Hydraulic system

Hydraulic system components

Warranty
Crane hydraulics and terrain steering
Hydraulic oil tank
Service valve
Valve assembly crane
Valve assembly base machine
List of pressure outlets
Working hydraulic pump
Vacuum and filling pump
Hydraulic oils
Working temperature
Change intervals
Oil sample
Water content
Oxidation
Hydraulic oil in machines supplied from the factory
Storage and handling
Cleaning after oil leaks
Hydraulic diagram
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Hydraulic system

3 Hydraulic system components

The hydraulic system is load-sensing with a variable
axial piston pump. The system detects signals from the
2 control joysticks, and distributes precisely the amount of
oil and pressure required.

The system is a “closed centre”, which means that

the directional control valves are closed in the neutral
position. No oil is pumped around other than that
5
currently being used.
4
1. Working hydraulic pump
1 2. Hydraulic tank
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3. Service valve
4. Valve assembly crane
5. Valve assembly base machine

Note!
• Repairs and adjustments to the pressure should
be performed by authorised service personnel, if
not otherwise stated in this Manual.
• To check and replace hydraulic oil, hydraulic
filters, etc., see the chapter “Maintenance and
Inspection”.
• Only hydraulic oil approved by Komatsu Forest
AB should be used in the hydraulic system.
• If a hose is disconnected for an extended period,
the connections should be plugged with plastic or
steel plugs.
• When replacing hoses, only use Komatsu Forest
original hoses.

Warranty
In the event of a breakdown of components in the
hydraulic system, where the oil is a possible cause, the
follow rules apply with regard to warranty.

• Oil samples and oil analyses should be performed at

the time of the breakdown.
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• Complaints should be submitted. Enclose oil analysis

report from the breakdown and reports from previous
oil samples.

Crane hydraulics and terrain steering

The crane hydraulics are controlled by the control
system, which facilitates individual settings for several
drivers.

The crane’s control joysticks are situated on the driver’s

seat. The joysticks are used to regulate the current to the
control system and on to the hydraulic valves.

The crane’s functions are automatically engaged with

operation, except when you select the transport gear. The
crane symbol on the MaxiXplorer’s screen lights green
when the crane functions are engaged.

The terrain steering is always activated (automatically)

and is controlled with a control by the right joystick. All
crane functions have infinitely variable controls, i.e. the
speed of movement increases with the movement of the
joysticks.

Electronic units
• MaxiPC: Computer with separate display, Windows
based operative system.
• MBU (Machine Base Unit): Basic computer, central
MHC2

MJU MCU ECU HTU control and bucking unit.

PC MBU
• MJU (Machine Joystick Unit): Joystick computer.

MHC1
• MHC1 (Machine Head & Crane Unit): Head
computer.
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• MHC2 (Machine Head & Crane Unit): Crane

computer.
• MCU (Machine Chassis Unit): Chassis computer.
• ECU (Engine Control Unit): Engine computer,
control unit for the diesel engine.
• HTU (Hydrostatic Transmission Unit): Transmission
computer.
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Hydraulic oil tank

The tank is shared by the hydraulics and the transmission.
All return oil from the system passes through a return
filter.

1 There is also a fine filter. This works as an extra internal

filter. The filter receives a continuous flow of oil from the
2 transmission’s feeder pump via the oil cooler.

The filter is environmentally adapted. You only need to

change the filter inserts (paper).
3
The hydraulic oil tank can be equipped with a heater coil,
for faster heating (optional extra).

1. Return filter (filter holder and insert)

4
2. Fine screen (filter holder and insert)
5 3. Ventilator
4. Hydraulic oil heater connection
5. Hydraulic oil sight glass
6. Drain plug

6
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Service valve
The service valve is a low pressure function which
controls chassis functions, e.g. differential locks.

1. To tank
2. Servo pressure test point
3. Servo pressure reducer
4. Pump pressure in
5. Differential lock, rear
12
6. Terrain gear
1 2 7. Transport gear
4
3 8. 2-/All-wheel-drive
9. Differential lock, front
10. Servo pressure thermostat block

6 11. To tank thermostat block

9 5 12. Sensor(s)
8
7
10
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Valve assembly crane

The valve assembly controls e.g. crane functions. The
adjoining diagram is schematic, on some heads the head’s
rotator functions are controlled from the base machine.
1 Detailed specifications can be found in the Owner’s
manual for just your head.

1. Crane pressure, test point

2. Serial
3. Cab swing
2
3 4. Telescopic
4 5. Crane lift/lower
5 9
8
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6 7 6. Outer boom in/out

7. Pump
8. Separate tank drainage
9. Tank
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Valve assembly base machine

The valve assembly controls, among others, the stabiliser
cylinders, steering, etc.

1. Crane pressure adjustment

3 2. Electric valve high/low pressure
4 3. Steering adjustment (only authorised service
5 personnel)
4. Tilt

2 5. Tilt
130002

List of pressure outlets

On pressure outlet 5 you measure:

• Idling pressure
1 • Loading pressure
2
3 • Maximum pressure
4
5
130003

Working hydraulic pump

2
1 1. Steering adjustment (only authorised service
personnel)
2. Idling pressure, adjustable (delta p)
3. Max pressure, adjustable (pressure cut-off)

2
130008
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Vacuum and filling pump

The machine can be fitted with an optional vacuum
pump to reduce oil spillage during servicing. The pump
creates a vacuum in the hydraulic tank so that the oil
remains in the system. The pump is started using the
switch on the panel in the cab.

Another optional extra is an electric pump for filling

hydraulic oil. When filling with the pump, the ventilator
should be disconnected.

Only use the vacuum pump for short periods!

If your machine is fitted with a vacuum pump, you
should attempt to use it for so short periods as possible.

The oil level drops in the filter housing and is replaced

by air with long periods of continuous use. If you
immediately start the machine and run up the working
revs for testing after this type of work, the air in the filter
housing will be pressed out through the filter at high
speed. The air bubbles that then form will be of the same
size as the filter’s filtration rating.

Environment-friendly oils need a long time to release

trapped air. Trapped air in the hydraulic oil can result in
damage, among others, cavitation.

Accordingly, try to use the vacuum pump only for short

periods:
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• Start the vacuum pump.

• Plug all open or broken pipes in the system.
• Switch off vacuum pump.
• Carry out the service work.
• Start the vacuum pump, refit the open pipes.
• Switch off the vacuum pump, test.
If the service work requires you to use the vacuum pump
during long periods, once the service is complete you
should start the engine and let it run at low speed and do
not activate any functions for at least a few minutes, so
that the oil fills slowly in the filter housing.

Hydraulic oils
Komatsu Forest machines can be supplied with mineral
or environmentally-friendly hydraulic oils. For approved
oils, see “Maintenance and Inspection”.
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The following guidelines apply to machines supplied

from the factory with hydraulic oil approved by Komatsu
Forest AB.

Working temperature
The working temperature should be between 40-60°C.
The hydraulic system is at its most efficient here, and
there is the least wear and tear on hydraulic components.
The higher the temperature, the faster the seals age.

For machines with environmentally-friendly hydraulic

oil, the hydraulic system's normal working temperature
should not exceed 70°C. At higher temperatures, the
lifetime of the oil is shortened.

If the temperature exceeds 80°C, the change intervals

must be halved. To avoid high working temperatures, the
outside of the cooler should be cleaned regularly.

Change intervals
It is recommended that an oil sample is taken for analysis
every 500 operating hours, in order to check when the
change should take place. This applies to both mineral
oils and environmentally-friendly oils. The change
interval can be continuously extended if the oil sample
analyses show that the oil is in a usable condition. The
interval is extended at most by 500 hours until the next
oil analysis.

If an oil analysis is not performed, the oil should be

changed every 2000 operating hours. This applies to both
mineral oils and environmentally-friendly oils.

Oil sample
Charge/Oil sample
The most appropriate time to do sampling is in
connection with start up in the morning before the
working temperature is reached. Exercise great care when
sampling.

The sample should be taken in good weather. Check that

no external dirt is added.

• Clean the pressure outlet for the feed pressure,

marked Charge/Oil sample (see figure).
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• Start the machine and let it idle for about 5-10

minutes.
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• Connect the sampling hose and flush the hose for

about 30 seconds in a collection tray.
• Open and fill the sampling bottle.
• When the bottle is closed, seal it well.

Water content
Environmentally-friendly oils have a tendency to
bind water to a greater extent than mineral oils. The
water content must not exceed 0.05% (500 ppm) for an
extended period.

Oxidation
Environmentally-friendly oils are more temperature-
sensitive than mineral oils and often age through
oxidation.

Hydraulic oil in machines supplied from the

factory
Before the first start-up, the hydraulic oil in the machine
is filtered with an external filter unit to clean the oil to
at least ISO 4406 level 15/11. To ensure that oils are not
mixed together, a different filter unit should be used for
each oil type.

Storage and handling

• Oil drums should be stored horizontally and
protected against rain, snow, excessive heat and cold.
They should always be well sealed.
• Storage tanks should have water-separating bleeding
filters, and it must be possible to drain off the water.
• Never use the last oil in a drum, as it is often
contaminated with water etc.

Cleaning after oil leaks

Oil can be harmful to both people and the environment. It
is therefore important to clean the machine and machine
components immediately in the event of leaks and oil
spillages. Remember that oil spillages also entail a risk of
fires and slipping.
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Environmentally-friendly oils have a tendency to form

a sticky surface when exposed to sunlight. You should
therefore take extra care cleaning the machine if this type
of oil is used.
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Hydraulic diagram

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