MAIN PUMP K3 K5 T5

DX Excavator

Dec, 2010

HYD0026
Training Material
Product Support Team, AP/E
INTRODUCTION

Applied model

T5 : DX140LC,DX225LC (Tong myung)

K3 : DX255LC (Kawasaki)
K5 : DX300LC (Kawasaki)

2
TABLE OF CONTENTS

1. COMPONENT IDENTIFICATION
2. OPERATION
3. MEASURE AND ADJUST

3
COMPONENT IDENTIFICATION

4
COMPONENT IDENTIFICATION

 Section drawing

5
COMPONENT IDENTIFICATION

 Pump schematic

6
COMPONENT IDENTIFICATION

7
COMPONENT IDENTIFICATION

8
COMPONENT IDENTIFICATION

 Pilot pump section drawing & schematic

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COMPONENT IDENTIFICATION

 Proportional valve section drawing & schematic

10
OPERATION

 P- Q Curve (DX225LC)

11
OPERATION

 P- Q Curve (DX255LC)

12
OPERATION

 P- Q Curve (DX300LC)

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 OPERATION

 Flow control (Decrease oil flow)

Control valve spools are neutral position ( no

working condition), main pump doesn’t need to
discharge lots oil.

High nega-con pressure comes up to pilot pist

on on main pump regulator.
The pilot piston makes spool move to decreas
e oil flow. How?
High nega-con pressure

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OPERATION

 Flow control (Decrease oil flow)

Oil tank
High nega-con pressure Under spool neutral position,
C/ V
discharge oil goes to oil tank directly
trough small orifice.

Decrease oil flow

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OPERATION

 Flow control (Increase oil flow)

When spool is moved ( for working), mai

n pump should be discharged lots oil to
control valve for supplying oil to actuator.

Low nega-con pressure comes up to pilot

piston.
The pilot piston makes spool move to inc
Low nega-con pressure rease oil flow. How?

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OPERATION

 Flow control (Increase oil flow)

Oil tank
Low nega-con pressure
Actuator
C/ V Spool is switched, all of discharge oil go
es to actuator, So nega con pressure is
drop.

Increase oil flow

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 OPERATION

 Power control (Decrease oil flow)

The com-pen spool senses both pump

system pressure. (average pressure of both
pump is applied on com-pen spool)
If average pressure over come spring set
force, oil flow is decreased. How?

com-pen spool

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OPERATION

 Power control (Decrease oil flow)

19
OPERATION

 Power control (Increase oil flow)

The com-pen spool senses both pump

system pressure. (average pressure of both
pump is applied on com-pen spool)
If average pressure is decreased, the com-
pen piston is moved to left side. oil flow is
increased. How?

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OPERATION

 Power control (Increase oil flow)

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OPERATION

 Power shift (1)

When pilot pressure is come to com-pen piston behind

chamber, it will help com-pen piston moving.
If no pressure there, moving com-pen piston is a little
bit harder then high pressure.
If there are no pilot pressure there, in order to move
the com-pen piston, more high system pressure is
applied on blue chamber, isn’t it?
Now. Let’s compare that high pressure and low
pressure on behind chamber (Red)
Controlling for decrease oil.
- Standard mode :
System pressure + Pilot pressure
- Power mode :
System pressure only

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 OPERATION

 Power shift (2)

Input current

2nd pressure 2nd pressure

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OPERATION

 Power shift (3)

* Data from DX300LC

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OPERATION

 Power shift (4) : Power mode – 150~400 mA (2nd pressure is 0~16 bar)

0 bar
(16bar)

150 mA (~400mA)

* Data from DX300LC 25

OPERATION

 Power shift (5)

26
* Data from DX300LC
OPERATION

 Power shift (6) : Standard mode – 400~600 mA (2 nd pressure is 16~32 bar)

16 bar
(32bar)

400 mA (600mA)

* Data from DX300LC 27

OPERATION

 Power shift (7)

28
* Data from DX300LC
OPERATION

 Power shift (8) : Low idle, Auto idle – 600 mA (2nd pressure is 32 bar)

32 bar

600 mA

* Data from DX300LC 29

OPERATION

 Power shift (8)

* Data from DX300LC

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OPERATION

 Power shift (9)

Model Working mode Current (mA) 2nd Pressure (bar)

Power 150 ~ 600 1 ~ 32

DX140LC Standard 250 ~ 600 6 ~ 32
Low engine 600 32
Power 200 ~ 600 0 ~ 28
DX225LC Standard 300 ~ 600 8 ~ 28
Low engine 600 28
Power 150 ~ 600 0 ~ 31
DX255LC Standard 300 ~ 600 7 ~ 31
Low engine 600 31
Power 150 ~ 400 1 ~ 16
DX300LC Standard 400 ~ 600 16 ~ 32
Low engine 600 32

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MEASURE & ADJUST

 Measure point (Power shift)

* Data from DX300LC 32

MEASURE & ADJUST

 Max. / Min. flow adjustment.

33
 MEASURE & ADJUST

 Pressure control (Power control) flow adjustment.

Outer adjust
screw - Flow adjusting (II) – Pressure control

Inner adjust
screw

Outer adjust screw

Inner adjust screw 34

MEASURE & ADJUST

 Flow control (Nega con control) flow adjustment.

Flow adjust screw 35