A (+) Output 21 | Governor motor drive B (+) Output 11 | Governor motor drive B (+) Output 10-153STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM CONTROL FUNCTION ELECTRONIC CONTROL SYSTEM Pump & engine mutual control function 2 Pump and valve control function 3 Power maximizing function 3 ‘Swift slow-down function 4 Electronic control system Auto-deceleration function 5 Engine automatic warming-up, overheat prevention function 6 ‘Swing priority function 1 ‘Swing control system 8 Travel control function * For details of the self-diagnostic function, see TROUBLESHOOTING. 10-154 Self-diagnostic function 2050620506 STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 1) Control method in each mode Heavy-duty operation (H/O) mode + Matching point in heavy-duty operation + When the load on the pump rises and the mode: . . pressure rises, the engine speed goes down. 96% partial output_point When this happens, the pump discharge Model amount is reduced, and the engine speed is Mode ha Pc24o controlled so that it becomes near the 96% partial output point. If the reverse happens controlled so that the pump discharge amount is increased until the engine speed becomes near the 96% partial output point. By repeating this control, the engine can al- ways be used at near the 96% partial output point. General operation (G/O), finishing operation (F/O), breaker operation (B/O) mode A i i + Matching point in general operation, finish- + When the load on the pump rises and the ir yn, and breaker operation modes: pressure rises, the engine speed goes down. 80% partial output point. When this happens, mutual control of the engine and pump is used to control the sys- tem so that the pump absorption torque fol- lows the equal horsepower curve of the en- }————— gine, and the engine speed is lowered while eon keeping the torque constant. soe emicy, [81 KW (108 HP)| 96 kW (128 HP) In this way, the engine is used in a range breaker operstion | er | eco which provides good fuel efficiency. Pc240 10-157 @OSTRUCTURE AND FUNCTION Lifting operation (L/O) mode Engine torque T Engine horsepower HP speed N + Matching point in lifting operation mod 60% partial output poi Model aaa Poat0 P20 Titing operation | B7 RW (76 HPT [76 RW (102 HPT ey 71306 him | soo bon Power maximizing mode 3 i Engine speed N ELECTRONIC CONTROL SYSTEM Pump discharge pressure P Pump discharge ammount Q + When the lifting operation mode is selected, the engine speed is automatically lowered to the partial position. In this condition, control is carried out in the same way as for the general operation, finishing operation, and breaker operation modes to match the load on the pump. In this way, the fuel consumption is reduced and the fine control ability is improved, Pump discharge pressure P Engine speed N + Matching point in power max. mode: Reted output point Moae ——W0%!|—pc210 C240 199 KW (133 HP)|IT7 KW (168 HP) poner 72,200 rpm _| 2,300 rpm 10-158 Engine speed N Pump discharge amount @ 208F06 151 205F061s2 When the pump load increases, the engine speed drops. When this happens, the pump discharge is reduced to prevent the engine speed from going down and to ensure that the engine is used at near the rated output point. 2050620506 STRUCTURE AND FUNCTION 2) Pump control function when traveling Engine torque T Engine speed N 208F06153 + When the machine travels in the heavy-duty operation (H/O) mode, the engine speed rises, and the pump is controlled in the ‘same way as when in the power maximizing mode. + When the machine travels in any mode other than the heavy-duty operation (H/O) mode, the working mode and engine speed are kept as they are, and the pump absorption torque is increased. 3) Control function when TVC prolix switch is ON PON (Prox) IN: OFF (Normalt + Even if any abnormality should occur in the controller or sensors, the TVC prolix switch can be turned ON to provide an absorption torque more or less equivalent to the gen- eral operation (G/O) mode, thereby allowing the machine to maintain is functions. Pump discharge pressure P ELECTRONIC CONTROL SYSTEM Pump discharge amount O 208F06187 Engine torque T Engine speed N Pump discharge pressure P Pump discharge amount Q 20806186. Pump discharge pressure P Pump discharge amount @ In this case, it is designed to allow a con- stant current to flow from the battery to the TVC valve, so oil pressure sensing is carried out only by the TVC valve, 10-159STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 2. PUMP AND VALVE CONTROL FUNCTION eet 1h zlg/Elal# faa 3/8) z)a}3) a i 3/2 Eis a He aE < | | = | | i I i FUNCTION + The following two functions are available to provide the optimum matching under vari- ‘ous working conditions: a 2-stage relief func- tion which increases the digging power, and a fine control mode function which improves ‘the ease of fine control. 10-160 2050620506 STRUCTURE AND FUNCTION 1)_LS control function + The switching point (LS set differential pres- sure) for the pump discharge amount inside ‘the LS valve is changed by changing the ‘output pressure from the LS control EPC valve to the LS valve according to the en- gine speed and operating condition of the actuator. + Because of this, the timing for starting the discharge amount from the pump can be optimized, to give excellent ease of com- pound operation and fine control. 2) Cut-off function For details of the operation, see CLSS. 3) 2-stage relief function + The relief pressure for normal operation is 31.85 MPa (325 kgicm*), but when the 2- stage relief function is actuated, the relief pressure rises to approx. 34.79 MPa (355 kg/ om’). Because of this, the hydraulic pressure is increased by one stage. + Actuating con tion jons for 2-stage relief func- + In lifting operation (V/O) a MS dot finetge| S55 kaemn are actuated ELECTRONIC CONTROL SYSTEM EPC pressure at 2.94 MPa (30 kam) (OMS (0 glee) Pump discharge amount Q LS set citferential pressure 20sF06160 10-161STRUCTURE AND FUNCTION 4) Fine control mode function + When the finishing operation (F/O) mode is selected from the working mode, the pump LS valve is controlled, and the pump dis- charge amount is reduced to improve the ease of fine control and the precision when finishing. + Relationship between working mode and pump discharge amount (for independent operation) ELECTRONIC CONTROL SYSTEM % ‘Actuator Boom Arm Bucket | Swing | Breaker Mode RAISE |LOWER| IN | OUT Heavy-duty operation (H/O) es 100 too | 100 | 50 | 5 | — General operation (G/O) Finishing operation (F/0) [100 <505] 50 | 100 | 40 (60) | 40 (60) | — Lifting operation (L/O) 50 so | so | a | a | — Breaket operation (8/0) 100 too | 100 | 50 | 50 | 60 The figures in (_) are for the PC210. The figures in < > are for when arm IN is operated. * In each working mode, the full flow of the pump at the set engine speed is taken as 100%. +t 10-162 k2050620506 STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 3. POWER MAXIMIZING. SWIFT SLOW-DOWN FUNCTION Control valve | 2tage ait solenoid valve oe Main pump i) Governor Fuel injection motor a ia : Cy Engine switeh speed [IS vate 1S valve Control pump L Potentiometersignall Engine throne see controller Network signal) | Pump controls Monitor panel 208F08169 FUNCTION + This function provides an increase in the digging power for a certain time or switches the working mode to the lifting operation (L/ ) and reduces the speed. It is operated us- ing the LH. knob switch to momentarily match the operating conditions. * The power max. function and swift slow- down function are operated with the same switch. Only one of these functions can be selected at any time; they cannot both be operated together. 10-163STRUCTURE AND FUNCTION 1) Power maximi 9 function + During digging operations, when that extra bit of digging power is needed (for example, when digging up boulders), the LH. knob ‘switch can be pressed to raise the hydraulic pressure by approx.10 % and increase the digging force. + If the LH. knob switch is pressed ON when the working mode is at H/O or G/O, each function is automatically set as follows. 3S Wortng | Engine, Faxaatn made’ | pumprcontol ‘ime Heavy | Matching at | Actuated | Automat duty” | rated output | (31.8 | cally poration | point $49 MPa) | Cantoled tap 5" | Shores 585 kaler’| Soe 2). Swift slow-down function + During normal operations, if it is de d to carry out lifting operations or finishing op- erations for 2 moment, the working mode can be switched to lifting operation (L/O) mode by operating the LH. knob switch. + If the LH. knob switch is pressed ON when the working mode is at H/O or G/O, each function is autor: & lly set as follows. Working mode ‘Actuating ume Ling operation ‘While switch Is kept pressed, 10-164 ELECTRONIC CONTROL SYSTEM 2050620506 STRUCTURE AND FUNCTION 4 Monitor pane! Ful AUTO-DECELERATION FUNCTION Engine Governor motor Fue injection pum ‘Main pump Fuel control dial ELECTRONIC CONTROL SYSTEM LH, work equipment lever Boom RR puctet e Control pump CURL RAISE uM =, Soupmens Arm CO (cowe swing LeFr our W ago ||| Travel lever ax re] r [LH travel Engine throttle INCTION If all the contro! levers are at neutral when waiting for work or waiting for a dump truck, the engine speed is automatically reduced to a midrange speed to reduce fuel consump- tion and noise. If any lever is operated, the engine speed returns immediately to the set speed. Pump controller 10-165STRUCTURE AND FUNCTION OPERATION Control levers at neutral If the engine is running at above the decel- eration actuation speed (approx. 1400 rpm), and all the control levers are returned to neutral, the engine speed drops immediately to approx. 100 rpm below the set speed to the No. 1 deceleration position. If another 4 seconds passes, the engine speed is reduced to the No. 2 deceleration position (approx. 1400 rpm}, and is kept at that speed until a lever is operated. ‘Speed (rpm) 100 No. 1 deceleration at? No. 2 deceleration (1,400) ELECTRONIC CONTROL SYSTEM When control lever is operated + If any control lever is operated when the engine speed is at No. 2 deceleration, the engine speed will immediately rise to the speed set by the fuel control dial. Levers at neutral 10-166 4 Less than 2 Less than 1 Time (eee) Lever operated 2osrosi6s. 2050620506 STRUCTURE AND FUNCTION 5. Ful ELECTRONIC CONTROL SYSTEM AUTOMATIC WARMING-UP AND ENGINE OVERHEAT PREVENTION. FUNCTION (Coolant temperature signal) Engine (Network signa INCTION If the coolant temperature is low, this auto- matically raises the engine speed to warm up the engine after it is started. (Automatic ‘warming-up function) In addition, if the coolant temperature rises too high during operations, it reduces the load of the pump to prevent overheating. (Engine overheat prevention function) )Coolant temperature ‘Main pump Monitor panel fh Re \ © a ion zg i Pump controler 208F06166 10-167STRUCTURE AND FUNCTION 1) Engine automatic warming-up function + After the engine is started, if the engine coot- ant temperature is low, the engine speed is ‘automatically raised to warm up the engine, ELECTRONIC CONTROL SYSTEM Conditions for actuation (both are necessary) ‘Actuation Coolant temperature: Less than 30°C Engine speed: Less than 1,400 rpm => Engine speed: 1,400 rpm Conditions for cancellation (any one) Coolant temperature: 30°C or above Cancellation Automatic : —i ‘Automatic warming-up time: ‘10 minutes or more Engine speed: As desired Fugl control dial: Held at more than Manual | 70% of full speed for more than 3 seconds. 10-168 2050620506 STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 2) Engine overheat prevention function + This function protects the engine by lower- ing the pump load and engine speeed to prevent overheating when the engine cool- ant temperature has risen too far. + This system is actuated in two stages. The first stage is when the water temperature is between 102°C and 105°C, and the second stage is when the water temperature is 105°C and above. Normal operation (coolant tempertature below 102°C) Coolant temperature: — J Selon sae {Coolant temperature Seuge" Green range) Normal operation ‘1st stage (Coolant temperature between 102°C and 105°C) ‘aan onion Fanon Fone Cancel oon Winimane_[ rene [Pome | | [Eason wreegars ea stage Coolant temperature Cys > jow 102°C jelow 102°C and 105% Mode kept as itis, eral ishing, | Mode op 2 ~ When the above condition 8 | (Cootan trperaire Breaker’ ut reduced pt te yen roe 2 | Gauge: Red range — is 5 ro the condition before the iting kept ae fUncton wae actuated {automatic reset ration 2nd stage (Coolant temperature 105°C and above) ‘Actuation condition ‘Actuation, remedy Cancel condition Working mode In any mode Coolant temperature: 8] Coolant temperature: Below 102°C | 1@C'and'above Engine speed Low idling Fuel gona dg 2 | (Cootans temperature Monitor caution lamp | Lights up low ialing position * [frise: Red one Caution buzzer ‘Sounds i Wien tie ati conciiona) ‘are met, the system returns. {fo the condition before the ‘overheat prevention {ncon ves actuated imanval reset 10-169STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 6. SWING PRIORITY FUNCTION + There is a SWING ACCEL switch on the moni- tor panel for the boom/swing priority selec- tion mode. This switch can be turned ON or ‘OFF to change the matching of the boom RAISE and swing operations, The oil flow is divided and sent to the swing to match the swing angle to allow compound ‘operations to be carried out easily. Boom/swing priority selection mode OFF: ‘90° swing and loading of dump truck Boom/swing priority selection mode ON: 180° swing and loading of dump truck sro 205F06167 ‘Swing priory ° 90 180 ‘swing angle (+) praroatas) + The change in the matching between the When boom/swing priority selection mode is OFF boom RAISE and swing is carried out by changing the signal to the pump merge-di- vider valve. Lo Boom RAISE and swing are parallel 20sFos6t gl When boom/swing priority selection mode is ON ix ae marge ever ave wf FT (scare [ cow The boom RAISE and swing use separate pumps, so swing is independent 10-170 2050620506 STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 7. SWING CONTROL FUNCTION Work equipment lever PPC val Shute vane 4 i ! Gil pressure ewiteh Cont valve Swing brake Pump margeT— solonia valve ay Ff Jowett 3) ‘ON rome sch VJ (Swing lock switch signal) oN OFF] (Drive si (Swing lever signal) Pump controller Swing motor Monitor pane! OFF Control pump ‘Main pump FUNCTION + The system is provided with a swing lock and swing holding brake function. 10-171STRUCTURE AND FUNCTION 1). Swing lock, swing holding brake function + The swing lock (manual) can be locked at any desired position, and the swing holding brake (automatic) is interconnected with the swing, so it prevents any hydraulic drift af- ter the swing is stopped. ¥ Operation of swing lock prolix switch if any abnormality should occur in the con- troller, and the swing holding brake is not actuated normally and the swing cannot be operated, the swing lock prolix switch can be operated to cancel the swing lock and allow the swing to be operated. * Even when the swing lock prolix switch is turned ON, the swing lock switch stays ON and the swing brake is not canceled ‘* When the swing brake is canceled, the swing has only a hydraulic brake operated by the safety valve, so if the swing is stopped on a slope, there may be hydraulic drift. 2) Hydraulic oil quick warm-up function when swing lock switch is ON + When the swing lock switch is turned ON, the relief pressure rises from 31.85 MPa (325 kg/cm?) to 34.79 MPa (355 kg/cm’). If the work equipment is relieved in this condition, the hydraulic oil temperature will rise more quickly and the warming-up time can be re- duced. 10-172 ® ELECTRONIC CONTROL SYSTEM Task] Ter S| ae [rovaion Operation Whon swing Ioyr i placed at metal syebrans eros Shor apron soe wee ort | oFF Suing levers oprats, bake Cechaaed and ong con be Sperted realy Swing oaks actuated nd swing | nisl ston wing | Even when swing iver ON | ON | jock” | operated, swing lock is not SEncted nd sang does hot Sarg ek] OW Tw controler] — OFF han protien [ON sbnerielontoter normal Swingtok | on | om | on | oF win swing |-swing | swing | S48, Suing tock” tock | ioce [hela Sta | Canceled | sppiog | B98 2050620506 STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 8. TRAVEL CONTROL FUNCTION - Travel motor Trovl over f ! 3M vet LH. RH. 1 HH Hiunetion| { \ ee \ a eI ! Regu mm) Oe ! EA ae ' ’ i 4 sane] Lf | cu preeue! — wich t Toon rae . - ET fSemeierc onl Thm Controt pump |__t Fuel contro! ‘Main pump t Gal ' Mi M } ' ce i a Ea ag ‘ iz t i {rave lever sional -4 & (Pressure sensor aie ine Pump controller [peste srs Engine throttle Throttle signal) Monitor panel 208F08179 FUNCTION + When traveling, the pump control is carried out, and the travel speed can be selected manually or automatically to give a travel performance that suits the nature of the work of the jobsite. 10-173STRUCTURE AND FUNCTION 1) Pump control function when traveling + Ifthe travel is operated in any working mode other than the heavy-duty operation (H/O) mode, this increases the pump absorption torque while keeping the working mode and engine speed as they are. * For details, see PUMP & ENGINE MUTUAL CONTROL SYSTEM. 2) Travel speed selection function i) Manual selection using travel speed switch H the travel speed switch is set to Lo, Mi, or Hi, the pump controller controls the pump flow and motor volume at each speed range as follows to switch the travel speed. Automatic selection according to engine speed I the engine speed is reduced to below 1400 rpm by the fuel control dial: + If the machine is traveling in Lo, it will Not shift even if Mi or Hi are selected. + Ifthe machine is traveling in Mi, it will not shift even if Hi is selected. + If the machine is traveling in Hi, it will automatically shift to iii) Automatic selection according to pump dis- charge pressure If the machine is traveling with the travel speed switch at Hi, and the load increases, such as when traveling up a steep hill, if the travel pressure continues at 33.32 MPa (340 kglom?) for more than 0.5 sec. the motor volume is automatically switched and the travel speed changes to Mi, (The travel speed switch stays at Hi.) The machine continues to travel in Mi, and when the load is reduced, such as when the machine travels again on fiat ground or goes downhill, and the travel pressure stays at 17.64 MPa (180 kg/erm*) or less for more than 0.5 sec, the motor volume is automatically switched and the travel speed returns to Hi 10-174 ‘Travel speed ELECTRONIC CONTROL SYSTEM Trove] ta] Mew sith | wow Spee) | rang soa | gh Sond Pure fow ag 5 wo | cor [wx | mn | Min raw! spca| P0|Pa0| PCO] Pao [rca rezIO fire) 32 | 34 | 45 | 45 | 56 | 55 Te 180) ‘Travel pressure (MPa (kglem) 33.32 (340) 2osros206 k20506k20506 STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 9. _COMPONENTS OF SYSTEM 1) ENGINE SPEED SENSOR 1 2 3 4 \ 5 0.7516 E LJ Composition of circuit 206F00176 1. Wire FUNCTION 2. Magnet + The engine speed sensor is installed to the 3. Terminal ring gear portion of the engine flywheel. it 4. Housing counts electrically the number of gear teeth 5. Connector that pass in front of the sensor, and sends the results to the pump controller. + This detection is carried out by a magnet, and an electric current is generated every time the gear tooth passes in front of the magnet. 2) PPC OIL PRESSURE SWITCH 1. Plug 3 2. Switch / 3. Connector tt SPECIFICATIONS | Composition of points: N.O. points Actuation (ON) pressure: 0.49 + 0.1 MPa (5.0 + 1.0 kglem’) Reset (OFF) pressure: 0.29 + 0.05 MPa (3.0 + 0.5 kg/cm’) FUNCTION + There are 8 switches installed to the PPC shuttle valve. The operating condition of each : [27 f) actuator is detected from the PPC pressure, 2/ and this is sent to the pump controller. a Composition of ecult 10-175‘STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM 3) PUMP PRESSURE SENSOR 1. Plug 2. Sensor 3. Connector FA Composition of circuit FUNCTION + This sensor is installed to the inlet port ci —- cuit of the control valve. It converts the pump discharge pressure to a voltage and sends this to the controller. ell sph OPERATION (stnnias stot + When the pressurized oil entering from the pressure introduction portion pressurizes the oa diaphragm of the pressure detection por- tion, the diaphragm deflects and changes sf 1 shape. | | ‘A gauge layer is installed to the face oppo- 7 site the diaphragm, and the resistance of the gauge layer converts the deflection of the diaphragm into an output voltage and 3 t sends it to the amp (voltage amplifier. | + The voltage is further amplified by the am- 2 plifier and is sent to the pump controller. + Relationship between P (kg/cm?) and output voltage (V) V = 0.008 x P + 1.0 | * 1 kg/om? = 0.098 MPa | 0100200 30000505 Pressure P(kg/cm!) Sensor output voltage 20sF0s161 10-176 k2050620506 STRUCTURE AND FUNCTION 4) PUMP CONTROLLER on-co2 en-003 en-col Input and output signals cx-cot ELECTRONIC CONTROL SYSTEM 208F06176 cn-coz cn-cos Ne Teneotrins [rewousa] [Re Tenectnps —[wentama) [he saver + [ao S 1 Soon ech woot | [A | Paenre neon S10) Tem 2 [eno S 2 [ Boom LOWER son Trout | [22 | Pressure seeor 25) = 2 [ts eet sleois ‘uo | [a | Teva eve Tepe | [22 | Prenuresenorsower2ev | — [Pomp mage avidersoois | Opa | | «| Soom RAISE swish Two | [2 S = = S = | Aen each Tepe | | 25 | Amo eclertion a | revel apne sles asa | [6 | Am out owen tnout | [a5 | Sreos ser Tea 7 | ecomel €FC -) ‘onpe | | 7 | eos cunt ewer Tope | [27 | nemon stout moniord [| — © [pero ‘usu | [6 | Bien OUP ower Tosa | [20 | Montor cre eine pera oupe | [| swine wn ee eo = 1 | Contoter power sous 267 | — 11] Medel steaion S| Tosa] fae = = 2 [1S pee ater Gasae | [72] Swirg oc etic vent | [i = : “u_[ aoe rot stra fousue | [ve tops] [at | Speeder eee 1 [eS coral BPE owe | [os Inout | [38 [Neon aut = ne [vere own | [os veo | [ae = = a [veae cese | [a = = 10-177STRUCTURE AND FUNCTION 5) TVC PROLIX RESISTOR 1. Resistor 2. Connector SPECIFICATION Resistance; 302 6) FUEL CONTROL DIAL, GOVERNOR MOTOR, ENGINE THROTTLE CONTROLLER * See ENGINE CONTROL SYSTEM. 7) MONITOR PANEL * See MONITORING SYSTEM. 8) TVC VALVE * See HYDRAULIC PUMP. 10-178 Ful 9) ELECTRONIC CONTROL SYSTEM 208F06178 INCTION This resistor acts to allow a suitable current to flow to the TVC solenoid when the TVC prolix switch is ON. No current flows when the TVC prolix switch is OFF. LS CONTROL EPC VALVE LS SELECT SOLENOID VALVE PUMP MERGE-DIVIDER SOLENOID VALVE 2-STAGE RELIEF SOLENOID VALVE TRAVEL SPEED SOLENOID VALVE SWING BRAKE SOLENOID VALVE * See EPC. SOLENOID VALVE. 2050620506 STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM Monitor panel Sensor signal sensors 5 source Battery FUNCTION + The machine monitor system uses the net- work circuits between the controllers and sensors installed to all parts of the machine to observe the condition of the machine. It processes this information, and displays it fon a panel to inform the operator of the condition of the machine. + The content of the information displayed on the machine can broadly be divided as fol- lows. 1, Monitor portion This gives an alarm if any abnormality ‘occurs in the machine. 2. Gauge portion This always displays the coolant tem- perature and fuel level. 3. Time display 1) This normally displays the time. 2) If this is set to the machine data monitoring mode, internal data from each controller, including the moni- tor panel itself, are displayed. Buzzer signal MACHINE MONITOR SYSTEM Controllers 2osrosz49 3) Ifitis set to the trouble data memory mode, the trouble data for each con- troller, including the monitor panel itself, are displayed. 4) It displays that the system has been set to the governor motor adjustment mode and automatic vibration offset adjustment mode. 5) In emergencies, it displays abnor- malities in any controller. * For details of the content of the dis- play and the method of operation, see TROUBLESHOOTING. The monitor panel has various built-in mode selector switches, and also functions as the control panel for the electronic control sys- tem. 10-179STRUCTURE AND FUNCTION 1. MONITOR PANEL C210, 210LC-6K PC240,240LC, 240NLC-6K = OUTLINE + The monitor panel consists of the time dis- play, monitor display, and mode selector switches. + Ithas a built-in CPU (Central Processing Unit), and processes, displays, and outputs the data from the sensors and controllers. + The time display and monitor display panels use a liquid crystal display (LCD). The mode switches are flat sheet switches. 10-180 MACHINE MONITOR SYSTEM on-Po on-Pov zosrosaso Input and output signals cnres [Lennon TS] 1 [Wontersomrsoom] =| [+ [Peotone [met 2 Jeno ower suco| ——] [2 [Ovens wo 2 [vm atieat [hoa | [2 [Sein mame To 1 Joeitesion mp] [Yao von [sania rich on [ser] [6 [wot ion 3 | wer [rete Tena] | |Reeor nie | et [Sars ino] [2 [sa tout | oor veo) [ro [eumer cae | tot [ono =] [te eoet tenses ie 73 Jae Daa] [isomer wer owt 1s |ePer Tot | [76 [engine seed | tt te [toss aon [roe] [oe] Ene wo 17 |e rire | ee 2050620506 STRUCTURE AND FUNCTION MONITOR DISPLAY ‘d 8s TIME & EG GE COOUNNNOOLODDD, 7 MACHINE MONITOR SYSTEM |. Clock Coolant temperature gauge . Fuel level gauge . Engine oil level caution lamp . Hydraulic oil level caution lamp . Preheating pilot lamp 1 2 2. 4 5. 6. 7 8. 9. 10, Engine oil pressure caution lamp 1. 12. 13. 14. 46. . Swing holding brake pilot lamp a . Battery charge caution lamp 5 . Air cleaner clogging caution lamp Coolant level caution lamp Fuel level caution lamp Coolant temperature caution lamp Overload caution (when lifting) ums 8 7 8 Low PPC pressure e of display 20806251 Symbol | Display item Display range | When engine is stopped | When engine is running Flashes and buzzer KE} | coolant tevel Below low level__| Flashes when abnormal | Eres ang Pune, Below 1,500 rpm: pelo O05 MPa | Lights up when normal oO | pans ‘Above 506 rpms | (oes out when ongine | Sneek abormal below 0.15 MPa | Starts) (1.5 kolo") DB | Azcieaner el aon ; meee en clogged OFF lashes when abnormal Lights up when normal Charge level Mien charging is | (goes out when engine defective Flashes when abnormal starts) WB) |eocine ottevet | soow ow iver | Fnehes when abnormal | OFF i] [reraute ot | suowtowinvet | Fishes when atnonmat | OFF von pong in| Light up when swing lock swith is ON, fashes Lights up for 30 seconds when soning atch i t Proheatng | During rabeating | HEAT Manatee esta a a reheating is completed 10-181 ®STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM ‘Symbol lay item Display range | When engine is stopped | When engine is running TILE 105 Flashes when’ above 102°C, flashes and buzzer ray] apenenel sounds when above 105°C eceeenlh Fuel evel Fas when below lowe level quem Fite overioad caution | when machine is close to tipping or near hydraulic unit yi «tif | Low PPC pressure | When pilot contol pressure is low * When the starting switch is turned ON, the buzzer sounds for 1 second, all the monitor display lamps light up for 3 seconds, and after this, all lamps except “Engine oil pressure" and "Charge level” go out. The "Engine oil pressure" and "Charge level" go out when the engine is started. 10-182 k2050620506 ‘STRUCTURE AND FUNCTION ‘SWITCHES 1 HO GO FO 10 6D — 2 Oo 0 0 06 GD AK Xo 4% 2 & — "—~2 1 *1G5% 6 6 8/3 —"@D @& + The switch portion consists of five mode selection switches, and the condition of the machine changes each time that any switch pressed. The LED above the switch lights up to display the present condition of the machine. MACHINE MONITOR SYSTEM Working mode switch ‘Auto-deceleration switch Boom/swing p riority mode switch 4, Travel speed switch 5. Power max/Swift slow-down switch oe _ zosroses2 ‘Switch actuation table ‘Symbol | _ Item Action’ AAR [BERENS 10 6 670 «£10 « UO + 810 + kos 4. [Si%fon | rowen ur — sees Down & [bea (ON <> OFF reaver o =| Hie Mi es bo swins me [see OFF & ON * The bold letters indicate the default position of the switch when the starting switch is turned ON. 10-183STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM 2. SENSORS + The signals from the sensors are input di- rectly to the monitor panel. The contact type sensors are always con- nected at one end to the chassis GND. Name of sensor | Type of sensor | When normal | When abnormal Coolant level Contact type ON (close) OFF (open) Engine oil level | Contact type | ON (close) OFF (open) eygieulc oll | Contact type | ON (close) | OFF (open) aol Contact type | OFF (open) | ON (clos Coolant =. Coolant ure | Resistance type = = Fuel level Resistance type = = ‘ir cl ead Contact type | ON (close) | OFF (open) 1) COOLANT LEVEL SENSOR ‘Sub tank Float Sensor Connector 2osrosies: 10-184 20506STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM 2) ENGINE OIL LEVEL SENSOR 3) HYDRAULIC OIL LEVEL SENSOR 1 2 1. Connector \ [ 3. Float S 4. Switch Mh \ — . 3 4) ENGINE OIL PRESSURE SENSOR (COMMON FOR BOTH Lo AND Hi) 1. Plug 2. Contact ring 3. Contact 6. Terminal Actuation (ON) pressure Lo: 0.05 + 0.02 MPa (0.5 + 0.2 kg/cm’) or less Hi: 0.15 + 0.02 MP3 (1.5 + 0.2 kg/cm) or less Composition of circuit 20sr0si69 10-185STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM 5) COOLANT TEMPERATURE SENSOR 1 2 3 Connector Plug Thermistor ere (=) 6) FUEL LEVEL SENSOR Float Connector Cover Variable resistor PeNe 20506253, Actuation (OFF) pressure: 7.47 + 0.49 kPa (-762 + 50 mmH;0) Composition of circuit 20sF06254 2050620506 ‘TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING tem are | __Remedy Check fuel level > | ‘Add fuel ie teeter tear cron . ener Bek rau oe - re B | aces rt ot sie - een Bs creck ing machinery oe - nae 2 | 6. chock engine ol level (Level of olin el pan - ‘oi © 7. check cooting water evel - Add water - Check condition of dust indicator - Clean or replace ee — Si oe eee - ones Sioa soesrne seer : oat ee - ropot Pe Wc - “an SS ay ra Pr - ane By ee eee - — F | checks for getting wet onto wiring Disconnect a ocean ine . ee |. Ghee tent ge oe 278-286 replace Noearhan toca is opated ; Replece 20-63TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS CONNECTOR TYPES AND MOUNTING LOCATIONS psetr | type | SF] tetiea component | Mt) leer | type | SP] let component | Att A01 | KES1 | 2 | Window washer circuit | J5 E11 | RING | 1 |Heater relay A2 ‘103 | KEST | 2 |LSsolect solenoid circuit] as || Hor |S _| 16 intermediate connector | R9,G9 fave | Kesi | 2 |Pume.merge-svder sole: ae || Ho2 |S | 16 [Intermediate connector | — ‘A05 | KEST | 2 [ning brake solenoid creat | — | | N02 | $__| 16 | Intermediate connector ‘A06 | KES1 | 2 |Patage rele solenoid creat | — || HO4 | S$ _| 16 Intermediate connector ‘A07 | KES1 | 2 |Travel peed solenoid creat | — || HOS | M_ | 6 |Intermediate connector ‘A08 | KES1 | 2 [Heater circuit Ta] [Hoe | t_ | 2_ [intermediate connector ‘A09 | KES1 | 2 |Lower wiper circuit — | Ho7 | s _| 12 [intermediate connector ‘ait | KES1 | 2 [Alarm buzzer circuit | me || H0@ | M_| & |Intermediate connector ‘A13 | KEST | 2 [Starter relay circuit a7 | |_H09_|_M_| 2 [Intermediate connector A14 | KES1 | 2 | Battery relay drive circuit | | — Kor = 1_|Aircon switch ‘Ate | KES1 | 2 [Fuel shut off circuit =] [koe |x [4 [Aircon pressure switch | 15 ‘a7 | KESt | 2 [Starter ciruit wr | [Moz |x | 2 [Safety relay ci cor | mic | 17 [Pump controlier os | [Mos | M_ | 4 |Heater switch PS 02 | 040 | 20 [Pump controller = Mos | KES1 | 2 {Right front light &5 cos | 040 | 16 [Pump controller ae] [mos | Kest | 2 [Working lamp (boom) | D6 cor TX] 2 [Rear pump Te vawe Pro | |_MI0 | M_| 1 [Intermediate connector | FS: cos | S| 10 [IVC prolix switch we] Mtr [| 2 |Fusibte tink 5 cos M 2 |TVC prolix resistor PS M2 | Kest | 4 |Heater ‘Ha co7 x 3. |Rear pump pressure sensor | 19 M13 | AMP | 8 | Speaker RO cos | X | 3 [Front pump preseure sensor | — || MM | L | 2 |Fusible link 5 cog | S$ | 8 |Model selection connector | Q6 M16 | - | 1 [Horn (high sound) Fa cio | x | 2 |iScontol PC sowncidvave| ra] |_M17 | - | 1 |Hern tow sound) — cis | x | 2 [Front pump Tvcvaive | uo || MIS | M | 4 [Wiper wosher switch | 08 £01 | Mic | 21 [Engine throttle controlier| pe || M20 | ~ | — (Cigarette lighter NB E04 | x | 3 [Governor potentiometer | | | M23 |_M_| 2 |Hom swith RH. knob ewich | H4,F7] £05 |X | 4 [Governor motor Te] [M26 | ame | 11 [Air conditioner Ha 0s | M | 2 [Fuel control dial Tana] {M28 | KesO | 2 [Window washer motor | Js £07 | x | 2 [Engine speed sensor wae [Smee | 1 | Electromagnetic citch for] Ha Eos | SWP | 14 [Intermediate connector M35 x 4 | Condenser for air conditioner | 15 E10 | -_| 1 [Fuel shut off mss | M_ | 3 |Light switch 08 + The Address column in the table above shows the address in the connector arrangement drawing (2-dimensional drawing). * This table includes connectors that are not shown in the drawing. 20-64 ® 20506HOB HO3 HO7 Hoo M13 HO2 i 8 el 5 x 5 / R11 COS R10 Ros ROS W10 4 4 3 2 i EB = &‘TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ‘The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion of the housing, pins Male (female housing) Female (male housing) 1 } \ / \ f ry 4 = fot + 14 ere 2 2 1 a \_ / MAC f : i ial [= ? \ 3 a 1 Cel er oe | 4 1 “ foo 5 13 G i 2 4 4 2 | peewee 20-68 2050620506 DISASSEMBLY AND ASSEMBLY REMOVAL OF CONTROL VALVE ASSEMBLY Ay Aur the engine at low idling, operate the cylinder to the end of its stroke without relieving the cir- cuit, lower the work equipment to the ground, then stop the engine. For details, see TESTING AND ADJUSTING, Releasing pressure in hydraulic circuit. After stopping the engine, do as follows. ‘© Loosen the oil filler cap slowly to release the pressure inside the tank. ‘© Operate the control levers. + Operate the control levers several times to release the pressure in the accumulator. © Start the engine and run at low idling for ap- prox. 5 seconds, then stop the operation and operate the control levers. + Repeat the above operation several times to release the remaining pressure completely 1. Open engine hood, and remove divider covers (1), then disconnect intake connector. 2. Disconnect hoses (2), (3), and (4), remove 2 connec tors (6) from holder, then disconnect. % Remove the hose mounting elbow from the valve body. 3. Remove block (6). 4, Disconnect hoses (7) and (8), and block (9). + When disconnecting block (9}, loosen the mount ing bolts of the block tube flange first. 5. Disconnect tubes (10), (11), and (12), and hoses (13), (14), and (15). + Disconnect 6 tubes and 7 hoses. % With hoses (15) there is another hose under each of the hoses. CONTROL VALVEDISASSEMBLY AND ASSEMBLY 6. Disconnect hoses (16) and (17). 7. Sling control valve assembly (18), then remove ‘mounting bolts, and lift off control valve assembly. (Ce) Control valve assembly: 170 kg INSTALLATION OF CONTROL VALVE ASSEMBLY © Carry out installation in the reverse order to remo- val. ‘© Refiling with oil (hydraulic tank) % Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again, © Bleeding air + Bleed the air from the circuit between the valve and the hydraulic cylinder. For details, see ‘TESTING AND ADJUSTING, Bleeding air. 30-68 CONTROL VALVE 2050620506 DISASSEMBLY AND ASSEMBLY REMOVAL OF CONTROL VALVE ASSEMBLY + T-spool control valve (1 service valve) Ay felease the remaining pressure in the hydraulic circuit. For details, see TESTING AND ADJUST- ING, Releasing pressure in hydraulic circuit. 4. Open engine hood and chassis bodywork cover, remove divider cover (1), then disconnect intake ‘connector (2) 2. Disconnect hoses (3), (4), and (5), and remove 2 ‘connectors (6) from clip, then disconnect. + Remove the hose mounting elbow from the valve body. 3. Remove block (7). 4. Disconnect hoses (8) and block (9). ‘* When disconnecting block (9), loosen the mount- ing bolts of the flange for the tubes at the bot- tom first. 5. Disconnect hose (10), and remove tube (11) and block (12) 6 Disconnect hoses (13) and (14), and remove tubes (15) and (16) CONTROL VALVE nD) ool) 30-69 @DISASSEMBLY AND ASSEMBLY 7. Remove tubes (17), (18), and (19), and disconnect hoses (20) and (21). 8 Disconnect hoses (22), (23), and (24) mounted to [7 =) CG. * @ ga7\ a] bottom of valve. 9. Lift off control valve assembly (25). Control valve assembly: 185 kg INSTALLATION OF CONTROL VALVE ASSEMBLY * T-spoo! control valve (1 service valve) © Carry out installation in the reverse order to remo- val ‘© Refiling with oil (hydraulic tank) %* Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system, Then check the oil level again. % Bleed the air from the circuit between the valve and the hydraulic cylinder. For details, see ‘TESTING AND ADJUSTING, Bleeding air. 30-70 CONTROL VALVE 20866615] 2050620506 DISASSEMBLY AND ASSEMBLY CONTROL VALVE From front of machine 16 17 18 19 20 21 2 My 1 oe ra RR, Right side of machine Left side of machine Front of machine 5 a From rear of machine 26 24 24 25 30 26 27 28 ai 7 12 8 b From top of machine. ara 4 1 pe a 30-73DISASSEMBLY AND ASSEMBLY ASSEMBLY OF CONTROL VALVE ASSEMBLY + Before assembling, coat the sliding surface with engine oil. 1. RiHitravel control valve, L.H. travel control valve 1) Assemble spool assembly (53) to valve body. 2) Assemble retainer (56) and spring (55) to spool, then fit O-ring to case (54) and install. Gare) Case mounting bolt: 30.9 3.4 Nm (2.9 + 0.5 kgm) 3) Assemble retainer (52) and spring (61) to spool, then fit O-ring to case (60) and instal ==) Case mounting bolt: 30.9 & 3.4 Nm (2.9 0.5 kgm) 2. Swing control valve 1) Assemble spool assembly (49) to valve body. 2) Assemble retainer (44) and spring (42)t 0 ‘spool, then fit O-ring to case (41) and install. Gz) Case mounting bol 30.9 + 3.4 Nm (29+ 0.5 kgm) 3) Assemble retainer (48), and spring (46) to ‘spool, then fit O-ring to case (48) and install w=) Case mounting bolt: 30.9 4 3.4 Nm (2.94 0.5 kgm) 3. Arm control valve, boom control valve, bucket control valve 1) Assemble spool assembly (40) to valve body. 2) Assemble retainer (44), and spring (42) to spool, then fit O-ring to case (61) and install == Case mounting bolt: 30.9 + 3.4 Nm (2.9 £ 0.5 kgrn) 3) Assemble retainer (38) and spring (38) to spool, then fit O-ring to case (37) and install. >=) Case mounting bolt: 30.9 = 3.4 Nm (2.9 + 0.5 kgm) 4. Covers 1) Fit O-ring to cover (36) and install 2). Fit O-ring to cover (35) and install. ==) Mounting bolt: 166.7 © 9.8Nm(17 + tkgm) Tighten the mounting bolts in the order shown in the diagram. 5. LS shuttle valve, pump merge-divider valve, counterbalance valve 1). Assemble valve (60) and spring (59) to valve body, and install arm counterbalance valve Go. ==) Mounting bolt: 66.2 + 7.4 Nm (6.8 + 0.8 kgm) + Tighten the mounting bolts in the order shown in the diagram. 2) Assemble valve (58) and spring (67) to valve body, and install pump mergedivider valve (33). SEE] Mounting bott: 166.3 + 9.4 Nm (17 +1 kgm) 30-74 ® ‘Tighten the mounting bolts in the order shown in the diagram. 3) Install LS shuttle valves (32) and (31). G3=) Mounting bolt: 66.2 + 7.4 Nm (6.8 + 0.8 kgm) LS select valve Install LS select valve(30). Gu LS select valve: 127.5 £19.6 Nm (13 2 kgm) Pressure compensation valves + Check marks made on each pressure com- pensation valve when disassembling, and install in correct position. 1) Before installing pressure compensation valves below, install check valves (28) and (22). 2). Fit O-rings, then install arm IN pressure com- Pensation valve (28], LH. travel FORWARD pressure compensation valve (27), left swing pressure compensation valve (26) boom LOWER pressure compensation valve (25), RH. travel FORWARD pressure compensa- tion valve (24), and bucket CURL pressure compensation valve (23). 3) Fit O-rings, then install arm OUT pressure compensation valve (21), LH. travel REVERSE pressure compensation valve (20), right swing press (18), boom RAISE pressure compensa- tion valve (18), F.H. travel REVERSE pressure compensation valve (17), and bucket DUMP pressure compensation valve (16) == Pressure compensation valve: 2255 + 19.6 Nm (23: 2 kgm) Unload valves, safety-suction valves, suction valves 1) Fit O-rings and install suction valves (18), (14), (13), and (12). GE) Suction valve: 147.1. 9.8 Nm (15 + 1 kgm) 2) Fit O-ring and installs afety-suction valves (11, (10), (9), (8), (7), and (6). GHz] Safety-suction vaive: 147.1 + 9.8. Nm (15 + 1 kom) 3) Fit O-ring and install unload valves (6) and (4). x=) Unload valve: 98.1 + 9.8 Nm (10 + 1 kgm) ‘Main reliefvalve, mair unload - LS relief valve 1). Fit O-ring and install main unload + LS reliet valve (3) GE) Main unload « LS relief valv 85.9 + 7.4 Nm (8.8 + 0.8 kgm) 2). Fit O-fing and install main relief valve (1. m=) Main relief vaive: 53.9 + 4.9 Nm (6.5 + 0.5 kam) 2050620506 DISASSEMBLY AND ASSEMBLY CONTROL VALVE From front of machine 18 17 18 19 20 21 22 ——_‘Le#t side of machine Right side of machine 5 From tear of machine 26 3B 7 gm 5 30 2 TO 6 Front of machine From top of machine "A. tftDISASSEMBLY AND ASSEMBLY DISASSEMBLY OF PUMP MERGE-DIVIDER VALVE ASSEMBLY PUMP MERGE-DIVIDER VALVE if 0 G l capa l 1. Remove plug (2) from valve body (1), then remove spring (3) and spoo! (4). Remove plate (5) 3. Remove plug (6), then remove spring (7) and spool @) Remove plug (9). * After disassembling, if there is any abnormality in body (1) or spools (4) or (8), replace the whole pump merge-divider valve assembly. ASSEMBLY OF PUMP MERGE-DIVIDER VALVE ASSEMBLY ‘* Before assembling, coat the sliding surface with en- gine oil 1. Fit O-ring to plug (9) and install to valve body (1) SBD Plug (9): 38.7 + 6.4.Nm (4.0 + 0.6 kar) 2. Assemble spool (8) and spring (7), then fit O-ring to plug (6) and instal GE) Plug (6): 98.7 + 5.4 Nm (4.0 + 0.6 kgm) 3, Fit O-ring to plate (5) and install to valve body. 4. Assemble spool (4) and spring (3), then fit O-ring to plug (2) and install, SED Plug (2): 152.3 + 24.8 Nm (15.5 + 25 kam) 30-76 @O 2osrossi8 2050620506 MAINTENANCE STANDARD CONTROL VALVE CONTROL VALVE ‘Figure shows 9-spool control valve (with 3 service valve). 9-spool control valve includes 6-spool, 7-spool and 8-spool control valves. re = OTD Don Gun 1047-988 5m 10672 981im (ne tim (rs tign) Bt / stands © / = ie / elt aS a Se 2 ‘ a \ ‘ ) J | 30.92 3.4Nm oan Ee EE de 2 em GMEG02+74Nm Gu 6622 74NM Go 9224 Nm {6.75 + 0.75 kgm) (6.75 + 0.75 kgm) / fbeo3btgm) J yt / wm 662274Nm Ga) 1887 298m (es 075 K9m) (irs tam WAAAAR, Stott Ee 40-17