Ciruitos de Boom, Stick y Bucket - Texto

SERV1852
February 2008
GLOBAL SERVICE LEARNING
TECHNICAL PRESENTATION
300D SERIES HYDRAULIC

EXCAVATORS - TIER III ENGINES
BOOM, STICK, AND BUCKET CIRCUITS
(Includes 320D, 321D, 323D, 324D, 325D,
328D, and 330D)
Service Training Meeting Guide

(STMG)
300D SERIES HYDRAULIC
EXCAVATORS - TIER III ENGINES
BOOM, STICK, AND BUCKET CIRCUITS
AUDIENCE
Level II - Service personnel who understand the principles of machine systems operation,
diagnostic equipment, and procedures for testing and adjusting.
CONTENT
This presentation provides an introduction and describes the components and systems operation
of the 300D Series implement circuits - boom, stick, and bucket. Additional presentations will
cover the machine walkaround, engines, pilot system, main control valve group, implements,
swing system, travel system, and tool control systems in more detail. This presentation may be
used for self-paced and self-directed training.
OBJECTIVES
After learning the information in this presentation, the technician will be able to:
1. identify the correct operation of the boom, stick, and bucket on the 300D Series hydraulic
excavators, and
2. diagnose problems in the boom, stick, and bucket circuits.
REFERENCES
320D Hydraulic Excavator Specalog AEHQ5856
323D L and 323D LN Hydraulic Excavators HEHH3327
NPI "325D Hydraulic Excavator - Introduction" SERV7105-12
NPI "330D Hydraulic Excavator - Introduction" SERV7106-02
Machine Monitoring System - Systems Operation RENR8068
Self-study "300D Series Hydraulic Excavators, 345C Hydraulic Excavator,
and 365C & 385C Large Hydraulic Excavators SERV7032
iTIM " '300C' Series Hydraulic Excavators-Electronic Control Systems" SERV2693
iTIM "325C Hydraulic Excavators-Hydraulic Systems" SERV2701
325D Hydraulic Schematic KENR6157
Estimated Time: 1 1/2 Hours

Illustrations: 36
Form: SERV1852
Date: February 2008
© 2008 Caterpillar Inc.
SERV1852 -3- Text Reference
02/08
TABLE OF CONTENTS
INTRODUCTION ........................................................................................................................5
Boom Circuit...........................................................................................................................8
Stick Circuit .........................................................................................................................30
Bucket Circuit .......................................................................................................................43
Cylinders ...............................................................................................................................44
CONCLUSION ..........................................................................................................................46
02/08
PREREQUISITES
"Fundamentals of Mobile Hydraulics Self Study Course" TEMV3002
"Fundamentals of Power Train Self Study Course" TEMV3003
"Fundamentals of Electrical Systems Self Study Course" TEMV3004
"Fundamentals of Engines Self Study Course" TEMV3001
NOTES
02/08
IMPLEMENT CIRCUITS
Stick Cylinder
Bucket Cylinder Boom Cylinders
Swing Motor Travel Motors
Main Control Valve Group

Pilot
Control
Valves
Priority
Pilot Manifold Valves
Main
Pilot M
Hydraulic
Pump
Pumps
Fan
Fan Pump
Motor
Tank
The Fan Motor and Pump are only used on the 330D
INTRODUCTION
This presentation covers in more detail each implement circuit used for the 300D Series
Hydraulic Excavators. The circuits to be covered include:
- boom
- stick
- bucket
The idler pump provides oil to the boom 2 and stick 1 control valves. The drive pump provides
flow to the bucket, boom 1, and stick 2 control valves.
The boom, stick, and bucket control valves are shifted by pilot oil from the joystick pilot valves
when they are activated.
NOTE: The main control valve group and return system are covered in another
presentation. The attachment/auxiliary circuits will be covered in the electronic or tool
control section. The ISO schematics were created primarily from "325D Hydraulic
Schematic" (KENR6157). Hydraulic schematics for other 300D Series excavators
may/will have variations from illustrations shown.
02/08
4 3
1 5
2
The boom circuit uses two control valves to control the boom operation, boom 1 (1) and boom
2 (2). Both spools shift when fast boom movement is required. Both pumps provide flow to
the boom for this condition. Boom 1 valve provides single pump flow, whenever the boom is
shifted for slow movement.
The stick circuit also uses to two control valves to control the stick operation, stick 1 (3) and
stick 2 (4). Both spools shift when fast stick movement is required.
The boom circuit and stick circuits also use regeneration valves and drift reduction valves. The
regeneration valves (not shown) provide improved efficiency and require less engine
horsepower for BOOM LOWER and STICK IN.
The drift reduction valves reduce cylinder drift when the boom or stick are in NEUTRAL.
Only requires one control valve is required to control the bucket. The bucket circuit is supplied
with oil only from the drive pump.
02/08
1
2
The two joysticks in the cab are used to control the movements of the boom, stick, swing and
bucket circuits.
- right joystick (1) to control the bucket and boom (SAE excavator pattern)
- left joystick (2) to control the swing and stick (SAE excavator pattern)
02/08
MAIN HYDRAULIC SYSTEM Boom

BOOM CIRCUIT COMPONENTS Cylinders
Drift
Reduction
Valve
Boom 2
Boom 1
NFC
Orifice Main
Relief
Boom Regen
Valve
Heavy Lift Idler Pump

Solenoid
Swing / Stick Boom / Bucket Pilot Pump
Pilot Valve Pilot Valve M
Drive Pump
Boom
PRV
AEC Pressure
Switch
Pilot Manifold
Boom Circuit
The boom circuit consists of the following major components:
- boom 1 spool
- boom 2 spool
- boom cylinders
- drift reduction valve
- boom lowering control valves (if equipped)
- boom regeneration valve
- SmartBoom™ (if equipped)
NOTE: 325D Hydraulic Schematic (KENR6157) was used to develop the ISO
schematics.
02/08
Boom 1 Spool: The boom 1 spool controls oil flow from the drive pump. The boom 1 spool
receives a BOOM RAISE pilot signal on the bottom of the valve, and a BOOM LOWER pilot
signal on the top of the valve.
Boom 2 Spool: The boom 2 spool controls oil flow from the idler pump. The boom 2 spool
receives a BOOM RAISE pilot signal from the joystick on the top of the valve stem, when
active. The boom 2 spool does not operate during BOOM LOWER. The boom 2 spool has no
provisions for return oil from the boom cylinders.
Boom Cylinders: The boom cylinders work in parallel to control the raise and lower
movement of the boom. When oil is supplied to the head end of the boom cylinders, the boom
will raise. When oil is supplied to the rod end of the boom cylinders, the boom will lower.
Boom Drift Reduction Valve: The boom drift reduction valve prevents oil from leaking from
the head end of the boom cylinders. For BOOM LOWER, pilot oil from the joystick is used to
unlock the lock check valve in the drift reduction valve.
Boom Lowering Control Valves: The boom lowering control valves are infinitely variable,
pilot operated control valves that control the movement of the boom during lowering. The
boom lowering control valves are a safety device and prevent boom cylinder drift with valving
mounted directly on each of the boom cylinders, that controls boom cylinder head end oil flow.
Because the valves are mounted directly to each of the boom cylinders, the boom lowering
control valves will prevent the boom from falling, even if a hose becomes defective from the
main control valve to the cylinders.
The boom lowering control valves also work in conjunction with the SmartBoom™ system to
control the boom with the function active.
Regeneration Valve: The regeneration valve allows return oil from the head end of the boom
cylinders to be directed into the rod end of the cylinders when the boom is lowered fast.
SmartBoom™: The SmartBoom™ attachment enhances operation of the boom function and
significantly reduces cycle times of the machine. The SmartBoom™ is essentially a boom float
attachment, which allows the operator to lower the boom under its own weight or for the boom
to raise up due to stick force. The SmartBoom™ attachment is typically used in EAME.
SERV1852 - 10 - Text Reference
02/08
Port A Port B CONTROL VALVE

NEUTRAL
Load
Check
Valve Line Relief
and Makeup
Valve
Pilot Pilot
Valve Valve
Control
Parallel Spool
Center
Feeder
Bypass
Passage
Passage
As previously discussed, the control valve operation is similar for all of the valves in the main
control valve group including the boom, stick, and bucket valves. Pump flow is provided by
the drive and/or idler hydraulic pump. Which pump is used depends on the circuit.
The centering spring force holds the valve spool to NEUTRAL when there is no pilot oil
pressure directed to shift the spool.
In NEUTRAL the valve spool allows oil to flow unrestricted through the center bypass passage,
which directs a high NFC pressure signal to the pump control valve. The high NFC pressure
causes the pump to destroke to a standby condition, as explained previously.
02/08
MAIN HYDRAULIC SYSTEM

BOOM RAISE - SLOW SPEED
Drift
Reduction
Valve
Boom 2
Stick 2
Boom 1
NFC
Orifice Main
Relief
Boom Regen
Valve

Solenoid
Drive Pump
Boom
PRV
AEC Pressure
Switch
Pilot Manifold
When the boom joystick is moved less than half of the travel distance for BOOM RAISE, low
pilot oil pressure is supplied to the boom 1 control valve and the boom 2 control valve.
The force of the centering spring in the boom 1 control valve is less than the force of the
centering spring in the boom 2 control valve. When the boom is raised at a low speed, the
boom 1 control valve opens and the boom 2 control valve remains closed due to the low pilot
pressure.
The drive pump supply oil supply oil flows past the boom 1 control valve and unseats the check
valve in the drift reduction valve and flows to the head end of the boom cylinders.
Return oil from the rod end of the boom cylinders returns back to the tank through the boom 1
control valve.
With the boom valve partially shifted less oil is directed to the NFC relief valve. Less oil to the
NFC relief valve results in a reduced NFC signal to the drive pump. The drive pump control
valve causes the pump to upstroke to provide flow to operate the boom.
A BOOM RAISE operation at low speed is accomplished when only the drive pump is supplied
to the head end of the boom cylinders.
02/08
BOOM 1 CONTROL VALVE

BOOM RAISE PARTIAL SHIFT
Boom Boom
Head End Rod End
Load NFC SIgnal

Check Valve
Parallel
Feeder
Passage
Joystick
Center
Bypass Boom
Passage Regen Valve
When the operator begins to move the joystick to shift the boom 1 control valve, metered pilot
pressure causes the control valve to shift slightly.
With the spool initially shifted, the center bypass passage is partially closed. This movement
causes NFC pressure to decrease, which signals the drive pump to begin to upstroke.
The load check valve prevents unexpected implement movements when a joystick is initially
activated at a low pump delivery pressure. The load check valve also prevents oil loss from a
high pressure circuit to a lower pressure circuit.
As the pump supply pressure increases, the load check valve opens to allow pump supply oil in
the parallel feeder passage to flow to the control spool.
The control spool meters pump supply oil to the head ends of the boom cylinders.
02/08

BOOM RAISE - FAST SPEED
Drift
Reduction
Valve
Boom 2
Boom 1
NFC
Orifice Main
Relief
Boom Regen
Valve

Solenoid
Drive Pump
Boom
PRV
AEC Pressure
Switch
Pilot Manifold
A BOOM RAISE operation at high speed is accomplished when supply oil from both the idler
pump and the drive pump is supplied to the head end of the boom cylinders.
Boom 1 control valve and boom 2 control valve are both shifted during high speed operation.
02/08

BOOM RAISE FULL SHIFT
Boom Boom
Head End Rod End
Load
Check Valve
NFC SIgnal
Parallel
Feeder
Passage
Joystick
Boom
Regen Valve
Center
Bypass
Passage
As the operator moves the joystick farther, the pilot pressure on the end of the spool increases.
The increased pilot pressure causes the boom 1 spool to shift further to the right.
The center bypass passage is now closed, which blocks the oil flow to the NFC signal port on
the right pump control valve. When the NFC signal is reduced, the pump upstrokes and flow is
increased. The increased flow can no longer return to tank through the center bypass passage.
All oil now flows through the parallel feeder path.
The increased oil flow to the parallel feeder passage causes pressure to rise in the parallel
feeder passage. The increased oil pressure overcomes the force of the load check spring and
the boom head end pressure, which causes the load check valve to unseat. Oil flows out to
boom cylinders.
The oil returning from the rod end of the cylinders flows past the spool and returns to tank.
02/08
Variable Swing
Priority Valve BOOM 2 CONTROL VALVE
FAST BOOM RAISE
Swing Priority
Pressure
Reducing Valve
Boom Cylinder
Rod End Boom Cylinder
Head End
Parallel Feeder
Passage Load Check
Valve
Center Bypass
Passage Control Spool
10
The pilot oil flow shifts the boom 2 control valve. The idler pump supply oil in the parallel
feeder passage flows past the check valve and flows out to the head end of the boom cylinders.
The idler pump supply oil combines with the drive pump supply oil at the boom drift reduction
valve (not shown) and flows to the head end of boom cylinders.
Return oil from the rod end of boom cylinders flows to the boom 1 control valve and then to
the tank. The boom 2 control valve does not handle any of the return flow for the boom circuit.
NOTE: The swing priority valve does not affect the operation of the boom 2 control
valve.
02/08

BOOM PRIORITY - BOOM RAISE AND STICK IN
Drift
Reduction
Valve
Stick Regen
Valve
Boom 2
Stick 2
Boom 1
Stick 1
NFC
Orifice Main
Relief
Boom Regen
Stick Unloading Valve
Valve

Solenoid
Drive Pump
Boom
PRV
AEC Pressure
Switch
Pilot Manifold
11
During combined operations of BOOM RAISE and STICK IN, the boom raise pilot oil pressure
shifts the pressure reducing valve for the boom priority valve to reduce the stick in pilot
pressure for the stick 2 control valve. With the reduction in stick in pilot pressure to the stick 2
control valve, more pump flow is directed to the boom cylinders during this combined
hydraulic operation.
NOTE: For STICK IN, the stick circuit regeneration valve will shift to direct return oil
from the rod end of the stick cylinder to the head end of the cylinders.
When the joystick for the stick is moved to the STICK IN position, a portion of the pilot oil
from the pilot control valve for the stick flows through the pressure reducing valve for the
boom priority to the stick 2 control valve. As the joystick for the boom is moved farther for a
BOOM RAISE, pilot oil pressure from the pilot control valve for the boom increases. This
gradual increase in pilot oil pressure causes the spool in the pressure reducing valve for the
boom priority to gradually shift.
A portion of the pilot oil to the stick 2 control valve from the stick pilot control valve is
restricted by the boom priority valve. The pilot oil pressure acting on the stick 2 control valve
decreases.
02/08
The stick 2 control valve shifts toward the NEUTRAL position. The amount of oil flow from
the main pumps to the stick hydraulic circuit decreases. This change causes a greater portion of
the oil flow from the main pumps to flow to the head end of the boom cylinders.
Since the pilot oil pressure from the boom pilot control valve directly corresponds to the
amount of movement or position of the boom joystick a gradual change to boom priority
occurs.
Thus, boom priority is controlled by the position of the joystick for the boom and boom priority
automatically activates when the joystick reaches a certain position during a BOOM RAISE
operation.
The above information describes the condition of BOOM RAISE and STICK IN. During any
combined function of BOOM RAISE and STICK IN, the pressure reducing valve for boom
priority reduces pilot pressure to the stick 2 control valve.
NOTE: If the joysticks are fully shifted for BOOM RAISE and STICK IN, stick in pilot
pressure on the bottom of the boom 2 cancels the boom raise pilot pressure on top of the
boom 2 spool. At the same time the boom priority valve prevents stick in pilot pressure
from going to the stick 2 control valve.
These two actions result in the drive pump supplying oil to the boom cylinders and the
idler pump providing oil to the stick cylinder.
02/08

BOOM LOWER WITH REGENERATION
Drift
Reduction
Valve
Boom 2
Boom 1
NFC
Orifice Main
Relief
Boom Regen
Valve

Solenoid
Drive Pump
Boom
PRV
AEC Pressure
Switch
Pilot Manifold
12
For BOOM LOWER only the boom 1 control valve is used. The drive pump partially strokes
to provide flow to the rod end of the boom cylinders.
When the joystick is shifted pilot oil moves the boom 1 control spool down, the regeneration
valve right, and unlocks the drift reduction valve. When the boom 1 control spool is fully
shifted, the center bypass valve is never fully closed off. By not closing off the center passage,
there is an NFC signal to the drive pump. The drive pump never fully upstrokes.
Due to the force of gravity, with the lock valve unlocked, the weight of the boom and the load
on the boom, force the return oil out of the cylinder head ends back to the regeneration valve
and the boom 1 control valve.
The boom 1 control valve restricts the return oil flow. Whenever the return oil pressure is
higher than the supply pressure in the rod end of the cylinders, the return oil from the boom
cylinder head ends unseats the check valve above the regeneration valve.
The return oil from the head end enters the supply passage to the rod end to help fill the
cylinders and prevent cylinder cavitation. The regeneration valve allows the excavator to
operate more efficiently. The main pump supply oil not required to lower the boom is available
to operate another circuit.
02/08

BOOM LOWER
Load Check Head End Rod End

Valve
NFC Signal
Parallel
Feeder
Passage
Center Boom
Bypass Regen Valve
Passage
13
The boom pilot oil flow from shifts the boom control spool to the left against the force of the
centering spring. Supply oil from the drive pump in the parallel feeder passage flows past the
load check valve to the rod end of the boom cylinders.
Some of the oil in the center bypass passage flows past the center land to provide a reduced
NFC signal. The reduced NFC signal causes the drive pump to only partially upstroke.
Part of the return oil from the head end of boom cylinders flows to the boom drift reduction
valve.
02/08
Low Boom Down

Pilot Pressure
BOOM REGENERATION VALVE
SLOW BOOM DOWN
Check
Valve
Boom A A
Cylinder
Rod End
Boom
Cylinder
Head End
Regen Spool
A-A
14
The boom regeneration valve has two components, the boom regeneration valve itself and the
check valve.
During a slow BOOM DOWN, the low pilot pressure is not able to move the regeneration valve
down so return oil from the the boom cylinder head ends is not able to flow to the boom
cylinder rod ends.
02/08
High Boom Down

Pilot Pressure BOOM REGENERATION VALVE
FAST BOOM DOWN
Check
Valve
A A
Boom
Cylinder
Rod End
Boom
Cylinder
Head End
Regen Spool
A-A
15
When boom lower pilot pressure increases, the boom regeneration valve is pushed down, a
passage is opened allowing boom head end oil to flow to the check valve. If the boom rod end
pressure is lower than the boom head end oil pressure, then the check valve opens allowing
boom head end oil to be directed to the boom rod end.
The check valve closes if the boom rod end oil pressure is higher than the boom head end oil
pressure, such as when the boom is being powered down.
02/08
BOOM DRIFT REDUCTION VALVE

BOOM RAISE
Manual Bleed
Valve
Line Relief
Valve B
Check Valve B
Boom 2
Shuttle
Valve
A-A
Boom 1
From Boom 1
And Boom 2
Control Valves
To Boom Cylinders Lock Check

Head End Valve
Shuttle Valve
A A
Line Relief Valve Line Relief Shuttle

Valve Valve
B-B
16
Boom Drift Reduction Valve: The boom drift reduction valve prevents oil from leaking from
the head end of the boom cylinders. The boom drift reduction valve is located on the main
control valve group. The boom drift reduction valve has the following components:
- the shuttle valve
- the check valve
- the line relief valve
In NEUTRAL, the shuttle valve and check valve are closed by spring force. Oil is blocked
between the boom control valve and the boom cylinders.
For BOOM RAISE, the shuttle valve is closed by spring force. When closed, the shuttle valve
allows oil from the boom control valves to act on one end of the check valve.
Oil pressure from the boom control valves acts on the other end of the check valve. The check
valve opens (due to pressure differential on check valve) to allow oil flow to the rod end of the
boom cylinders.
02/08
BOOM DRIFT REDUCTION VALVE

BOOM LOWER
Manual Bleed
Valve
Line Relief
Check Valve Valve B B
Boom 2
Shuttle To Tank
Valve
Boom 1
To Boom 1
Control Valve
From Boom Cylinders

Head End Check
Valve
Shuttle Valve
A A
Line Relief Valve Line Relief Shuttle

Valve Valve
B-B
17
For BOOM LOWER, the shuttle valve is opened by pilot oil from the joystick. The shuttle
valve allows oil from the spring end of the check valve to return to tank.
Oil pressure from the boom cylinder head end opens the check valve. The check valve allows
oil flow from the head end of the boom cylinders to return to the boom control valve.
02/08
5 4
2
6
18
The boom lowering control valves (1 and 2) are mounted on the head end of the boom
cylinders.
The boom lowering control valves serve several purposes:

- prevent the boom from falling rapidly in case of hose failure
- provide BOOM LOWER control with SmartBoom™ (if equipped) activated
- prevent boom drift
The lowering control valves are equipped with head end line relief valves (3) to protect the
cylinders from sudden shocks.
A pilot line (4) directs pilot oil to unlock the lowering control valve so the boom can be
lowered.
The tube (5) provides supply oil from the boom control valve.
A hose (6) connects both lowering control valves. The line provides for equalization of
pressures in the head end of the cylinders when the boom is raised or lowered to provide
smooth movement.
02/08
Boom
Down Pilot
BOOM LOWERING CONTROL VALVE
NEUTRAL
Boom Cylinder Head End

Line Relief Valve Tank
Boom Control
Valve Check Valve
Boom Control
Boom Lowering Valve
Control Valve
Equalization
Passage
Opposite
Cylinder
Manual
Lower
Boom Orifice Opposite

Down Pilot Cylinder
Boom Control
Valve
Head End
19
Boom Lowering Control Valves
The boom circuit is equipped with boom lowering control valves (or load control valves),
which are attached directly to each of the boom cylinders.
The boom lowering control valves contain the following major components:
- boom head end line relief
- check valve
- boom lowering control valve spool
- orifice
- manual lower
02/08
Boom Head End Line Relief: The boom head end line relief protects the boom head end
circuit from damage if the pressure in the circuit exceeds the line relief setting.
Check Valve: The check valve holds the high pressure of the boom cylinder head end
from leaking off. Because the weight of the boom, stick, and work tool are always applied
to the head end of the boom cylinder, the check valve is needed to prevent the high
pressure from leaking off and allowing the boom to drift. The check valve also provides
an unrestricted means for the high pressure/high flow oil from the main control valve to
enter the boom cylinder head end during BOOM UP.
Boom Lowering Control Valve Spool: The infinitely variable boom lowering control
valve spool controls the flow of oil exiting the boom cylinder head end. The top of the
spool receives pilot pressure from the boom lower joystick. When the valve opens, oil
flows from the head end back to the main control valve. Because the valve is infinitely
variable and controlled by boom lower pilot pressure, the speed that the boom lowers is
controlled by the boom lowering control valve spool.
Orifice: The boom lowering control valves on each cylinder are connected by a small
hose. The hose ensures that pressure is always equal in the two cylinders. The orifice in
each of the boom lowering control valves restricts the amount of oil that flows from one
cylinder to the other. The restriction created by the orifice will allow control over the
boom in the event that the hose ruptures. Under normal operation the orifice plays no role
in boom operation.
Manual Lower: Manual lower allows the boom to be lowered if the engine will not run.
The valve allows the oil pressure in the head head end of the cylinder to bleed to the tank.
NEUTRAL: When no boom function is performed the boom lowering control valve is in
NEUTRAL. In NEUTRAL no oil flows to or from the boom cylinders, and the boom does
not move.
In NEUTRAL, the check valve is seated by the combination of the spring force and the high
pressure oil in the head end of the boom cylinders.
The boom lowering control valve spool is seated by the combined force of the high pressure oil
from the boom cylinder head end and the force of the spring on the left of the spool.
The boom lowering control valves have no effect on the flow of oil to/from the rod end of the
boom cylinders.
02/08
Boom
BOOM LOWERING CONTROL VALVE Down Pilot
BOOM UP

Boom Control
Valve
Check Valve
Boom Control
Boom Lowering Valve
Control Valve
Equalization
Passage
Opposite
Cylinder
Boom
Orifice Opposite
Down Pilot
Cylinder
Boom Control
Valve
Head End
20
When BOOM UP is performed the boom lowering control valve allows oil to pass from the
main control valve to the head end of the boom cylinders.
High pressure oil from the main control valve enters the boom lowering control valve on the
right side.
As the supply pressure increases, the check valve opens and allows oil to flow to the head end
of the boom cylinder.
The boom lowering control valve spool remains seated by the force of the spring on the left of
the spool.
The boom head end line relief ensures that the maximum pressure in the boom cylinder head
does not exceed specifications.
02/08
Boom
BOOM LOWERING CONTROL VALVE Down Pilot
BOOM LOWER (METERED)

Boom Control
Valve Check Valve
Boom Control
Boom Lowering Valve
Control Valve
Equalization
Passage
Opposite
Cylinder
Orifice
Boom
Down Pilot
Boom Control
Valve
Head End
21
When a partial BOOM LOWER is performed the boom lowering control valve allows oil to
flow at a controlled rate from the head end of the boom cylinders to the return system.
The boom lower pilot oil from the operator joystick enters the boom lowering control valve
above the boom lowering control valve spool. The pilot pressure that moves the spool down
against the spring force.
The movement of the spool partially opens a passage to allow flow from the boom cylinder
head end to the return system. Since this flow is restricted by the spool, the boom lowers at a
controlled rate.
The farther the joystick is moved, the higher the pilot pressure on the spool, the greater the
movement of the spool, and the greater the flow from the boom cylinder head end to the tank
past the boom control valve.
The check valve remains closed.

02/08
Boom
Down Pilot
BOOM LOWERING CONTROL VALVE
BOOM LOWER

Boom Control
Valve
Check Valve
Boom Control
Boom Lowering Valve
Control Valve
Equalization
Passage
Opposite
Cylinder
Orifice
Boom
Down Pilot Boom Control
Valve
Head End
22
For a full BOOM LOWER, the boom lowering control valve allows oil to flow with little
restriction from the head end of the boom cylinders to the return system.
The full boom lower pilot signal from the operator joystick enters the boom lowering control
valve above the boom lowering control valve spool. The pilot moves the spool fully down
against the spring force.
The movement of the spool fully opens the passage to allow oil to flow from the boom cylinder
head end to flow to the tank past the boom control valve. This flow of oil causes the boom to
lower quickly.
The check valve remains closed.

02/08

STICK CIRCUIT COMPONENTS
Stick
Cylinder
Drift
Reduction
Valve
Stick Regen
Valve
Stick 2
NFC Stick 1
Orifice Main
Relief
Variable Swing
Stick Unloading Priority Valve
Valve

Solenoid
Swing / Stick Boom / Bucket Swing Pilot Pump
Pilot Valve Pilot Valve PRV M
Drive Pump
Boom
PRV
AEC Pressure
Switch
Pilot Manifold
23
Stick Circuit
The stick circuit consists of the following major components:
- stick 1 spool
- stick 2 spool
- stick cylinder
- stick regeneration valve
- stick unloading valve
- stick lowering control valves (not shown)
- stick drift reduction valve
NOTE: The stick priority systems and the stick drift reduction valve will be discussed
in more detail later in this presentation.
02/08
Stick 1 Spool: The stick 1 spool controls oil flow from the left pump. The stick 1 spool
receives a STICK IN pilot signal on the bottom of the valve, and a STICK OUT pilot signal on
the top of the valve.
Stick 2 Spool: The stick 2 spool controls oil flow from the drive pump. The stick 2 spool
receives a STICK IN pilot signal from the joystick on the bottom of the valve stem. The stick
2 spool receives a STICK OUT pilot signal from the joystick on the top of the valve stem.
Stick Cylinder: When oil is supplied to the head end of the stick cylinder, the stick will retract
for a STICK OUT. When oil is supplied to the rod end of the stick cylinder, the stick will
extend for a STICK IN.
Stick Regeneration Valve: The stick regeneration valve opens during STICK IN to allow
returning oil from the rod end of the stick cylinder to be directed to the head end of the stick
cylinders during STICK IN. Regeneration is used to reduce "stick wag" and increase the stick
in speed.
Stick Unloading Valve: The unloading valve allows the oil to return to the tank when
regeneration is not necessary.
Stick Drift Reduction Valve: The stick drift reduction valve is placed in the stick circuit
between the main control valve and the stick cylinder. The stick drift reduction valve prevents
oil from leaking from the rod end of the stick cylinder. The stick drift reduction valve also
incorporates the line relief valve for the rod end of the stick cylinder.
02/08
MAIN HYDRAULIC SYSTEM Boom

STICK OUT Cylinders
Stick
Cylinder
Drift
Reduction
Valve
Stick Regen
Valve
Stick 2
NFC Stick 1
Orifice Main
Relief
Variable Swing
Valve

Solenoid
Drive Pump
Boom
PRV
AEC Pressure
Switch
Pilot Manifold
24
When the stick hydraulic circuit is operated independently of other hydraulic circuits, stick 1
control valve and stick 2 control valve are operational for both the STICK IN and STICK OUT
operation. When the stick 1 control valve and the stick 2 control valve are operated, the supply
oil from the idler pump and the drive pump is combined. The supply oil from both pumps
flows to the stick cylinder.
The supply oil from the drive pump flows through the parallel feeder passage in the main
control valve group to the stick 2 control valve. The supply oil fromthe idler pump flows
through the center bypass passage in the main control valve group to the stick 1 control valve.
When the joystick for the stick is moved to STICK OUT, the pilot oil flows from the pilot
control valve to the stick 1 control valve and the stick 2 control valve.
The pilot oil shifts the stick 1 and stick 2 control valve spool. Supply oil is directed from both
spools to the stick drift reduction valve. The lock check valve in the drift reduction valve shifts
and combined pump oil flows to the rod end of stick to retract the cylinder.
Return oil from the head end of the stick cylinder flows back to the stick 1 and stick 2 control
valves and to the tank.
02/08

STICK IN - SLOW WITHOUT REGENERATION
Stick
Cylinder
Drift
Reduction
Valve
Stick Regen
Valve
Stick 2
NFC Stick 1
Orifice Main
Relief
Variable Swing
Valve

Solenoid
Drive Pump
Boom
PRV
AEC Pressure
Switch
Pilot Manifold
25
Slow STICK IN - No Regeneration
Depending on the position of the stick, for a slow stick in, regeneration may not be required due
to the supply oil from the pump being able to fill and pressurize the head end of the stick
cylinder to force the stick in.
For a slow STICK IN the pilot signal is reduced and will only partially shift the stick 1 spool.
The stick 2 control valve may or may not shift.
Pilot oil shifts the regeneration valve to the left, which allows return oil to be sensed at the
check valve.
The regeneration valve also allows pump supply oil pressure to be sensed at the unloading
valve. The unloading valve does not shift due to the supply oil pressure being below the setting
of the unloading valve spring.
A reduced NFC signal is sensed at the idler pump, and the pump upstrokes to provide flow.
02/08
Most of the supply oil from the idler pump is directed to the stick cylinder head end through
the stick 1 control spool.
Return oil from the rod end flows to the drift reduction valve. The lock check valve in the drift
reduction valve is unseated and return oil flows back to the tank through the stick 1 control
valve.
Even though the return oil is restricted through the stick 1 control spool, the back pressure
created is insufficient to cause the return oil pressure to be above the supply pressure. The
check valve remains seated.
02/08
From
STICK REGENERATION VALVE
Stick Out REGENERATION OFF
Pilot
Stick
Regeneration
Valve
Check Stick
Valve Unloading
Valve
To
Head End
From
Rod End
A A
A-A
26
The stick 1 spool restricts the return oil from the stick rod end. The restriction at the stick 1
spool creats back pressure in the stick cylinder rod end return circuit. Because the stick is
moving slow, the back pressure is relatively low.
The returning oil also is directed to the stick regeneration valve. The stick regeneration valve is
opened by the STICK IN pilot signal from the joystick. The return oil flows to the check valve
between the rod end and head end circuits.
Because the returning oil pressure is not great enough to overcome the combined force of the
check valve spring and the pump supply oil, the check valve remains closed. When the check
valve is closed, regeneration does not occur.
The stick cylinder head end pressure or pump supply pressure is sensed by the stick unloading
valve. Due to low head end pressure, the valve remains closed, which blocks the passage to
drain.
02/08

STICK IN - FAST WITH REGENERATION
Stick
Cylinder
Drift
Reduction
Valve
Stick Regen
Valve
Stick 2
NFC Stick 1
Orifice Main
Relief
Variable Swing
Valve

Solenoid
Drive Pump
Boom
PRV
AEC Pressure
Switch
Pilot Manifold
27
Fast STICK IN - Regeneration: For a fast STICK IN, or whenever the return oil pressure
from the rod end is higher than the supply pressure to the head end, the check valve will unseat.
When the check valve unseats, the return oil is added to the supply oil going to the head of the
stick cylinder.
The regeneration valve allows the excavator to operate more efficiently. The main pump supply
oil not required to move the stick in is available to operate another circuit.
02/08
From
Stick Out
STICK REGENERATION VALVE
Pilot REGENERATION ACTIVE
Stick
Regeneration
Valve
Stick
Check Unloading
Valve Valve
To
Head End
From
Rod End
A A
A-A
28
The restriction at the stick 1 spool, and the lack of return provisions in the stick 2 spool create
back pressure in the stick cylinder rod end return circuit. Because the stick is moving fast, the
back pressure is relatively high.
The returning oil also is directed to the stick regeneration valve. The stick regeneration valve is
opened by the STICK IN pilot signal from the joysticks.
The return oil flows to the check valve between the rod end and head end circuits. The
returning oil pressure overcomes the combined force of the check valve spring and the pump
supply oil, and the check valve opens. Returning oil from the rod end of the stick cylinder now
is redirected to the head end of the stick cylinder.
The stick cylinder head end pressure is sensed by the stick unloading valve. Due to low head
end pressure, the valve remains closed, which blocks the passage to drain.
02/08
From STICK REGENERATION VALVE

Stick Out
Pilot UNLOADING ACTIVE
Stick
Regeneration
Valve
Stick
Check Unloading
Valve Valve
To
Head End
From
Rod End
A A
A-A
29
Stick unloading occurs when the stick reaches vertical to the ground and as the stick moves
further in towards the machine. A pressure spike occurs which helps to open the unloading
valve to rapidly reduce rod end pressure. When the unloading valve opens, the oil flow to the
stick cylinder is from the pumps.
When the regeneration valve is shifted and the supply oil to the head end of the stick cylinder is
higher than the return oil from the rod end, the check valve will close.
No return oil enters the passage to the head end. As the pressure in the head end of the cylinder
increases, the pressure moves the unloading valve lower.
When the unloading valve moves down, most of the return oil from the rod end of the cylinder
returns to the tank past the unloading valve instead of through the stick 1 control valve.
Stick regeneration and stick unloading will not be active at the same time.
02/08
Summary of stick regeneration functions: The lack of a passage to drain in the stick 2 valve
and the restricted oil flow through the stick 1 valve maintains back pressure in the rod end as
STICK IN is performed.
This back pressure maintains pressure on the stick cylinder, which prevents "stick wag" from
occurring. Stick regeneration allows the returning oil from the rod end of the cylinders to
combine with main pump flow to move the stick cylinders out.
The unloading valve allows a means to relieve the back pressure from the returning rod end oil,
when the oil is no longer needed for regeneration.
02/08
STICK DRIFT REDUCTION VALVE

A
From Stick 1 NEUTRAL

and Stick 2
Control
Valve
B To Stick
Cylinder
Rod End
To Stick
Cylinder
Rod End
From Stick 2
Control
A Valve
From Stick 1
From Stick 1 Control
and Stick 2 Valve
Control Stick In
Valve Pilot Shuttle
Pressure Valve
Lock Check
Valve
To Stick Drain
Cylinder
Rod End
B-B
Stick Out
Line Relief
Valve
30
The stick drift reduction valve is located in the stick circuit on the main control valve group as
part of the stick 1 spool. The stick drift reduction valve prevents oil from leaking from the rod
end of the stick cylinder. The stick drift reduction valve has the following components:
- shuttle valve
- lock check valve
- line relief valve
In the NEUTRAL position, the shuttle valve and lock check valve are closed by spring force.
Oil is blocked between the stick control valve and the stick cylinder.
02/08

A
From Stick 1
STICK OUT
and Stick 2
Control
Valve
B
To Stick
Cylinder
Rod End
To Stick
Cylinder
Rod End
From Stick 2
Control
A Valve
From Stick 1
From Stick 1 Control
and Stick 2 Valve
Control Stick In
Valve Pilot Shuttle
Pressure Valve
Lock Check
Valve
To Stick Drain
Cylinder
Rod End
B-B
Stick Out
Line Relief
Valve
A-A
31
For STICK OUT, the shuttle valve does not shift. The shuttle valve allows oil from the stick
control valves to act on one end of the lock check valve.
Oil pressure from the stick control valves acts on the other end of the check valve. The check
valve opens (due to the pressure differential on the check valve) to allow oil flow to the rod end
of the stick cylinder.
02/08
A
To Stick 1 STICK IN
To Stick 1
Control
Control
Valve
Valve
B From Stick
Cylinder
Rod End
From Stick
Cylinder
Rod End
To Stick 2
To Stick 1 Control
Control Valve
A Valve
To Stick 1
Stick In Control
Pilot Shuttle Valve
Pressure Valve
From Stick Drain

Cylinder
Rod End
B-B
Stick Out
Line Relief
Valve
A-A
32
For STICK IN, the shuttle valve is moved down by pilot oil from the joystick.
The shuttle valve allows oil in the lock valve spring chamber to flow to the tank.
Return oil from the stick cylinder rod end moves the lock check valve to the left against the
lock check valve spring.
The open lock check valve allows oil flow from the rod end of the stick to return to the stick 1
control valve and the regeneration valve.
02/08

BUCKET CLOSE
Bucket
Cylinder
Bucket
NFC
Orifice Main
Relief

Solenoid
Drive Pump
AEC Pressure
Switch
Pilot Manifold
33
Bucket Circuit
The bucket circuit control valve operates as previously discussed. Two line relief valve and
makeup valves are used to protect the lines from high pressures.
The bucket is only supplied by the drive pump. Pilot oil from the joystick is directed to the
bucket control valve to shift the control spool.
When the control spool shifts, the NFC signal to the drive pump is reduced and the pump
upstrokes to provide flow.
For BUCKET CLOSE, the return oil from the rod end of the cylinder is restricted by the
control spool to control the bucket speed.
02/08
Boom
Cylinder
Snubber Snubber
Stick
Cylinder
Bucket
Cylinder
34
Cylinders
The boom, stick, and bucket use dual acting cylinders. The boom has a snubber for the rod
end, while the stick uses snubbers on the rod and head end.
Snubbers slow the speed of the cylinder as the cylinder reaches the end of the cylinder stroke.
02/08
SNUBBER OPERATION Passage Snubber
BOOM AND STICK CYLINDER

EXTENDING ROD
Snubber Passage
STICK CYLINDER
RETRACTING ROD
35
As the boom or stick cylinder moves to the end of the extension stroke, oil in the passage will
be restricted by the snubber, which will slow the cylinder lower.
As the stick cylinder moves to the end of the retraction stroke oil in the passage will be
restricted by the snubber, which will slow the cylinder down.
02/08
36
CONCLUSION
This presentation has provided information for the 300D Series Caterpillar Hydraulic
Excavators.
This section of the presentation covered the boom, stick, and bucket circuits.
When used in conjunction with the service manual, the information in this package should
permit the technician to do a thorough job of analyzing a problem in these systems.
For service repairs, adjustments, and maintenance, always refer to the Operation and
Maintenance Manual, Service Manuals, and other related service publications.

Ciruitos de Boom, Stick y Bucket - Texto

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SERV1852

GLOBAL SERVICE LEARNING

300D SERIES HYDRAULIC

Service Training Meeting Guide

Estimated Time: 1 1/2 Hours

Swing Motor Travel Motors

Main Control Valve Group

MAIN HYDRAULIC SYSTEM Boom

Heavy Lift Idler Pump

The boom circuit consists of the following major components:

- drift reduction valve

- boom lowering control valves (if equipped)

- boom regeneration valve

- SmartBoom™ (if equipped)

Port A Port B CONTROL VALVE

MAIN HYDRAULIC SYSTEM

Heavy Lift Idler Pump

BOOM 1 CONTROL VALVE

Load NFC SIgnal

MAIN HYDRAULIC SYSTEM

Heavy Lift Idler Pump

BOOM 1 CONTROL VALVE

MAIN HYDRAULIC SYSTEM

Heavy Lift Idler Pump

MAIN HYDRAULIC SYSTEM

Heavy Lift Idler Pump

BOOM 1 CONTROL VALVE

Load Check Head End Rod End

Low Boom Down

High Boom Down

BOOM DRIFT REDUCTION VALVE

To Boom Cylinders Lock Check

Line Relief Valve Line Relief Shuttle

- the shuttle valve

- the check valve

- the line relief valve

BOOM DRIFT REDUCTION VALVE

From Boom Cylinders

Line Relief Valve Line Relief Shuttle

The boom lowering control valves serve several purposes:

Boom Cylinder Head End

Boom Orifice Opposite

Boom Lowering Control Valves

Boom Cylinder Head End

BOOM LOWER (METERED)

Boom Cylinder Head End

The check valve remains closed.

Boom Cylinder Head End

The check valve remains closed.

MAIN HYDRAULIC SYSTEM

Heavy Lift Idler Pump

The stick circuit consists of the following major components:

- stick regeneration valve

- stick unloading valve

- stick lowering control valves (not shown)

- stick drift reduction valve

MAIN HYDRAULIC SYSTEM Boom

Heavy Lift Idler Pump

MAIN HYDRAULIC SYSTEM

Heavy Lift Idler Pump

Slow STICK IN - No Regeneration

MAIN HYDRAULIC SYSTEM

Heavy Lift Idler Pump

From STICK REGENERATION VALVE

STICK DRIFT REDUCTION VALVE

STICK DRIFT REDUCTION VALVE