1. 1.1, SUMMARY (2) Outside view and hydraulic port a3_ Dr PNI Psv2 feve Bout sm) Psvi PN2 esvay 2 BL TT Fig. 1-1 Hydraulic pump « regulator @y) al a2 HYDRAULIC PUMP - REGULATOR Applicable maheines : LCO7-06001~ ‘YC07-02801~ al PHI PH2 92 an, FLOW RATE. ‘Table 1-1 Hydraulic ports Code Ports name Size A1,2 [Delivery port SAB 6oodpsi 8/4" No. NAME QTY __B1_|Suction port SAB 2500psi 2 Yn" 1 [MAIN PUMP ASSY 1 Dr_[Drain port PFS/4-20 2 | REGULATOR ASSY 2 _PSVi.2| Servo assist port PRva-15 3. | GEAR PUMP ASSY(FOR PILOT) 1 PN1.2 [Servo assist port PFU4-15 4 |Reboane va 2 PHL,2 | Pressure sensor port PFS/8-17 5 |pro UNIT 1 _al~ag | Gauge port. PFU4-15 a5_|Gauge port PFV4-14 ‘AS [Delivery port of gear pump | PFa/8-15 B3_[Suction port of gear pump | PF3/4-20.5 Dr3_[Drain port of gear pump PFSI8-15 HI-1@) Hydraulic circuit dingram cdatearmey eas) ‘Solenoid proportional Solenoid proportional MS qonoes_Teducing valve(PSV-2) reducing valve(PSV-1); Regulator regulator Gear pump for pilot Fig. 1-2 Hydraulic eixeuit diagram of pump (8) Specification = Main pomp ens Pom any Texavem = re ‘Hyd. pump LC10V00008F 1 -YN10V00014F2 =a nee ee eases Max displacement capacity | cm*/rev 115X2. 10 swing [Ps¢ | Bacvin 2at0 = speed Trias [enenSscee 2385 or less - awa ; a0 Pressure ferrie kketflem? (psi) a 50 (710) ‘Max. flow €hmin(gal/min) | 250 (66)X2 at 80kgficm*(1100psi) 226.8) ‘Max. input horse power | kW {PS} 169 {230} 3.4 {4.6} Max. input torque _| kef-m (Ibf-ft) 7 (540) 1.5 (11) a Moda Tasco Contin Ean aad ae on cae eT aaa ‘aro RENEEE ALBION Weight kg (lb) 131 (290) Note: The max. input power and the max. input torque of the main pump include those of the gear pump. mi-2smd apenpgyewosenayuey 61 PUL ‘yes oe ovate ease ype oa ta NE You oes anf eeu ofamses vy spc [—] oon ‘ed Eins 2/2 Slel2|2 aa nas a, a NOLS 3 weak oh ak & \yh Tek de ieee 1 UE gorse anne onnvEGAH &pot TOE TBOOS T 1 1 oe 3 frxanxesoossoNvas|eo| coLt Oe eos ma] MeN ST a tHe ‘eons op an) damdnen) p-rSts 9 wp sep or som oF trgspwiege Sram, ter vaumes ome Sumit " “pfiad : Doe UaEENS es cone demas @1.2.2 OPERATION ‘The pump assy is equipped with two pumps PTO.GEAR ee GaSe arranged on the same axis that are connected with gear (116) and distribute the rotating power to the gear trains on a different axis, Thus the engine rotation is transmitted to front shaft (111) that drives the two pumps and, at the same time, drives the pilot gear pump arranged on a rear shaft. ‘The pump assy consists largely of the rotary group, the main part of the pump that makes rotary on; the swash plate group that changes the delivery rate; the valve block group that selects between oil suction and delivery ; and the PTO group that transmits the drive power to the gear pump @) Rotary group ‘The rotary group consists of shaft(111), cylinder block (141), piston (151), shoe (152), plate (158), spherical bushing (156), and cylinder spring (157). ‘The shaft is supported by bearings (128) and (224) at its both ends. The shoe, which is caulked to the piston, forms a spherical joint and relieves it of thrust force that is generated by load pressure 182 Further, the piston is provided with a pocket soit moves lightly on shoe plate (211), taking a 4 ‘The sub group of the piston-shoe is pressed against the shoe plate by the cylinder spring, via the retainer plate and the spherical Fig. 1-7 Rotary group bushing, so that it moves smoothly over the 592 shoe plate. The cylinder block (141) is also ei se pressed against valve plate (315) by the action of eylinder spring (157). @) Swash plate group kare The swash plate group consists of swash plate (212), shoe plate (211),swash plate support < @51), tilting bushing (214), tilting pin Cas (631),and servo piston (532). The swash plate 9 is the cylindrical part that is formed on the au 3 opposite side ofthe shoe sliding surface and is 24 supported by the swash plate support. Lee ‘The hydraulic force controlled by the aR regulator flows into the hydraulic chamber that is provided on both sides of the servo piston. This moves the servo piston to the right and left. The result is that the swash Fig. 48 Swach plate group plate swings on the awash plate eupport via ‘the spherical part of the tilting pin and changes the tilting angle («). HI-5(8) Valve block group ‘The valve block group consists of valve block (612), valve plates (813 or 314), and valve plate pin (885). The valve plates having two crescent-shaped ports are installed to valve block (812) to feed oil and recycle it from cylinder block (141). The oil switched over by the valve plate is connected with the external pipe by way of the valve block. Now, if tha shaft ia driven hy the ongine, the cylinder block rotates together by the spline linkage. If the swash plate is inclined, the pistons arranged in the cylinder block make reciprocating motion with respect to the cylinder while rotating with the cylinder Block. Ifwe keep an eye on a single piston, it makes a motion away from the valve plate (oil ‘suction process)in the first 180° and a motion toward the valve plate (oil delivery process) in the remaining 180°. If the ewash plate is not inclined (zero tilting angle), the piston does not stroke ie. delivers no oil. @ PTO group ‘Tho PTO group ic composed of 1st goar (116), 2nd gear (117) and 3rd gear (118). The 2nd and the Srd gear are supported by bearings (125) and (126) respectively and installed to the valve block. ‘The shaft rotation is taken up by the let gear (116) and transmitted to the 2nd gear (117) and the 3rd gear (118), in that order, to drive the gear pump that is linked to the 3rd gear. mi-6 Delivery port 813(No.1) 314(No.2) Suction port 85 312, Fig.1-9 Valve cover group ut 125 Fig. 1-10 PTO groupsovesaryowononnoeg 111 Ra geod one sae ange GE 9 Tease newness ees © P= aL [—] DNESELOTE mais oxtisneay|sr| @ vas oxrtas| | gost eS ss NOLS B)-n ene wwe denne nen elie nna ee ne carer (Piet esi we 9 Oe Nousnuusnog 65 woLWINEY © er“tudo Bus ye 29 Sop “peop Retin et sera cons Gg) und ese yaw owe ATEOPESFig-1-15 Functional explanation of regulator m-92) Flow return When the front pump delivery pressure P1 or rear pump delivery pressure P2 is lowered, compensating rod (628) is pushed back by the spring force of outer spring (625) and inner spring (626) and lever 1 rotates centered on the E section. Feed back lever 1 (611) rotates putting fulerum on the D point and spool moves leftward. Consequently the pressure flows into the tank port through Cé port, the pressure of the large bore section of the servo piston is released, servo piston moves Tefiward, and the pump delivery flow rate is raised. ‘The movement of servo piston is transmitted to spool with the feed back mechanism, and continues the action until the openings of spool and sleeve are closed. () Low tilt angle (ow flow rate) command priority mechanism ‘As deseribed above, the tilt angle command for the flow rate control and horse power control is transmitted to feed back lever and spool through lever 1 and large bore sections (CF sections) of lever 2, but the C and F sections are constructed so that pin O4 (0.15tin) is protruded from large hole 8 (0.315in), and the pin (897) comes in contact, with the large hole @8 (0.315in) of lever which makes the tilt angle smaller, and other large hole 28 (0.316in) of the lever in the condition of tilt angle in large radius is free ‘without contact with pin (897). This way, the command for smaller tilt rotation side of flow control and horce power control hao a priority according to the mechanical selecting system. (© Back-up function ‘As shown in Fig.1-14, loosen nut (801) and change the position of rod (642). This causes the electric flow control to be switched to the hydraulic control In the electric flow control, the secondary pressure Pi of the solenoid proportional reducing valve is admitted to the pilot piston to perform flow control of the pump. In case the solenoid proportional reducing valve is disabled, the control mode is switched over to the hydraulic control if rod (642) is switched over. Psv| ‘The primary pressure PSV of the solenoid proportional reducing valve is admitted to pin (898) and controlled at a constant power level in a powor shifted (reduced power) condition. ‘The pressure of the Pni port is admitted to the pilot piston and performs flow control as the pressure goes up and down. Do not use the back-up select rod(642) when the front and rear regulators are fully closed or fully loosened. The pump can not be controlled if the position of the front regulator differs from that of the rear regulator. 801 in) ol soe th ‘Atbackup control Fig.1-16 Switching to back-up function Dalivery ow rate Q Delivery pressure (PaP2) Fig.1-17 Power shift control HI-101.8.3 ADJUSTING THE REGULATOR ‘The regulator may be adjusted in terms of max- imum flow, minimum flow, horsepower (at back- up control) control characteristics, flow control characteristics using the adjust screw. (2) Adjusting the maximum flow (See Fig.1-3) ‘Adjust the maximum flow by loosening nut (G08) and by tightening sat corew (054) (or loosening it). Tightening sot screw (954) decreases the delivery rate, as indicated in Fig.1-16. Only the maximum flow varies, but other control characteristics remain unchanged. ‘Adjust screw No. 954 No. of turns for tightening va Pilot pressure Pi put current I) Min. increase in delivery flow ‘nin (galinic)| 88 0-5) Nochange (2) Adjusting the minimum flow (See Fig.1-3) Adjust the minimum flow by loosening nut (806) and by tightening socket screw (953) (or loosening it). Tightening socket screw increases the delivery rate, as indicated in Fig.1-17. Other control characteristics remain ‘unchanged in the same way as maximum flow adjustment care should be used of the fact that overtightening may increase a required power at the maximum delivery pressure (at relieving action), ‘Adjust screw No. 953 ‘No.of turns for tightening wa Pilot pressure Pi Gnput curent-1)] Necbanse Min seas mg Oy [ 460. (8) Adjusting the input horsepower (at back-up control) Se control type, turn the adjust screws of both the front (No.1) and rear (No.2) pumps when Sac eee ta aga pened vat eee level. The pressure change values by adjustment are based on two pumps easiest casey onc ad einai eee ae pa iad HI-11 Delivery flow rate @ Input current I (Pilot pressure Pi) Fig.1-18 Adjusting the max. delivery flow Delvery flow rate Input current I (Pilot pressure Pi) Fig.1-19 Adjusting the min. delivery flow1) Adjusting the Outer Spring (See Fig. 1-9) (At back-up control) Adjust it by loosening lock nut (630) and by tightening adjust screw C (628) (or loosening it). Tightening the adjust screw shifts the control chart to the right and increases the input horsepower, as indicated in Fig. 1-18, Since turning the adjust screw C by N turns changes tha setting of the inner spring, return the adjust ecrew (925) by 2.2N turn at fst : = Talus erew No. ea : No.of turns for tghtoning mm : Increase in delivery pressure kgdtm* (psi) | 17.8 (250) a Increase in input torque _kgfm (ft-lbs) | 4.7 (34) a SS 2) Adjusting the Inner Spring Se Fit. 1-8) Deter ress (P12) (At back-up control) ‘Adjust it by loosening nut (801) and by adjust, serew (925) (or loosening it). Tightening the adjust screw increases the flow and then the Fig.1-20 Adjusting the input horsepower (1) input horsepower, as indicated in Fig.1-19. ° ‘And the input torque raises. 3 i = ‘Adjust screw No. 2 2 (No. of turns for tightening WA é Tnerease in low nin (galmin) | 18.4 (4.9) Trereas ininput torque extn ibe) | 3.2 (25) a Delivery pressure (P1#P2) (A) Adjusting the flow control characteristics (See ‘Fig.1-21 Adjusting the input horsepower (2) Fig. 1-9) ‘Adjust them by loosening nut (801) and socket screw (924) (or loosening it). Socket screw ‘causes the control chart to move as shown in Fig-1-20. Socket screw raises the flow control start pilot pressure. And the to the right iia e oS 2 ease eee [ae Increase Pilot pressure Pi keflem’ (psi) 1.3 (18) Increase input current 1 mA 2imA ae o reser fimin (gal/min)| (4) _ _Fig.1-22. Adjusting the flow control characteristics, mi-1218.4 CAUSES OF FAULT RESULTING FROM REGULATOR When trouble due to this regulator occurs, Disassemble and inspect it referring to “Chapter 1033". (@) When the engine is overloaded, ‘Load every unit of pump, and check on pumps fon the right and left sides for possible damages. When pumps on both sides are failed, check on them for the following failures 1), 2. When pump on the one side is failed, start checking from par. 3). 3) Check that the power shift command current Tis normal. 2) The power shift prescure is low. * Check the dither of amp. + Replace solenoid proportional reducing valve. 3 Stick of compensating piston and compensating rod + Disassomble and clean it. 4) Stick of pin (698) + Disassemble and clean it. () The max. flow rate is not delivered. 1) Check that pilot differential pressure Pi is normal, 2) Stick of pilot piston * Disassemble and clean it. 8) Stick of spool + Disassemble and clean it. Note : When the damage of part is severe, replace the part with new one. HI-131.4 CONTROL CURVE OF PUMP () At electric flow control Input evolution 2200xpm 250-7 (65) Single load ‘. |a0K P2=0K - 190K [38 = 200 Bat} 1 Simultaneays toad | € 150 }____} ss — S «0 o 2 100 B 28) 350K & Bak s 2 50 8 13) 060 100 160 200 250 300 380 © (70) (1420) 2130) (@e40) (2560) (4270) (4980) Delivery pressure Pd [kgticm*(ps!)] (2) Atback-up mode (simultaneously loaded 2-pump conflux) Delivery low rate Q [g/min (galimin}] 155K 230K Input revolution pare Daal. 250 PE BOK (68) P=0K [E=40GmA} {Single load 250, 200 9.4K 63) 237K 7B0L 150. (a0) 356 oan 186L 100. 5) 1=725mA 35t2L | Pa=80K 269K —|at G=max. 50 «ay o 50 100 180200250 300350 © (740) (1420) (2130) (2840) (3560) (4270) (4880) bt $ £ toa __Celivery pressure Pat fkatom(si 0 (70) (140) (@t0) (280) Bi Se pump pressure )pposite pump prossure Pilot pressure Pi [kgtlom(psi)] PF ; Power shift pressure Fig.1-23 Control curve of pump HI-14 2200rpm, 385K 145L 385K 3.8L 1‘Skssowae OPT2 amano usr «0a on) ‘Tebea.1 02 HiisvamaessCo1 | RAGsTRRS909sC1 fskssasee OSD Skansen Gun o7rn| ‘ebloa2 al BIA 2. CONTROL VALVE Fig. 21 Control ve outside view nd yaaa port, (The shows he valve with OPT1 and OPT2) (2) oneal view and hydra prt 24 SPECIFICATIONsues soo aopenneteg (Gr) 22 Ee e wu LW a eu S 8 7 a YE 16 me ee oar. on a st aaa ne oot yer FT 76 WV ROUSE ag We aa = , Ie) sey 3 | iC ata wf ran Nowonussnos =sues ameceyouomonsiae) (er) ot 9 = a # e aaa a — = mo_ | 08 : 10028 XNTENOO WAY 00a Honsasa yuo 70 wane) (8) 2B Z i i 5 eae ee RRR EF a =a gagalseea alae ee sla aa & -|s enzo |e | canvas wav sa2 ona ' anes oc + | eemoapanszeoaeyog ab sve senmins [ XB PRETO a GSGEMURUTAGY GE AGBL Zl@S he ge E Saale ae i digas * A1 1 1 1 1 t er onal i a 4 ea x13] oom ose ozra ste opis yea veg sige ors gee T [eae 1 1 1 1 1 t 1 t 1 i i eo~10) 92 way BL a] aa sab j T B19 109 129 ZOE LOT SET HEL ERT TOT 8 195 (eorz00) 284 en0" PIE nD same HRI EIa Tae aa i ceauno) ones F eae Cem) oneal i seroma I ut] ee seus Tee 1 ont 1 ‘xmas 1 "Tooas| 1 22x: oar| par9¢—1 |r ID AWN on | OURS [aa] Ske saree sonore, re Qr@errama Toone seen a“Tor aaawas ea] mga serene, won orem 101s (212 seve qs sow aue6 BOT) GLO srrAEA evopse ay wea ee;a a ONO] T1aatONREO| ‘na: ona HOM ‘uaa: ota Hou ‘oNISvO ax Elen--4] ia] ove res| hoes teen nema (eager pi) Gem@orcaea Patsare emer ODuae ne Foe ut jdeeass|seeee|s mom MEP gre A sinowo onnvaaan £2souomaanc Banepa uma ue se em,2.4 OPERATION () Control valve in neutral Purpose : To reduce the pump flow rate by means of the negative control signal. Principle = ‘The negative control signal pressure is output when the flow rate at the extreme down stream ie raised. Operation ‘The oil delivered from the hydraulic pump P1 {lows into P1 port of the control valve, passes. ‘through the travel spool (307) and main passage (51), is led into bypass circuit which passes through the travel right, bucket and boom control sections and Pl bypass cut spool (809). ‘The oil delivered passes through P1 bypass cut spool (809) and flows into negative control relief valve (N611) located in negative control relief valve block (212) because P1 bypass cut ‘spool (309) is not switched. ‘The poppet section of negative control relief valve (NG11) has many small holes, and the oil delivered passes these holes and returns into the tank port. Consequently the rise of flow rate causes the rise of Pal pressure and the negative control signal is output through Pal port or Pni’ port. When the pressure of the negative control valve rises higher than the specified pressure, the poppet opens and the oil is led into the tank port (1). ‘The oil delivered from the hydraulic pump P2 also passes through main passage (54) and is, ed into bypass circuit (65) which passes through the travel left, boom conflux and arm control sections and P2 bypass cut spool (309) like the oil delivered from the hydraulic pump Pl. The oil delivered flows into negative control relief valve (N61) like P1 side, causes, the rise of Pn2 pressure, and the negative control signal is output through Pn2 port or Pn2" port. 307 309 coy 3) 215 (NEGATIVE CONTROL RELIEF VALVE BLOCK) 2 pump sie ° Pur] is 7 : P2| y mH foe Oc i 6D 2 212 (NEGATIVE CONTROL RELIEF VALVE BLOCK) Pi pump side Fig. 2-14 Functions at neutval He-11(2) Functions for travel action 1) At independent travel Port name Operation [Pilot secondary [Main pressure pressure side [oil supply side [Forward| Ar ‘Ar Right lReverse | PBr ‘Br [Forward | PAL AL Left [Reverse PBL. BL If travel operation (forward) is performed, the secondary pilot pressure from ports] an of the travel pilot valve acts upon ports PAr and PAL of the control valve and moves the right and left travel spools (806). ‘The pressurized oil delivered by pump (P1) flows to the main passage (61) past the travel straight spool (307), passes between the outer circumference of the right travel spool (806) and the easing and is supplied to the right travel motor B by way of port Ar. In the meantime, the pressurized oil delivered by pump (P2) passes between the outer circumference of the left travel straight spool (06) and the casing, runs to port AL and is supplied to the left travel motor P2 side, the same way as the pressure oil by pump (P1), Meanwhile the oil which has returned from the right travel P1 side and the left travel P2 side passes between the outer circumference of the left travel epocl (806) and the casing and returns to the hydraulic tank via the tank port (T) of the low pressure circuit (D). ‘At backward travel action (when the secondary pilot pressure nets upon ports PBr and PBL of the control valve), the pressurized cil works the same way as in the forward travel action. RIGHT TRAVEL MOTOR PL P2 Br] PBr PILOT PORT [par Fig. 2-15 At right travel forward (when PAr is pressurized) H2-122) ‘Travel straight valve switching at TraveVATT combined operation Purpose : While travelling, it is possible to travel straight even if the attachment is operated. Principle ‘The travel and attachment operation can be performed by separate pump. Operation When the actuator other than that for travelling and travelling are simultaneously operated, the pilot secondary pressure acts on PTb port of the control valve, moves travel straight spool (807) upward to the position tay, ‘The result is that the pressurized oil delivered by pump PI flows from A to B in most amount of oil and becomes the pressure for the actuators except one for travel action. ‘The pressure oil delivered by pump P2 flows, in most. amount of oil, in the C-*D direction und the main passage (64), becomes the oil pressure for the right travel and the left travel motions and realizes simultaneous operation of the actuator and travel action. (travel straight function) sor pi PLy| yy Hy A cw Q Hp ore HH a oH Pe : i iat fom Postion [1] PT ‘Attravel straight action Fig. 2-16 Functions at travel straight spool He-13(8) Bucket 1) When the bucket is digging the check valve open, enters the parallel circuit (53), pushes the load check valve LUU CH Fort name Operation [Pilot econdary [Main pressure G11) open, goes between the outer pressure side |oil supply side circumference of the bucket spool (304) and Bucket digging PBe ‘Be the casing by way of the U-shaped passage When the bucket is digging, secondary pilot pressure coming from port @) of the pilot valve enters port PBe of the control valve and moves the bucket spool (304) to the right. ‘The pressure oil delivered by pump (PI) flows to the bypass circuit (62) past the main passage (51), but since it is blocked by the bucket spool (304) that has shifted, it pushes Pac and is supplied to the bucket cylinder head (A) via port (Bo). In the meantime, the oil which has returned from the bucket cylinder rod side goos ‘between the outer circumference of the bucket. spool (904) and the casing through the port (Ao) and returns to the hydraulic oil tank by way of the low pressure circuit (D) and the tank port (1), 63) 304 PILOT PORT PBe U-SHAPED PASSAGE As, Be ‘BUCKET CYLINDER, Fig. 2-17 When bucket is digging2) When the bucket is dumped CIV Port name Operation [Pilot secondary Main pressure pressure side_|oil supply side Bucket dump PAc he When the bucket is dumped, secondary pilot pressure from port D of the pilot valve antora port PAc of the control valve and ‘moves the bucket spool (304) to the right. ‘The pressure oil detivered by the pump PI flows to the bypass circuit (62) through the ‘main passage (51), but since it is blocked by the bucket spool (804), it pushes the check U-SHAPED PASSAGE 51 valve open, enters the parallel circuit (53) the load check valve LCe (511) open, goes between the outer circumference of the bucket spool (804) and the casing via the U-shaped passage and supplied to the bucket cylinder rod (R) via port (Ac). In the meantime, the oil which has returned from the buckot aylinder head goos between the outer circumference of the bucket spool (804) ‘and the casing through the port (Be) and is supplied to the hydraulic oil tank by way of the low pressure circuit (D) and the tank port (1) 63) D 304 PBe BUCKET CYLINDER Fig. 2-18 When bucket is dumped H2-158) Bucket conflux If the bucket performs single dump or digging work, travel straight spool (807) and P2 bypass cut spool (899) are switched over. Then the pressurized oil streams delivered by pump (P1) and (P2) are combined in the control valve. (Oil stream conflux does not occur when the bucket is operated with other attachment at the same time ; the operation is the same as 1) and 2) above.) In the above operation, the secondary pressure of the solenoid proportional valve acts on the pilot port PTb of travel straight spool (307) and changes the travel straight spool (807) to the right-hand direction. Aléo, the secondary pressure of the solenoid proportional valve acts on the pilot port PCa of P2 bypass cut spool (309) and changes over bypass cut spool (809). a A 307 (TRAVEL STRAIGHT SPOOL) D — CONFLUX Pac ‘The pressurized oil delivered by pump (P1) runs in A to B, passes through poppet (with a restrictor) (615) from B, and runs into parallel passage (53) on the P1 side. In the meantime, the pressurized oil delivered by pump (P2) runs into C and D, passes through main passage (51) from D and runs into bypass passage (52), but since the oil passage is shut off as bucket spool (904) is shifted, the oil pressure pushes the check valve open and enters parallel passage (53). As the result, the oil delivered by pump (PI) is combined with the oil delivered by pump (P2) and then runs into the bucket spool. (or subsequent actions, refer to Par. 1) and 2) above.) \ FROM P2 PUMP FROM 1 PUM « 04 ore be BUCKET CYLINDER, Fig. 2-19 Conflux when bucket is digging H2-16() Boom 1) When the boom is up Ci Port name Operation [Pilot secondary|Main pressure” pressure side | il supply side Pab. Boom up PBL Ab PCa When the boom is up, secondary pilot pressure from port @ of the pilot valve enters port PAb of the control valve and moves the boom spool (301) to the right. It also acts upon port PBI (Refer to next page) and change over the boom conflux spool (805). And at the same time, the pilot secondary pressure acts on PCa port of the control valve and switches P2 bypass cut spool (809). ‘The pressure oil delivered by pump P1 flows into bypass circuit (52) through main circuit (61), but since the circuit is eut with boom spool (301), the pressure oil opens check valve CPi and enters in parallel circuit 63), and opens load check valve LCb (511) and flows in the chamber BH through U-shaped passage and botwoon the cuter aenfoos of boca peo) (G01) and the casing, then opens lock valve poppet CRb (514) and finally is led in the boom cylinder head (H) side through port (Ab). Meanwhile, the oil port (Bb) which returns from the boom eylinder rod (R) goes between the outer circumference of the boom p00! (S01) and the casing, flows unto the tank port (T) via the low pressure circuit (D) and returns to the hydraulic tank INSIDE CONFLUX PASSAGE (3) 301 wey LI ZEo ES i CHAMBER BH (AD) 511 U-SHAPED PASSAGE Fig. 2-20 When boom is up (Boom spec!)2) Conflux for boom up Purpose : Speed up of boom raise operation Principle : Confluxing 2-pump delivery flows The oil delivered by the pump P2 flows into the main passage (54), but since the bypass circuit (65) and the parallel circuit (56) are closed by the P2 bypass cut spool (809) which has shifted as explained in 1) above (Refer to Fig. 2-21), the oil enters the parallel circuit (66) from travel spool. (Refer to Fig. 2-22) ‘The oil then pushes the load check valve CCb (12) open, passes between the outer circumference of the boom conflux spool (305) and the easing via the A side of the U-shaped passage, enters port Ab through the conflux passage in the casing and combines with the pressure on the pump P1 side. P2 BYPASS OUT SPOOL vie STANK PASSAGE Fig. 221 P2 bypass cut valve GONFLUX CHECK VALVE cc @) 66) pri =a Paz ¥ 305 To port Ab through the conflux passage in casing BOOM CONFLUX SPOOL. Fig. 2-22 When boom is up (Boom conflux spool) H2-183) When the boom is down If the boom down action is performed, the secondary pilot pressure from port @ of the pilot valve acts upon port PBb of the control valve and lock valve selector port PLe and shifts the boom spool (301) to the left, it also change over the lock valve. The pressure oil delivered by the pump (P1) flows into the bypase ciseuit (62) through the main passage (51), but since it is blocked by the boom spool (301), it pushes the check valve (CP1) open, enters the parallel circuit (3), pushes the load check valve LCb (512) open, enters the U-shaped passage, goes between the outer circumference of the boom spool (801) and the casing and is supplied to the boom cylinder rod side via port (Bb). On the other hand, the return oil from the boom cylinder (H) side flows in the control valve through port (Ab). The lock vale poppet CRb (614) is located just before boom spool (B01), but since the pilot secondary pressure acts on PLel port and the lock valve selector spool is switched and the back pressure of lock valve poppet CRb (514) is connected to BOOST CHECK LOCK VALVE ‘SELECTOR SPOOL PLel LOCK VALVE SELECTOR, ~ CONFLUX PASSAGE INCASING Dre, the valve opens, And the return oil enters in the chamber BH, and flows in the chamber E inside of boom spool (801) through, the circular notch of boom spool (801). Since the returned oil has sufficient pressure by the weight of the boom, arm, ete. , it pushes the poppet on the right of the illustration through in the spool, passes through circumference and is supplied to the boom cylinder R side as the hydraulic oil for boom down motion. (Boom fixed recirculation function). Some of the return oil from the head end of the ‘boom cylinders forces open the boost check valve, and flows through the low pressure circuit D to the tank port T, and back to the hydraulic oil tank. The purpose is to allow excess return oil to escape to the tank. This excess oil is caused by the fact that the area of the piston at the head end is larger than the area of the piston at the rod end. ‘The boost check valve acts on oil flowing to the tank to secure an adequate amount of recirculating oil ite outer CHAMBER E: [pooworanoen| Si RiaL ” Garden 514 ho sit “ U-SHAPED PASSAGE Fig. 2-23 When boom is down (in Mor A mode) H2-19© Arm 2)_Arm out operation | CW Port name Operation | Pilot secondary | Main pressure pressure side | oil supply side Ba PAL PC PAad Arm out, Ba AE arm out operation is performed, the secondary pilot pressure from port @ of the pilot valve acts upon ports PBa, PAa2 and PAL, PCh of the control valve. (refer to Fig. 2-24, 2-25) ‘The pressure oil which enters port PBa shifts the arm spool (802) leftwards. The pressure oil which enters port PAa2 shifts the arm T2 spool (811) leftwards. The pressure oil which enters port PAI changes over the arm conflux: valve (308). And, the arm out secondary pressure after high pressure selection in the proportional valve block aete on PCb port of the control valve and switches PI bypass cut valve (309). H2-20 The pressure oil delivered by pump P2 flows into the bypass cixcuit (65) by way of the main passage (64), but since it is blocked by the arm spool (302), it pushes the check valve CP2 open, flows into the parallel circuit (56), pushes the load check valve LCa (611) open, goes between the outer circumference of the arm spool and the easing by way of the U-shaped passage, runs into chamber AR, pushes the lock valve poppet CRa (614) open and is supplied to the arm cylinder rod R side via port Ba). In the meantime, the oil which returns from the arm cylinder H side passes between the outer circumference of the arm spool ($02) and the casing by way of the port (Aa), flows into the tank port (I) from the low pressure circuit (D) and returns to the hydraulic oil tank Further, part of the oil that returns from the arm eylinder (H) passes through port Aa? and the gap betwoon the outor surface of arm T2 spool (811) and the casing, runs into tank port, (D) from the low pressure circuit (D) and retums to the hydraulic tank.AM CYLINDER CHAMBER SARL Diustaben USHAPED | (65) ‘CONFLUX PASSAGE co) Paa2 Fig. 2-24 At arm out operation (Arm spool and arm T2 spool) H2-212) Arm out conflux In operation 1), the oil delivered by pump P1 flows into the bypass circuit (62) through the main passage (61), but since the bypass circuit (52) and the low pressure circuit (D) are blocked by the bypass cut spool (309), it does not run into the low pressure circuit (D). Meanwhile, since the arm conflux spool (308) has now been changed over, the pressure oil of the bypass circuit (52) goes between the outer circumference of the arm conflux spool (308) and the casing, Prour 309 Part of the delivered oil passes through the parallel circuit (63) and the restrictor, combines with the pressure oil of the bypass circuit (52), pushes the conflux check poppet 11) open, enters port Ba by way of the conflux circuit in the casing and finally combines with the pressure oil on the pump P2 side To port Ba through the confux passage in the casing 308 SST 3) Bul Fig. 2:25 At arm out operation (Bypass cut spool and arm conflux spool) H2-22‘This page is left blank for editing convenience. H2-238) When the arm is in (under light load) Operation [RPE Pia ‘rm in {ander light loa} © PLC2 Purpose Speed up of in operation and prevention of cavitation when operating the arm at light load. Principle ‘The return oil from the axm cylinder (R) side js recirculated into the eylinder (H) side in the on. If the arm in operation is performed, the secondary pilot pressure coming out of port @ of the pilot valve acts upon the Paa port of the control valve and the PLe2 port of the lock valve selector. This causes the arm spool (302) to move to the right and changes the Jock valve selector spool (211), ‘The pressure oil delivered by the pump P2 flows into the bypass circuit (65) past the main passage (64), but since the bypase circuit (66) is blocked by the arm spool (302), the oil pressure pushes the check valve (CP2) open, flows into the parallel circuit (66), pushes the load check valve LCa (511) open, goos between the outer circumference of the arm spool (302) and the casing through the U-shaped passage and is supplied to the arm cylinder (F) side via port (Aa). H2~24 ‘Meanwhile, the oil which has returned from the arm cylinder (K) enters the control valve through the port (Ba). ‘The lock valve poppet CRa (614) is located just before arm spool (302), but since the pilot secondary pressure acts on PLe2 port and the lock valve selector spool is switched, lock valve poppet (514) opens and the pressure is, led into chamber AR. In addition, the return coil has sufficient pressure because of the weight of the arm, etc., consequently the secondary pressure is led in the arm spool. Consequently, the return oil from the arm cylinder (R) side passes through the inside of arm spool and notches on the arm spool, and flows through recirculation circuit and led in arm recirculation spool (810). In that case, the secondary pressure of the solenoid proportional valve (Pis) is acting on the Pis port of the control valve and the arm recirculation spool is in position (UD. ‘Therefore, the oil pressure enters the passage (61) through the inside of the arm recirculation spool (310), pushes open the arm recirculation check valve poppet (512) and is, supplied once again to the arm cylinder (H) as ‘the operating oil for arm digging operation. Part of the hydraulic oil admitted to arm recirculation spool (310) flows into tank port (1) from low pressure circuit (D) and returns to the hydraulic oil tankPies [pra ARM CYLINDER f Lock valve. Took vaLve SeLecrTOR x Re cyawecn an SELECTOR 51d 60/36) ise CHAMBER F 1) 10512 oD Position [11] Fig. 2.26 When arm is in (under light load) He-254) When the arm is in (under heavy load) CF Por name sera an Operation [any arn it et aemanr Ree ira Pha (under heavy load)| PLC2 Pis Ab ‘The arm oil recirculation function is effective when operating the arm cylinder quickly under a light load, but under @ heavy load (when heavy duty is required), this function ‘wastes power. ‘The control valve switches automatically between oil recirculation under light load conditions and no recirculation under heavy oad conditions hy detecting pump pressure ‘This is called the variable recirculation function. When the arm is under a heavy load, H2~26 that is, when no recirculation occurs, the oil supply passage to the arm cylinder is the same as during recirculation described above, but the return oil passage is different. In a heavy duty condition (‘The pump pressure=Arm cylinder (H) pressure is more than 200kgf/em? (2840psi).) , the secondary pressure of the solenoid proportional valve (Pis) is reduced and the arm recirculation ‘spool (310) is switched to position (). As the result, the passage (61) connects with ‘the low pressure circuit (D). Then the oil returning from the arm cylinder (R) runs from the low pressure circuit (D) to the tank port (1) and votuens to the hydranlie ail tanle ‘The result is that no oil is supplied to the arm cylinder (H). (recirculation cut)| pra Afi CYLINDER _ in VALVE SELECTOR 4 — | fdecomse bento SPOOL ie CHAMBER AR, aid / (60)/ (66) (65) @ B 5 mae tern Position [1] Fig. 2-27 When arm is in (under heavy load) H2-275) Simultaneous operation of swing and arm in GI Port name Operation [Pilot secondary Main pressure pressure side oil supply side PAa Swing left a As PBs ‘Swing right oe Bs PAa Arm in rae Aa Purpose : Improvement of simultaneous operation when starting swing operation for swing / arm in operation Principle ‘The arm in side circuit pressure is raised intentionally because they are used with parallel circuit. If the swing and arm in actions are performed at the same time, the hydraulic oil from pump P2 passes through the parallel circuit (66) and flows into the swing motor and the arm cylinder al (he sme time, However, since the swing system is more heavily loaded than the arm system at the start of swing action and during arm in (at light load), most of the hydraulic oil flow to the arm cylinder that is lighter loaded, This causes the simultaneous operation to deteriorate. H2-28 In order to improve such a condition, the load on the arm in side is increased intentionally 0 the simultaneous operation of swing and arm in motions is performed easily. (owing priority) In the above condition, the system detects the pilot pressure that actuates the swing spool The secondary pressure of the solenoid proportional valve (Pis) acts upon the Pis port, of the control valve and changes the arm recirculation spool (810) to position {IL} The result is that the hydraulic oil lowed into arm recirculation spool (S10) is higher on the arm cylinder (R) heenuse the passage to the arm cylinder (H) and the passage to the low pressure circuit (D) are restricted. The result, is that the pressure on the arm cylinder (8) side rises which in tum increases the operating pressure for the arm in operation,Pez | pra ‘ARM CYLINDER TT TOCK VALVE SELECTOR Lock VALVE SELECTOR SPOOL, cuausen an / 514 PAa (60) /(66) (65) @) Pis D (0) “| mT GH Position {11} Fig. 228 Simultaneous operation of swing and arm in H2-29(©) Swing action CH Port name Operation | .diGt., | Main pressure petcondary, | cil supply side Swing left Pas | AS Swing right PBs Bs If swing action is performed, the secondary pilot pressure from port D or @ of the pilot valve acts upon port PAs or PBs of the control valve and shifts the swing spool (303) rightward or leftward, ‘The oil delivered by pump (P2) enters the bypass circuit (65) past the main passage (54), but since the circuit is shut off as the swing pool (303) ie chifted, the pressure puchee the check valve CP2 (11) open, enters the parallel circuit (56) and pushes the swing load check valve LCs (511) open. The pressure, which enters the U-shaped passage in the swing spool (803), passes between the outer surface of the swing spool ($03) and the casing and is supplied to A or B of the swing motor from the As port or the Bs port. In the meantime, the oil which has returned from the B or A side of the swing motor passes, between the outer circumference of the swing spool (303) and the casing through the port (Bs) or (As), flows from the low pressure circuit (D) to the tank port (T) and returns to ‘the hydraulic oil tank, B ‘SWING MOTOR ou A nM Tas U-SHAPED PASSAGE FOR SWING MOTION ~: 303 PAs| PBs 65) Fig. 2-29 Swing left action H2~30(1) Action of option valve (for P2 pump) CN Fort name Operation | Pilot secondary] Main pressure pressure side [oil supply side PA02 Uz ion we PBo2 Boz With the operation of attachment which requires the option valve like nibbler & breaker, ete. to operate, the pilot secondary pressure discharged by the pilot valve acts on PAo? or PBo2 of the control valve, and moves the option spool rightward or leftward, and concurrently the pilot secondary pressure acte on PCa port of the control valve and switches P2 bypass cut spool (308). ‘The hydraulic oil delivered by pump P2 runs into bypass circuit (65) through the main passage (64), but since it is cut off by P2 bypass cut spool (309) that has shifted, the oil pushes the check valve CP2 open, flows into parallel cireuit (66), pushes the load check valve open, passes through the clearance between the outer circumference of the option spool and the easing and ie aupplicd to each attachment from port (Ao2) or (Bo2) In the meantime, the oil returned from the attachment enters the control valve from port (Bo2) or (Ao2), passes through the clearance between the outer circumference of the option spool and the casing and returns to the hydraulic oil tank from the low pressure circuit (D) and the tank port (T) LOAD CHECK VALVE 603 BYPASS CUT SPOOL 309 ‘TANK PASSAGE PCa Fig. 2-30 Action of option valve H2~81© Functions of lock valve After connection of the arm eylinder (R) side and the boom cylinder (I) aide, lock valve 14) housed between Ba port and Ab port of the control valve and between arm spool (302) and boom spool(302) reduces the amount of Jeak due to the hold pressure received from the respective eylinder. 1) To prevent natural fall when the main spool is at neutral ; The boom spool (01) will be explained hereinunder. The arm spool (802) will be explained also. When boom spool (801) is in neutral position, it is held in the position shown in Fig. 2-31. BOOM CYLINDER HEAD (H) SIDE CHAMBERRH 514 That is to say, lock valve selector cub spool (8511) is pressed against bushing (S541) by the action of spring (8512), In this position, the holding pressure from boom cylinder (H) side passes through passage Sa, passage (a) of bushing (S541) and around spool (S511), and connects to (0), then flows through passage Sb, consequently poppet (514) of the lock valve is pressed down maintaining the seated condition, and the leakage results in minimal quantity. DETAIL OF LOOK VALVE SELECTOR SPOOL (211) spi S512 pu PLet Dre @ @ S541 Fig. 2-81 Functions of lock valve (when the main spool is neutral) H2—-322) Atboom lower action : GW Port name Operation [Pilot secondary [Main pressure ressure side |oil supply side PB ‘Boom lower Bua Bb Arm in eee ‘Ab ‘The secondary pilot proseure from port © of the pilot valve acts upon the PBb port of the control valve and the PLel port of the lock valve selector and shifts the boom spool (301) to the right. At the same time, the pressure shifts the spool ($511) of the lock valve selector to the right. AS the spool (S311) is shifted, the orifice (a) in the bushing ($541) closes. This shuts off the continuity from passage Sa to passage Sb in the lock valve selector (211) and the hold pressure received from the boom cylinder (H) side ceases to act upon the spring chamber (RE) of the lock valve poppet (614). As the spool (S511) moves, continuity is established from the orifice (b) of the bushing BOOM CYLINDER HEAD (H) SIDE | CHAMBER RH 514 Pressurized pat of poppe (514) (8541) to the drain port (Dre) through the inside of the bushing (S541). This causes the orifice (6) of the bushing (S541) to connect with the passage Sb, the spring chamber of the lock valve poppet (514) and the low pressure circuit. The lock valve poppet (514) is received by the ring-shaped prescure bearing area that consists of the guide diamotor and the coat diameter of the lock valve poppet (514), so that the lock valve poppet is pushed open upwards to release the lock function. ‘The operation described above is performed before the opening (meter out opening) which {is used to return the return oil from the boom cylinder (H) side of boom spool. (801) to the tank while performing the boom lower operation, Therefore, the action does not affect the controllability of the boom lower motion. ‘The operation is the same as the arm in operation. DETAIL OF LOCK VALVE SELECTOR SPOOL (211) 511 $512 fu pi | bre sb Fie Sa @ @ 8541 Fig. 2-32 Functions of lock valve (at boom lower) 2-33® D » 4 Operation of main relief valve ‘The main relief valve is built in casing and operates as follows ‘The pressure oil is filled up in chamber A through the orifice (B) of the plunger (612) and seats the plunger (512) securely against the body (541). When the hydraulic pressure of (P) reaches a set pressure of the spring (621), it pushes p D ‘open the poppet (G11) through the orifice (B) ‘and flows through the hole (D) to @) ‘When the poppet (611) opens, the pressure in chamber A falls, which causes the plunger 12) to open and the pressure oil of port (P) A to flow directly to (R). Press the boost Press the boost button, and the pilot pressure enters in PL port. The pilot pressure pushes Piston (614) leftward, the epring (621) foros i= raised, and finally the relief pressure is raised, © The numbers of the parts of the main rrelief valve in this section correspond er eu ww ‘to those in Fig.2-3. Fig. 2-36 Ho-s4(10) Operation of over load relief valve » 2 ‘The over load relief valve is located between the cylinder port and the low pressure passage, functions as both a relief valve and an anti cavitation check valve, as mentioned below ‘Operation as a relief valve ‘The pressurized vil enters the ole A througls the clearance between piston (01) and plunger (611) and fills up chamber B. Thus plunger (611) is seated tightly against seat oan), When the hydraulic pressure of the port (P) arrives at a set pressure of the spring (621), it pushes the poppet (611) open, flows on the circumference of the poppet (611) and passes through the hole (C) to (R). When the poppet (611) opens, the hydraulic pressure in chamber B falls which eauses the plunger (611) to open and allows the hydraulic pressure of port (P) to flow directly to ®), Operation of anti cavitation check valve ‘Tho check valve supplies oil from port (R) when a negative pressure is built up at port @). When the pressure at (R) gets higher than that of port ), the push-up force of circuit (®) gets stronger than the pressing force of chamber B. ‘This causes seat (641) to move to the right. ‘Then the oil passes through the clearance of seat (541) and enters port (P) in sufficient ‘quantity to fill up the vacancy © ‘The numbers of the parts of the over load relief valve in this section correspond to those in Fig. 2-4. 301A B Bin san wo ell eb Fig. 2:38 wens‘This page is left blank for editing convenience, H2~363, PILOT VALVE (ATT) 4 OUTLINE (2) Outside view (2) Specification snale — snete 1 OPERATION OPERATION = ————_____Teble31__ ANGLE ANGLE Tem Specification Treagisina —— FOFTEA) (PORTIA = ao To0vo000sr2 Sao Model Vas 1008 (opposing flats : 22) \ Operating torque Refer to the when the lever is installed ge 2 weiteicereineees | | Max. primary presure | 0kgfen® 710pa) ‘Then tighten the mating lock Primary pressure ‘5Okgf/em? (710psi) hut to 4.2:0.3kghsm t ao ee een eee eens wi Rated ow 20 hin (Sgn) Weight ARROR 2k be) (B) Performance characteristics (oR a3} gy (90)500) oa 3 a : ie € G) sooo same sere cess 3 TesE05(064) 3) alas fnaga? sey aang & 3] asia WITS Blown 5 3 oh tt 8 a os 0 15 19 Operation angle (den) (oz) - 3] (710)S0.07 — soo.) 8 =| i z| §]_ssvos{| ht ono BD) compass neva. Bl 5) alesse Reba 2 8) zon abi» 5 8) eet 2 I T | 3] asoys02 Ba) 5] ovchbsscBis| | 30 zl i 3 ot Ls ili] dy é ots a as Operation angle (dea) rn: ae Hycraulc symbol al H3-1‘8.2 CONSTRUCTION,FUNCTION AND OPERATION. (2) Cross section view 501 216-2— 241-2 201-2 o1—2 ‘Secondary ~ _— | Oo Uh 101 ‘adjusting shim Designed value 126" 312 502 rotating sing see ease. 801. Beware of the assembly rection 212, y aa Aoplyorease a Poste port 24 PORT 1.3 ioe Fig. 3-2 Pilot valve (for ATT) Apply Locktite #277 to areas marked yy. “ioe” | No. NAME. ary] mises | No. NAME gi 101 [CASING 1 Zié=1 [SPRING SEAT] 2 un |porr pLave 1 216-2 [SPRING SBAT 1 seaLwasuer — | 2 ait | WASHER 2 SHIN) oniNG 1 2181 |SPRING SEAT 2 2105 | SOCKET BOLT; M835) 2 __| 218-2 |sprna sears 126 | SPRING PIN 7 011-1 |sPRING 131 |BUSHING 1 011-2 |SPRING 151 |PLATE. 1 241-1 | SPRING: 201-1 |SPOoL 2 241-2 [SPRING spoon f2 |__| aae_|sprina au fPLue «| ase) [301 [oon xa 1 a2 [pusurop 4 soe locuLarriare | 1 213 |SEAL 4 751) & | 312 |ADJUST NUT ; M14 1 214 |ORING;1B P20 4 501_| BOOTS 1 Hi: 3-2@) Construction, ‘The pilot valve is constructed as shown in the cross-sectional view (Fig.3-2). The casing has a vertical shaft hole in which a reducing valve is assembled ‘The reducing valve consists of spool (201), spring (241) (for secondary pressure setting), spring (011) (for return), spring seat (216), and washer (217). The spring (241) (or secondary pressure setting) is 20 set as to achieve the secondary pressure conversion 5-10kgf/cm* (71~140psi) (varies with the model.). The spool (201) is pressed against, push rod (212) by spring (011) (for return). If push rod (212) is pushed down by tilting the control part of the handle, the spring seat (216) falls at the same time and changes a set pressure of spring (241) (for secondary pressure setting). ‘The casing (101) and the port plate (111) are provided with an oil inlet (primary pressure) port P and an outlet (tank) port T. They are further provided with ports 1, 2, 3, 4 from Which secondary pressure is discharged. @) Function 1) Basie functions ‘The pilot valve controls the stroke and the direction of the control valve spank. This is achieved by applying the output pressure of the pilot valve to the end of the control valve spool. In order to satisfy the functions, the pilot valve is constructed with the following elements : ®D Inlet port @) w which the oil of the hydraulic pump is supplied. ® Multiple output ports (1, 2, 3, 4) that exert the supply pressure from the input port upon the end of the spool of the control valve. @® Tank port (T) to control the above mentioned output pressure. ® Spool that connects the output port with the inlet port or the tank port. © The mechanical means including springs ‘that act upon the above- mentioned spool, in order to control the output pressure. A: 2) Main funetions ‘The function of spool 201) is to receive the supply pressure ofthe hydraulic pump hy part P and admit the hydraulic pressure at port P to output ports (1, 2, 8, 4) or admit the hydraulic pressure at the output ports to port T. Spring (241) (for secondary pressure setting) acts upon spool (201) and determines the output presoure Pash rod (212) that changes the deflection uf spring (241) (for secondary pressure setting) is inserted in plug (211) so as to enable smooth movement. Spring (011) (for return) acts upon casing (101) and spring seat (216) and brings push rod (212) toward zero displacement regardless of output pressure, in order to positively bring spool (201) back to neutral. The spring also acts as a reactive force that gives the operator a proper operating feeling() Funetion Now, let us explain the function of the pilot valve, using diy hydraulic diagram (Use Sgure on the right) and the functional explanation drawing (Fig.8-3 to 3-5). 1) Lever in neutral (See Fig8-3) ‘The action of spring (241) (for secondary pressure setting) that determines the output pressure of the pilot valve does not act upon spool (201). Therefore, spool (201) (or return) is pushed up by spring (011) [spring seat 1 (216). The output ports (2,4) connect with the TT port. The result is that the output pressure is equal to the tank pressure. 1. | a) | ' Pilot valve @Pilot pump Lever in neutral 216 2a ou Za PoRT(2.4) 201 Fig. 33 Lever in neutral H3~42) When the pilot lever is tilted (See Fig. 3-4) When the lever is tilted and the push rod (212) strokes, the spool (201) spring seat (216) moves down-ward to make the port P to connect with the port 2, 4, with the result that the oil of the pilot pump flows to the port 2 4 to produce a pressure. PORT(2,4) Fig. 3-4 When the lever is tilted 8) Lover held (See Fig.8-5.) When the pressure at ports (2,4) rises to a level equivalent to the action of spring (241) that is set by tilting the lever, the hydraulic iL pressure balances the spring action. When the pressure of ports (2,4) rises above a set value, ports (2,4) and the P port close while aoe ere eetaees aoe ee Ol T PORT ALD ii : ree. P PORT: = = ] a EB a Fig. 3.5 When the lever is held (When the secondary pressure is higher than a set value) 3-5This page is left blank for editing convenience 13-64, PILOT VALVE (TRAVEL) 44 OUTLINE @) Outside view | © © VIEW FROM MACHINE FRONT SIDE — ou Port | MEER Dore ‘Trough Bar | rite ste Function xe 1 [Ril tavel reverse port actos | 2 [RH travel foward port Pras] 75505 | 5 [Ltt travel evere port 4. |LH travel forward port 1 [Tank port 5 [Travel pressure sensor port a7£02 Priv 6. | Travel pressure sensor part @7#14) |p [pitt primary pressure port Fig. 41 Outside view @ Speciieation (2) Performance characteristics ——_len_| Speeibeation SS Parts No. ¥xs0VO0004F en oka —— kts) katan (tlie) Type (07201-00000 oso Bots Primary pressure | 5Okef/em? (710pei) (caoyes| 013) Secondary pressure |5.5~2akgtlem* (78~340psi) row coca Rated flow 10 eimin (@.6gal/nin) (50035 0410) Ratedftow [10 ¢/min @.6galinin) 0 Weight Approx. 11kg (24 Ibs) (e200 20087) 5002 i csrosary2h eb Ae (2020-4 » EPs | adc fs aon = y (aor oa) I osswssenttt a sa ota) PF oa e808 2 = pean eal (eo) Hyeraute symbol Conte agra Ha-14.2 CONSTRUCTION AND OPERATION 332 36 a3 1s a 6 33 Ta4.9-+0.4(91+3) SECTION B—B Fig. 42 Construction Apply Locktite #262 to areas marked yy. Tightening Tightening torque No. NAME \Q" torque No. NAME. Q'ty “kgm Geb) | kein bo 1 | ORIFICE(SHIM) 4 22 | SPRING 4 1.511) 2 |SEAT 2 1.0(7.2) 24 | PLUG : PFS 3 3 | ORIFICE(SHIM) 4 2.5(18) 25 |PLUG : PFW/4 3 a |sroor a] coax | 26 |sockerBoLr:muxe0| 2 _____| 5 |popy _ _1} 05.6) _| 27 |FLANGE BOLT 4 6 |STOPPER 4] 10a) [28 [SETSCREW: Me 4 7 | SPRING 4 29 | WASHER 4 8 | SPRING 4 30 | WASHER 2 NAME PLATE 1 31 [RIVET 2 SHIM t=02 af a2 [pn o5_ 4 SHIM t=0.1 4 33 BALL $ cAM 2 34 BALL 4 BooTs 2 35 [BALL 4 PIN, 2 36 |BALL 6 come _—i|_2 | a7 |U PACKING 4 PISTON 38 [O RING 4 GUIDE 4 39 JORING: 4 SLEEVE 4 40 |ORING 4 HOLDER 4 41 [ORING: 3 20 [RING 2 42 [ORING: : 3 ORIFICE(SHIM) 4 44 | PISTON 4 Ha-243 OPERATION @) Construction ‘The valve consists of the following parts in terms of hydraulic function ‘A: Damper section B : Reducing valve section C: Shuttle section 2) Operation 1) Damper section © If the primary pressure is eupplied by P, it is flowed to the damper chamber by way of circuits D and ® ‘The pressure is then filled up in the damper chamber via the orifice and the check valve. In that case, the air present in the damper chamber is pushed out to the T port from circuits ® and @ , in order to prevent the damper characteristics from fluctuating by air mixture, cam PISTON. ¢ COVER, cup ‘SPRING FOR. ‘SECONDARY PRESSURE If the cam operates during travel operation, the oil in the damper chamber is kept from flowing back by the check valve. Thus the oil flows to part @ only from the orifice. Damper ‘action operates by the resistance that is built, ‘up as the oil passes through the orifice. Let us explain the profile of the piston (Gee Fig. 44) ‘The upper part of the piston has a diameter of 12mm(0.472in), while the lower part of it has a diameter of 11mm(0.433in). This results in ‘an areal difference, with the result that the piston is constantly subject to a vertical force. For this reason, the orifice rises by the pressure caused by the areal difference between the operating part of the cam and the piston on the ‘opposite side i. the piston follows the cam. That is to say, constant damper action operates wherever the cam is located Since the larger diameter of the piston, the cover, the 11mm diameter part of the piston and ‘the guide are manufactured with minimal clearance, only a little leakage ‘cours, Conseqiently, the damper performanen is not affected at all, HECK ‘VALVE ‘@DAMPERSECTION nice DANPER CHAMBER o ig sPoot lg ig E oO 46 SECONDARY PRESSURE FORT soo" Fig H4~32) Reducing valve section © At neutral The primary pressure supplied by P is shut off by the seal between the circumference of the spool and the body hole. The secondary pressure port is connected with the T port through the vertical hole ® and the horizontal hole (Din the center of the spool. This causes the pressure to be reduced © Atoperation If the cam tilts toward the operating direction, the piston goes down, The spool sub assy moves down. If the notch GD on the circumference of the spool conneets with the secondary presse port, the primary pressure supplied by P enters the secondary pressure port. In that ease, the horizontal hole (D enters the hole of the body and seals it. As the result, the circuit from the secondary pressure port to the T port is shut off. ae} 0.472") ou 0.433") RETURN SPRING 8 SECONDARY PRESSURE PORT Ha-4 Fig. 44 If the pressure at the secondary pressure port rises above the action of the secondary ‘pressure spring, the spool is pushed up by the pressure, The result is that the notch @) enters the hole of the body, shuts off the circuit from the primary pressure port to the secondary pressure port, and causes the horizontal hole (D to connect with the T port to let the preseure of the secondary pressure port out to the T port, If the above-mentioned action is repeated, the pressure at the secondary pressure port becomes a level that balances the compressive load of the secondary pressure spring proportional to the cam stroke. ‘The retuen spring provides proper reactive force and positively brings the spool of the reducing valve back to its neutral position.8) Shuttle section Ifpressure is built up at port 1 or 3, the ball is pressed against the seat by the pressure, The pressure goes through from port 1 to port 5(or from port 3 to port 6). Only a little leakage occurs from port 2or 4 as the ball is metallical sealed by the seat. If pressure occurs at port 2 or 4, the ball is presged againat the body by the precoure. The result is that the pressure connects with port 5 from port 2(with port 6 from port 4). Only a little leakage occurs at port 1 or 3 as the ball is metallical sealed against the body. PORT 2 SEAT PonT 4 PORT 6 Fig. 4.5 Shuttle section M45 PORT 1 PORT 3"This page is left blank for editing convenience H4-65. SWING MOTOR UNIT 5.1 SPECIFICATION (1) Outside view Fon | Tightening ome fae $20 Net Geib) AB [Main pore pra] 17 20) DB [Drain port Pri2| 10.9) M._ [Make-up port Pri | 22.460) PA,PB)Pressure measuring port. |2-PF1/4] 3.7 (27) PR_|Parking brake release port| PF1/4 | _3.7 (27) L [Gearcillevel Gauge | PTV2| 6.6 (48) Gesnon FLLNG PORT GIN |Gear oil filling port PT3/4 10 (72) ee ‘RELIEF VALVE. (6 PORT SIDE) PRESSURE MEASURING PORT PARKING BRAKE. RELEASE PORT I ware Oasys PRESSURE THREAD FOREYe LEVEL GAUGE BOLT 2412 0EPTH 23 PAPB Fig. 5-1 Outside view of swing motor unit H5-1@) Specification Swing movor unit part No LC 18000001 Part No. LC15V00003F 1 Type ‘M2X210CHB—10A~39M/260—197 Displacement em? (cwyd) 197 (260) Working precoure epem® (pei) 200 (4270) "Max. pressure etem® (psi) 350 (4980) 5 | Working flow ¢/min (gal/min) 253 (67) z Braking torque ‘kgfim (ft-lbs) 89°F (12703) J | Release pressure (Stroke end) —kgflem* (si) 29° 410%) = Relief set pressure kgficm! (psi) 280 (3980) Weight kg (bs) 745 064) Part No. ‘YN22V00014F4 Sree cree | Type 2KARGP12/240-712 Weight kg dbs) 256.5) Hydraulic motor any weight eg (bs) 77070) Part No. - Speed reduction type Planctary 2-stage 2 Reduction ratio 23.385 : & [iatiateoa Gear oi SABO (APT dass GL~* gad) = ‘Grease Extreme pressure multipurpose grease Grease volume Asmall amount — Weight ke (bs) 411 (906) ‘Total weight kg (bs) 488 (1080) H5—25.2 CONSTRUCTION (1) Swing motar IBC OC oO ost 401 3 RELIEF VALVE VALVE CASING = oeen 3 ‘O 983 5 asm eAtrarion (OS SaUNaee A a 361 5 355 488 9 oO. 464. 09" A EofS 65 ON. swine | SHOCKLESS SECTION A~A VALVE Lock sag 052-909-985. 498 444 994 106 191 451 ne ° ° DEL - — ALL 952 rt ek MOVEY |! 01 S 982 Et i 712 749 a i 121 ae 124 16— oy «SECTION BB nt Fel za 9027 f 198 192 113 443 106432 © 101491 304 437 47101 Fig. 5-2 Swing motor 5-3Tightening Tightening ae NAME larry, cares, | No NAME QTy 18 (130) | 051 | RELIEF VALVE ;wiaa-Pi5 | 2 438 | SNAP RING 1 (051-1] ORING ; 1B G30 2 443 | ROLLER BEARING L oe | 444| ROLLER BEARING 1 101 | DRIVE SHAFT 1 451) PIN 2 BEARING SPACER _| 3 | 3.7@ | 464| vp PLUG; PFL4_ 1 CYLINDER BLOCK 1 | 55 400) [469] ROMH PLUG; Mae-Pis [2 SPHERICAL BUSHING | 1 HIB Gi10 i CYLINDER SPRING =| 1 1 PUSH ROD 2 1 SPACER ®) 1 | |O RING ;1B_ 2 SPACER ®) Y OIL SEAL 7 PISTON 9 BRAKE PISTON a SHOE 9 ORING a SBT PLATE 1 ORING 1 ____| 124 | soos pare 1 BRAKE SPRING 22 181 | VALVE PLATS a FRICTION PLATE 2 301 | CASING 1 SEPARATORPLATE | 3 303 | VALVE CASING 1 | 0.09 0.65)| 982) PLUG ; Pra a sus | FRONT COVER 1 | 049 s | vss] PLUG ; PFS 2 avricaviration pLuNcer| 2 || 0.28 @) | 984| PLUG; PV 1 355 | SPRING 2 | 067 (48) [985] PLUG; PFI a 390 | NAME PLATE, 1 | 66 cs) | 992| PLUG; Pri2 7 391 RIVET 2 | 10(72) | 994| pug; prs 1 64 (460) | 401] SOCKET BOLT; M2245 | 4 432| SNAP RING 2 497 [SNAP RING 1 493] SNAP RING. a H5—4@) Swing reduction unit, ple “| ik 2634 24 23 {ithe oo of pressing DETAL 8 aah ae DETAIL A Fig. 5-3 Crose-sectional view of swing reduction unit, Tightening Tightening I torque | N, SAME torque igtim (ibs) [N° neue meee ve new an T [PINION SHAFT T 34 | LOOK PLATE 7 2 | SLEEVE 1 25 | SHAFT 4 3 | SNAP RING 1 26 | SHIM ; t=1.0) 1 4 | PLATE 1 27 | SHIM: 1.1 1 5 [ORING 1 25 | SHIM ; e=12| 1 6 [OIL SEAL a Ya Tsai 13] 1 7 | RETAINER 1 30 | SHIM: t=14) seLecr | 1 sorzziz@sei9) 8 | socker pour: miexao | 14 a1 | SHIM : 1. 1 9 | SPACER 1 se [SMM i i.e 1 : 10 {Router pearinc |i] __| 33 | sum: t=17 1 11 [HOUSING 1 34 | SHIM: 1.9 T 12 | SPACER i 35 | #2 PLANETARY PINION | 4 13 ROLLER BEARING | 1 36 | ROLLER BEARING 8 14 | SNAP RING i a7 | THRUST WASHER 8 15 | SPACER 1 3 | #1 PLANETARY PINION |_ 4 16 | #2 SPIDER ASSY 1 39 |NEEDLE BEARING | 4~ a7 | #2SUNGEAR 1 40 | SNAP RING 4 18 | INTERNAL GEAR 1 a1 [PLUG 1 19 | #1 SPIDER ASSY 1 42 | SETSCREW 2 _x2as:20 01022) 20 | socKET BOLT; a16x190 | 15 43 | PIPE i 21 | SPACER 1 44 | ELBOW a 22 | #1 SIN GRAR 1 45 | SNAP RING 1 ensoz sees | 23 |carscrew:muoxes | 8 oaply Locktte #242 5% Coat the matching surface with Locktite #515,53 OPERATION 5.3.1 OPERATION OF HYDRAULIC MOTOR, If the high pressure oil fows ity dhe eilynder through the inlet port (A) of valve plate (181), as shown on the figure on the right, the hydraulic pressure acts upon piston (121) and creates force F in the axial direction. ‘The force F may be divided into force F1 vertical to shoe plate (124) via shoe (122) and force Fa at right angles with the shaft. ‘The force Fs is transmitted to cylinder block (111) via pistons (121) and causes drive shaft to turn 60 as to produce a rotating moment. ‘The cylinder block (111) has nine pistons equally arranged. Rotating torque is transmitted to drive shaft by turns by pistons connected to inlet port of high pressure oil. If the oil supply and discharge directions are reversed, the drive shaft rotates in the opposite direction, ‘Theoretical output torque T can be given by the following equation, pxq Xe p : Bileetive differential pressure kegflem? 4: Displacement per revolution cc. /rev 6.3.2 VALVE CASING SECTION (Q) Operation of anti-cavitation plunger Since the system using this type of motor is not equipped with a valve having a counterbalance function, the motor is rotated beyond the oil feed rate in some cases. ‘The system has anti-cavitation plunger(351) and sucks in dificient oil, in order to prevent cavitation from occurring due to oil deficiency. CYLINDER BLOCK(11i) SHOE SHOE PISTON v2 PLATE (122) (121) (124) (LOW PRESSURE OIL) (HIGH PRESSURE OIL) tT Fig. 5-4 Operation of hydraulic motor ¢ } 351 M PORT (MAKE UP PORT) [ DIRECTIONAL VALE Fig. 5-5 Operation of anti-cavitation plunger H5-6@ 1) 2) Operation of relief valve Consider where the P pot is pressurized from fee tants presse ‘The pressure at the P, R ports is equal to the tank pressure at the beginning, as shown in Fig.5-6-(), ‘The relief valve begins to operates when the hale pressure that is determined by the product of the pressure-receiving area Al of plunger(G01) and the pressure P. balances the hydraulic pressure that is determined by te product ote preaurerecoiving ara AZ of the"piungen0D snd the preanure Pe of chamber g ‘Thereafter, the pressure of chamber ¢ rises and the piston 1 (302) begins to stroke. The Toad to" spring (G21) tmereases by’ this movement ofthe piston, Xs the result, the relief pressure P is raised fand controlled in the pressure boost time from Pi till Bs ‘hie process is explained in the following in the relationships between the movements of the components shown in 2) to (A) of Fig. 5-6 and the ree pressure Condition shown in Fig. 5-6, 2) Ifthe P port of the relief vaive is pressurized, pressure ie built up in chamber @ via the Festrictor m of plunger (901) ‘The hydraulic pressure acting on plunger (Gin) snerenes and whon st hatenens the ond ap of spring (321), the relief valve performs relieving action by the pressure Pl ‘he relationships expreed a PIXAL= PSPIPPgI NAD whore Fepl: Primary set load value of spring (321) Condition shown in Fig.5-6. 3) ‘The pressure of chamber g acts upon the presstre-recriving area ASA4 of piston Gioia." When ‘the Ryarauhie pressure rises above the load of spring (321), the piston 1 ‘begins to move to the left On that occasion, since the machine turns to the let whale discharging the ail of chamber h arranged between piston 1 and adjust plug G01) into chamber & via restrictor n provided In piston 1 (302), chamber serves as @ dumping chamber. ‘The fond of the spring increases slowly til piston I reaches ihe'end of the adjust plug. he relief pressure P rises smoothly. Condition shown in Fig.6-6. () ‘The machine does not travel tothe left further when piston 1 (02) arrives at the end of Adjuat plug (401), Therefore, the relief valve iceeps its normal relieving action whereby the relief pressure is held at P2 In the processes 1. to 3 above, the relief easure changes as shown in Fig 5-1 Function ‘when the relief valve pressure is reduced TEDSS consider the pressure ofthe P port is When the pressure at port P is reduced to zero, the pressure of chamber ¢ falls to the tank pressure level, ‘The result is that the plunger (201) which is now open moves tothe Leth Ss sented om yews G41). At Che ware time, the piston 1 (202) moves to the right by the action of spring (21) and returns to ehe condition of Fig.3-6 (0), fonmicem ——sPravaisi) “TT Teeter bs 82 oRFCEn PRESSURE pLUNGER 201) ecelvine Hig. 5-6-(1) ORIFICEm SPRINGIS2H) chawen PLUNGER (01) Fig. 5-6-2) cHAMBERN 401 puuncen gor) OPES Cawsey Fig. 0-6-3) ORIFICE SPRING(S2") ——_—PINS03) PISTON (302) uncer on ORE" crwaen Fig. 5-6-() Fig. 5-6 Functional explanation of relief valve Fig. 5-7 Pressure boost characteristics H5-7(8) Operation of ewing shockless valve 1) Neutral condition : Fig.5-8 illustrates the relationship between the neutral condition of the swing shockless valve and the hydraulic circuits. Now, let us consider a braking condition in which brake pressure generates on the AM port side. 2) When brake pressure occurs : If pressure (P) generates at the AM port, it passes through the passage 1, the hole on the shaft of seat (313) and the passage m of plunger (811) and is admitted to the n chamber. When the pressure P rises above a value (Ps) set by spring (321), plunger (311) compresses ‘spring (321) and shifts it to the left. Seat (813) compresses weak spring (922) as pushed by plunger (311) and moves to the left 38) At swing shockless action When inertia Ioad stops moving (point Y, Fig.5-10), brake pressure (P) tries to fall, When P See ‘ Pe 7 322 318 321 3 Fig. 5-9(2) When brake pressure occurs fp 322 318 & Tr 821 sn Fig. 5-9(8) At swing shockless action = =a Fig. 5-9 Operation of swing shockless valve Pa 7 Fig. 5-10 Pressure change diagram of swing. shockless operation, H5-8