Ew140c Ew180c Step1 Eng PDF
September 13, 2022 | Author: Anonymous | Category: N/A
Short Description
Download Ew140c Ew180c Step1 Eng PDF...
Description
EW140C-180C, Step 1
In this course we will discuss the wheeled excavators EW140C, EW160C and EW180C. The course is set up in the function groups that we use in service literature for Volvo equipment. We will, amongst others, talk about the electrical system, hydraulic system but also a lso off course about brake and steering system, etc.. Target group: Technical personal Objectives - To understand several systems that are integrated on the C-series w wheeled heeled excavators - To understand and carry out tasks concerning the new I-ECU according to the Instruction book. - To carry out troubleshooting on the electric system. Prior knowledge: Knowledgehydraulics. corresponding to our basic courses in electrical systems and hydraulics, specific about load-sensing Recommended duration: 32 hrs
Picture text:
General
Topics: General information about the wheeled excavator C-series C -series per function group. Objectives: After completing this section the student should be able to: - Recognize the major components on the C-series wheeled excavators.
Picture text:
General
1. Improve Reliability and Durability - New cooling module - Undercarriage - New drive motor - New upgraded gear box - New upgraded front and rear axle - New Swing motor on EW 160 C - Updated Swing motor on EW 180 C 2. New Cab & Interior 3. Better serviceability - Remote filter locations - Long life Coolant (VCS) 6000hr - I-ECU Service mode 4. New electric system -- Electronic New V-ECUClimate (3-connector), I-ECU & Keypad Control (ECC) - Electric distribution box - Care Track (W-ECU) 6. Hydraulic system updates 7. New options - Cold start kit (Block heater, fuel warmer) - X1/X3 with proportional control - X1 maximum pressure control I-ECU - CD player - FOG on frame - Rear view camera - Auto-greasing system 8. Law & Regulation - New Volvo Tier3 engine - Noise reduction - Excavator Operator Protective Structure (EOPS)
Engine
EW 140 C EW 160 C EW 180 C
: D5E EAE3 : D6E EDE3 : D6E ECE3
1. New Tier-3 Engine (Common Rail Ra il Direct Injection) 2. Open loop circuit for blow-by gas 3. Waste gate actuator in turbo charger cha rger 4. New expansion tank 5. Remote fuel filter 6. Water separator 7. Remote engine oil filter 8. Hydraulic motor for cooling fan 9. Charge Air Cooler(CAC) 10. Radiator 11. oil cooler 12. Hydraulic E-ECU (EMS2)
Picture text:
Cooling fan system
On the C-models excavators we have a hydraulic controlled cooling fan. The proportional valve acts like a fail safe shunt valve. 6. Fan pump 5. PMW9103 12. Fan motor Picture text:
*
Electronic control system
EECU (Engine Electronic Control Unit) - Common rail injection system control VECU (Vehicle Electronic Control Unit) - Three Connector (More input & Output) IECU (Instrument panel Electronic Control Unit) - TFT LCD ECC (Electronic Climate Control) - Aircon system control Keypad: Convenient input system WECU (Wireless Electronic Control Unit) -CareTrack (Machine location, Logged data transmission etc.) ** From C-series, SDU function is transfered to IECU (Service-mode).
Picture text:
#
Cabin
1. New IECU 2. Improve defrost duct 3. Aircon unit with ECC 4. Change on the location of VECU 5. Excavator Operator Protection Structure 6. Change on the location of hourmeter
Picture text:
Interior
1. Left instrument panel 2. Right instrument panel 3. Information panel (I-ECU) 4. Rear instrument panel
Picture text:
Electrical boxes
On the machine 2 boxes are installed: The Electrical distribution box (EDB), located behind the cabin, and an d the Power distribution box (PDB) located in front of the Hydraulic tank. In the boxes next components are located: 1. DC-DC convertor 2. Windshield wiper controller 3. Pre heating relay 4. 80 A automatic circuit breaker 5. 150 A Automatic circuit breaker 6. Relays: NO/NC-relay, NO-relay, timer relay 7. Blade fuse 8. Connectors: CN01-CN06 9. Diodes 10. Power connection from battery. 11. Battery
Picture text:
Rearview camera
When pushing the CAM button on the key pad the I-ECU screen changes in to a screen where you can see the image from the rearview camera
Picture text:
Aircon
C-series improvement 1. Display on IECU using keypad 2. In Auto-mode, fan spped increase smoothly.(No resistance) 3. Error displayed on IECU 4. ECC can be programmed. 5. MATRIS is available on Aircon system. 6. Coolant temp sensor on AC unit is removed.(EECU signal) 7. Many relayes are removed. 8. In Auto-mode, followings are possible - AC on/off - Fresh/Recirculation selection - Bidirectin of air flow selection in heater mode - Soft start function using Engine E ngine speed signal.
Picture text:
Hydraulic system
On the C models Wheeled excavators the location of the solenoid valves have changed compared to the old B-models. Also some of the sensors have changed. And since FWD and REV drive electrically controlled we even have some additional valves
Picture text:
Drive Line
The drive line has been drastically changed on the C-models. New updated axles, front, f ront, or steering axle, and rear axle, are installed. The Th e setup is similar over all three machines: drive motor mounted on the gearbox which is distributing its power through propeller shafts to the front and an d rear axle.
Picture text:
Joystick & Pedal
1. 4-Button Joystick 2. Slide joystick for proportional control 3. Travel pedal 4. Travel brake 5. Pedal for X2 and X4 6. Pedal for X1 7. Joystick for support blade and support legs
Picture text:
X1 control
For the X1 function we have 2 valve blocks. One is controlling the X1 maximum flow and the direction of that flow. The other is controlling the maximum ma ximum pressure for X1. PWM 9109 for X1 Flow MA9104 for X1 Right MA9103 for X1 Left
Picture text:
X1 control
For the X1 function we have 2 valve blocks. One is controlling the X1 maximum flow and the direction of that flow. The other is controlling the maximum ma ximum pressure for X1. 1. Input from IECU : Switch operation type 2. Input from VCADS Pro - PAR_On/Off control 3. Input from x1 selection switch 4. Input from Safety lever 5. Input from joystick - PAR_Control lever 4 switch - PAR_Control lever propo proportional rtional 6. MA9103, Left side (A side, hammer) 7. MA9104, Right side, in case of double acting (B-side) 8. PWM9109, Flow control 9. PWM9123 for pressure control on X1 Picture text:
X3 control
1. Input from IECU : Switch operation type 2. Input from VCADS Pro - PAR_On/Off control 3. Input from Safety lever 4. Input from joystick - PAR_Control lever 4 switch - PAR_Control lever propo proportional rtional 5. Output for proportional control 6. Output for toggle control 7. Output for push-button control 8. Direction valve for X3
Picture text:
Engine
Topics: Basic engine design. Objectives: After completing this section the student should be able to: - Basic knowledge in engine sub systems and components. - Knowledge in wheeled excavator specific functionality. - Recognize the relevant components on the machine. Duration: 1 hour
Picture text:
Power and torque charts
Below are listed all D6E V-ACT applications: D6EEBE3 D6EEA 6EEAE3 E3 D6EEDE3 D6EECE3 D6ELCE3 D6ELBE3 D6ELAE3
EC160C 180C EU+US EC EC2 210C 10C EU EU+ +US EW160C EU+US EW180C EU+US L60F EU+US L70F EU+US L90F EU+US
The engine designation code consists of: Engine type D6E Volvo CE Company A - Articulated Hauler L - Wheel Loader C - Compact equipment G - Grader E- Excavator Performance version A - First version B - Second version Etc. Emission Level E0 - Non regulated E1 - E Em mission S Sttep 1 E2 - Emission Step 2 E3
-E Em mission S Sttep 3
Main components
1.The most advanced Volvo engine controller, EMS2, will be utilized u tilized to provide the highest level of electronic features and to enhance reliability. 2.The IEGR(Jacobs system) creates a small second exhaust valve lift. This extra lift feeds exhaust gases back into the cylinder during the inlet stroke to reduce NOx. 3. Common Rail Whereas in conventional diesel engines injection pressure is generated for each injector individually, a common rail engine stores the fuel under high pressure in a central container (common ( common rail) and delivers it to the individual injectors on demand. Benefits of common rail injection are reduced noise levels, stronger performance, improved emission control and greater efficiency. 4.The new high-pressure solenoid diesel fuel injector.(BOSCH-CRIN 2nd Generation Injector)
Picture text:
External view, 1
1. Cam speed sensor 2. Coolant temp. sensor 3. Solenoid(IEGR) 4. Boost press. & temp. sensor 5. Waste gate actuator 6. Preheat unit 7. Injector 8. Rail pressure sensor 9. Engine oil press. sensor 10. Fuel control PWM valve(FCU) 11. Fuel pressure sensor 12. PTO
Picture text:
External view, 2
1. Fuel feed pump 2. Water pump 3. Crank speed sensor 4. Water in fuel sensor 5. Engine oil level & temp. sensor 6. Coolant level sensor 7. Ambient air temp. & press. sensor 8. Starter
Picture text:
Electric circuit, EMS2
Picture text:
Wire harness drawing
Picture text:
Fuel line
In conventional diesel engines injection pressure is generated for each injector individually. A direct injection engine based on the common rail principle separates the two functions pressure generation and injection by first storing the fuel under high pressure in a central container ("common rail") and delivering it to the individual injection valves (injectors) only on demand. This way an injection pressure of u up p to 1,600 bar is available at all times, even at low engine speeds. The high pressure produces a very fine atomisation of the fuel leading to better and cleaner combustion. Moreover, the fuel supply is not n ot dependent on the engine revolutions but can be optimised independently. The time and duration of injection is not fixed (as in older conventional engines) en gines) but can be chosen independently for every operation point in order to optimise combustion and emissions. Benefits of the common rail principle compared to conventional engines are lower engine noise levels, stronger performance and greater combustion efficiency leading to lower emissions and enhanced enhan ced fuel economy. Picture text: 1: Manual feed pump 2: Pre filter & water separator 3: Fuel feed pump 4: Fuel fil filter ter 5: Fuel pressure sensor(low) 6: Fuel control unit (PWM) 7: High pressure pump 8: Rail 9: Rail pressure sensor 10: Max. pressure limit valve 11: Injector 12: Thermostat valve
Water seperator
1: 2: 3: 4: 5: 6: 7: 8:
Manual feed pump Manual nobe for thermostat valve Pre filter & water separator Water in fuel sensor Water drain valve Normal position(thermostat function) Open position(Return fuel to tank) Fuel warmer
L, M : For fuel warmer N,O : For water in fuel sensor
Picture text:
Injector
The main injector components are: Hole-type nozzle(c), hydraulic servo-system(b), solenoid valve(a). The forces required to open and close the nozzle needle cannot be generated by the solenoid valve on its own. The nozzle needle is therefore indirectly triggered via a hydraulic force-amplification system. 1. Injector closed With the solenoid valve closed, the complete chamber volume and the rail are at the same pressure. The nozzle needle is forced against its seat by a spring. 2-1. Solenoid ON When the solenoid valve opens, fuel flows f lows from the valve control cavity and into the fuel return.The feed throttle prevents complete pressure equalization, and the pressure in the cavity drops. 2-2. Start of injection Hydraulic servo spool move up side and the excess pressure in the chamber volume overcomes the spring force and lifts the needle so that tha t injection can start.
Picture text:
Rail
1. High pressure storage of injection system 2. Rail contains pressure relieve valve(a) and rail pressure sensor(b). 3. Pressure relief valve - Pressure relieve valve is a mechaninical safety device, which opens at 1950(-100) bar and protects the system concerning over pressure caused by any malfunction. -If opened the rail pressure remains in the range of 650 - 850 bar (dependend on speed and load). The engine keeps running but if necessary n ecessary with decreased performance (limp home mode) -Under usual conditions the relief valve will not open during engine operation. 4. Rail pressure sensor - Output signal goes to ECU and ECU controls FCU by using this signal. - If any malfunction is detected, the ECU may force the pressure relief valve to open by putting over pressure onto the system.
Picture text:
Fuel control unit (FCU)
FCU controlles filling of high pressure pumps. It is just delivered as much mu ch as needed to reach or keep the rail pressure set-point. This is an inverse proportional PWM valve. At the inside of valve, there are overflow valve and bleed-off orifice.
Picture text:
IEGR (Jacobs system)
NOx reduction solution is provided by Internal Exhaust Gas Recirculation (IEGR) which is altering engine valve lift. Jacobs IEGR reduces peak combustion temperatures and, therefore, reduces the formation of Nitrogen Oxides (NOx) to levels acceptable to meet upcoming emissions standards. Picture text: A: IEGR Solenoid B: Control valve C: Slave piston D: Master piston E: Connection passage F: Bleed hole(1mm)
IEGR operation
1. IEGR consists of a solenoid valve, control valve, and master and slave pistons. These components are assembled into a housing. 2.When the solenoid is de-energized, the control valves move down and the high-pressure oil is released through the tops of the control valve bores. 3. When the IEGR is activated, the th e solenoid allows oil to pass to the control valve. The control valve moves up and the check ball in the control valve is unseated, allowing oil to fill the master/slave piston circuit. 4.The oil pushes the master piston out, and a nd when rocker motion pushes the master piston back, high pressure is created which seats the check ball in the th e control valve. 5.Continued rocker motion causes the high-pressure oil to move the slave piston. The slave piston motion causes the exhaust valves to open. As the rocker moves back down, the master piston follows, and the slave piston moves up, allowing the valves to close again, ready rea dy for the next cycle. These cycles continue as long as the brake solenoid is energized. Picture text: 1: IEGR Solenoid 2: 3: 4: 5: 6: 7: 8:
Bleed hole(1mm) Slave piston Master piston Intake rocker arm Exhaust rocker arm Control valve Oil supply line(2~5 bar)
Electrical System Topics: General - Overview machine - Overview cab - IECU & Key pad - Battery, master switch - Electrical boxes -
Solenoids and PWM valves Sensors Controls system overview Controls system diagram
ECU's - V-ECU inputs and outputs - I-ECU inputs and Outputs - E-ECU inputs and Outputs - ECC Inputs and outputs Software functions - Limp Home Control -
Auto Idle Power Boost 1&2 Hydraulic fan control Thermostatic Function
-
Float position Parking Brake, Travel Q-max, turtle and Hare mode, P-T-W-C Control lock out solenoid Travel Direction Control
- Main Pump Pressure Calibration - Axle lock control - Starter lock Elec El ectr tric ic di diag agra rams ms Sta tart rt ci circ rcu uit Diagrams
Overview Cab
1. Left instrument panel 2. Right instrument panel 3. Information panel (I-ECU) 4. Rear instrument panel
Picture text:
Left instrument panel
1. Control lever for stabiliser leg / stabiliser blade 2. Light control 3. Left control lever 4. Radio remote control 5. Attachment bracket (quickfit) switch (optional equipment) 6. Confirm switch for attachment bracket (quickfit) (optional equipment) and buzzer sound stop 7. Stabiliser leg switch, front (if the machine is equipped with stabiliser blade, this switch is unassigned) 8. Stabiliser leg switch, front / stabiliser blade switch 9. Interior light switch 10. Stabiliser leg switch, rear 11. Stabiliser leg switch, rear 12. Travel manual switch 13. Auto/manual select switch 14. Emergency engine speed control switch
Picture text:
Right instrument panel
1. Cigarette lighter 2. Temperature sensor for air conditioning (optional equipment) 3. Rotating warning beacon switch 4. Fuel heater switch 5. Front working light switch 6. Rear working light switch 7. Travel speed control 8. Mode selector control 9. Right control lever 10. Drink and cup holder 11. Lower windscreen-wiper switch 12. Lower windscreen-washer switch 13. Cruise control switch 14. Axle pivoting lock switch 15. Engine speed control 16. Key pad 17. X1 operation switch 18. Ignition switch 19. Fog light switch 20. Power outlet
Picture text:
IECU & Key pad
1. Increase fan speed 2. Increase temperature 3. Air flow direction 4. Decrease fan speed 5. Decrease temperature 6. Air flow circulation 7. Auto mode 8. Air conditioning 9. Defroster 10. AC on/off 11. Arrow up 12. Back camera 13. Escape 14. Arrow down 15. Select 16. Auto idle. The engine speed will be lowered automatically, if any of the control levers, pedals or engine speed control are not operated for a period between 3-10 seconds. 17. Overload alarm 18. Shut off travel alarm. 19. Central warning lamp screen 20. Gauges, direction indicators and travel direction screen 21. Engine speed screen 22. Mode, travel speed and flow screen 23. Time and HVAC screen 24. Indicator lamp screen
Picture text:
IECU, Booting
1. Volvo Logo - If key OFF --> ON, logo will be shown for seconds. 2. Initilalizing status - This is required by OS (LINUX). ( LINUX). IECU will initialize all internal devices and settings. 3. Anti-theft system - If PAR (Option code lock) = ON, the display will be like this. - After inputing 4-digit number, SELECT button should be pressed as confirming. - Within certain time period, when you turn off engine and start again, IECU does not ask the PIN code again. Above time period can be programmed in VCADS Pro (0~15 minutes). 4. Daily maintenance - Operator can see the list of daily maintenance once a day. 5. Default screen - Gauge, rpm display, time, Aircon, indicator.
Picture text:
IECU (EXC & EXW)
1. EXC - Default screen 2. EXC US - RPM screen (no P-mode) 3. EXW - Turn signal - Gear position (Forward, Neutral, Reverse) - Mode display (Parking, Travel, Work, Customer) - Travel speed mode (Creep, Low, High) - Pump flow setting in C-mode Picture text:
IECU, Main menu
Menu tree, User mode Engine - Oil pressure - Oil level Hydraulic - Oil temperature - Hammer Op. hr. - X1 work tool - Response mode - Soft - Normal - Active Electrical system - Vol Voltag tage e Vehichle information - Model -
Serial number Work timer Current fuel cons. Average fuel cons.
- Ambient temp. Service - Interval: - Time remaining: Setup - X1 work tool tool - X3 ope pera rati tion on - Lan Langua guage ge Vehicle message
- Units - Ti Time me/d /dat ate e - Dis Displa play y lig light ht
- Keypad backlight
IECU, Service mode
I-ECU changes from OPERATOR MODE to SERVICE MODE when pressing SELECT button in keypad for more than 3 s on the SERVICE menu. Menu tree: Engine 1. Engine rpm 2. Engine sensor-1 3. Engine sensor-2 Hydraulic 1. Cooling system 2. Pressure switch 3. Pressure sensor 4. Solenoid 5. Proportional valve Electrical system 1. Power supply 2. On/Off input 3. Analog input 4. PWM input 5. On/Off output 6. Climate system
Picture text:
Battery, Masterswitch
Because of a change in the European law (EN 474), we are now able to install the master switch to disconnect the positive battery lead. This is standard on ALL C-models. Picture text: C-models: Masterswitch disconnects positive lead
Electrical boxes
On the machine 2 boxes are installed: The Electrical distribution box (EDB), located behind the cabin, and an d the Power distribution box (PDB) located in front of the Hydraulic tank. In the boxes next components are located: 1. DC-DC convertor 2. Windshield wiper controller 3. Pre heating relay 4. 80 A automatic circuit breaker 5. 150 A Automatic circuit breaker 6. Relays: NO/NC-relay, NO-relay, timer relay 7. Blade fuse 8. Connectors: CN01-CN06 9. Diodes 10. Power connection from battery. 11. Battery
Picture text:
Solenoid valves, PWM valves and sensors
Locations: 1. SE9101, Auto Idle pressure sensor (LS pressure) SE9401, Overload pressure sensor SE9114, Boom down pressure sensor 2. MA9109, Quick fit valve block with valve 3. MA9120, Float position valve block with valve 4. Gear selector valve block with MA4303 high and MA4302 low gear valves va lves 5. PWM9103, PWM valve for hydraulic oil cooler fan motor 6. MA9107, Power boost valve NA, Not applicable 7. MA9152, Axle lock valve MA4214, Q-max valve MA9108, Control lock out valve PMW9101, PWM pump control valve 8. SE2303_SE2304, Fuel level sender 9. SE8503 & SE8504, Control lock out switches 10. SE9105, Hydraulic oil temperature sensor 11. SE9106, Hydraulic return pressure sensor 12. SE9115, Auto Idle dipper arm in sensor 13. SE4218, Steering pressure sensor SE5205, Max brake pressure sensor (alarm) SE5201, Brake pressure sensor (stop light/ Axle lock function) SE4217, Travel pedal pressure sensor MA4218/MA4219, Forward/Reverse valve block with valves 14. SE4901, Turret alignment sensor
Picture text:
*
Control system overview
The wheeled Excavator C series contain, standard 4 ECU s and a key pad: VECU: MID187 EECU: MID 128 IECU: MID 140 ECC ECU: MID146 Key pad: MID 234 As an option an additional ECU can be installed for the Care track system: The W-ECU: MID 142 EECU (Engine Electronic Control Unit) - Common rail injection system control VECU (Vehicle Electronic Control Unit) - Three Connector (More input & Output) IECU (Instrument panel Electronic Control Unit) - TFT LCD ECC (Electronic Climate Control) - Aircon system control Keypad : Convenient input system
WECU (Wireless Electronic Control Unit) -CareTrack (Machine location, Logged data transmission etc.) ** From C-series, SDU function is transferred to IECU (in Service-mode).
Picture text:
#
Controls system diagram
Inputs and outputs.
Picture text: Zoom in with the + key. Press the spacebar to move around the media with the mouse.
V-ECU inputs and outputs
In the diagram you find the Inputs and outputs connected to the V-ECU. The arrows indicate whether it concerns an input or a output. The double arrows indicate PWM signals to the PWM valves. Input Signal: 1. Mode selector control switch 2. Travel mode selector control switch 3. Engine speed control switch 4. Ignition switch 5. Left hand control lever switches: 6. Right hand control lever switches: FWD/N/REV switch Shear switch Hammer/Power boost switch Float position switch 7. X1 Select switch 8. CDC switch 9. Quick fit switch 10. Confirm/Buzzer stop switch 11. Axle lock switch 12. Cruise control switch 13. Super structure alignment switch 14. Return oil filter pressure switch 15. Steering pressure switch 16. Parking brake pressure switch 17. Arm-in/Boom-down auto idle pressure switches 18. LS auto idle pressure sensor 19. Feed for pressure sensors 20. Brake pressure sensor 21. Hydraulic oil temperature sensor 22. Travel pedal sensor 23. swing wheel speed sensor
Output Signal: 25. Travel alarm/Stop light relays 27. Power boost Valve 28. Float position valve 29. FWD/REV valve 30. Control lockout/Q-max/Axle lock valve 32. High/Low speed Gear box valves 36. X1Left/X1Right valve 38. Main relay 39. Start lock function PWM signals: 31. Oil cooler proportional valve 33. Thermostatic function proportional valve 35. Cruise control proportional valve 36. X1 flow control proportional valve 37. X1 pressure up proportional valve
I-ECU inputs and outputs
1. Direction indicator RH 2. Direction indicator LH 3. Fuel level sensor 4. Rear view camera 5. Overload pressure sensor 6. Auto/manual switch 7. Auto lubrication switch 8. Light selector switch 9. Quickfit switch and valve 10. ALT-L terminal 11. Power feed 12. Memory power feed
Picture text: Zoom in with the + key. Press the spacebar to move around the media with the mouse.
E-ECU inputs and outputs
In the picture the inputs and outputs on the E-ECU are shown: 1. Injector units 1-3, 2. Injector units 4-6, 3. Flow control valve 4. Cam shaft speed sensor 5. Crank shaft speed sensor 6. Intake air temperature sensor 7. Intake air pressure sensor 8. Charge air pressure sensor 9. Charge air temperature sensor 10. Rail pressure sensor 11. Engine oil temperature sensor 12. Engine oil level sensor 13. Ground to starter motor 14. Auto manual switch 15. IEGR valve 16. Pre-heating 17. Coolant level sensor 18. Water in fuel sensor 19. Engine oil pressure sensor 20. Fuel feed pressure sensor 21. Coolant temperature sensor
Picture text: Zoom in with the + key. Press the spacebar to move around the media with the mouse.
ECC inputs and outputs
1. EECU inputs about engine speed and cooling liquid temperature 2. Refrigerant temperature 3. Ambient and in-car temperature 4. Communication from Key pad via IECU to ECC controller 5. Time control unit 6. Diesel cabin heater 7. Diesel heater water pump 8. Diesel heater fuel pump 9. Actuator, foot, RH 10. Actuator, intake 11. Actuator, face 12. Actuator, air mix 13. Actuator, foot, LH 14. A/C fan motor 15. A/C refrigerant pressure monitor 16. A/C compressor
Picture text: Zoom in with the + key. Press the spacebar to move around the media with the mouse.
Limp home control
When the VECU is working normal but the communication between the VECU and the other ECU s work abnormally, the system changes to a limp hom home e function. When a input signal either from f rom the auto idle pressure sensors or from the travel pedal pressure sensor reaches the VECU, the VECU sends out a fixed signal of 450 mA, to the pump control proportional valve. This results in a decrease of flow from f rom the pump by 50%
Picture text: Press the travel pedal symbol (1), auto idle pressure sensor (2) (VECU Inputs) and see the outputs from the VECU.
Auto Idle control
Auto idle is an energy saving function that makes that when the machine is not used the engine RPM drops to 1000 RPM. This animation describes the auto idle function. When: 1) the engine speed is over 1000 RPM (1) ( 1) 2) the RPM switch (2) is not used 3) the auto idle select switch (3) on the key pad is activated 4) the travel pedal sensor (4) registrates a pressure of less than 3 bar/43,5 psi 5) the auto idle pressure sensor (5) registrates a pressure less than 15 bar/217,5 psi Then the VECU will send a request to the EECU to lower the RPM of the engine to 1000 RPM. The EECU will send in its turn a message to the IECU to indicate the actual engine speed. With VCADS Pro you can change the time delay before au auto to idle activation. The delay varies between 3 and 10 seconds, the default value is 5 seconds.
Picture text: Press the engine speed symbol (1), RPM switch (2), Auto Idle select switch (3), travel pedal symbol (4), auto idle pressure sensor (5) (VECU Inputs) and see the outputs from the VECU.
Boost control 1
This animation describes the boost (working pressure increase) function. Travel: When the control lockout lever (3) is in upper position and the travel pedal (2) sensor, underneath the travel pedal, registrates a pressure higher than 7 bar (/101,5 psi). And the P-T-W-C P-T- W-C mode selector (1) is in T or W or C mode, the VECU sends an output of 24 V to the power boost solenoid valve.
Picture text: Press the the P, T, W, C symbol (1 (1), ), the travel pedal symbol (2),the contol lock out lever symb symbol ol (VECU Inputs) and see the outputs from the VECU
Boost control 2
This animation describes the boost (working pressure increase) function When pushing the power boost function button on the right hand ha nd RCV. When the control lockout lever (4) is in upper position and the power boost function button is pressed (3). When on the X1 mode selector switch (2) X1 function is NOT selected And the P-T-W-C P-T -W-C mode selector switch (1) is set to W or C mode, the VECU sends out a 24 V signal to the power boost solenoid valve for a period of 9 seconds. Then the VECU also sends a signal to the IECU that displays the power boost symbol. This function is a repetitive function: When the power boost switch is depressed within the period of 9 seconds the timer starts to count from zero again.
Picture text: Press the P, T, W, C symbol (1), hammer, shear or neutral function (2), the power boost function button symbol (3) and the control lock out lever symbol (4) (VECU Inputs) and see the outputs from the VECU
Hydraulic fan control
The cooling fan speed varies according several systems in the machine. This describes the control algorithm and method of the cooling fan speed control. Fan Speed Control Algorithm: The Fan Speed is determined by 4 coefficients. The 4 coefficients are: A) Engine Coolant Temperature (KENG) B) Charge Air Temperature (KCAC) C) Hydraulic Oil Temperature (KH) D) Air Conditioner Operation (KAIRCON) The VECU gets all the inputs of the separate sensor values, either direct or via the EECU. Then the VECU will calculate all coefficients ((KENG, KH, KCAC, KA/C) and then compute Kf = max * (KENG, KH, KCAC, KAIRCON) to a fan speed (see chart H). Each of the coefficients can be acquired from the charts E), F), G) Which ever temperature of the engine en gine coolant, charge air or hydraulic oil is highest is prioritized. If the Air Conditioner is activated, the fan speed has to be over specified value (KAIRCON). Then the VECU will send out a proportional (mA) signal, according to chart I)
Picture text:
Float position control
This animation describes the float position electrical control regarding the boom. When the boom float select switch on the RCV joystick is pressed and when the boom float parameter is programmed, with help of the VCADS Pro tool, the VECU will send out a feed of 24 V to the boom float position valve. The VECU will send a signal to the IECU to display the float position symbol. The input signal is of a pulse type: you don t have to keep the switch depressed. To in activate the float function press the float select switch one more time.
Picture text: Press the Boom float select switch (1), VCADS Pro computer (5) (VECU Inputs) and a nd see the outputs from the VECU.
Parking brake
This animation describes what inputs are needed for the parking brake control. At least one of the gear selector valves (turtle or hare), needs n eeds to be energized to de-engage the parking brake, which is located in the gearbox. When the control lockout lever is pointing down and also when the P-T-W-C mode selector switch is set to P-mode, both gear selector valves are unenergized and the parking brake is engaged. Snail speed: In the snail transport mode the Q-max valve as well as the lower speed valve to the gear box are energized. In turtle speed: Is only the lower speed valve to the gear box energized. In hare speed: Is only the high speed valve to the gear box energized. In P-mode: Both valves to the gear box are un-energized.
Picture text: Press the P-T-W-C switch (1), the travel speed control selector switch (2), control lock out lever (3) (VECU Inputs) and see the outputs from the VECU.
Control Lockout
The remote control valve operations (RCV) should be carefully limited for safety in some cases. One way of limiting this is through cutting of the pilot pressure to the RCV s. When the P-T-W-C switch (1) is in T position and the turret is not aligned with the under carriage (2), the VECU will send and output to the control lock out relay. This will in its turn feed 24 V to the Pilot cut-off solenoid valve. This means that the RCV is NOT disabled in T-mode when the turret is not aligned. The pilot cut-off-relay will get in W- and C-mode an external feed coming directly from the mode selector switch (2).
Picture text: Press the P, T, W, C symbol (1), the EXC alignment symbol (2) (VECU Inputs) and see the outputs from the VECU.
Travel direction Control
This animation describes the control of the travel direction function. fun ction. 1) If the selection for the th e travel direction is forward, the forward solenoid is energized and th the e control pressure from the travel pedal is directed to that side of the travel spool that makes the excavator move forward. The VECU sends a signal to the IIECU ECU to di display splay the F symbol 2) If the selection is neutral, none of the travel direction solenoid valves are energized and, both sides of the travel spool are connected to tank pressure. The VECU sends a signal to the IIECU ECU to di display splay the N symbol 3) If the selection for the travel direction is reverse, the reverse solenoid is energized and the control pressure from the travel pedal is directed to that side of the travel spool that makes the excavator move reverse. The VECU sends a signal to the IIECU ECU to di display splay the R symbol 4) When the control lock out lever pointing down, independent of the position of the forward-reverse selector switch, the results is the same as if neutral n eutral would have been selected: none of the travel direction solenoid valves are energized and, both sides of the travel spool are connected to tank pressure. The VECU sends a signal to the IIECU ECU to di display splay the N symbol
Picture text: Press the FWD/N/REV selector switch (1), control lock out lever (2) (VECU Inputs) and see the outputs from the VECU.
Control Pressure Calibration
To be able to check the main pump control pressure a fixed signal needs to be send to the pump control proportional valve which is located on the regulator unit on the main pump. Only when the control lock out lever is pointing down and a nd the P-T-W-C mode selector switch is set to Tmode, the VECU will send a fixed output signal of 300 mA to the pump control proportional valve. In all other positions the signal will be variable (indicated with xxx).
Picture text: Press the P-T-W-C selector switch (1), control lock out lever (2) (VECU Inputs) and see the outputs from the VECU.
Axle lock control
When the axle lock solenoid is not energized, the pivoting axle is locked. 1. When the control lock out lever (5) ( 5) is pointing down, the axle lock solenoid is not energized a and nd thus the axle is locked. The VECU sends a signal to the IECU to display the axle lock symbol. 2. When the P-T-W-C mode selector switch (1) is set to P-mode, the a axle xle lock solenoid is not energized and thus the axle is locked. The VECU sends a signal to the IECU to display the axle a xle lock symbol. 3. When the axel lock select switch (3) is activated, the axle lock solenoid is not energized and thus the axle is locked. The VECU sends a signal to the IECU to display the axle lock symbol. 4. When the P-T-W-C mode selector (1) switch is set to T, W, C-mode, -And the travel speed selector switch (2) is set to snail, turtle OR HARE -And the brake pressure (4) exceeds 50 bar/725 psi the axle lock solenoid is not energized and thus the axle is locked. The VECU sends a signal to the IECU to display the axle lock symbol. However -When the P-T-W-C mode selector switch (1) is set to T, W, C-mode -And the travel speed selector switch (2) is set to snail, turtle OR HARE -And the brake pressure (4) is lower than 50 bar/725 psi the axle lock solenoid is energized and a nd thus the axle is unlocked.
Picture text:
Starter lock
1. Starter lock relay - Key OFF --> ON - Safety lever=Down - If there is code-lock option, PIN code should be matched. - When every condition above is ok, VECU will energize RE3301. - When key is in start position, RE3302 will be ON. From now on, power can go to the th e magnet of starter(MO3301). 2. Magnet on the starter will be off - When Engine is running.(RPM > 650) - During 6 seconds after EECU checked engine running. (to prevent over running of starter) - During 2 seconds after EECU checked engine stop. (Confirmation of engine stop after starting failure) - During 1 seconds after key position changed from START --> ON. (To prevent an quick retry after starting failure)
Picture text:
Start circuit
Picture text: Zoom in with the + key. Press the spacebar to move around the media with the mouse.
RPM Control Switch
In comparison of B-series, This is new type of PWM signal generator. It also has illumination funtion.
Picture text:
Power Transmission
Topics: - Slew system EW140C/EW160C - Gear box and Travel motor - The different travel speeds Objectives: - Understand the functionality of the gear box and travel motor and a nd the corresponding travel speeds. Also to understand the slew function on the EW140C/EW160C
Picture text:
Slew unit
Slew unit for EW140C and EW160C. 1. Cylinder block 2. Piston 3. Bearing 4. Shaft 5. Valve block 6. Brake body 7. Brake piston 8. Spring washer 9. Snap ring 10. Brake discs 11. Valve cover 12. Brake shaft 13. Cam track 14. Bearing support body 15. Valve A. Increased return pressure B. Return pressure C. Servo/Control pressure D. Pump pressure
Picture text:
Control valve, slew brake
When the lever for slew is activated, the valve change over and deliver servo pressure to the th e slew motor to release the brake.
Picture text:
Diagram, EW160C A. Increased return pressure B. Return pressure C. Servo/Control pressure D. Pump pressure E. LS-pressure Slew system, slew left 2 Working pump 6 Valve block MCV 6:K Pressure back-up valve 6:T Pressure back-up valve 6:8 Directional valve, slew 6:80 6:81 6:82 6:83
Signal line Shuttle valve Relief valve, max slew pressure Relief valve, LS-pressure slew
6:84 Pressure reducing valve 6:85 Non-return valve 91 Control valve, slew brake 9:1 Directional valve 9:2 Shuttle valve E LS-pressure 12 Fan motor 13 Slew motor 13:1 Damping valve 13:2 Slew brake 13:A Shock valve 13:B Shock valve 13:G Shock valve 30 40 68 76
Control valve, left Solenoid valve block Hydraulic oil cooler Double pump
79 Propo Proporti rtiona onall relief relief valv valve, e, fan fan 87 Fa Fan n pum ump p
MA9108 MA9 108 Con Contro troll lockou lockoutt soleno solenoid id
Torque control for slew
A. Adjustment on valve A, torque control B. Adjustment on valve B, max slew pressure
Picture text:
Center passage
1 A. Hub B. Shaft C. Locking plate 2 A. Hub B. Shaft C. Cap D. Seal sliding E. O-ring F. Thrust bearing G. O-ring H.Seal O-ring I. sliding J. Bolt K. Plug L. Plug M. Plug N. Plug
Picture text:
Travel system
1. Adjusting screw for auto change to Q-max 9. Gearbox 10. Travel motor
Picture text:
Hydraulic motor 30km/H
10. Travel motor 10:1. Refilling valve 10:2. Counterbalance valve 10:5. Shock valve 10:8. Retardation valve 10:9. Control piston 11. Q max valve 12. Adjusting screw Q max 13. Adjusting screw Q min. 14. Adjusting screw regulation point
Picture text:
30km/H, Diagram
1. Start in, high gear 2. Down hill, released travel pedal 10. Travel motor 10:2. Counterbalance valve 10:5. Shock valve 10:8. Retardation valve 10:9. Control piston retardation 40. Servo block 70. Centre passage 76. Servo pump A. Return pressure B. C. Pump Raisedpressure return pressure D. Servo pressure E. LS-pressure
Picture text:
20km/H, Diagram
10. Travel motor 10:1. Shuttle valve 10:2. Counterbalance valve 10:3. Damping valve 10:4. Non-return valve 10:5. Shock valve 10:6. Control piston 10:7. Regulating valve 10:8. Retardation valve 10:9. Control piston retardation 40. Servo block 70. Centre passage 76. Servo pump A. Increased return pressure B. Return pressure C. Servo/Control pressure D. Pump pressure
Picture text:
Counterbalance valve
Close up picture of the counter balance valve and refilling valves.
Picture text:
Cut away picture
1. Cup springs for multi-disc brake and clutch 2. Input shaft 2:a. Ring gear 2:b. Planetary gear 2:c. Sun gear 3. Planetary drive (carrier) 4. Spur gear drive 5. Out put flange - Rear axle 6. Out put flange - Front axle 7. Attachment Hydro-motor 9. Transmission housing 9:1a. Lube oil pump LB. Multi-disc brake LB:1. Brake piston LK. Multi-disc clutch LK:1. Clutch piston N:1. Ring emergency actuation N:2. Pressure ring emergency actuation
Picture text:
P, Snail, Turtle, Hare
1. Snail or Turtle, Off-road gear (creep- and low speed) 3. Planetary drive carrier 9. Transmission housing 2:a. Ring gear 2:b. Planetary gear 2:c. Sun gear X. Symbol, nail 2-2:c. Input shaft and sun gear 2. Hare, On-road gear (high speed) 4. Output shaft and spur gear drive 2:a. Ring gear 2:b. Planetary gear 2:c. gear nail X:1. Sun Symbol, 3. P, Parking brake X. Symbol, nail X:1. Symbol, nail
Picture text:
Daigram Gearbox, Snail, Turtle
Snail or Turtle, Off-road gear (creep- or low speed) 9. Gear box transmission 9:a. Shift modulation valve 9:b. Sump oil circuit 9:c. Output 9:1. Shift interlock 9:1a. Lube oil pump & control pressure shift interlock 9:1b. Pressure limiting valve 9:1c. Strainer 9:1d. Gearshift spool 9:1e. Change-over check valve 9:1f. Leakage check valve 9:1g. Check valve 9:1h. Restriction 10. Travel motor 40. Servo block 65. Hydraulic oil tank 70. Centre passage 75. Valve block 76. Servo pump A. Servo / control pressure B. Return pressure C. Lubricating oil, transmission D. Lubrication pressure E. Suction line lube oil pump
Picture text:
Daigram Gearbox, Hare
Hare, On-road gear (high speed) 9. Gear box transmission 9:a. Shift modulation valve 9:b. Sump oil circuit 9:c. Output 9:1. Shift interlock 9:1a. Lube oil pump & control pressure shift interlock 9:1b. Pressure limiting valve 9:1c. Strainer 9:1d. Gearshift spool 9:1e. Change-over check valve 9:1f. Leakage check valve 9:1g. Check valve 9:1h. Restriction 10. Travel motor 40. Servo block 65. Hydraulic oil tank 70. Centre passage 75. Valve block 76. Servo pump A. Servo / control pressure B. Return pressure C. Lubricating oil, transmission D. Lubrication pressure E. Suction line lube oil pump Picture text:
Power Transmission
Topics: - Slew system EW180C - Gear box and Travel motor - The different travel speeds Objectives: - Understand the functionality of the gear box and travel motor and a nd the corresponding travel speeds. Also to understand the slew function on the EW180C
Picture text:
Slew unit
Relief valve B (6) have changed position and function. 1. Distrubution valve 2. Planetary gear 3. Hydraulic motor with negative disk brake 4. Rebound damping valve 5. Relief valve A, Torque control 6. Relief valve B, max slew pressure
Picture text:
Port locations for slew unit
The hoses from the control lever are now connected to the cups instead of X and Y. There is a measuring point for the control pressure in MST.
Picture text:
Slew motor with negative brake
1. Slew motor 2. Cylinder block 3. Dampening valve 4. Spring washer 5. Brake discs 6. Distributor valve 7. Piston 8. Slide rail 9. Brake piston 10. Bearing 11. Pinion shaft 13. Relief valve with time delay 14. Drive shaft 12. Planetary gear A. Return pressure B. Servo pressure
Picture text:
Diagram, EW180C
The valve 13:2 for the max ma x slew pressure is now releasing the LS pressure to tank when we have reach the maximum slew pressure. On the B models, the control pressure from the lever was released to ta tank nk at maximum. 13. Slew unit 13:0. Signal line 13:1. Relief valve A, Toque control 13:2. Relief valve B, max slew pressure 13:3. Shuttle valve 13:4. Directional valve 13:5. Non-return valve 13:6. Directional valve 13:7. Non-return/restriction valve 13:8. Shock valve 13:9. Relief valve 13:10. Damping valve 13:11. Relief valve 13:12. Slew brake 13:13. Slew motor 13:14. Relief valve with time delay 13:15. Non-return valve 13:16. Pressure reducing valve 2. Working pump 30. Control valve, left 40. Solenoid valve block 64. Drain filter 68. Hydraulic oil cooler 76. Double pump MA9108. Control lockout solenoid 6:K. Pressure back-up valve 6:T. Pressure back-up valve
Torque control for slew
A. Adjustment on valve A, torque control B. Adjustment on valve B, max slew pressure
Picture text:
Relief valve with time delay
A. Cone B. Spring C. Spool D. Spring chamber E. Piston F. Spring G. Restriction
Picture text:
Damping valve operation
1. Neutral position 2. Start of slew movement 3. Slew movement in progress 4. Rebound damping start
Picture text:
Center passage
1 A. Hub B. Shaft C. Locking plate 2 A. Hub B. Shaft C. Cap D. Seal sliding E. O-ring F. Thrust bearing G. O-ring H. O-ring I. Seal sliding J. Bolt K. Plug L. Plug M. Plug N. Plug
Picture text:
Travel system
1. Adjusting screw for auto change to Q-max 9. Gearbox 10. Travel motor
Picture text:
Hydraulic motor 30km/H
10. Travel motor 10:1. Refilling valve 10:2. Counterbalance valve 10:5. Shock valve 10:8. Retardation valve 10:9. Control piston 11. Q max valve 12. Adjusting screw Q max 13. Adjusting screw Q min. 14. Adjusting screw regulation point
Picture text:
30km/H, Diagram
1. Start in, high gear 2. Down hill, released travel pedal 10. Travel motor 10:2. Counterbalance valve 10:5. Shock valve 10:8. Retardation valve 10:9. Control piston retardation 40. Servo block 70. Centre passage 76. Servo pump A. Return pressure B. Pump pressure C. Raised return pressure D. Servo pressure E. LS-pressure
Picture text:
20km/H, Diagram
10. Travel motor 10:1. Shuttle valve 10:2. Counterbalance valve 10:3. Damping valve 10:4. Non-return valve 10:5. Shock valve 10:6. Control piston 10:7. Regulating valve 10:8. Retardation valve 10:9. Control piston retardation 40. Servo block 70. Centre passage 76. Servo pump A. Increased return pressure B. Return pressure C. Servo/Control pressure D. Pump pressure
Picture text:
Counterbalance valve
Close up picture of the counter balance valve and refilling valves.
Picture text:
Cut away picture
1. Cup springs for multi-disc brake and clutch 2. Input shaft 2:a. Ring gear 2:b. Planetary gear 2:c. Sun gear 3. Planetary drive (carrier) 4. Spur gear drive 5. Out put flange - Rear axle 6. Out put flange - Front axle 7. Attachment Hydro-motor 9. Transmission housing 9:1a. Lube oil pump LB. Multi-disc brake LB:1. Brake piston LK. Multi-disc clutch LK:1. Clutch piston N:1. Ring emergency actuation N:2. Pressure ring emergency actuation
Picture text:
P, Snail, Turtle, Hare
1. Snail or Turtle, Off-road gear (creep- and low speed) 3. Planetary drive carrier 9. Transmission housing 2:a. Ring gear 2:b. Planetary gear 2:c. Sun gear X. Symbol, nail 2-2:c. Input shaft and sun gear 2. Hare, On-road gear (high speed) 4. Output shaft and spur gear drive 2:a. Ring gear 2:b. Planetary gear 2:c. Sun gear X:1. Symbol, nail 3. P, Parking brake X. Symbol, nail X:1. Symbol, nail
Picture text:
Daigram Gearbox, Snail, Turtle
Snail or Turtle, Off-road gear (creep- or low speed) 9. Gear box transmission 9:a. Shift modulation valve 9:b. Sump oil circuit 9:c. Output 9:1. Shift interlock 9:1a. Lube oil pump & control pressure shift interlock 9:1b. Pressure limiting valve 9:1c. Strainer 9:1d. Gearshift spool 9:1e. Change-over check valve 9:1f. Leakage check valve 9:1g. Check valve 9:1h. Restriction 10. Travel motor 40. Servo block 65. Hydraulic oil tank 70. Centre passage 75. Valve block 76. Servo pump A. Servo / control pressure B. Return pressure C. Lubricating oil, transmission D. Lubrication pressure E. Suction line lube oil pump
Picture text:
Daigram Gearbox, Hare
Hare, On-road gear (high speed) 9. Gear box transmission 9:a. Shift modulation valve 9:b. Sump oil circuit 9:c. Output 9:1. Shift interlock 9:1a. Lube oil pump & control pressure shift interlock 9:1b. Pressure limiting valve 9:1c. Strainer 9:1d. Gearshift spool 9:1e. Change-over check valve 9:1f. Leakage check valve 9:1g. Check valve 9:1h. Restriction 10. Travel motor 40. Servo block 65. Hydraulic oil tank 70. Centre passage 75. Valve block 76. Servo pump A. Servo / control pressure B. Return pressure C. Lubricating oil, transmission D. Lubrication pressure E. Suction line lube oil pump Picture text:
Brake System
Topics: In this chapter we will describe the brake system. The brake system is the same on EW140C-EW180C. Objectives: - to understand the working of the brake system
Picture text:
Brake valve
The brake valve controls the brake pressure to the wet brakes in the wheel hubs. The brake pedal is a also lso equipped with a latch to lock the wheel brakes. This is the so called digging brake.
Picture text:
Brakesystem
20. Steering cylinder 37. Priority valve, steering 38. Brake valve 38:1. Priority valve, brake 38:2. Non-return valve with spring 38:3. Non-return valve 38:4. Non-return valve 70. Centre passage 77. Rear axle brake 78. Front axle brake A. Servo pressure B. Return pressure C. Pump pressure D. Oil without flow E. Increased return pressure
Picture text:
Steering System
Topics: This chapter will cover the steering system on EW140C-EW180C. Objectives: To understand the working of the steering system on EW140C-EW180C.
Picture text:
Diagrams
6. Valve block MCV 20. Steering cylinder 34. Control valve steering 34:1. Primary steering 34:3. Secondary steering 34:4. Spool 34:6. Valve 34:7. Shock and anti-cavitation valves 37. Priority valve steering 38. Brake valve 70. Centre passage 76. Pump A. Return pressure B. Pump pressure C. Raised return pressure D. Oil without flow
Picture text:
Priority valve
76. Pumps 34:LS. To steering valve port LS 34:P. To steering valve port P 37. Priority valve steering 37:1. Slot restriction 37:2. Restriction 37:3. Restriction 37:4. Restriction
Picture text:
Frame
Topics: - Front and rear axel - Cut section pictures of input and output Objectives: - Note the position of the disk brakes, inside of sun gears instead of outside. Duration: 15 minutes
Picture text:
Specification, Front axle
20. Steering cylinder 20:a. Steering rod left 20:b. Steering rod right
Picture text:
Input
1. Drive pinion 2. Differential (with crown wheel) 3. Shim for contact pattern (Bevel gear set) 4. Spacer ring (Bearing rolling moment/pinion bearing) 5. Shim for backlash 6. Shim (bearing rolling moment/differential bearing) 7. Input flange 8. Seal ring 9. Axle drive housing 10. Axle housing /part I (10a = O-ring) 11. Axle housing/part II (crown wheel side) Just for .New part. assembly or if disassembled: Install o-ring (10a) on axle housing/part I (10) and a nd mount axle drive housing (9). observe installation position ! Tightening torque ...... MA = 390 Nm (M 18/10.9)
Picture text:
Input Flange
1. Drive pinion 2. Hex. nut 3. Washer 4. Input flange 5. Screen 6. Seal ring 7. Bevel roller bearing 8. Spacer ring 9. Input housing X. Installation dimension MS-E 3050/3060 - 13.0+0.2 mm MS-E 3070 - 13.5+0,2 mm
Picture text:
Output
1. Axle housing 2. Knuckle housing 3. Hub 4. Multi-disc brake 5. Planetary carrier
Picture text:
Rear Axle
Picture text:
Cab
Topics: - The ECC (Electronic Climate Control) system - Diagrams and components Objectives: - Understand the control of the ECC system system.. - The ECC is now integrated in machines communication system. - To control the ECC you use the standard Key pad in the cabin. Picture text:
1 1
13 51
1
Air conditioning system overview
-
Heating and cooling system is installed in a single unit. Can select indoor or outdoor air. The mix door controls target temperature of system by mixing cold and hot air. There are two filters.
Picture text:
Aircon system layout
1. Aircon unit 2. Diesel heater 3. Diesel heater-Water pump 4. Diesel heater-Timer 5. Diesel heater-Fuel pump 6. Condenser 7. Receiver dryer 9. Water supply 10. Water return 11. Cumulated water drain hose
Picture text:
Aircon system electric circuit
C-series improvement 1. Display on IECU using keypad 2. In Auto-mode, fan spped increase smoothly (no resistance) 3. Error displayed on IECU 4. ECC can be programmed. 5. MATRIS is available on Aircon system. - HVAC Auto_Manual mode selection distribution (%) - HVAC Air distribution mode and Blower motor selection distribution - HVAC Air temperature setting for f or auto control distribution (%) - HVAC Ambient temperature - AC High Pressure - AC Compressor usage 6. Coolant temp sensor on AC unit is removed (EECU signal) 7. Many relayes are removed 8. In Auto-mode, followings are possible - AC on/off - Fresh/Recirculation selection - Bidirectin of air flow selection in heater mode - Soft start function(After starting engine, 10sec compressor working when the machine is OFF for more then 4hr) for oil circulation
Picture text:
Air conditioner unit
1. Actuator - RH foot 2. Connection point - Refrigerant 3. Actuator - LH foot 4. Connection point - Coolant 5. Actuator - Mix door 6. Actuator - Face door 7. Filter - Main 8. Blower fan 9. Heater core 10. Evaporator 11. Duct temp. sensor 12. Expansion valve 13. Filter - Ambient
Picture text:
Sensors
1. Duct temp. sensor(SE8702) 2. Cabin temp. sensor(SE8706) 3. Ambient temp. sensor(SE8702)
Picture text:
Diesel heater components
1. Timer The timer controls the diesel heater, and displays the operating status. The display shows current date, current time and operating time. 2. Controller & Heating unit The heating unit raises the temperature of the coolant using the fuel combustion unit, consists of the glow plug, the thermostats, the flame sensor, the controller, the electric motor and the fuse. The Th e case of the unit has the fuel supplying port, the coolant inlet/outlet port, the air inlet port a and nd the exhaust port. 3. Fuel pump The fuel pump supplies the diesel heater with the fuel from the tank. 4. Water pump The water pump is located between the diesel heater and the engine block, and supplies the diesel heater with the coolant from the engine block. a: Water flow b: Fuel c: Fresh air d: Exhaust gas
Picture text:
Hydraulic system EW140C
Topics: - Main pump, incl. regulating device - Servo pump - Brake/Steering pump - Fan pump - MCV EW140C, incl. component locations - Other hydraulic components, like: Remote control valve, Hydraulic tank, And pivot axle lock
Picture text:
Overview, EW140C
C. Right side D. Left side 1. Sleew 2. Two piece boom, X2 3. X1 4. Out riggers and support blade 5. Boom 6. Slew 7. Bucket 8. Travel 9. X3 10. LS line 11. Main pump
Picture text:
Hydraulic diagram, EW140C
Picture text: Press the Adobe PDF file icon for opening and printing the picture in Adobe Rea Reader. der.
Working pumps
1. Accumulator and pressure relief valve for Servo S ervo pump 2. Regulator for Main pump 3. Servo pump 4. Steering and brake pump 5. Main pump 6. Fan pump
Picture text:
Main, Servo, Steering and Brake Pump
1. Control valve 2. Main pump 3. Steering and brake pump 4. Servo pump
Picture text:
Working pump
1. High pressure 2. Low pressure 3. Regulating pressure 4. Control pressure (VD3) 5. External control (not used for EW160B &EW180B) 6. Load sensing pressure from MCV 7. Case pressure 8. Servo cylinder 9. Valve block 10. Working pistons with slipper 11. Servo piston 12. Drive shaft 13. 2-bolt SAE-flange 14. Cylinder barrel 15. Leakage oil to tank 16. Main circuit from tank and to MCV Picture text:
Working pump, Regulating device
1. Set screw delta p 2. Set screw control pressure
Picture text:
Fan pump
1. Fan motor 2. PMW9103 3. Fan pump
Picture text:
Main valve block
1. Boom 2. Dipper arm 3. Bucket 4. Travel 5. Slew 6. X2 7. X1 8. Out riggers and support blade 6A. Front valve block MCV 6B. Rear valve block MCV 92. Control valve, increased return pressure XT. Testing nipple for return pressure SpT. Pressure gauge
Picture text:
Valve location
Here you can see the valve va lve locations for the MCV for the EW140C. Picture text: Move the mouse over the shaded areas!
Directional valve
The directional valves on the wheeled excavators consist of several components. A load holding valve and a compensator valve are integrated in the spool.
Picture text:
One movement
This animation describes the working of the load holding valve and the LS signal that regulates the pump.
Picture text:
Two movement
This operation shows how combined operations and different loads influence the load holding valve, compensator in the spool an the regulator on the pump.
Picture text:
Flow dividing
1. Spool controlled by the operator 2. Compensator controlled by the system 3. The operators dream 4. Divided flow
Picture text:
Shock and refilling valve
1. High pressure 2. To tank
Picture text:
Shock and refilling valve
Shock function The pressure from the user side acts a cts on both sides of the piston (1). The piston diameter is larger than the cone diameter which, together with the force from the spring (2) keeps the piston in the closed position. Through the channel in the piston (3) the pressure comes into the chamber (4) and, when the set opening pressure (adjusted with adjusting screw) is reached, the pilot cone (5) ( 5) opens to tank. This causes a pressure-drop in the chamber resulting in both pistons moving to the right and opening a connection between the user side and the tank connection, enabling the pressure to drop. Anti-cavitation function If the pressure on the user side becomes lower than in the tank connection, the pressure from the tank acts on the additional ar ea on the piston (6) and lifts the piston.
Picture text:
LS-pressure relief valve
The valve limits the LS-pressure to two levels. When the solenoid valve MA9107 is without voltage is the DA-valve port Z connected to tank via the solenoid valve and standard LS-pressure and pump pressure is obtained. This provides a pump pressure of LS + delta p. When the travel or booster function is actuated the solenoid valve MA9107 is with voltage and the valve becomes pressurized with servo pressure. This causes a raising of the LSpressure, which provides the high pump pressure (power boost). 1. To tank 2. LSC-signal
Picture text:
Safety relief valv
The function of the valve is to prevent pressure peaks in the system, when the spools in the block move to neutral position the opening pressure is 6 M Pa. When operating the machine the opening pressure of the valve is the LS-pressure +6.0 M Pa. 1. From LS channel 2. From pump channel (P) 3. To tank
Picture text:
Refilling valve for travel
This anti-cavitation valve is a non-return valve connected between the travel motor and the hydraulic oil tank. At vacuum pressure in one side of the travel motor, the function of the valve is to refill with oil with the tank line pressure. The bar between the two valves helps to open up the low pressure side.
Picture text:
Hydraulic oil tank, Diagram
6. Valve block MCV (Main Control Valve) 12. Hydraulic driven cooling fan 62. Indicator, hydraulic oil level 64. Drain filter, tank 65. Hydraulic oil tank 66. Return oil filter 67. Air filter breather 68. Hydraulic oil cooler 69. Suction strainer 87. Fan pump
Picture text:
Pivot axle lock
The non return valve with a spring 21:5 helps the spring 21:1b to close when the cylinders are moving. 21. Axle locking cylinder 21:1a. Piston 21:1b. Spring 21:1c. Con 21:2. Channel between piston and Z-channel 21:3. Piston 21:4. Spring housing 21:5. Non-return valve 21:6. Steel ball 21:7. Vent air 21:10 Seal (wiper) 21:8. Seal 21:11 Ring 21:9. Ring and seal MA9108. Solenoid valve control lockout MA9152. Solenoid valve axle lock MA4214. Solenoid valve creep speed (Q-max)
Picture text:
Remote Control Valve
The remote control valve is a pressure reducing valve that is used to control the pilot pressure that is used to move the spool.
Picture text:
Hydraulic system EW160C
Topics: - Main pump, incl. regulating device - Servo pump - Brake/Steering pump - Fan pump - MCV EW160C, incl. component locations - Other hydraulic components, like: Remote control valve, Hydraulic tank, And pivot axle lock Picture text:
Overview, EW160C
A. Right side B. Left side 1. X1 2. Travel 3. Bucket 4. Dipperarm 5. Boom 6. Slew 7. Out riggers and support blade 8. X2 9. LS line 10. Main pump
Picture text:
Hydraulic diagram, EW160C
Picture text: Press the Adobe PDF file icon for opening and printing the picture in Adobe Rea Reader. der.
Working pumps
1. Accumulator and pressure relief valve for Servo S ervo pump 2. Regulator for Main pump 3. Servo pump 4. Steering and brake pump 5. Main pump 6. Fan pump
Picture text:
Main, Servo, Steering and Brake Pump
1. Control valve 2. Main pump 3. Steering and brake pump 4. Servo pump
Picture text:
Working pump
1. High pressure 2. Low pressure 3. Regulating pressure 4. Control pressure (VD3) 5. External control (not used for EW160B &EW180B) 6. Load sensing pressure from MCV 7. Case pressure 8. Servo cylinder 9. Valve block 10. Working pistons with slipper 11. Servo piston 12. Drive shaft 13. 2-bolt SAE-flange 14. Cylinder barrel 15. Leakage oil to tank 16. Main circuit from tank and to MCV Picture text:
Working pump, Regulating device
1. Set screw delta p 2. Set screw control pressure, VD3
Picture text:
Fan pump
1. Fan motor 2. PMW9103 3. Fan pump
Picture text:
Main valve block
1. X1 2. Travel 3. Bucket 4. Dipperarm 5. Boom 6. Slew 7. Out riggers and support blade 8. X2
Picture text:
Valve location
Here you can find out the valve locations on the MCV on the EW160C. MA9107 is the Solenoid valve for power boost.
Picture text: Move the mouse over the shaded areas!
Directional valve
The directional valves on the wheeled excavators consist of several components. A load holding valve and a compensator valve are integrated in the spool.
Picture text:
One movement
This animation describes the working of the load holding valve and the LS signal that regulates the pump.
Picture text:
Two movement
This operation shows how combined operations and different loads influence the load holding valve, compensator in the spool an the regulator on the pump.
Picture text:
Flow dividing
1. Spool controlled by the operator 2. Compensator controlled by the system 3. The operators dream 4. Divided flow
Picture text:
Shock and refilling valve
1. High pressure 2. To tank
Picture text:
Shock and refilling valve
Shock function The pressure from the user side acts a cts on both sides of the piston (1). The piston diameter is larger than the cone diameter which, together with the force from the spring (2) keeps the piston in the closed position. Through the channel in the piston (3) the pressure comes into the chamber (4) and, when the set opening pressure (adjusted with adjusting screw) is reached, the pilot cone (5) ( 5) opens to tank. This causes a pressure-drop in the chamber resulting in both pistons moving to the right and opening a connection between the user side and the tank connection, enabling the pressure to drop. Anti-cavitation function If the pressure on the user side becomes lower than in the tank connection, the pressure from the tank acts on the additional ar ea on the piston (6) and lifts the piston.
Picture text:
LS-pressure relief valve
The valve limits the LS-pressure to two levels. When the solenoid valve MA9107 is without voltage the spring house is connected to tank via the solenoid valve and standard LS-pressure and pump pressure is obtained. This provides a pump pressure of LS + Äp. When the travel or booster function is actuated the solenoid valve MA9107 is with voltage and the spring house becomes pressurized with servo pressure. This causes a raising of the LSpressure, which provides the high pump pressure (power boost). 1. LS - Signal
Picture text:
Safety relief valv
The function of the valve is to prevent pressure peaks in the system, when the spools in the block move to neutral position the opening pressure is 6 M Pa. When operating the machine the opening pressure of the valve is the LS-pressure +6.0 M Pa. 1. From LS channel 2. From pump channel (P) 3. To tank
Picture text:
Arm holding valve
1. Arm out 2. Arm in
Picture text:
Back-up valve
One 7 bar to cooler, controlled by the PWM9104 for the thermostatic function. One 9 bar to the tank.
Picture text:
LS-drain to tank
Picture text:
Refilling valve for travel
This anti-cavitation valve is a non-return valve connected between the travel motor and the hydraulic oil tank. At vacuum pressure in one side of the travel motor, the function of the valve is to refill with oil with the tank line pressure. The bar between the two valves helps to open up the low pressure side.
Picture text:
Hydraulic oil tank, Diagram
6. Valve block MCV (Main Control Valve) 12. Hydraulic driven cooling fan 62. Indicator, hydraulic oil level 64. Drain filter, tank 65. Hydraulic oil tank 66. Return oil filter 67. Air filter breather 68. Hydraulic oil cooler 69. Suction strainer 87. Fan pump
Picture text:
Pivot axle lock
The non return valve with a spring 21:5 helps the spring 21:1b to close when the cylinders are moving. 21. Axle locking cylinder 21:1a. Piston 21:1b. Spring 21:1c. Con 21:2. Channel between piston and Z-channel 21:3. Piston 21:4. Spring housing 21:5. Non-return valve 21:6. Steel ball 21:7. Vent air 21:10 Seal (wiper) 21:8. Ring 21:9. Seal Ring 21:11 and seal MA9108. Solenoid valve control lockout MA9152. Solenoid valve axle lock MA4214. Solenoid valve creep speed (Q-max)
Picture text:
Remote Control Valve
The remote control valve is a pressure reducing valve that is used to control the pilot pressure that is used to move the spool.
Picture text:
Hydraulic system EW180C
Topics: - Main pump, incl. regulating device - Servo pump - Brake/Steering pump - Fan pump - MCV EW180C, incl. component locations - Other hydraulic components, like: Remote control valve, Hydraulic tank, And pivot axle lock - Option hydraulics
Picture text:
Overview, EW180C
A. Right side B. Left side 1. Boom 2. X3 3. X1 4. Bucket 5. Dipperarm 6. Travel 7. Out riggers and support blade 8. X2 9. LS line 10. Main pump 11. Slew Picture text:
Hydraulic diagram, EW180C
Picture text: Press the Adobe PDF file icon for opening and printing the picture in Adobe Rea Reader. der.
Working pumps
1. Accumulator and pressure relief valve for Servo S ervo pump 2. Regulator for Main pump 3. Servo pump 4. Steering and brake pump 5. Main pump 6. Fan pump
Picture text:
Main, Servo, Steering and Brake Pump
1. Control valve 2. Main pump 3. Steering and brake pump 4. Servo pump
Picture text:
Working pump
1. High pressure 2. Low pressure 3. Regulating pressure 4. Control pressure (VD3) 5. External control (not used for EW160B &EW180B) 6. Load sensing pressure from MCV 7. Case pressure 8. Servo cylinder 9. Valve block 10. Working pistons with slipper 11. Servo piston 12. Drive shaft 13. 2-bolt SAE-flange 14. Cylinder barrel 15. Leakage oil to tank 16. Main circuit from tank and to MCV Picture text:
Working pump, Regulating device
1. Set screw delta p 2. Set screw control pressure, VD3
Picture text:
Fan pump
1. Fan motor 2. PMW9103 3. Fan pump
Picture text:
Main valve block
1. X1 Tool 2. Bucket 3. Dipper arm 4. Travel 5. Blade/Out riggers 6. Ls drain to tank 7. Adjustment for main relief pressure pressure 8. Pump valve 9. PWM for Thermostatic function 10. Solenoid for power boost
Picture text:
Valve location
Here you can find out the valve locations on the MCV on the EW180C. MA9107 is the Solenoid valve for power boost.
Picture text: Move the mouse over the shaded areas!
Directional valve
The directional valves on the wheeled excavators consist of several components. A load holding valve and a compensator valve are integrated in the spool.
Picture text:
One movement
This animation describes the working of the load holding valve and the LS signal that regulates the pump.
Picture text:
Two movement
This operation shows how combined operations and different loads influence the load holding valve, compensator in the spool an the regulator on the pump.
Picture text:
Flow dividing
1. Spool controlled by the operator 2. Compensator controlled by the system 3. The operators dream 4. Divided flow
Picture text:
Shock and refilling valve
1. High pressure 2. To tank
Picture text:
Shock and refilling valve
Shock function The pressure from the user side acts a cts on both sides of the piston (1). The piston diameter is larger than the cone diameter which, together with the force from the spring (2) keeps the piston in the closed position. Through the channel in the piston (3) the pressure comes into the chamber (4) and, when the set opening pressure (adjusted with adjusting screw) is reached, the pilot cone (5) ( 5) opens to tank. This causes a pressure-drop in the chamber resulting in both pistons moving to the right and opening a connection between the user side and the tank connection, enabling the pressure to drop. Anti-cavitation function If the pressure on the user side becomes lower than in the tank connection, the pressure from the tank acts on the additional ar ea on the piston (6) and lifts the piston.
Picture text:
LS-pressure relief valve
The valve limits the LS-pressure to two levels. When the solenoid valve MA9107 is without voltage the spring house is connected to tank via the solenoid valve and standard LS-pressure and pump pressure is obtained. This provides a pump pressure of LS + delta-p. When the travel or booster function is actuated the solenoid valve MA9107 is with voltage and the spring house becomes pressurized with servo pressure. This causes a raising of the LSpressure, which provides the high pump pressure (power boost). 1. LS - Signal
Picture text:
Safety relief valv
The function of the valve is to prevent pressure peaks in the system, when the spools in the block move to neutral position the opening pressure is 6 M Pa. When operating the machine the opening pressure of the valve is the LS-pressure +6.0 M Pa. 1. From LS channel 2. From pump channel (P) 3. To tank
Picture text:
Arm holding valve
1. Arm out 2. Arm in
Picture text:
Back-up valves
One 7 bar to cooler and one 9 bar to the tank.
Picture text:
LS-drain to tank
The LS drain to tank valve, makes sure that when the system is not used that the LS regulating regulating pressure is very low and thus making sure that the pump is in minimum displacement.
Picture text:
Boom movement
1. Boom up movement 2. Boom down movement
Picture text:
Hydraulic oil tank, Diagram
6. Valve block MCV (Main Control Valve) 12. Hydraulic driven cooling fan 62. Indicator, hydraulic oil level 64. Drain filter, tank 65. Hydraulic oil tank 66. Return oil filter 67. Air filter breather 68. Hydraulic oil cooler 69. Suction strainer 87. Fan pump
Picture text:
Pivot axle lock
The non return valve with a spring 21:5 helps the spring 21:1b to close when the cylinders are moving. 21. Axle locking cylinder 21:1a. Piston 21:1b. Spring 21:1c. Con 21:2. Channel between piston and Z-channel 21:3. Piston 21:4. Spring housing 21:5. Non-return valve 21:6. Steel ball 21:7. Vent air 21:10 Seal (wiper) 21:8. Seal 21:11 Ring 21:9. Ring and seal MA9108. Solenoid valve control lockout MA9152. Solenoid valve axle lock MA4214. Solenoid valve creep speed (Q-max)
Picture text:
Remote Control Valve
The remote control valve is a pressure reducing valve that is used to control the pilot pressure that is used to move the spool.
Picture text:
X1 Tool
X1 tool or Hammer and Shear function have several different applications, dependent of functions. The machines are always delivered with the same valve for controlling the X1 tool (2). This valve can be used for: - Single acting, one way, without pedal (only Hammer function). - Double acting, with or without pedal. - Flow control (I-ECU). The valve is controlled from the V-ECU. The inputs to the V-ECU can be from the on/off switch joystick or the proportional switch joysticks. In additional, the machines can also be equipped with pressure control for the X1 (I-ECU). To get the expected function you need to have the correct parameter setting in V-CADS PRO. Funktion Parameter Funktion Parameter Code CON_X1 CON _X1_FL _FLOW_ OW_CON CONTRO TROL_O L_OPTI PTION ON BFJ CON_X1_HAM CON_X 1_HAMMER_C MER_CONTROL ONTROL_EL_P _EL_PEDAL EDAL HXW CON_X1_2W CON_X 1_2WAY_SWI AY_SWITCH TCH CVS CON_X1_1W CON_X 1_1WAY_SWI AY_SWITCH TCH FYW CON_X1_PR CON_X 1_PROPORT OPORTIONAL_ IONAL_CONTRO CONTROLL FYV CON_X1_PRESETTING_CONTROL FYX PAR_ PAR_X1 X1/X /X3 3P PIN IN CODE CODE OPTI OPTION ON HX HXZ Z
Picture text:
Control valve
Valve for flow control and single/double acting of X1 tool 1. MA9103, Left side (A side, hammer) 2. MA9104, Right side, side, in case of double acting (B-side) 3. PWM9109, Flow control 4. Ports for X1 pedal 5. Port for main valve A side 6. Port for main valve B side
Picture text:
X1 Pressure control
1. Pressure control valve 2. Pressure relief valves
Picture text:
X1 Pressure control valve
The pressure value is set in I-ECU and the valve is controlled from the V-ECU. 1. PWM9123 for pressure control on X1
Picture text:
X3 Rotator
In the IECU the operator can choose between different control modes. These setting is in dependency of the installed option: Push, Toggle and Proportional. A parameter is needs to be activated in VCADSPRO: - CON_X3 CONTROL parameter BFK BFK 1. PWM9105 X3 left side on boom 2. PWM9106 X3 right side on boom 3. Flow control, max 60 l/min 4. Pressure control 5. Pressure relief valves
Picture text:
X3 Rotator, diagram
Operating to the leftWhen the servo pressure passes through the proportional valvePWM9105 it change to be a control pressure. The control pres-sure continue and a nd activates the controls pool's S left side. Thepump flow now passes through the spool to the X3 equipment.The return flow from the X3 equipment passes through the spooland via the main control valve (MCV) to the tank.The flow for the equipment can be adjusted from 6 60 l/min.(1.59 15.9 US gal/min.) with the adjust adjustable able restriction valve D4 D4.The .The pump pressure for the equipment is adjusted with the pres-sure limiting valve A:3.NOTE! The maximum pump pressure for the pressure limitingvalve A:3 is 23 MPa (3340 psi) and for the shock and refillingvalves A:1 and A:2 25 MPa (3630 psi). The pressure limiting valveshould always be set 2 MPa (290 psi) lower than the shock andrefilling valves. A:1. Shock and refilling valve A:2. Shock and refilling valve A:3. Pressure limiting valve B. Non return valve C. Pressure reducing valve D1. Restriction for LS-pressureto valves A:3 and C D2. Restriction for valve C regulation D3. Resctriction for LS-signal D4. Adjustable restriction valve for the flow PWM9105. Proportional valve, X3 leftc PWM9106. Proportional valve, X3 right S. Control spoole X3V. Control valve X3
Picture text:
Cruise control
This function works in two ways: - When HIGH speed is selected (Hare) the function follows the requested speed from the travel pedal sensor. - When LOW or CREEP speed is selected (Turtle or Snail) the function is the same as for High speed but you can also change the speed with help of the keypad. Use arrow up and down to change the speed in 5% steps. A parameter needs to be connected in VCADSPRO: - CON CRUISE CONTROL PPV parameter BFO 1. PWM4211
Picture text:
Quick fit
A: Tank pressure B: Servo and control pressure C: Pump pressure D: LS pressure E: Trapped oil
Picture text:
Valve for quick fit
The location of the valve for the quick fit is underneath the boom attachment
Picture text:
Support blade and outriggers
Support blade up A: Front B: Left side of MCV C: Rear right D: Rear left
Picture text:
Float position
1: From main valve port PZAV 2: To main valve port TZAV 3: To swing drive port LS
Picture text:
View more...
Comments
