Ex550 SECTION 02 UPPERSTRUCTURE: CONTENTS Group 01- Outline Group 05- Control Valve Outline ‘T02-01-01 Outline ..... seen T02-05-01 Construction and Function T02-05-02 Group 02- Tanks Hydraulic Circuit = 70205-06A Construction and Function .... 02-02-01 Flow Combiner Valve « — T02-05-10A Main Relief Valve T02-05-11A Group 03- Pump Device Pump Control Valve 02-05-13 Outline - T02-03-01 Overload Relief Valve . 02-05-14 Main Pump ‘T02-03-02 Make-Up Valve . 02-05-16 Regulator . T02-03-05 Holding Valve 1702-05-17 Pilot Pump. tees T02-03-07 Arm Regenerative Valve... . 02-05-18 Pressure Sensor uence T02-03-07 Automatic Air Ble Circuit T02-05-20 {Pesed page: O64, O7A, OBA, ODA, 10A, 118, 128) Group 04- Swing Device Outine te 02-04-01 Group 06- Pilot Valve ‘Swing Motor . 02-04-02 Outline 02-06-01 Brake Valve .... 02-04-04 Operation T02-06-05 ‘Swing Parking Brake 7102-04-07 ‘Swing Reduction Gear 02-04-08 Group 07- Others Pilot Shutoff Valve 02-07-01 Shockless Valve. : 702.07-02A Accumulator .....e.eees6e. 0207-03 Solenoid Valve ......... T02-07-04 (Revised page: 024) 116T-02-01A 9603EX550 116T-02-02UPPERSTRUCTURE / Outline OUTLINE The upperstructure consists of main frame (12), en- gine (7), fuel tank (6), hydraulic oil tank (15), contro! valve (8), operator's cab (1), counterweight (11) and other components, as illustrated below. The main frame is a welded steel structure bolted to the outer race of swing bearing (2). Counterweight (11) is bolted to the rear end of the main frame (12) and functions to balance the ma- chine. The front attachment is mounted to the front end of the main frame (12). 1 cab 5~ Control Valve 2— Swing Bearing 6— Fuel Tank 3— Center Joint 7 Engine 4— Swing Device (2used) 8 Mutter 9— Radiator 10— Oil Cooler M1 Counterweight 12— Main Frame 13— Pilot Pump 14— Main Pump (2 used) 15— Hydraulic Oil Tank T02-01-01UPPERSTRUCTURE / Outline T02-01-02UPPERSTRUCTURE / Tanks CONSTRUCTION AND FUNCTIONS Hydraulic Oil Tank 1+ Filter Retief Vaive 1 2— Full-Flow Fitter 8 3 fydrutc Ol Tank a aes & iseamia © ob eae 8— Drain Cock 9— Suction Line Fuel Tank = Fron So s-——_© Snmis 1+ Capwithakey 4~ Fuel evel Gauge 2 Fuel Tank 5— FuelFiter 3 FuelLevel Sensor 6 Drain Plug Tuec202002 02-02-01UPPERSTRUCTURE / Tanks T02-02-02UPPERSTRUCTURE / Pump Device OUTLINE ‘The pump device consists of a transmission, main pumps, and pilot pump. The transmission divides and transmits the power to front pump (2), rear pump (1) and pilot pump (3) via gears. Gear ratios, on the main pump drive side is 1:0.849 (45/53) and the pilot pump side is 1:1 The transmission is lubricated with engine oil, The main pump is a variable displacement, bent-axis plunger-type pump equipped with a regulator for controlling pump oil flow. The pilot pump is a goar- type pump. 1 Main Pump (Rear) 2— Main Pump (Front) Angle sensor (A Sensor) detects the pump displace- ment angle, and sends signals to the PVC to control pump flow. Engine speed sensor (N Sensor) is attached on the engine flywheel housing Pressure sensors (P Sersur) are located on the pump delivery blocks. ise02.00001 3~ Pilot Pump 4— Angle Sensor (Sensor) T02-03-01UPPERSTRUCTURE / Pump Device MAIN PUMP: Main pump consists of front and rear pumps, and supplies hydraulic oll to actuate main components such as motors and/or cylinders, ‘The pump shaft (6) is connected to the cylinder block (8) via seven plungers (2). 1 Housing 2 Plunger 3 Cylinder Block 4— Regulator Therefore, the rotation of the shaft is transferred to the cylinder block, causing the plungers to recipro- cate in the cylinder bores, thus discharging hydraulic oil to the hydraulic circuits. 5~ Valve Plate 6 Shatt T02-03-02UPPERSTRUCTURE / Pump Device Operation Engine torque is transferred to seven plungers (2) via shaft (1), causing cylinder block (8) to slide along the surface of valve plate (4); Plungers (2) move in and out of their bores in cylinder block (8) to alternatively suck and deliver hydraulic ol. 1 Share 2— Plunger 3— Cylinder Block 4= Valve Plate T02-03-03UPPERSTRUCTURE / Pump Device Increasing And Decreasing Main Pump Oil Flow Rate When the displacement angle of cylinder block (3) is changed, the stroke length of plunger (2) changes. Thus, oil flow rate of the main pump is controlled by changing the displacement angle of oylinder block (3). Servo piston (6) Is Jointed to valve piate (4) with pin (8). Maximum displacement angle ‘Minimum displacement angle 4= Valve Plate 2~ Plunger 3 Cylinder Block When servo piston (6) is moved up or down, valve plate (4) moves too, changing the displacement an- gle of cylinder block (3); cylinder block (3) is kept in contact with the surface of valve plate (4) and slides along i Pin Servo Piston T02-03-04UPPERSTRUCTURE / Pump Device REGULATOR Function of The Regulator Each front and rear pump is equipped with one regu- lator to control pump oil flow rate. Pump control solenoid valve (1) is provided with ‘each pump. The pump displacement angle is propo- ‘sional to the intensity of electrical signal from PVC to solenoid valve (1). + When the intensity of electrical signal to solenoid valve (1) is increased: The secondary pressure from solenoid valve (1) to servo spool (2) is increased. When the secon- dary pressure overcomes spring KS (3) force, servo spool (2) moves upward. As large chamber (©) of servo piston (4) opens to the hydraulic cil tank port, the pressure in large chamber (6) is de- creased. The pressure in small chamber (7) pushes servo piston (4) downward, increasing the pump dis- placement angle, The resistance of control spring KL (5) weakens due to the movement of servo piston (4), de- creasing the force against servo spool (2). The position of servo piston (4) is determined by the balance of three elements:secondary pressure from solenoid valve (1), compression of control spring KL (6) and spring KS (8). Increasing ‘Purp Displacement Angle 1— Pump Control Solenoid. 3— Spring KS 5~ Control Spring KL. ‘Small Chamber Valve 2— Servo spot 4— Servo Piston 6— Large Chamber T02-03-05UPPERSTRUCTURE / Pump Device + When the intensity of electrical signal to solenoid valve (1) is decreased: The secondary pressure from solenoid valve (1) to servo spool (2) is decreased. Spring KS (3) pushes servo spool (2) downward. The pump de- livery oil or pilot oil is led to large chamber (6) of servo piston (4). Servo piston (4) moves upward due to the aifference of pressure receiving area between small chamber (7) and large chamber (6), decreasing pump displacement angle. The re- sistance of control spring KL (6) strengthens, in- creasing the force against servo spool (2) ‘The position of servo piston (4) is determined by the balance of three elements:secondary pressure from solenoid valve (1), compression of control spring KL (5) and spring KS (3). Decreasing Pump Displacement Angle 1— Pump Control Solenoid valve 2~ Servo Spool 3— Spring KS 4— Servo Piston Detection for Pump Displacement Angle ‘Angle sensor (A Sensor) detects the pump displace- ment angle, and sends signals to the PVC to control pump flow. 5— Control Spring KL. ‘16 0203.08 7— Small Chamber 6— Large Chamber T02-03-06UPPERSTRUCTURE / Pump Device PILOT PUMP J scien 2 1 Drive gear (1) is rotated via the transmission to ! driven gear (2). Ce bas Delivery Port 1 Drive Gear 2 Driven Gear ara. PRESSURE SENSOR (P SENSOR) The P sensor detects oil pressure. Oil pressure is a necessary signal for various controls of the machine. Oil pressure is received by diaphragm (4). Depending on the extent of deformation of the dia- phragm, oil pressure is detected as an electrical sig- nal 41 Grounding Terminal 3— Power Supply (5 V) ermine 2> Output Terminal 4— Pressure Receiving Section (Diaphragm) T02-03-07UPPERSTRUCTURE / Pump Device T02-03-08UPPERSTRUCTURE / Swing device OUTLINE The swing device consists of brake valve unit (1), swing motor unit (2), and swing reduction gear unit (3). Tor2.oe.o10 2— Swing Motor Unit 3— Swing Reduction Gear Unit T02-04-01UPPERSTRUCTURE / Swing device SWING MOTOR The swing motor is a swash-plate-type axial plunger mo- tor. The major parts of the motor are: fixed-type swash plate (6), rotor (8), plungers (8), valve plate (3), motor hous- ing (6), and the parking brake. The parking brake is a wet-type multiple disc brake, consisting of center plates (1) and friction plates (2). ‘Shoes (4) are caulked to each plunger (8) and nine plungers with shoes are provided in rotor (9). Rotor (9) is installed onto shaft (7) with a spline cou- pling. 1— Conter Plate 4— Shoe Motor Housing 8— Plunger 2— Friction Plate 5~ Fixed-type Swash Plate 7 Shaft 8 Rotor 3 Valve PlateUPPERSTRUCTURE / Swing device ‘Swing speed varies depending on the amount of oil delivered from the pump. From port (A), high pres- sure oil is fed so that plunger (3) is moved upward from the bottom dead center to the top dead center. ‘Shoe (4) then slides along swash plate (5), develop- ing turning force. Turing force is transmitted to the swing reduction ‘gear unit via shaft (6). The return oil flows to outlet Port (B) and returns to the hydraulic oil tank. When pressure oil is fed to port (B), the motor ro- tates in the opposite direction. 1— Valve Plate 3~ Plunger 2 Rotor 4— Shoe 5~ Swash Plate 6— Shatt T02-04-03UPPERSTRUCTURE / Swing device BRAKE VALVE The brake valve consists of the make-up valve and the relief valve. Reliet Vave Make-Up Valve } When swing is stopped, if th wing Is stopped, if the upperstructure tends to Make-Up Vaive keep rotating due to swing inertia force, causing the swing motor to continue rotating further, and to begin | sucking oil from the pump, developing cavitation in the q motor. The make-up valve sucks hydraulic oil through the re- tum circuit (port C) to compensate for the lack of cil, and prevent cavitation. Port (Control Valve eran oeors Control Valve T02-04-04UPPERSTRUCTURE / Swing device Reliet Valve When starting or stopping swing operation, oll pressure in the swing circuit becomes high. The relief valve pre- vents the circuit pressure from rising higher than the specified pressure. Plunger (5) is pushed to the left by pressure Pp at port (P) and pressure-receiving area A2. However, plunger (6) is also pushed back to the right by spring (6) force and pressure Py al chamber (g) and pressure-receiving area A3. Chamber (g) is routed to port (P) through orifice (m).. When force acting on the left is higher than that on the right, the relief valve operates. 1_[ iera2o4.c20 1= Spring 4 Piston 1 7— Housing (Body) 9— Adjusting Plug 2 Ball Check Valve 5— Plunger 8 Spring 10— Piston2 3~ Sleeve 6 Seat + Pressure Increasing Operation When pressure Pp at port (P) increases, pressure Pg in chamber (g) also increases, as chamber (g) is ‘opened to port (P) through orifice (m) in plunger (6).Therefore, this increased pressure acts on pressure-receiving area A4 of piston 2 (10). When force pushing piston 2 (10) to the left exceeds spring (1) force, piston 2 (10) moves to the left, re- ducing pressure Pg in chamber (g) to lower than pressure Pp. Then, plunger (5) moves to the left, opening port (P) to port (R), decreasing pressure at port (P). When pressure at port (P) decreases, plunger (5) moves back to the right, and the opening between ports (P) and (R) is closed, increasing pressure Pp at ort (P) and pressure Pg in chamber (g) until piston 2 (10) begins to move further to the left. This operation is repeated until piston 2 (10) reaches its stroke end. ‘As piston 2 (10) moves to the left, oil behind piston 2 (10) is pushed out through orifice (n) and gradually returns to port (R). smoothly raising relief pressure. Pressure change at this stage is shown in the P1 to 2 range found in the relief pressurejtime diagram on the next page. T02-04-05UPPERSTRUCTURE / Swing device When piston 2 (10) reaches its stroke end, piston 1 (4) starts to move to the right due to force developing on pressure receiving area A1 by pressure Pg in chamber (g), as a result compressing spring (8). When piston 1 (4) begins to move to the right, oil trapped in chamber {() leaks through oil grooves (h) provided on the sliding surface between adjusting plug (9) and piston 1 (4). Accordingly, pressure Pg in chamber (g) smoothly in- creases until piston 1 (4) reaches the stepped bore end of adjusting plug (9). As spring (8) is compressed, its spring force increases. Then, relief pressure P smoothly increases from P2 to Ps, as illustrated. When piston 1 (4) reaches the stepped bore end of adjusting plug (8), piston 1 (4) cannot move further to the right so that Pressure in chamber (g) comes to equal specified pres- sure Ps. After this point, steady relief operation starts. In summary, as moverents of piston 2 (10) and piston 1 (4), and spring (8) force change, it takes a certain amount of time (t) to reach the specified relief pressure Ps, thus reducing shocks during swing operation. + Pressure Lowering Operation When pressure Pp at port (P) is reduced, pressure Pg in chamber (g) is also reduced to oil tank pres- sure. Then, plunger (5) moves to the right, closing seat (6). Piston 1 (4) is pushed by spring (8) to the left, to its original location. Piston 2 (10) is moved by spring (1) to the right. At the same time, ball check valve installed in sleeve (3) opens to supply oil from port (A), ‘preventing vacuum from occurring behind piston 2 (10), helping piston 2 (10) to return without time lag. Relief pressure Time T02-04-06UPPERSTRUCTURE / Swing device SWING PARKING BRAKE The parking brake is a wet-type multiple disc brake. The brake is released only when brake release pressure SI enters into brake piston chamber (b), (negative type brake). When swing and/or front attachment operation is made (that is, when solenoid valve 1 (SC) (9) is not en- ‘orgizod), brake release pressure SI is supplied from pilot pump (10). During operations other than swing andjor front attach- ment, or while the engine is stopped, brake release Pressure SI is routed to the hydraulic oil tank and the parking brake is automatically applied by spring (1). * While the brake is ON" (except when swing and/or front attachment function is operated): Signals from swing pressure switch (7) and/or front attachment pressure switches (8) are not sent to the pump and valve controller PVC, keeping solenoid valve 1 (SC) (9) energized (ON). While solenoid valve 1 (SC) (9) is energized, brake release pressure SI is released to the tank port, al- lowing the force of spring (1) to apply downward via piston (2), to keep center plates (3) engaged with the circumferential part of rotor (6) and friction plates (4) engaged with the internal side of motor housing (6). By friction force equivalent to this thrust load, center plates (3) and rotor (6) are braked. While the brake is "OFF" (swing andjor front attach- ment function operated): Signals from swing pressure switch (7) and/or front attachment pressure switches (8) are sent to pump and valve controller PVC, which in tum deenergizes solenoid valve 1 (SC) (9). Then, brake release pressure SI moves piston (2) up- ward against spring (1), breaking contact between center plates (3) and friction plates (4), releasing the brake 1— Spring 6 Rotor 2 Piston 7 Swing Pressure Switch 3— Center Pate 8— Front Attachment Pressure Switches 4— Friction Ptate ‘9— Solenoid Valve 5 Motor Housing 40— Pilot Vatve While brake te O*) ox While brake ts “OFF* OFF 02-04-07UPPERSTRUCTURE / Swing device SWING REDUCTION GEAR The swing reduction gear is a two-stage planetary gear type. Ring gears (2 and 4) in the first and sec- ond stages are provided on the inside of the hous- ing. ‘The housing is bolted to the main frame so that ring gears (2 and 4) are held stationary. Motor output shaft (10) of the swing motor drives: first stage sun gear (9). Then, rotary power is transmitted to second stage sun gear (7) via first stage planetary gear (1) and cartier (8). Second stage sun gear (7) rotates drive shaft (5) via second stage planetary gear (3) and cartier (6). AAs drive shatt (5) meshes with the internal gear ot the swing bearing bolted to the undercarriage, the upperstructure Is rotated. 1— First Stage Planetary Gear 4— Second Stage Ring Gear 2— First Stage Ring Gear 5— Drive Shaft (Output Shar) 3— Second Stage Planetary Gear 6— Second Stage Carrier Second Stage Sun Gear \— First Stage Carrer 1 First Stage Sun Ge 40— Motor Output Shaft T02-04-08UPPERSTRUCTURE / Control Valve OUTLINE The control valve controls oil pressure, flow rate, and flow direction in the hydraulic circuit. The control valve consists of the right block (four spool sections) and left block (five spool sections). Both are of vert- ‘cal manifold design and are bolted together, back- to-back ‘The spools in the right block (four spool sections) ‘are arranged from port 4P in the following order: right travel, bucket, boom (1) and arm (11), In the left block (five spool sections) the spools are ar- ranged from port SP, in the following order: swing, arm (1), boom (i), auxiliary, and left travel, ‘Swing ‘Overioad Relet Valve Load Check Valve (Travel) Load Check Valve (Aux,) Load Check Valve (Boom) ‘Arm Holding Valve Load Check Valve (Arm) ‘Load Check Valve (Swing) Make-Up Valve (Overload Reet Valve ‘Load Check Valve (Arm) Load Check Valve (Boom) Flow Combiner Vaive 5P Port ‘A main relief valve, two pump control valves, a flow combiner valve, a arm regenerative valve, a arm holding valve, etc are provided with the control valve. ‘A pump control valve is provided at the farthest end of the neutral oll paseage in each block to control the main pump delivery amount. Arm Regenerative Valve DP Sensor (¢-spoo!) Pump Control Valve (4-ep00}) Fight Block (4-spoo!) Manifors 2 (To Hyd, O4 Tank) TH (To Hyd. 04 Tank) Left Block (5-spoo) DP Sensor (6-spoo!) Pump Control Valve (5sp00!) Ri Front Main Rell! Vawve ‘Shuttle Valve ight side view ioe rinre.c08 02-05-01UPPERSTRUCTURE / Control Valve CONSTRUCTION AND FUNCTION (Check Valve 1: For main relief pressure combining ftom the &:sp00l ede. (Check Valve 2: Load check valve (Aux). (Check Valve 3: Load chack valve (Arm 1) ‘Check Valve 4: For aux. flow combining from the 4-spoo side. ‘Check Valve 5: For bucket low combining from the 5-spoo! side. Travel (0) 5P Pont Pict Signal Passage Peer Rear Noutral Oil Passage MANIFOLD (o-Spool Side View) CONTROL VALVE CROSS SECTION (6-Spoo)) T02-05-02UPPERSTRUCTURE / Control Valve MANIFOLD (4-Spool Side View) T02-05-03 Main Relist Vave Pot Signal Passage = CONTROL VALVE CROSS SECTION (Spool)UPPERSTRUCTURE / Control Valve Oil Flow Main ret valve Shutge vale. High-Low speed change ‘a es” 02-05-04UPPERSTRUCTURE / Control! Valve HYDRAULIC CIRCUIT ‘Signal cores are divided into two systems: one for traveling, and one for front attachment / swing. When the travel lever is operated, the travel pres- sure switch comes ON. The solenoid valve 1 (SA) sends a signal to the main relief valve to change the relief pressure to 34.3, MPa ( 350 kgl/cm® ). The travel parking brake is re- leased by pressurized oil from travel motor. When a control lever other than the travel levers is moved, the pressure switch of that lever sends a signal to open the solenoid valve 1 (SC) for swing parking, thereby releasing the swing parking brake. The flow-combining passages are provided in the ‘manifold block, located between the 4-spool and 5- spool control valve blocks, controlling oil flow for combined operations. The main relief setting pressure is set at two levels: 34.3 MPa (350 _kgtfom®) for traveling and 29.4 MPa (300 kgt/em?) for other functions. Overload relief valves with make-up function are pro- Vided in boom 1, arm I, bucket and auxiliary ports. Make-up valves are provided in boom Il and arm I ports. T02-05-06A 9603UPPERSTRUCTURE / Control Valve ‘Swing Motor Travel Motor ey CH Holding Valve Oi1Cooler Main Pu (Fron) ——Th cout | ee ! cl Hydraulic Oi Tank Oo Pilot Pump Pot Fiter T02-05-07A 9603UPPERSTRUCTURE / Control Valve Neutral Passages ‘When all spools are in the neutral position, system cil from the main pumps flows into the control valve via ports 4P and SP. Then, system oil flows through the neutral passages in each section, pump control valves, and ports T1 and 72, and retums to the hydraulic oil tank. The make-up lines for swing motors are connected to ports RI and R2. When any of the spools is operated, the neutral passage is blocked, preventing system oil from flowing further to the next section through the neutral passage. Main Pump Front) LL1I Hiyarauic oF Tani T02-05-08A 9603UPPERSTRUCTURE / Control Valve Parallel Passages When any of the spools is operated, system oil cannot flow through the neutral passage to the next section Thus, parallel passages are provided to allow system oil to flow to other sections, enabling combined operations. T02-05-09A 9603UPPERSTRUCTURE / Control Valve FLOW COMBININER VALVE When travel, and front attachment or swing operations are made at the same time, the spools for the right and left travel motors, and spool for cylinder or swing motors are moved. In combined operations of bucket and travel, the bucket spool movement blocks the pilot signal pressure routes. Then, the pilot signal pressure increases and shifts the flow combiner valve spool. ‘System oll from the main pump (Rear) is routed in parallel to both right and left travel motors. System oil from main pump (Front) flows through the neutral passage in the auxiliary section, opens the check valve located in the manifold, and flows into the bucket spool. OH Travel Motor T02-05-10A 9603UPPERSTRUCTURE / Control Valve MAIN RELIEF VALVE ‘The main relief pressure has two set levels. For traveling, power boost and precision mode (M4) operations, main relief pressure is set high, while the pressure is set low for all other operations. High Preceure Setting When the travel pressure switch or power boost switch is activated or the precision mode (M4) is selected with the work mode selector, the solenoid valve 1 (SA) is excited by a control signal from the controller (the PVC), then pilot oil flows into port pF2 of the main-relief- pressure-change valve, pushing the piston and compressing the spring to Increase the main reliet pressure to the high level. Travel pressure switch |-—>{ controller |_, | Solenoid vatve 1 |_.[ Main-eliet Power boost switch L_.| (voy (SA) aa Saeae Work mode selector (ma)? T Main relief valve 1 2 3) 4 EG SEA _— Manat reanue care Vabe | ‘Solenoid Valve 1 (SA) |— Main Poppet 2 Pilot Poppet 3~ Spring 4— Piston T02-05-11A 9603UPPERSTRUCTURE / Control Valve Low Pressure Setting When the travel pressure switch and power boost switch are not activated or the precision mode (M4) is not selected, the solenoid valve 1 (SA) does not function. Thereby, the main relief pressure is automatically set to the low level. 7 Matreet geemredoane Vere Solenoid Valve 1 (SA) | Main Poppet 2 Pllot Poppet 2 Spring 4— Piston T02-05-12A 9603UPPERSTRUCTURE / Control Valve PUMP CONTROL VALVE The pump control valve is located at the most down- stream side of the control valve at the neutral pas- sage of each left and right control valve. It routes pressure (fp) from the neutral passage and pressure (fp) after oil passes through the orifice to the DP sensor, ulizing Uiese pressures as pump flow rate control signals. When the pressure difference is large, the flow rate is reduced; when the pressure difference is small, the flow rate is increased. \ From Neutral Passage Y, Tank Passage When neutral passage pressure (Ip) overcomes spring (0) force, the poppet opens, releaving system oll to hydraulic oil tank, Va loo When all control valve spools are in neutral, all sys- tem pressure oil flows through the orifice located in- side the pump contro! valve. Thus, the differential pressure sensed by the DP sensor is large. When any control lever is moved, system oil flows Into the actuator, reducing the oll flow to the neutral passage, thus reducing the differential pressure. Ditforertiat LL SEae0 sn a Spring D Poppet A 02-05-13UPPERSTRUCTURE / Control Valve OVERLOAD RELIEF VALVE An overload relief valve is provided in each of the fol lowing cylinder ports: Boom 1, Bucket, Arm 1 and ‘Aux., 80 a8 to protect these cylinder circuits from exces- sive oil pressures. Moreover, this overload relief valve has an anti- cavitation function. When pressure at the cylinder port becomes negative, the overload relief valve sucks oll from the hydraulic oil tank, preventing cavitation from ocourring. (1) When the pressure at port HP overcomes spring (4) torce, pilot poppet (3) opens, routing pressure oil to port LP via around main poppet (2). (2) As the pressure inside the chamber (a) is reduced, piston (1) moves to the right. (8) As the pressure inside the chamber (a) is reduced, main poppet (2) also moves to the right. Thus, the system oil at port HP directly flows to port LP. 1 Piston 2 Main Poppet 3~ Pilot Poppet 4— Spring T02-05-14UPPERSTRUCTURE / Control Valve Auti-Cavitation function 2 Cavitation is prevented by supplying oil from port LP to port HP when the system oil pressure at port HP be- ele comes negative. When the oil pressure at port HP becomes negative, main poppet (2), which is normally seated due to the size difference between pressure receiving areas di and a2, is forced to open to the right by the pressure at ort LP, supplying oil from port LP to port HP. oe T02-05-15UPPERSTRUCTURE / Control Valve MAKE-UP VALVE ‘A make-up valve is provided in each of the following ports: Boom Il (Lower) and Arm Il, so as to assist the anti-cavitation function of the overload relief valve. (1) The pressure oil at port HP is routed to chamber (b) via a passage inside poppet (1). Since pressure re- ceiving area d1 is smaller than pressure receiving area d2, poppet (1) is securely seated to port HP. (2) When the pressure at port HP becomes negative (lower than that at port LP), poppet (1) opens, also because of the difference in the size of the pressure receiving areas; that is, area d2 is larger than di. Thus, oil flows from port LP to port HP, preventing cavitation from occurring. HP 2 Spring T02-05-16UPPERSTRUCTURE / Control Valve HOLDING VALVE A holding valve is provided in each of the following ports: boom raise and arm roll-out, so as to prevent cyl- inder retractions from occurring. + When the control valve is in neutral, a cylinder hold- ing pressure is routed to chamber (a) via orifice (b) of check valve (2). Because of the difference in the sizes of pressure receiving areas d1 and d2, check valve (2) is securely seated on cylinder port (¢), clos- ing the cylinder port. yinder Holding ° Preseure + When boom lowering or arm rol-in are operated, pilot 1— Poppet 3~ Spool pressure Pi is exerted on poppet (1), connecting 2 Check Valve ‘chamber (a) to the hydraulic oil tank line. As the pres- sure in chamber (a) is reduced, check valve (2) opens. At the same time, spool (3) is moved to form a circuit ( (c)+(4)->(0) ) to the hydraulic oil tank. Thus, the actuating cylinder (boom or arm) can move. T02-05-17UPPERSTRUCTURE / Control Valve ARM REGENERATIVE VALVE ‘The arm regenerative valve is provided to prevent negative pressure from occurring at the bottom side of arm cylinder. + When the arm cylinder is extented from fully re~ tracted position, the arm cylinder is extended very quickly because of the combined weight of the arm and bucket. The oil flow to the bottom side of the cylinder cannot catch up with the needed quantity. Thus, the bottom side pressure (PB) does not rise. To prevent this phenomenon from happening: The return oil from the cylinder rod side is restrict- ed al two points, orifice (A) in spool (2) and orifice (8) in regenerative valve (7), increasing the rod side pressure (PR). ‘4 Piston 5— Spool 1— Arm Cylinder 2— Spool 3— Check Valve When rod side pressure (PR) raises higher than bottom side pressure (PB), check valve (8) opens '80 as to route the return oil from the rod side to ‘supplement the pump oil flow to the bottom side. nO) rn22.05.0%8 Holding Valve 9 Load Check Valve — Spring 7— Regenerative Valve T02-05-18UPPERSTRUCTURE / Control Valve + When bottom side pressure (PB) is higher than rod Lo side pressure (PR), check valve (3) closes. More- — PB ‘over, bottom side pressure (PB) via passage (b) pres- FA sure against piston (4) to move spool (5) so as to widen orifice (B). Thus, the return oll trom the rod Oe side flows faster to tank passage (d). 3 me ‘ 2 a e| [Le 10 pTTpee® tT 1 1 Arm cylinder 4— Piston 6 Spring Holding Valve 2— Spool 5— Spoo! 7— Regenerative Valve Load Check Valve 3— Check Valve T02-05-19UPPERSTRUCTURE / Control Valve AUTOMATIC AIR BLEEDING CIRCUIT If air enters the pilot circuit, machine operability will be severely affected. A time lag between lever control op- eration and machine action may become noticeable. To prevent this and to ensure machine responsiveness, an air bleeding circuit is provided at the upper portion of the control valve. This air bleeding circuit automatically bleeds air trapped in the control valve to the hydraulic oll tank. ‘Ar Bioeaing Gireut |» To Hyérauic OF Tank T02-05-20UPPERSTRUCTURE / Pilot Valve OUTLINE The pilot valve controls pilot pressure oil to move the control valve spools. There are two types of pilot valves. One is for front and swing operation; the oth- er is for travel operation. Both have standard four oil ports. Connection positions of oil ports on the tront and swing operation pilot valves Port No.| Hitachi standard] ISO standard 1_| Bucket rol-out = Right [2 [Boom lower = valve [3 [Bucket rollin < ‘4 | Boom raise = [Ann rollin ‘Swing right Left 2 | Swing right ‘Arm roll-out valve [73 [am rotout__| Swing left 4 [Swing left ‘Arm rollin | ‘An optional two-oil-port type is available. Except for the cam construction to push the pusher down, the construction of the reduging valve in both the front and swing operation pilot valves and the travel pilot vaive is the same. Connection positions of oil ports on the travel pilot valve Port No.| Hitachi standare/ISO standard Left travel forward Left travel reverse Right travel reverse Right travel forward T02-06-01UPPERSTRUCTURE / Pilot Valve Construction ‘+ Front And Swing Pilot Valve 8 Spring Guide 17 Sorew Joint 5 Oil seal 2- cam 5— Busing 9 Balance Spring 3— Universal Joint 7— Spacer 10— Return Spring 4— Pusher + Travel Pilot Valve 1 Pin 4— Ol'Seal 7— Spring Guide 10— Spool 2— cam 5— Rushing AX Ralanea Spring 41— Plug 3— Pusher 6— Spacer 9— Return Spring 12 Piston T02-06-02UPPERSTRUCTURE / Pilot Valve ‘The lower face of spool (8) head is suspended by the upper face of spacer (4); they are kept in con- tact by setting force of balance spring (6). Spacer (4) is installed between pusher (3) and spring guide (©) and supported by return spring (7). Piston (8) is located inside spool (8). The lower end of piston (9) makes contact with the piate, preventing the piston from moving further downward. © 1= Control Lever 4— Spacer 2- Cam 5~ Spring Guide 3 Pusher ‘Above piston (9), a chamber is provided and itis led to the outside of spoo! (8) through holes provided in ‘spool (8). When control lever (1) is in neutral, the notch be- tween the output port and port T is open, conner the ports. Port T (To hydraulic ol tank) Output Port Port (From pilot pump) = 6 Balance Spring 1 Spo! 7— Return Spring T02-06-03UPPERSTRUCTURE / Pilot Valve Function When control lever (1) at the operator's cab is oper- ated, the pilot oil pressure in proportion to the con- trol lever stroke arises at the delivery port of pilot valve (2) To Hy¢rauile OlTank 1 Control Lever, 2 Pilot Valve The pilot oll pressure is applied onto the end face of the spool in control valve (3) and moves the spool Until pilot pressure force comes to balance against spring force. From Main Purp To Hydraulic Ol Tank 3— Control Valve T02-06-04UPPERSTRUCTURE / Pilot Valve OPERATION + Inneutral (Corresponding to A to B in the output diagram) When control lever (1) is in the neutral position (no pusher stroke), spool (8) completely blocks pressure ail fram entering port P. Since the deliv- ery port is open to port T, pressure at the delivery ort equals that in the hydraulic oil tank. When control lever (1) is slightly moved, cam (2) moves together, pressing down on pusher (3). Then, pusher (3), spacer (4), and spring guide (5) move downward as a unit, compressing return spring (7). Section (a) AES He 1 Control Lever, 2- cam The lower face of spool (8) is kept in contact with, the upper face of spacer (4) by setting force of balance epring (6) and moves downward together with spacer (4) However, even if control lever (1) is moved fur- ther, until clearance (A) at section (a) reaches 0, the delivery port remains open to port T, keeping pressure at the delivery port equal to that in the hydraulic oll tank. Delivery Port Pressure (Pict Pressure) Pusher Stroke OUTPUT DIAGRAM 7— Return Spring 8 Spool! 5 Spring Guide 6— Balance Spring T02-06-05UPPERSTRUCTURE / Pilot Valve + Ready to start operation (Corresponding to B to C section in the output diagram) ‘When control lever (1) is tted slightly further from the position where clearance (A) in section (a) reaches zero, and pusher (3) is pushed down- ward, spool (8) is moved downward, opening notched section (b) to allow pressure oil at the P port to flow into the detivery port. This oil pressure is also led to the inside of spool (@) via orifice (10), and acts to push spool (8) up- ward. Until this oil pressure force reaches the set- ting force of balance spring (6). balance spring (6) will not be compressed so that spool (8) is not moved upward, closing the clearance at section (a), keeping the notch at section (b) opened, and letting the oil pressure to increase at the delivery port. If the oil pressure at the delivery port increases, and the upward-pushing force of spool (8) slightly exceeds the setting force of balance spring (6), spool (8) moves upward against setting force of balance spring (6). Section (a) Clearance (A) Reaches Zero 3— Pusher 6— Balance Spring 1 Spool (Once spool (8) moves upward, upper clearance at section (a) is opened and lower notch section at section (b) is closed, leading oil pressure at the delivery port to T port, and decreasing oil pres- sure at the delivery port. When oil pressure at the delivery port decreases, force to push up spoo! (8) is reduced so that bal- ance spring (6) stretches to move spool (8) down- ward, closing both the clearance and the notch at sections (a and b). Thus, original posi sumed, The oil pressure will continue to increase until it is equal to setting force of balance spring (6) (shown by the point C in the output diagram), of spool (8) is Kept re- Delivery Port Preasure (PlotPressure) Pusher Stroke OUTPUT DIAGRAM 8 Piston 40— onitice T02-06-06UPPERSTRUCTURE / Pilot Valve ‘+ Operation corresponding to the control lever stroke (Corresponding to C to D in the output diagram) ‘As control lever (1) is moved further to push usher (3) downward, spool (8) is pushed down to ‘open the notch at section (b), increasing oil pres- ‘sure at the delivery port. As pressure increases, force to push up spool (8) increase. Then, when force to push up spool (8) exceeds the setting force of balance spring (6), ‘spool (8) starts to move upward, compressing bal- ance spring (6). When spoo! (8) moves upward until the clearance at section (a) opens, the delivery port is opened 1w purl T, stopping oll pressure Increase at the de- livery port and stopping movement of spool (8). Accordingly, when compressed by pusher (3), spring force of balance spring (6) increases in proportion to the pusher stroke, Then, oil pres- sure intreases {9 counteract agalnst this spring force. Dolvery Por Pressure Z (Pilot Pressure) | Pusher Soke OUTPUT DIAGRAM 3 c . qt ee a co ot | or ey Section 8) al . ANE all ko oe persis [saan PoE ae eed pesos eae So op Lee Senne 1 Controt Lever Pusher {6— Balance Spring 8 Spoo! T02-06-07UPPERSTRUCTURE / Pilot Valve + Operation close to pusher stroke end (Corresponding to D to E in the output diagram) ‘As pusher (8) is pressed down, balance spring (6) is compressed, reducing clearance (B) between usher (3) and the top of spool (8) (shown at sec- tion (c)), finally to zero. After that, pusher (8) directly pushes spool (6). Even if oil pressure at the delivery port increases, spool (8) cannot move upward, closing the oil passage from the delivery port to port T, and ‘opening the oil passage from the delivery port to port P. Then, oil pressure at the delivery port increases Until it reaches port P pressure, by which the op- erator feels that the control; lever is being operat- ad close to the stroke end. Delivery Port e Pusher Soke 3 OUTPUT DIAGRAM iC Section Ciearance (8) Reaches Zero é TE doin Pon gi oe Pox P pe 3~ Pusher 6 Balance Spring 8 spool! T02-06-08UPPERSTRUCTURE / Pilot Valve * Full stroke operation (Corresponding to E to F section in the output dia gram) Even if control lever (1) is titted further to push down pusher (3), spool (8) moves downward along with pusher (3), only widening the notch at lower section (b) of spool (8). Thus, oil pressure at the delivery port is kept same as at port P. Pusher (3) can be pressed down until spring guide (5) comes into contact with the shoulder (section (d)) of the casing. This position is the stroke end of pusher (8) (cor responding to F position in the output diagram). C ome FE | a 1— Control Lever 3— Pusher This process corresponds with E to F section in the output diagram. The total stroke of the control lever is decided by dimension C. Delivery Port Prossure (Pit Pressure) Pusher Stoke OUTPUT DIAGRAM © Seaton (0) 5~ Spring Guide 8— Spool! T02-06-09UPPERSTRUCTURE / Pilot Valve T02-06-10UPPERSTRUCTURE / Others PILOT SHUT-OFF VALVE The pilot shut-off valve is a manual-operated changeover valve. The spool in the pilot shut-off valve is rotated by moving the pilot contro! shutoff lever to turn on or off the pilot hydraulic oil flow sent to the pilot valves. Phot Shut.OH Vas Tor. 02.7-000| * Neutral Position (OFF) When the pilot shut-off valve is set in the neutral Position, the pilot pressure oll flow from the pilot Pump is blocked, and the oil passage after the pilot shut-off valve to the pilot valves are opened to the hydraulic oll tank. Accordingly, the pilot oil on the pilot valve side flows in the hydraulic oil tank port, and the pilot valves cannot be operated. + Operating Position (ON) When the pilot shut-off valve is set in the operating Position, pilot pressure oil from the pilot pump flows into tha pilot valve and the drain circuit is closed. Accordingly, the pilot valves can be operated using the control levers. From Pilot Valves ws) Psy So $ | To Hyeraule JZ Tank From Pilot Pump OFF er280.008 To Pilot Valves 4 From Plot Pump T02-07-01UPPERSTRUCTURE / Others SHOCKLESS VALVE The shockiess valve regulates the pilot oil flow between the pilot valves and the control valve spools to cushion abrupt movement of the spools Major parts of the shockless valve are: orifices (2 and 6), check valve (3), oll flow release valve (4), check valve (for heat circuit) (1), and shuttle valve (6). Boom Circuit + When the boom raise operation is made, pilot pressure oil flows from the pilot valve to port (At), and port (A2) is opened to the hydraulic oll tank. Pressure oil at port (A1) flows through only orifice (2) to the control valve spool while the oil pressure is low. As the cil pressure increases, check vaive (3) opens to provide the main passage of the pressure oil + The return oil from the boom cylinders arrives at port (62). However, while the oil pressure at port (A1) is low, the cil flow from port (B2) to (A2) is restricted by oil flow release valve (4) and check valve (3), so that the return oll can flow only through orifice (6). AAs the oll pressure Increases at port (At), il flow release valve (4) is opened to provide main passage for the return oil low. Heat Circuit Warm released return oil from the pilot relief valve is led to port (T1) and flows to the pilot valves from ports A (At, A2, A3, and A4) a check valve (1) (for the heat circuit). Shuttle Valve Pilot oil pressures at ports (A2) (boom lower) and (A3) {arm roll-out) are led to the pressure switch of other functions through port (P2). 1— Check Valve 4— Oll Flow Release Valve (for heat cireuty 2 Oritice Shuttle Valve 3— Check Valve Oritiee From Port (At) 82 T02-07-02AUPPERSTRUCTURE / Others ACCUMULATOR ‘The accumulator is provided in the pilot circuit to buffer fluctuations in oll pressure, and to maintain the pilot Pressure for a short ime period after the engine is stop- ped in an emergency. ‘The accumulator is mainly composed of body (5), holder (4), bladder (2) enclosing nitrogen gas (Nz ), and poppet a. Tios<2.10.00% 1— Poppet 4— Holder 7 Solenoid Valve 1 10— Pilot Pump Body Plot Reiet Valve 11— Suction Filter 3 ollPort Gas Plug Pilot Filter The pilot relief valve sets the pressure of oil delivered from pilot pump (10). Pilot pressure oil is conducted into the accumulator through port (A), and compresses nitro- gen gas in bladder (2) unti pilot oil pressure comes to balance with nitrogen gas pressure in bladder (2) If pressure oil supply is stopped due to engine stall or any other reason, nitrogen gas starts expanding as pilot oll pressure decreases, supplying the pressure oll accu- mulated in the bladder into the plot creult through port @) Tos.2-10.000| 02-07-03UPPERSTRUCTURE / Others SOLENOID VALVE Three types of solenoid valves are used on the ma- chine: solenoid valve 1 (three valves used), solenoid valve 2, and pump control solenoid valve. Solenoid Valve 2 (For Swing Priority) Solenoid Valve 1 (Three Valves Used) Solenoid Valve ($8) Solenoid Valve (SA) forsniting Solenoid Vale (SC) for Changing Travel Motor Swash Angle for Releasing Man Rete! Pressure Seting ‘Swing Parking Brake Plot Relist Vawve T02-07-04UPPERSTRUCTURE / Others Directional Solenoid Valve + Whennotenergized: Pilot pressure (P) is + Whenenergized: Pilot pressure (P) is routed blocked as spool (2) is to output ports (SA, SB, SC) pushed to the right by as spool (2) is pushed to the spring (1) force. left by the magnetic force of the solenoid (3). 1 Spring 2— Spool 3— Solenoid Pilot Relief Valve a The pilot relief valve functions to maintain pilot pur Pressure supplied to port P at a preset level. Port Tt is connected to the pilot heat circuit, and port A is con- nected to the pilot shut-off valve. 1 Poppet 2— Spring T02-07-05UPPERSTRUCTURE / Others Pump Control Solenoid Valve ‘The. pump control solenoid valve is activated by an electrical current signal from the PVC; in proportion to the current signal received, the solenoid valve ‘sends out pressure to control pump displacement angle. + When not energized: Spool (1) is pushed by spring (2) to the right, con- necting output port (A) to hydraulic oil tank port ™. + When energized: Magnetic force develops in proportion to the sig- nal current flowing into solenoid (3), and solenoid (@) pushes spool (1) to the left. Then, pilot pres- sure oil flows from port (P) to output port (A), in- creasing pressure at output port (A). The pressure force at output port (A) pushes spool (1) to the right, as the pressure force acts fon area (4) of spool (1). When this pressure force exceeds the magnetic force of solenoid (3), spool (1) is moved back to the right, closing the oil pas- ‘sage from port (P) to output port (A), and stop- ping the pressure from rising at output port (A). 1— Spoo! 2- Spring 3+ Solenotd T02-07-06