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SY215C9 HYDRAULIC EXCAVATOR

COURSEWARE
HYDRAULIC SYSTEM

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1. Table of Contents

I. Basic Hydraulic Circle

II. Main Pump

III. Main Valve Pipelines

IV. Swing Motor

V. Traveling Hydraulic motor

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Ⅰ Advanced Hydraulic System- Positive Control System

Bucket、swing、travel

Boom、Arm

Superior operation performance and Safe hydraulic system: System support a brief
increase in operating pressure and resulting force
1、Boom and Arm: The superior reaction function, operation function and safe function
are free from any influence that the burden brings
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Ⅰ Basic Hydraulic System Circle ------- Manual valve

Arm out Boom down

Bucket dig
horn

Left right

Swing Bucket
left dump

Boom up
Arm in Swing right
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Ⅰ Basic Hydraulic System Circle

Joystic-released
Joystic-Left

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Ⅰ Basic Hydraulic System Circle -------Pedal

Piston

spring
spring

Spring cavity

Steel ball

Pilot oil

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Ⅰ Basic Hydraulic System Circle

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Ⅱ Structure of Main Pump and Control principle

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Ⅱ Structure of Main Pump and Control principle

Kawasaki K3V112DTP1N9R-0E41-1AV Positive Control pump

Engine: 4M50

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Ⅱ Structure of Main Pump and Control principle

Angle:big Angle:small
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Ⅱ Structure of Main Pump and Control principle

Pressure and Flow rate curve

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Ⅲ Main Valve layout and Control principle

1-1. Main Valve overview

model 10阀杆
Control type Hydraulic pilot control valve
Overflow pressure 34.3Mpa
Boost pressure 37Mpa
Boom
Arm 39±0.5Mpa
Bucket
Relief Valve
opening pressure 36±1Mpa
Swing
(Measured value from the motor)
26.5±1.1Mpa
Travel
(Measured value from the motor)
Boom
Maintaining valve
Arm
Flow regeneration Apply to arm digging
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3.2Main Valve overview：

1. valve element layout and function

2. Function of Main Valve

3. attachment

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Ⅲ Main Valve Layout and Function------3.1. valve element layout 1

⑥
⑦ ① ① TS Travel straight
⑧ ② ② TLTralvel L , XAtL Travel reverse
⑨ ③ ③ Boom1 down XBb1
⑩ ④ ④ Bucket dig XAk
⑪ ⑤ ⑤ Arm2 dig XBa2
⑥ TR Travel R XAtr Travel reverse
⑦ Swing XBs

⑧ Boom confluence XAb2

⑨Option XBo
⑩ARM1 dig XBa1
⑪Bypass cut XBp1

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Ⅲ Main Valve Layout and Function------3.1. valve element layout 2

(6) (17) (1)

(6)
(7) (1) (7) (2)
(8) (2)
(9) (3) (17)
(8) (3)
(10) (4)
(5) (16) (16)
(11)
(15)
(13) (13)
(9) (4)
(14)

(12)
(15)
(18)
(10) (5)
(18)
(14)

(11) (12)

(19) (19)

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Ⅲ Main Valve Layout and Function------3.1. valve element layout 3

(2) (3) (1) (6)
(7) (8)(9)
(4)
(5)
(11)

(4) (3)

(10) (1)
(2)
(11) (5)
(8)(7)
(6) (9)

(10)

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Ⅲ Main Valve Layout and Function------3.1. 1main relief valve 1

● Main relief valve: protect the whole
system

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Ⅲ Main Valve Layout and Function------3.1.1main relief valve principle 2

1.System pressure(p)< elastic

force of spring (38)，Working oil
flows into chamber from B, but Main
valve element sand pilot spool is
closed.

2.System pressure(P)>elastic
force of spring，cone valve 24
opened , in this way, spool 38is
pushed open，working oil in
passage(p) flows into low-pressure
path (R)directly. 18
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Ⅲ Main Valve Layout and Function------3.1.1main relief valve principle 2

3.由功率提升电磁阀提供的压力信号油 Pz
进入主溢流阀内部，推动增压阀芯41向左移
动，压缩设定弹簧，从而达到增压的功能。

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Ⅲ Valve Spool Layout-----4.port relief valve

port relief port relief

valve valve

1) Standard pressure set

39±0.5Mpa

2）when machine park , to

escape damages from
impulsion load , in order to
prevent cavitation in the path main relief
when negative pressure is valve
formed.

▲
MAIN PUMP
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三. Valves Spool Layout- -------4.port relief valve movement 1

● port relief
valve pressure of the cylinder circuit, , to escape
Keeping
damages from impulsion load , in order to prevent
cavitation in the path when negative pressure is
formed.
Port relief valve
MCV Spool
Load check valve
Main relief valve

AaR
AoR

AbR

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三. Valves Spool Layout- -------4.port relief valve movement 1

BYPASS CUT
ARM1,BOOM2
OPTION
PRIORITY SWING
SWING
RIGHT TRAVEL
STRAIGHT TRAVEL
LEFT TRAVEL

AaR
AoR

AbR

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Ⅲ Valves Spool Layout- -------4.port relief valve movement 1

Oil pressure Elastic force of spring

유압 <
Oil 유 Elastic
는 오일통로 “A”를 지나
force 포핏 을 밀지
of spring , cone “B”실에서
못하여valve 머물고
and 있다valve(9) are stack
pilot
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Ⅲ Valves Spool Layout-------4.port relief valve movement 1

Oil pressure Elastic force of spring

라인 압력이 포트릴리프 셋팅 압력보다 높을 때 “2”번 포핏 이 뒤로 밀리면서 “9”번 피스톤이 동시에

Oil pressure
뒤로밀려 > elastic
리턴 통로”R”을force
열어주어of spring
오일이 리턴 ,cone 2 is pushed open fist ,then valve rod
9 is pushed open, working oil flow into tank by path R.
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Ⅲ Valves Spool Layout-------4.port relief valve movement 1

Anti-cavitation oil complement

“P” pressure < ”R” pressure

Pressure of cylinder rod end is lower

pressure of air, then, working oil is
supplied form tank by path(R) to path(P)
in to prevent cavitation
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Ⅲ Valves Spool Layout-----5.Boom、Arm pressure

retaining valve pressure retaining
valve layout and
entity
BOOM1保持阀

BOOM1 pressure retaining valve

ARM2 pressure retaining valve

( Boom、Arm
valves element ) 26
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Ⅲ Valves Spool Layout-----5.Boom、Arm pressure retaining function

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Ⅲ Valves Spool Layout-----5.Boom、Arm pressure openned

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ⅢHydraulic Basic System Circuit ----Boom up

Description：
1.Pilot pressure oil is supplied
into port XAb1（main valve
bottom），Boom 1 spool moves ，
pump1 working oil is introduced
into Boom cylinder head end ；
2. 1.Pilot pressure oil is supplied
into port XAb2， Boom 2spool
moves ， pump 2 working oil is
introduced into Boom cylinder
head end，the two pump flow
are meeting ，push boom up
together 。

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ⅢHydraulic Basic System Circuit ----Boom down

Description ：
1. Pilot pressure oil is supplied
into port XBb1（ main valve
top），push spool 1 movement，
pump1 working oil is introduced
into Boom cylinder rod end via
spool 1；
2.The flow will not be meeting ,
just Boom1 spool do it。
3、flow from cylinder head to
cylinder rod head via the hole of
spool1,this is called boom
regeneration function

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Ⅲ Main Control Valve --- MCV Fundamental Circuit of Linear Travel

Travel straight ： During Travel straight ，The machine will keep travelling straight although
to swing or any action of Work device ,the other hand, the flow of two motor are the same.
Basic theory：After satisfied other action flow need ,The flow via straight valve and
confluence and supply to the two travel motors

Right travel
L/R travel

& other

Right travel
travel

& other

& other

L/R travel
travel
Right

Left
travel &
Left

other

Right travel
P1
Pilot
Pump
All pilot oil P2
circuits
connect to
tank T by
passage of
Safety

valve rod
valve

Only when L,R neutral road

travel valve and any
other valve rod
operate at same time, Pilot
this point can Pump
establish pressure. 31
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Ⅲ Hydraulic Basic System Circuit ---5.Boom given a priority to swing-pns

When do the combined action of boom
and arm ， the pressure from A2 make
the opening area become small ,and
restrict the flows in the front of arm,
and then ,the swing motor get the
priority , in this way, the velocity of
swing become quickly

Pns To Boom Cylinder

Boom
valve
element

Boom given a priority to swing

Main Valve
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Ⅲ Hydraulic Basic System Circuit ---5.Boom given a priority to swing-pns

To Boom
Cylinder

Boom given a priority

to swing

Main Valve

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Ⅲ Hydraulic Basic System Circuit ----arm regeneration

XBP2 arm
regeneration

XBP2 arm
regeneration

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Ⅰ Hydraulic basic system circle -----Pilot Control Circuit

Pilot oil control

system is used to
open the port or
not :Bucket pilot
port、Boom pilot
port 、Arm pilot
port 、Swing pilot
port 、Left or right
travel、Pump return
oil pipelines、
Travel motor high or
low speed、Swing
holding brake.

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ⅠHydraulic basic system circle -----Main Pipeline

Main curcuit：
Pump1and pump 2 supply the
pressurized oil to control valve and
sump oil from the tank，pressurized
oil will enter motor or cylinder
according to the control, and then
drive cylinder or motor to swing or
travel. Pressurize oil return to the
tank via control valve and radiator.
When oil temperature below the
normal( high viscosity ) ，oil
resistance will become so big in
hoses that the oil return to tank
when the check valve opened for the
resistance
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Ⅳ. Swing motor structure and function

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IV. Swing motor structure and function

1、Structure of swing motor overview——port
Oil Drain Safe
compleme Port Valve
nt Port

Main
Port

Main
Port Check
Valve
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IV. Swing motor structure and function----swing valve timing function:

•1．Theory
•When the swing control lever is neutralized , The motor keep on rotate
for inertia，Swing brake will work delay5-8s after pressured oil cut off.

•2. SPC Brake star 0.5～0.7 MPa

pressure
Delay 5～8 sec.

•3. Structure
Brake
Dismiss
Pressure
PG

Brake start
pressure
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IV. Swing motor structure and function ----Swing holding brake：

brake spring
1. Swing stops-hydraulic
- pressurized oil from the pump
pump to port is cut off. The pressurized oil PG
from the motor outlet can't return to the tank
since the return circuit
to the tank is closed, Swing resistance is
generated on the motor and hence the brake
starts working.
2. Swing stops-machanica
- As parking brake
3. PG pressurized oil is from the pilot pump,
and the pressure is 3.9Mpa；
4.Port SH connect to main control valve port
PX，Some action start except travel,PX get
The pressurized oil ，The pressurized oil
compresses brake spring and pushes the
brake piston up. Disc is separated from
plate , releasing the brake.
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IV. Swing motor structure and function ----swing valve-timing function：

(±5~20 bar)

Brake 活塞
piston (35 bar)

. PG connect to pilot pump all the time，3.9Mpa；

※ Note : pressured oil in valve-timing last 4s ,and then drain out，
Brake piston push down。
SH connect to PX，Some action start except travel , PX get The pressurized
oil ，The pressurized oil compresses brake spring and pushes the brake piston
up. Disc is separated from plate , releasing the brake. otherwise，A high braking
torque is applied on the motor, thereby stopping the motor.
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IV. Swing motor structure and function ----Oil complement：

Oil complement： When negative pressure is formed in path, pressure in path (R) gets
higher than pressure in path drain pipe, working oil is supplied from tank to motor via the
periphery of valve seat in order to prevent cavitation.
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IV. Swing motor structure and function ----Safety valve：

Safety valve： the backlash and rigidity of the machinery system,

and the compression of the hydraulic oil all may cause the machine
to shake during swing operation. The reverse prevention valve is
designed to reduce this effect.
KRD22EK series
the
hydraulic oil
cause the
Safety valve
machine to
shake

Pressure wave
0.2～0.3sec
PSET

Pressure curve become

smoothly: pressure wave
shrinkingly

KRD20EK60 KRD22EK Swing motor

t
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IV. Swing motor structure and function ----Safety valve：

pressured relief valve action

restrictive hole spring

spool

slide valve restrictive hole

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IV. Swing motor structure and function ----Safety

valve：
Pressure
Valve Opening
time

Valve rod move right，for the pressure restrictive。Pressure in port A will raise，
and will get the set pressure。

Cushion valve

T T

Valve rod Adjustable slot throttle

During the once swing process，as the motor start swing，the safety opened for a
short time，and shut later 。This function called start-up counter balance， and during
process smooth the oil sway.
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IV. Swing motor structure and function ----

reverse prevention valve
1．specialty (1) preventing the second reverse rotation(2)
can assemble on the swing motor (3) design compactly

2.To stop the swing ，stop moment is set by overload

valve ,when the swing motor haven’t reverse
prevention valve, moment become big ,the motor to
release pressured oil by relief valve opening and
shut repeating.
3.To set reverse prevention valve ， moment become big, the
valve can connect the low pressure and high port
directly, then swing just reverse once

have reverse
prevention valve

Haven’t reverse
prevention valve
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V. travel motor structure and function

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V. travel motor structure and function

travel motor
travel motor
hose，the pipe
connected to
Center swivel
joint

Function :To switch

the high speed and
travel motor low speed, the
drain hose，the pipe connected to
pipe connected Center swivel joint
to Center swivel
joint

travel motor
hose，the pipe
connected to
Center swivel
joint

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V. travel motor structure and function

Safety
valve

counterbal
ance valve,
function :
To limit
rotation
and
prevent
stall (travel
down

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V. travel motor structure and function----safety valve：

travel motor port
travel motor port

Check valve
Check valve

counterbala
nce valve

pressure relief pressure relief

valve valve
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THE END

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