PC130-7
January 3, 2017 | Author: Fernando Sabino | Category: N/A
Short Description
Download PC130-7...
Description
SEBM036300
MACHINE MODEL
SERIAL NUMBER
PC130-7
70001 and up
• This shop manual may contain attachiments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. • PC130-7 mounts the SAA4D95LE-3 engine. For details of the engine, see the 95-3 Series Engine Shop Manual.
© 2004 All Rights Reserved Printed in Japan 03-04(02)
00-1
CONTENTS No. of page
01
GENERAL ................................................................................................................01-1
10
STRUCTURE AND FUNCTION .................................................................10-1
20
TESTING AND ADJUSTING .......................................... To be issued next time
30
DISASSEMBLY AND ASSEMBLY ............................. To be issued next time
40
MAINTENANCE STANDARD......................................................................40-1
90
OTHERS ....................................................................................................................90-1
00-2
PC130-7
01 GENERAL
GENERAL ASSEMBLY DRAWING ........................................... 01-2 SPECIFICATIONS ..................................................................... 01-4 WEIGHT TABLE ........................................................................ 01-7 LIST OF LUBRICANTS AND WATER ....................................... 01-9
PC130-7
01-1
GENERAL
GENERAL ASSEMBLY DRAWING
GENERAL ASSEMBLY DRAWING SPECIFICATION DIMENSIONAL DRAWING
Item
Unit
PC130-7 2.5 m arm, 500 mm shoe
3.0 m arm, 700 mm shoe
A
Overall length
mm
7,595
7,485
B
Overall height
mm
2,810
3,170
C
Overall width
mm
2,490
2,490
D
Shoe width
mm
500
700
E
Cab height
mm
2,810
2,810
F
Trail swing radius
mm
2,190
2,190
G
Crawler overall length
mm
3,610
3,610
H
Distance between tambler center
mm
2,880
2,880
01-2
PC130-7
GENERAL
GENERAL ASSEMBLY DRAWING
WORKING RANGE DRAWING
Working range (mm)
PC130-7 2.5 m arm
3.0 m arm
A
Maximum digging radius
8,290
8,785
B
Maximum digging depth
5,520
6,015
C
Maximum digging height
8,610
8,790
D
Maximum vertical wall digging depth
4,940
5,360
E
Maximum dumping height
6,170
6,535
F
Minimum swing radius of work equipment
2,450
2,610
G
Maximum reach at ground level
8,170
8,665
PC130-7
01-3
GENERAL
SPECIFICATIONS
SPECIFICATIONS PC130-7
Machine model
2.5 m arm, 500 mm shoe
Bucket capacity (SAE)
0.5
0.5
Operating weight
kg
12,200
13,050
Max. digging depth
mm
5,520
6,015
Max. vertical wall depth
mm
4,940
5,360
Max. digging reach
mm
8,290
8,785
Max. reach st ground level
mm
8,170
8,665
Max. digging height
mm
8,610
8,970
Max. dumping height
mm
6,170
6,535
kN {kg}
93.2 {9,500}
93.2 {9,500}
Swing speed
rpm
11.0
11.0
Swing max. slope angle
deg.
2.0
2.0
Travel speed (Hi/Lo)
km/h
2.7/5.5
2.7/5.5
Gradeability
deg.
35
35
Ground pressure
{kg/cm 2}
38 {0.39}
29 {0.30}
7,595
7,485
Max. digging force (bucket)
Dimension
Overall length (for transport)
kPa
mm
Overall width
mm
2,490
2,490
Overall height (for transport)
mm
2,810
3,170
Overall height to top of cab
mm
2,730
2,730
Ground clearance of counterweight
mm
855
855
Min. ground clearance
mm
400
400
Tail swing radius
mm
2,190
2,190
Min. swing radius of work euipment
mm
2,450
2,450
Height of work equipment at min. swing radius
mm
6,455
6,455
Length of track on ground
mm
3,610
3,610
Distance between tumbler center
mm
3,880
3,880
Track gauge
mm
1,990
1,990
Overall height of machine cab
mm
1,885
1,885
Model
SAA4D95LE-3
Type
4-cycle, water-cooled, in-line, vertical, direct injection, with turbochatger, after cooler
No. of cylinders-bore x stroke
mm
4 – 95 x 115
l {cc}
3.260 {3,260}
Rated horsepower
kW/rpm{HP/rpm}
66.2/2,200 {88.7/2,200}
Max. torpue
Nm/rpm{kgm/rpm}
353/1,500 {36.0/1,500}
High idling speed
rpm
2,400
Low idling speed
rpm
1,100
g/kWh{g/HPh}
224 {165}
Performance
Piston displacement Engine
70001 and up m3
Working ranges
Performance
Serial No.
3.0 m arm, 700 mm shoe
Min. fuel consumption ratio
01-4
PC130-7
GENERAL
SPECIFICATIONS
PC130-7
Machine model
2.5 m arm, 500 mm shoe
Serial No.
70001 and up 24V, 3.0 kw
Alternator
24V, 25A
Battery
12V, 64 Ah x 2
Radiator type
Aluminum wave (4-line)
Carrier roller
1 on each side
Track roller
7 on each side
Track shoe (iron shoe)
Asembly-type triple grouster, 43 on each side
Hydraulic pump
(road liner) Type x no.
Hydraulic motor Control valve
Type x no.
Road liner, 43 on each side Variable displacement piston type x 1
Discharge Set pressure (at operation)
l /min
226 (at 2,200rpm)
MPa {kg/cm2}
31.9 {325}
(at traveling)
34.8 {355} 7-spool type x 1
Control method
Hydraulic type
Travel motor
Variable displacement piston type (with brake valve, holding brake) x 2
Swing motor
Fixed displacement piston type (with safety valve, holding brake) x 1
Hydraulic tank
Box-shaped, open
Hydraulic filter
Tank return side
Hydraulic cooler
Air cooled
PC130-7
Boom cylinder
Work equipment cylinder
Type
Reciprocating piston tipe
Reciprocating piston tipe
Cylinder inner diameter
mm
105
105
Piston rod diameter
mm
70
70
Stroke
mm
990
990
Max. length betwiin pins
mm
2,490
2,490
Min. length betwiin pins
mm
1,500
1,500
Reciprocating piston tipe
Reciprocating piston tipe
Type Arm cylinder
Undercarriage
Engine
Starting motor
Hydraulic system
3.0 m arm, 700 mm shoe
Cylinder inner diameter
mm
115
115
Piston rod diameter
mm
75
75
Stroke
mm
1,175
1,175
Max. length betwiin pins
mm
2,877
2,877
Min. length betwiin pins
mm
1,702
1,702
01-5
GENERAL
SPECIFICATIONS
PC130-7
Machine model
2.5 m arm, 500 mm shoe
01-6
70001 and up
Type Bucket cylinder
Work equipment cylinder
Hydraulic system
Serial No.
3.0 m arm, 700 mm shoe
Reciprocating piston tipe
Reciprocating piston tipe
Cylinder inner diameter
mm
95
95
Piston rod diameter
mm
65
65
Stroke
mm
885
885
Max. length betwiin pins
mm
2,263
2,263
Min. length betwiin pins
mm
1,378
1,378
PC130-7
GENERAL
WEIGHT TABLE
WEIGHT TABLE
k
This weight table is a guide for use when transporting or handling component. Unit: kg Machine model
PC130-7
Serial No.
70001 and up
Engine assembly (excl. water, oil)
449
• Engine (excl. water, oil)
345
• Engine mount
19.6
• PTO
4.1
• Hydraulic pump
80
Radiator, oil cooler assembly
83
Revolving frame
1,110
Operator's cab
279
Operator's seat
35
Fuel tank (excl. fuel)
101
Hydraulic tank (excl. hydraulic oil)
89
Control valve
116
Self pressure reducing valve
4.8
Counterweight
2,455
Swing motor (with brake valve)
26
Swing circle
155
Swing machinery
72.2
Center swivel joint
28.6
Track frame assembly
2,260
• Track frame
1,280
• Idler assembly
79 x 2
• Recoil spring assembly
69.5 x 2
• Carrier roller
16.5 x 2
• Track roller
21 x 14
• Travel motor, final drive assembly
144 x 2
• Sprocket
33.7 x 2
Track shoe assembly • Triple grouser shoe (500mm)
725 x 2
• Triple grouser shoe (600mm)
815 x 2
• Triple grouser shoe (700mm)
905 x 2
• City pad shoe (500mm)
720 x 2
• Road liner (500mm)
780 x 2
PC130-7
01-7
GENERAL
WEIGHT TABLE
Unit: kg Machine model
PC130-7
Serial No.
70001 and up
Boom assembly
1,088
Arm assembly
392.4
Bucket link assembly
92.7
Bucket assembly
369
Boom cylinder assembly
92.7
Arm cylinder assembly
135
Bucket cylinder assembly
82.6
01-8
PC130-7
GENERAL
LIST OF LUBRICANTS AND WATER
LIST OF LUBRICANTS AND WATER
RESERVOIR
KIND OF -22 FLUID -30
AMBIENT TEMPERATURE -4 -20
14 -10
32 0
50 10
68 20
CAPACITY ( ) 86 30
104°F 40°C
Specified
Refill
17.5
16
0.75
0.75
2.5
2.5
2.5
2.5
0.090 --0.105
0.090 --0.105
0.075 --0.085
0.075 --0.085
0.068 --0.076
0.068 --0.076
140
90
SAE 30 SAE 10W
Engine oil pan
SAE 10W-30 SAE 15W-40 PTO case Swing machinery case Final drive case (each)
SAE 30 Engine oil
Idler (each) Track roller (each)
SAE 30
Carrier roller (each) SAE 10W SAE 10W-30
Hydraulic system
SAE 15W-40 Hydraulic oil
Fuel tank
HD46-HM (a) ASTM D975 No.2
Diesel fuel
240
ASTM D975 No. 1 Cooling system
PC130-7
Coolant
Add antifreeze
18.2
01-9
10 STRUCTURE AND FUNCTION
PTO ...........................................................................10- 2 COOLING SYSTEM ..................................................10- 3 POWER TRAIN .........................................................10- 5 SWING CIRCLE ........................................................10- 6 SWING MACHINERY................................................10- 7 TRACK FRAME.........................................................10- 8 IDLER CUSHION ......................................................10- 9 HYDRAULIC COMPONENT LAYOUT ......................10- 10 VALVE CONTROL.....................................................10- 12 HYDRAULIC TANK AND FILTER..............................10- 14 HYDRAULIC PUMP (PISTON PUMP) ......................10- 15 CONTROL VALVE .....................................................10- 36 SUCTION SAFETY VALVE .......................................10- 46 CLSS .........................................................................10- 47 SELF PRESSURE REDUCING VALVE ....................10- 79 CENTER SWIVEL JOINT..........................................10- 86 TRAVEL MOTOR (FINAL DRIVE).............................10- 87 SWING MOTOR ........................................................10- 96 SOLENOID VALVE....................................................10-102 PPC ACCUMULATOR...............................................10-104 PPC VALVE ...............................................................10-105 WORK EQUIPMENT ................................................. 10-116 AIR CONDITIONER PIPING ..................................... 10-117 ENGINE CONTROL ..................................................10-118 ELECTRIC CONTROL SYSTEM ..............................10-123 MONITOR SYSTEM..................................................10-150
PC130-7
10-1
STRUCTURE AND FUNCTION
PTO
PTO
1. 2. 3. 4.
Coupling Shaft Cage Hydraulic pump
10-2
5. Level plug 6. Oil filler plug 7. Breather
PC130-7
STRUCTURE AND FUNCTION
COOLING SYSTEM
COOLING SYSTEM
PC130-7
10-3
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5. 6. 7. 8.
COOLING SYSTEM
9. 10. 11. 12. 13. 14. 15. 16.
Reservoir tank Shroud Oil cooler Fan Radiator Fan guard Oil cooler Radiator cap
Charge air inlet hose Radiator inlet hose Charge air outlet hose Oil cooler outlet Drain valve Radiator outlet hose Air condenser Oil cooler inlet
SPECIFICATION Radiator
Oil cooler
Charge air cooler
Aluminum wave (4-line)
CF40
Aluminum wave
(mm)
3.5/2
3.5/2
4.0/2
(m 2)
25.58
11.60
9.54
Pressure valve cracking pressure (kPa {kg/cm2})
49.0 ± 14.7 {0.5 ± 0.15}
—
—
Vacuum valve cracking pressure (kPa {kg/cm2})
-4.9 – 0 {-0.05 – 0}
—
—
Core type Fin pitch Total heat dissipation surfase
10-4
PC130-7
STRUCTURE AND FUNCTION
POWER TRAIN
POWER TRAIN
1. 2. 3. 4. 5. 6. 7.
Idler Control valve Self pressure reducing valve Travel motor Hydraulic pump Engine 2-stage relief solenoid valve
PC130-7
8. 9. 10. 11. 12. 13. 14.
Swing hold brake solenoid valve 2-speed travel changeover solenoid valve PPC lock solenoid valve Swing motor Center swivel joint Swing machinery Swing circle
10-5
STRUCTURE AND FUNCTION
SWING CIRCLE
SWING CIRCLE
1. Outer race 2. Ball 3. Inner race a. Inner race soft zone "S" position b. Outer race soft zone "S" position
10-6
SPECIFICATIONS Reduction ratio: – 90 = – 8.182 11 Amount of grease: 6.5
l (Grease: G2-LI)
PC130-7
STRUCTURE AND FUNCTION
SWING MACHINERY
SWING MACHINERY
1. 2. 3. 4. 5. 6. 7. 8. 9.
Swing pinion (No. of teeth: 11) Case No. 2 sun gear (No. of teeth: 17) No. 2 planetary carrier (No. of teeth: 17) Ring gear (No. of teeth: 61) No. 1 planetary carrier (No. of teeth: 17) No. 1 sun gear (No. of teeth: 14) Oil level gauge/ oil filler port Swing motor
PC130-7
10. 11. 12. 13.
No. 1 planetary gear (No. of teeth: 24) No. 2 planetary gear (No. of teeth: 22) Drain plug Swing circle
SPECIFICATION + 61 + 61 Reduction ratio: 14 14 x 17 17 = 24.58
10-7
STRUCTURE AND FUNCTION
TRACK FRAME
TRACK FRAME
1. 2. 3. 4.
Idler Track frame Carrier roller Travel motor
10-8
5. 6. 7. 8.
Sprocket Track roller Idler cushion Track shoe
PC130-7
STRUCTURE AND FUNCTION
IDLER CUSHION
IDLER CUSHION
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Idler Support Yoke Cylinder Recoil spring U-packing Pilot Nut Valve Grease fitting
PC130-7
SPECIFICATION Grease : G2-LI Amount of filled grease : 140 m
l
10-9
STRUCTURE AND FUNCTION
HYDRAULIC COMPONENT LAYOUT
HYDRAULIC COMPONENT LAYOUT
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
11. 12. 13. 14.
Bucket cylinder Arm cylinder Boom cylinder Hydraulic tank Swing motor Hydraulic pump Oil cooler L.H. travel motor Control valve 4-spool solenoid valve • PPC lock • 2-speed travel speed selection • Swing holding brake • 2-stage relief L.H. PPC valve R.H. PPC valve Travel PPC valve Center swivel joint
10-10
PC130-7
STRUCTURE AND FUNCTION
PC130-7
HYDRAULIC COMPONENT LAYOUT
10-11
STRUCTURE AND FUNCTION
VALVE CONTROL
VALVE CONTROL
10-12
PC130-7
STRUCTURE AND FUNCTION
VALVE CONTROL
1. R.H. work equipment PPC valve 2. R.H. work equipment control lever (for boom and bucket operation) 3. Main pump 4. Control valve 5. 4-spool solenoid valve 6. L.H. work equipment control lever (for arm, swing operation) 7. L.H. work equipment PPC valve 8. Safety lock lever 9. L.H. travel pedal 10. R.H. travel pedal 11. L.H. travel lever 12. R.H. travel lever 13. Travel PPC valve 14. Attachment PPC valve (Attachment installable machine) 15. Attachment pedal (Attachment installable machine) Lever and Pedal Positions (A) HOLD (B) Boom LOWER (C) Boom RAISE (D) Bucket CURL (E) Bucket DUMP (F) HOLD (G) Arm OUT (H) Arm IN (J) Swing LEFT (K) Swing RIGHT (L) L.H. travel FORWARD (M) L.H. travel REVERSE (N) R.H. travel FORWARD (P) R.H. travel REVERSE (Q) PPC FREE (R) PPC LOCK
PC130-7
10-13
STRUCTURE AND FUNCTION
HYDRAULIC TANK AND FILTER
HYDRAULIC TANK AND FILTER
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Hydraulic tank Drain plug Oil filler cap Pressure valve Vacuum valve Sight gauge Suction strainer Filter element Bypass strainer Bypass valve
10-14
SPECIFICATION Tank capacity : 130 Hydraulic oil amount in tank : 90 Pressure valve cracking pressure : 16.7 ± 6.9 kPa {0.17 ± 0.07 kg/cm2} Vacuum valve cracking pressure : -0.49 – 0 kPa {-0.005 – 0 kg/cm2} Bypass valve set pressure : 103 ± 29.4 kPa {1.05 ± 0.2 kg/cm2}
l
l
PC130-7
STRUCTURE AND FUNCTION
HYDRAULIC PUMP
HYDRAULIC PUMP (PISTON PUMP) MAIN PUMP Type : HPV95 (for 105cc/rev.)
1. 2. 3. 4. 5. 6.
Main pump LS valve PC valve Fixed choke valve PC-EPC valve (for PC mode selection) LS-EPC valve (for LS set selection)
PC130-7
IM : PC mode change current PA : Main pump delivery PB : Main pump pressure input PS : Main pump absorption PD1 : Case drain PLS : Control valve LS pressure inlet PEPC : EPC valve basic pressure inlet
10-15
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5. 6. 7.
Shaft Cradle Case Rocker cam Shoe Piston Cylinder block
10-16
HYDRAULIC PUMP
8. 9. 10. 11. 12. 13.
Valve plate End cap Spring Servo last chance filter Servo piston Slider
PC130-7
STRUCTURE AND FUNCTION
HYDRAULIC PUMP
FUNCTION • This pump converts engine rotation and torque transmitted to the pump shaft into hydraulic energy and discharges pressurized oil according to load. • This pump can change delivery when the swash plate angle is changed.
STRUCTURE • The cylinder block (7) is supported to the shaft (1) with the spline a, and the shaft (1) is supported with the front and rear bearings. • The shoe (5) is punched to the tip of the piston (6) with a concave ball so that the piston (6) and the shoe (5) form a spherical bearing. • The shoe (5) is always pressed to the plane A of the rocker cam (4) and slides in a circle. The rocker cam (4) leads highly pressurized oil together with the cylindrical plane B with the cradle (2) fixed to the case, forms a static pressure bearing and slides. • The piston (6) moves in the axial direction relatively in each cylinder of the cylinder block (7). • The cylinder block (7) rotates relatively while sealing pressurized oil against the valve plate (8), and the plane is designed to balance the oil pressure properly. • Oil in each cylinder of the cylinder block (7) is absorbed and discharged through the valve plate (8). PC130-7
10-17
STRUCTURE AND FUNCTION
HYDRAULIC PUMP
OPERATION 1. Pump Operation • The shaft (1) rotates together with the cylinder block (7), and the shoe (5) slides on the plate A. When the rocker arm (4) moves along the cylindrical plane B, the inclination to the centerline X of the rocker cam (4) and the axial direction of the cylinder block (7) changes. The inclination is called "swash plate angle."
•
•
•
•
•
When the swash plate angle of the center line X of the rocker cam (4) is to the axial direction of the cylinder block (7), the plane A works like the cam against the shoe (5). Therefore, the piston (6) slides inside the cylinder block (7), and the capacities E and F of the cylinder block (7) come to change differently. Then, the pump absorbs and discharges the difference E-F. When the capacity in the E chamber contracts as the cylinder block (7) rotates, the pump discharges oil during the process. On the other hand, when the capacity in the F chamber increases, the pump absorbs oil during the process. (The figure shows the end of the absorbing process in the Chamber F and the end of the discharging process in the Chamber E. When the centerline X of the rocker cam (4) comes to the axial direction of the cylinder block (7) (when the swash plate angle is 0), the difference between the capacities E and F in the cylinder block (7) comes to 0. And the pump comes to stop absorbing or discharging oil, i.e., the pump stops. (However, the swash plate angle never comes to 0 practically.) In the other words, the swash plate angle and the pump delivery are in the proportional relations.
10-18
PC130-7
STRUCTURE AND FUNCTION
HYDRAULIC PUMP
2. Delivery Control • When the swash plate angle increases, the difference between the capacities E and F becomes larger and the delivery Q increases. The servo piston (12) changes the swash plate angle . • The servo piston moves in the direction of straight reciprocation according to signal pressures of the PC and LS valves. This straight motion is transmitted to the rocker arm (4) through the slider (13), and the rocker cam (4), which is supported with the cylindrical plane to the cradle (2), slides in the direction of rotation.
•
•
•
The servo piston's (12) area receiving the pressure is different on the right and left sides, and the discharge (self) pressure PP from the main pump is always led to the pressure chamber of the small diameter piston. The output pressure Pen of the LS valve is led to the pressure chamber of the large diameter piston. Motions of the servo piston are controlled according to the relations between the small diameter piston pressure PP and the large diameter piston pressure Pen and the rate of area receiving pressure of the small diameter piston to that of the large diameter piston.
PC130-7
10-19
STRUCTURE AND FUNCTION
HYDRAULIC PUMP
LS AND PC VALVE LS valve
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Sleeve Piston Spool Seat Plug Spring Sleeve Nut O-ring Nut
PA : Pump pressure inlet PB : Pump pressure inlet PDP : Drain PLP : Control pressure outlet PLS : Over load pressure inlet PPL : Control pressure intle PSIG : LS mode switching pressure inlet
PC Valve
1. 2. 3. 4. 5. 6. 7. 8. 9.
Piston Spring Seat Spring Seat Spool Piston Sleeve Lock nut
10-20
10. Plug 11. Lock nut PA PA2 PD PM PPL
: Pump discharge pressure inlet : Pump discharge pressure inlet : Drain pressure outlet : PC mode switching pressure inlet : PC valve signal pressure outlet
PC130-7
STRUCTURE AND FUNCTION
HYDRAULIC PUMP
FIXED THROTTLE VALVE
1. Plug 2. Plug PA : Drain pressure outlet POUT : Control pressure outlet PIN : LS valve signal pressure inlet
PC130-7
10-21
STRUCTURE AND FUNCTION
HYDRAULIC PUMP
FUNCTION 1. LS Valve • The LS valve detects loads and controls delivery. • This valve controls the main pump delivery Q with the differential pressure PLS (PP – PLS) [that is called LS Differential Pressure] between the main pump pressure PP and the control valve outlet pressure PLS. • This valve is applied with the main pump pressure PP, the pressure PLS that is obtained from the control valve output [that is called LS Pressure] and the pressure PSIG from the LS-EPC valve [that is called LS Selection Pressure]. • The relations of the differential pressure PLS (= PP – PLS) between the main pump pressure PP and the LS pressure PLS with the delivery Q vary with the LS selection current ISIG of the LSEPC valve as shown in the right figure. • As ISIG changes from 0 to 1A, the spring set force changes accordingly, and the selector point for pump discharge amount changes from 0.64 to 2.1 MPa {6.5 to 21.5 kg/cm2} at the standard median. 2. PC Valve • When the pump discharge pressure PP rises, the control valve spool stroke will increase and the opening area will enlarge. So, the PC valve controls the pump delivery Q so that the delivery Q does not increase above a certain level depending on the discharge pressure PP. The valve also controls the pump absorbing hydraulic horsepower to approximately equal horsepower so that the pump absorbing horsepower does not exceed the engine horsepower. • This means that, when a load to the actuator increases during operation and the pump discharge pressure PP rises, this valve will reduce the pump delivery Q, or when the pump discharge pressure PP drops, this valve will increase the delivery Q. • In this case, the relations between the pump discharge pressure PP and the pump delivery Q change as shown in the right figure since the current value given to the PC-EPC valve solenoid is regarded as a parameter. • However, some PC valves have the function to sense actual engine speeds in the heavy-duty operation mode and to reduce the pump delivery and recover the speed when the speed reduces due to increase of load. • In the other words, when an increase of load reduces the engine speed below the set value, the command current from the controller to the PC-EPC valve solenoid will increase as the engine speed reduces and will reduce the pump swash plate angle.
10-22
PC130-7
STRUCTURE AND FUNCTION
HYDRAULIC PUMP
OPERATION
1. LS Valve 1) When the control valve is at the center value position • The LS valve is a 3-way selector valve, and the pressure PLS (LS pressure) from the control valve inlet is being led to the spring chamber B and the pump discharge pressure PP is being led to the H port of the sleeve (8). • The spool (6) position is determined depending on the force of the LS pressure PLS + the force of spring (4) Z and the force of the pump discharge pressure (self-pressure) PP.
PC130-7
10-23
STRUCTURE AND FUNCTION
•
•
•
HYDRAULIC PUMP
Before the engine starts, the servo piston (12) is pressed to the right side. (See the right figure.) If the control lever is at the "center value" position when the engine starts, the LS pressure PLS will be 0 MPa (0 kg/cm2). (The LS valve interconnects to the drain circuit through the control valve spool.) At the time, the spool (6) is pressed to the left side and the C port is connected to the D port. The pump discharge pressure enters from the K port to the piston large diameter side and from the J port to the piston small diameter side respectively. So, the area difference of the servo piston (12) minimizes the swash plate angle.
10-24
PC130-7
STRUCTURE AND FUNCTION
2) Operation in direction for maximum pump delivery • When the LS differential pressure PLS between the pump discharge pressure PP and the LS pressure PLS reduces (when the control valve is large and the discharge pressure PP drops, for example), the combined force of the LS pressure PLS and the spring (4) pushes the spool (6) to the right side. • When the spool (6) moves, port D is connected to port E to bring the PC valve in line. At the time, the PC valve is connected to the drain port, and the circuit D – K is applied with the drain pressure PT. (The operation of the PC valve will be explained later.)
PC130-7
HYDRAULIC PUMP
•
•
•
Therefore, the pressure on the piston large diameter side of the servo piston (12) comes to the drain pressure PT, and since the pump dischargepressure PP is applied to port J on the small diameter side, the servo piston (12) is pushed to the right side and the swash plate is moved to the delivery increasing direction. When port G is applied with the output pressure of the EPC valve for the LS valve, the piston (7) is pushed to the left side. This is effective to reduce the spring (4) set force, and the differential pressure between the oil pressure PP when ports D and E of the spool (6) are connected and PP changes.
10-25
STRUCTURE AND FUNCTION
3) Operation in direction for minimum pump delivery • The following explains move of the servo piston (12) to the left side (in the direction for minimum pump delivery). When the LS differential pressure PLS increases (when the control valve opening area becomes small and the pump discharge pressure PP increases, for example), the force of the discharge pressure PP pushes the spool (6) to the left side. • As the spool (6) moves, the pump discharge pressure PP flows from port C to port D and comes from port K to the piston large diameter side.
10-26
HYDRAULIC PUMP
•
•
Though the pump discharge pressure PP comes to port J of the piston small diameter side, the servo piston (12) is pushed to the left side due to the area difference between the piston large diameter side and the piston small diameter side of the servo piston (12) and the swash plate is moved in the delivery reducing direction. When port G is applied with the LS selection pressure, it is effective to reduce the spring (4) set force.
PC130-7
STRUCTURE AND FUNCTION
4) When the servo piston balances • The area receiving the pressure on the piston large diameter side is supposed to be A1, the one on the small diameter side is supposed to be A0 and the pressure flowing to the piston large diameter side is supposed to be PEN. • When the pump discharge pressure PP of the LS valve balances with the combined force of the LS pressure PLS and the spring (4) force Z and the relations of A0 x PP = A1 x PEN are satisfied, the servo piston (12) stops at the position and the swash plate is held at the intermediate position (stops where the opening from port D to port E of the spool (6) is almost equal to the one from port C to port D). PC130-7
HYDRAULIC PUMP
•
•
•
At the time, the relations of areas receiving the pressure on the both ends of the servo piston (12) are A0 : A1 = 1 : 1.75, and the ones of pressures applied on the piston both ends at the balancing time are PP : PEN = 1.75 : 1 approximately. The spring (4) force has been adjusted so that the balance stop position of the spool (6) is determined when PP – PLS = 2.21 MPa {22.5 kg/cm 2 } is satisfied at the standard center. When port G is applied with PSIG (EPC valve output pressure for LS valve of 0 – 2.9 MPa {10 – 30 kg/cm 2 }), however, the balance stop position changes proportionally to the PSIG pressure in the range of PP – PLS from 2.1 to 0.6 MPa {21.5 to 6.5 kg/cm2}.
10-27
STRUCTURE AND FUNCTION
2. PC Valve (1) When the pump controller is normal, the load to the actuator is small and the pump discharge pressure PP is low 1) Function of PC-EPC Valve Solenoid (1) • The pump controller provides a command current to the PC-EPC valve solenoid (1). This command current actuates the PC-EPC valve and outputs a signal pressure. When receiving the signal pressure, the PC valve changes the force given to the piston (2). • The spool (3) stops where the force to the piston (2) balances with the combined force of the spring setting force of the springs (4) and (6) on the opposite side and the force given to the spool (3) by the pump discharge pressure PP.
10-28
HYDRAULIC PUMP
•
And the pressure output from the PC valve (the pressure at the C port) varies with the spool position. The value of the command current X is determined depending on type of work (lever control), selection of working mode, set point of engine speed and actual speed.
PC130-7
STRUCTURE AND FUNCTION
2) Function of Spring • The loads to the springs (4) and (6) of the PC valve are determined depending on swash plate position. • As the servo piston (9) moves, the piston (7) connected to the slider (8) moves to the right or the left. • When the piston (7) moves to the left, the spring (6) will be contracted. If the piston moves further to the left, the spring will be brought to the seat (5) and be fixed there. Thereafter, the spring (4) will only move. This means that the spring load changes as the piston (7) extends or contracts the springs (4) and (6).
PC130-7
HYDRAULIC PUMP
•
•
Also, since the pressing force of the piston (2) changes as the command current input to the PC-EPC valve solenoid (1) changes, the load to the springs (4) and (6) changes depending on the value of the command current. The C port of the PC valve is connected to the E port of the LS valve. The self pressure PP is provided to the A port, the small diameter side of the servo piston (9) and the B port.
10-29
STRUCTURE AND FUNCTION
•
•
•
10-30
HYDRAULIC PUMP
When the pump discharge pressure PP is small, the spool is located at a position in the left direction. At the time, the C port is connected to the D port, and the pressure to the LS valve becomes the drain pressure PT. If the E port of the LS valve is connected to the G port at the time, the pressure from the J port to the large diameter side of the piston will become the drain pressure PT. And the servo piston will moves to the right side. Then, the pump delivery will come to increase. Also, as the servo piston (9) operates, the slider (8) moves the piston (7) to the right side, and the spring force becomes weak because the springs (4) and (6) expand. As the spring force becomes weak, the spool (3) moves to the right side to disconnect the C port from the D port. Then, the pump discharge pressure ports B and C are connected. As a result, the pressure at the C port rises and the pressure on the large diameter side of the piston rises as well, and the servo piston (9) stops moving to the right side. This means that the stop position of the servo piston (9) (= pump delivery) is determined where the pressing force caused the pressure PP to the spool (3), the pressing force of the PCEPC valve solenoid and the forces of the springs (4) and (6) balance with each other.
PC130-7
STRUCTURE AND FUNCTION
(2) When the pump controller is normal, the load to actuator is large and the pump discharge pressure PP is high • When the load is large and the pump discharge pressure is high, the force pushing the spool (3) to the left side increases and the spool (3) comes to the position shown in the above figure. • Then, the pressure flowing from the C port to the LS valve becomes about 3/5 of the pump discharge pressure PP because the pressure from the A port partly flows from the C port to the D port through the LS valve as shown in the above figure.
PC130-7
HYDRAULIC PUMP
•
•
When the E port of the LS valve is connected to the G port, this pressure is led from the J port to the large diameter side of the servo piston (9) and the servo piston comes to stop. When the pump discharge pressure PP increase and the spool (3) moves further to the left side, the discharge pressure PP will flow to the C port so as to minimize the pump delivery.
10-31
STRUCTURE AND FUNCTION
•
•
HYDRAULIC PUMP
When the servo piston (9) moves to the left side, the piston (7) will move to the left. Then, the springs (4) and (6) will be compressed and will push the spool (3) back. If the piston (7) moves further to the left, the ports C and D will open wide. As a result, the pressure at the port C (= J) will drop, and the servo piston (9) will move to the left and will stop. At the time, the servo piston (9) is located further to the left than where it is when the pump discharge pressure PP is low.
•
The positional relations between the pump discharge pressure PP and the servo piston (9) are shown by a broken line because the springs (4) and (6) are 2-stage ones. And the relations between the discharge pressure PP and the pump delivery Q are as shown in the right figure.
•
Also, when the command current X to the PC-EPC valve solenoid increases, the relations between the pump discharge pressure PP and the pump delivery Q will move in parallel in relation to the pushing force of the PC-EPC valve solenoid. Therefore, the force of the PC-EPC valve solenoid (1) will be added to the leftward pressing force of the discharge pressure PP to the spool (3), and the relations between PP and Q will move from to as X increases.
10-32
PC130-7
STRUCTURE AND FUNCTION
3) When the pump controller is out of order and the PC redundant switch is set to ON 1) In case of light load to main pump • When the pump controller is out of order, set the PC redundant switch to ON to change the circuit to the resistor side. In this case, since the current is too large when the power is directly taken from the battery, the resistor is connected to control the current to the PC-EPC valve solenoid. • At the time, the current becomes constant and the piston (2) pressing force becomes constant as well.
PC130-7
HYDRAULIC PUMP
•
•
When the pump discharge pressure is low, the combined force of the force of the PC-EPC valve solenoid (1) and the discharge pressure PP is smaller than the spring set force. So, the spool (3) balances at a position in the left side. At the time, the C port has the same pressure as the drain pressure at the D port, and the drain pressure PT is led to the large diameter side of the servo piston (9) through the LS valve. Then, the servo piston (9) moves in the diction where the delivery increases because the pressure on the small diameter side of the piston is large.
10-33
STRUCTURE AND FUNCTION
HYDRAULIC PUMP
2) In case of heavy load to main pump • When the PC redundant switch is set to ON just like in the previous paragraph, a constant command current is sent to the PC-EPC valve solenoid (1). So, the piston (2) pushes the spool (3) with a constant force. • When the pump discharge pressure PP rises, the spool will moves further to the left side than when the main pump is lightly loaded and will balance at the position shown in the above figure. • In this case, since the pressure from the A port is led to the C port, the servo piston (9) will move to the left side (small delivery) and will stop at a position further to the left than when the pump is lightly loaded.
10-34
PC130-7
STRUCTURE AND FUNCTION
•
•
PC130-7
HYDRAULIC PUMP
This means that the current, which is sent to the PC-EPC valve solenoid through the resistor when the PC redundant switch is set to On, determines the curve between the pump discharge pressure PP and the delivery Q as shown in the figure. When the PC redundant switch is set to ON, the curve is further to the left than the curve drawn when the pump controller is normal.
10-35
STRUCTURE AND FUNCTION
CONTROL VALVE
CONTROL VALVE OUTLINE There are the following 2 types of contral valve. • 6-spool valve (without service valve) • 7-spool valve (with service valve) • 7-spool valve (with blade) • 8-spool valve (with blade and service valve) Each service valve is a single add-on type, so it is possible to add or remove the extra valve at any time. Extermal oppearance and cross section is given only for the 7 spool valve.
a
AA A1 A2 A3 A4 A5 A6 A7 B1 B2 B3 B4 B5 B6 B7 BP LS PA1 PA2 PA3 PA4 PA5 PA6 PA7 PB1 PB2 PB3 PB4 PB5 PB6 PB7 P PP PX SA SB TS1 TS2 TB TC TSW
: Pressure sensor port (pressure sensor is intalled) : To swing motor MB : To L.H. travel motor A : To R.H. travel motor A : To boom cylinder bottom : To arm cylinder head : To bucket cylinder head : To attachment 1 : To swing motor MA : To L.H. travel motor B : To R.H. travel motor B : To boom cylinder head : To arm cylinder bottom : To bucket cylinder bottom : To attachment 1 : From boom RAISE PPC/EPC valve : To pump LS valve : From swing L.H. PPC/EPC valve : From L.H. travel forward PPC valve : From R.H. travel reverse PPC valve : From boom RAISE PPC/EPC valve : From arm OUT PPC/EPC valve : From bucket DUMP PPC/EPC valve : From service 1 PPC valve : From swing R.H. PPC/EPC valve : From L.H. travel reverse PPC valve : From R.H. travel forward PPC valve : From boom LOWER PPC/EPC valve : From arm IN PPC/EPC valve : From bucket CURL PPC/EPC valve : From service 1 PPC valve : From main pump : To main pump : From 2-stage relief solenoid valve : From swing stroke contral solenoid valve : From swing stroke contral solenoid valve : To tank : To tank : To tank : To oil cooler : To swing motor
10-36
1. Swing bleed valve 2. Travel junction valve 3. Arm regeneration valve 4. Cover 5. Service valve 6. Bucket valve 7. Arm valve 8. Boom valve 9. R.H. travel valve 10. L.H. travel valve 11. Swing valve 12. PT port block 13. Safety-suction valve
PC130-7
STRUCTURE AND FUNCTION
CONTROL VALVE
7 spool valve (6 spool valve + service valve)
PC130-7
10-37
STRUCTURE AND FUNCTION
CONTROL VALVE
CROSS-SECTIONAL DRAWING Cross-sectional drawing shows 7-spool valve (6-spool + service valve). (1/8)
a
1. 2. 3. 4. 5. 6. 7.
Safety-suction valve Suction valve (L.H. travel A) Suction valve (R.H. travel A) Suction valve (Boom bottom) Suction valve (Arm head) Suction valve (Bucket head) Safety-suction valve mount (service A)
10-38
8 Safety-suction valve mount (service B) 9. Suction valve (Bucket bottom) 10. Suction valve (Arm bottom) 11. Suction valve (Boom head) 12. Suction valve (R.H. travel B) 13. Suction valve (L.H. travel B) 14. Lift check valve
PC130-7
STRUCTURE AND FUNCTION
CONTROL VALVE
(2/8)
1. 2. 3. 4. 5. 6. 7. 8.
Main relief valve Spool (swing) Spool (L.H. travel) Spool (R.H. ravel) Spool (boom) Spool (arm) Spool (bucket) Spool (service)
PC130-7
10-39
STRUCTURE AND FUNCTION
CONTROL VALVE
(3/8)
1. 2. 3. 4. 5. 6. 7. 8.
Pressure compensation valve F (swing) Pressure compensation valve F (L.H. travel) Pressure compensation valve F (R.H. travel) Pressure compensation valve F (boom) Pressure compensation valve F (arm) Pressure compensation valve F (bucket) Pressure compensation valve F (service) Unload valve
10-40
9. 10. 11. 12. 13. 14. 15.
a
Pressure compensation valve R (service) Pressure compensation valve R (bucket) Pressure compensation valve R (arm) Pressure compensation valve R (boom) Pressure compensation valve R (R.H. travel) Pressure compensation valve R (L.H. travel) Pressure compensation valve R (swing) The above F and R means the following valves : F : Flow control valve R : Pressure reducing valve
PC130-7
STRUCTURE AND FUNCTION
CONTROL VALVE
(4/8)
1. 2. 3. 4. 5. 6.
LS pressure detection plug LS bypass plug Pump pressure detection plug Check valve (bucket head) Check valve (arm head) LS selection valve
PC130-7
10-41
STRUCTURE AND FUNCTION
CONTROL VALVE
(5/8)
1. 2. 3. 4. 5. 6.
Main relief valve Cooler bypass valve Lift check valve LS selection valve Spool (swing) Pressure compensation valve R
10-42
7. Swing bleed valve 8. Pressure compensation valve F F : Flow control valve R : Pressure reducing valve
PC130-7
STRUCTURE AND FUNCTION
CONTROL VALVE
(6/8)
1. 2. 3. 4. 5. 6. 7.
Suction valve (A) Suction valve (B) Spool (L.H. travel) Pressure compensation valve R Travel junction valve Pressure compensation valve F Suction valve (A)
PC130-7
8. 9. 10. 11.
Suction valve (B) Spool (R.H. travel) Pressure compensation valve R Pressure compensation valve F
F : Flow control valve R : Pressure reducing valve
10-43
STRUCTURE AND FUNCTION
CONTROL VALVE
(7/8)
1. 2. 3. 4. 5. 6. 7.
Suction valve (A) Suction valve (B) Spool Pressure compensation valve R Pressure compensation valve F Suction valve (A) Suction valve (B)
10-44
8. 9. 10. 11.
Spool Pressure compensation valve R Arm regemeration valve Pressure compensation valve F
F : Flow control valve R : Pressure reducing valve
PC130-7
STRUCTURE AND FUNCTION
CONTROL VALVE
(8/8)
1. 2. 3. 4. 5. 6. 7. 8.
Suction valve (A) Suction valve (B) Spool Pressure compensation valve R Pressure compensation valve F Safty-suction valve mount (A) Safty-suction valve mount (B) Spool
PC130-7
9. 10. 11. 12.
Pressure compensation valve R Pressure compensation valve F Pressure relief plug Unload valve
F : Flow control valve R : Pressure reducing valve
10-45
STRUCTURE AND FUNCTION
SUCTION SAFETY VALVE
SUCTION SAFETY VALVE
(SAFETY VALVE WITH SUCTION FOR SERVICE PORT) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Suction valve Main valve Piston Piston spring Poppet Poppet spring Suction valve Sleeve Adjustment screw Lock nut
SPECIFICATION Part No. (Reference)
Set pressure
Use
709-70-74600
24.5 MPa {250 kg/cm2} (at the time of 5l/min.)
For crusher
709-70-74700
17.2 MPa {175 kg/cm2} (at the time of 5l/min.)
10-46
PC130-7
STRUCTURE AND FUNCTION
CLSS
CLSS OUTLINE OF CLSS Features CLSS stands for Closed Center Load Sensing System and is featured as follows : • Fine controllability without affect of load • Controllability that allows digging even in the fine control mode. • Ease of compound operation in which the flow distribution performance depends on spool opening area during compound operation. • Saving of energy by variable pump control
PC130-7
Configuration • The CLSS consists of a variable displacement piston pump, a control valve and actuators. • The pump body consists of a main pump, a PC valve and an LS valve.
10-47
STRUCTURE AND FUNCTION
CLSS
Basic principle 1. Control of pump swash plate angle • The pump swash plate angle (pump delivery) is controlled so that the LS differential pressure PLS, which is the difference between the pump discharge pressure PP and the LS pressure PLS (actuator load pressure) at the control valve outlet, becomes constant. (LS differential pressure PLS = Pump pressure PP - LS pressure PLS)
•
a
When the LS differential pressure PLS reduces below the set pressure of the LS valve (when the actuator load pressure is high), the pump swash plate angle will move in the direction of maximum. When the set pressure is raised (when the actuator load pressure is low), the pump swash plate angle will move in the direction of minimum. For the detail of the operation, see the paragraph of "Hydraulic Pump."
10-48
PC130-7
STRUCTURE AND FUNCTION
CLSS
2. Pressure compensation control • A valve (pressure compensation valve) is mounted on the outlet side of the control valve. In case of compound operation of the actuator with this valve, the differential pressure P between the spool upstream (inlet) and the downstream (outlet) of each valve becomes constant irrespective of load (pressure). So, the flow from the pump is distributed (compensated) in proportion to the opening areas S1 and S2 of each valve being operated.
PC130-7
10-49
STRUCTURE AND FUNCTION
CLSS
EACH FUNCTION AND OPERATION OF EACH VALVE Hydraulic circuit diagram and valve names
10-50
PC130-7
STRUCTURE AND FUNCTION
CLSS
1. Unload valve Set pressure : 3.38 MPa {34.5 kg/cm2} 2. Safety-suction valve Set pressure : 35.8 MPa {365 kg/cm2} 3. Pressure compensation valve 4. Suction valve 5. Main relief valve Set pressure : normal: 31.9 MPa {325 kg/cm2} High pressure : 34.8 MPa {355 kg/cm2} 6. Lift check valve 7. Cooler bypass valve 8. LS selection valve 9. Swing bleeding valve 10. Travel junction valve 11. Arm regeneration valve
PC130-7
10-51
STRUCTURE AND FUNCTION
CLSS
UNLOAD VALVE 1. When the control valve is neutral FUNCTION • When the control valve is neutral, the delivery Q equivalent to the pump minimum swash plate angle is released to the tank circuit. At the time, the pump discharge pressure PP is set to 2.45 MPa {25.0kg/cm2} with the spring (3) inside the vale. (The LS pressure PLS is 0 MPa {0kg/cm2}.)
OPERATION • The pump discharge pressure PP is applied to the left end face of the spool (4) and the LS pressure PLS is applied to the right end face. • Since the LS pressure PLS is 0 when the control valve is neutral, the pump discharge pressure PP is only applied and is set with the lead to the spring (3). • When the pump discharge pressure PP rises to the spring (3) load (2.45 MPa {25.0 kg/cm2}), the spool (4) will move toward the right side and the pump circuit PP will interconnect to the tank circuit T through the drill hole. • Therefore, the pump discharge pressure PP is set to 2.45 MPa {25.0 kg/cm2}.
10-52
1. 2. 3. 4.
Unload valve Sleeve Spring Spool
PLS : LS circuit (pressure) PP : Pump circuit (pressure) T : Tank circuit
PC130-7
STRUCTURE AND FUNCTION
CLSS
2. When the control valve is in the fine control mode
When the differential pressure between the discharge pressure PP and the LS pressure PLS comes to the spring (3) load (2.45 MPa {25.0 kg/ cm2}), the unload valve will open and the LS differential pressure PLS will come to 2.45 MPa {25.0 kg/cm2}.
FUNCTION • When the control valve is in the fine control mode and the requested flow of the actuator is less than the pump minimum swash plate angle, the pump discharge pressure PP is set to the LS pressure PLS + 2.45 MPa {25.0 kg/cm2}.
OPERATION • When the control valve is operated in the fine control mode, the LS pressure PLS will occur and will be applied to the right end face of the spool (4). At the time the differential pressure between the LS pressure PLS and the pump discharge pressure PP increases because the opening area of the control valve spool is small. • When the differential pressure between the pump discharge pressure PP and the LS pressure PLS comes to the spring (3) load (2.45 MPa {25.0 kg/cm2}), the spool (4) will move to the right side and the pump circuit PP will interconnect to the tank circuit T. • This means that the pump discharge pressure PP is set to the spring force (2.45 MPa {25.0 kg/ cm2} + LS pressure PLS, and the LS differential pressure PLS comes to 2.45 MPa {25.0 kg/ cm2}.
PC130-7
1. 2. 3. 4.
Unload valve Sleeve Spring Spool
PLS : LS circuit (pressure) PP : Pump circuit (pressure) T : Tank circuit
10-53
STRUCTURE AND FUNCTION
CLSS
3. When the control valve is operated FUNCTION • If the required flow of the actuator increases over the pump minimum swash plate angle when the control valve is operated, the flow to the tank circuit T will be interrupted and the pump delivery Q will be completely flown to the actuator circuit.
OPERATION • When the control valve is operated with large stroke, the LS pressure PLS will occur and will be applied to the right end face of the spool (4). At the time, the opening areas of the control valve spool is large and the difference between the LS pressure PLS and the pump discharge pressure PP is small. • So, the differential pressure between the pump discharge pressure PP and the LS pressure PLS does not reach the spring (3) load (2.45 MPa {25.0 kg/cm2}) and the spring (3) pushes the spool (4) to the left side. • Then, the pump circuit PP and the tank circuit T are interrupted, and the pump delivery Q is completely flown to the actuator circuit.
10-54
1. 2. 3. 4.
Unload valve Sleeve Spring Spool
PLS : LS circuit (pressure) PP : Pump circuit (pressure) T : Tank circuit
PC130-7
STRUCTURE AND FUNCTION
CLSS
LEADING OF LS PRESSURE FUNCTION • The LS pressure is load pressure to the actuator on the outlet side of the control valve. • In case of a work equipment valve, the pressure reducing valve (3) of the pressure compensation valve reduces the pump discharge pressure PP to the same level as the actuator circuit pressure A and leads the pressure to the LS circuit PLS.
•
Also, the orifice C is mounted on the piston (5) halfway from the pump circuit PP to the pressure reducing valve (3), and the orifice has the damper function. The travel valves leads the actuator circuit pressure A directly to the LS circuit PLS.
1. Work equipment valve (boom, arm, bucket, swing)
OPERATION • When the spool (1) is operated, the pump discharge pressure PP will be led to the actuator circuit A through the bridge passage b from the flow control valve (2) and the spool notch a. • Since the pressure reducing valve (3) moves to the right at the same time, the pump discharge pressure PP led from the orifice c is reduced due to pressure loss at the notch d and is led to the LS circuit PLS and to the spring chamber PLS1. • At the time, the LS circuit PLS is connected to the tank circuit T from the LS bypass plug (4).
PC130-7
•
•
The both end face areas of the pressure reducing valve (3) are the same (SA = SLS), and the actuator circuit pressure PA (= A) is applied to the SA side and the reduced pump discharge pressure PP is applied to the SLS side on the opposite side. Therefore, the pressure reducing valve (3) balances at the position where the actuator circuit pressure PA becomes equal to the pressure of the spring chamber PLS1. The pump discharge pressure PP reduced at the notch d comes to the actuator circuit pressure A and is led to the LS circuit PLS.
10-55
STRUCTURE AND FUNCTION
CLSS
2. Travel valve
OPERATION • When the spool (1) is operated, the pump discharge pressure PP will be led to the actuator circuit A through the bridge passage b from the flow control valve (2) and the spool notch a. • At the same time, the actuator circuit pressure PA moves the pressure reducing valve (3) to the right side, and the notches c and d interconnect to the travel junction circuit e and the LS circuit PLS respectively. • So, the actuator circuit pressure PA (= A) is led from the notch c to the LS circuit PLS through the notch d. The travel circuit is different from the work equipment circuit, the actuator circuit pressure PA is directly led to the LS circui PLS.
a
10-56
PC130-7
STRUCTURE AND FUNCTION
CLSS
LS BYPASS PLUG FUNCTION • This plug released residual pressure of the LS pressure PLS. • This plug slows the rising speed of the LS pressure PLS, causes pressure losses at the spool and the throttle of the shuttle valve by the discarded throttled flow and reduces the effective LS differential pressure for higher safety.
OPERATION • Pressurized oil in the LS circuit PLS flows from the clearance filter a in the space between the LS bypass plug (1) and the valve body to the tank circuit T through the orifice b.
PC130-7
1. LS bypass plug PLS : LS circuit (pressure) T : Tank circuit (pressure)
10-57
STRUCTURE AND FUNCTION
CLSS
PRESSURE COMPENSATION VALVE FUNCTION • When the load pressure becomes lower than another actuator and the flow is going to increase during a compound operation, this valve compensates the load pressure. (At the time, the load pressure of another actuator under compound operation (the upper side) is higher than that of the actuator on this side (the lower side).
10-58
PC130-7
STRUCTURE AND FUNCTION
CLSS
OPERATION • When the load pressure of another actuator side (the upper side) rises during a compound operation, the flow in the actuator circuit A on this side (the lower side) is apt to increase. • In this case, the LS pressure PLS of another actuator is applied to the spring chamber PLS1 and pushes the pressure reducing valve (1) and the flow control valve (2) to the left side. • The flow control valve (2) throttles the opening area between the pump circuit PP and the spool upstream PPA and causes a pressure loss between PP and PPA. • The flow control valve (2) and the pressure reducing valve (1) balance each other where the pressure difference between PA applied to the both end faces of the pressure reducing valve (1) and PLS becomes the same as the pressure loss between PP before and after the flow control valve and PPA. • So, the pressure differences between the upstream pressures PPA and the downstream pressures PA of the both spools under compound operation become the same, and the pump flow is distributed in proportion to the opening area of each spool notch a.
PC130-7
10-59
STRUCTURE AND FUNCTION
CLSS
AREA RATIO OF PRESSURE COMPENSATION VALVE FUNCTION • The pressure compensation valve slightly adjust the ratio (S2/S1) of the area S1 on the left side of the flow control valve (2) and the area S2 on the right side of the pressure reducing valve (1) to suite the characteristics of each actuator and determines the compensation characteristics. S1 : Area of the flow control valve (2) - area of the piston (3) S2 : Area of the pressure reducing valve (1) - area of the piston (3)
Area ratio (S1:S2) and compensation characteristics • When the ratio is 1.00 : The expression [Pump (discharge) pressure PP - Spool notch upstream pressure PPB] [LS circuit pressure PLS - Actuator circuit pressure PA (= A)] can be held, and the flow is distributed as per the spool opening area ratio. • When the ratio is more than 1.00 : The expression PP - PPB > PLS - PA (= A) can be held, and the flow is distributed less than the spool opening area ratio. • When the ratio is less than 1.00 : The expression PP - PPB < PLS - PA (= A) can be held, and the flow is distributed more than the spool opening area ratio.
10-60
PC130-7
STRUCTURE AND FUNCTION
CLSS
ARM REGENERATION CIRCUIT 1. At arm in and own weight fall FUNCTION • When the arm falls due to its own weight because the head pressure A in the arm cylinder (1) is higher than the bottom pressure B during arm digging, this circuit brings the return flow on the head side to the bottom side to increase the cylinder speed.
OPERATION • When the arm falls for digging due to its own weight, the head side pressure A in the arm cylinder (1) will rise above the bottom side pressure B. • At the time, part of the return flow on the head side passes through the regeneration passage a of the arm spool (2), pushes the check valve (3) to open it and flows to the bottom side. • This increases the arm digging speed.
PC130-7
1. Arm cylinder 2. Arm spool 3. Check valve A : Head circuit (pressure) B : Bottom circuit (pressure) PP : Pump circuit (pressure)
10-61
STRUCTURE AND FUNCTION
CLSS
2. At arm in process FUNCTION • When the bottom pressure B of the cylinder (1) rises above the head pressure A and the arm enters the digging process, the check valve (3) will be closed and the circuits on the head side and the bottom side will be interrupted.
OPERATION • When the arm is in the digging process, the bottom side pressure B of the arm cylinder (1) will rise, close the check valve (3) and interrupt the circuits on the head side and the bottom side.
10-62
1. Arm cylinder 2. Arm spool 3. Check valve A : Head circuit (pressure) B : Bottom circuit (pressure) PP : Pump circuit (pressure)
PC130-7
STRUCTURE AND FUNCTION
CLSS
TRAVEL JUNCTION VALVE
(L.H. and R.H. travel junction circuit) 1. When traveling straight
10-64
PC130-7
STRUCTURE AND FUNCTION
CLSS
FUNCTION • When the L.H. and R.H. travel spool is operated to compensate flow errors in the L.H. and R.H. travel circuits during straight travel, the junction circuit will open. • Then, the flows to the L.H. and R.H. travel motors will become the same during the straight travel, and travel deviation will decrease. • At the time of steering, load pressure difference brings back the pressure reducing valve of the travel valve inside the steering and closes the spool notch opening of the travel junction valve to close the junction circuit for steering. OPERATION • When the L.H. and R.H. travel spool (1) is operated, the pump delivery will flow from the pump circuit PP to A through the actuator circuit PA. • When traveling straight, the actuator circuit PA will be equalized and the L.H. and R.H. pressure reducing valves (2) will be pressed the same stroke to the right. Then, the notch a and the junction circuit will open. • The L.H. travel forward oil pressure P1 and the R.H. travel forward oil pressure P2 are led to the spring chamber on the both end of the travel junction valve spool (4) through the respective shuttle valves (5). So, P1 = P2, and the spool is at the neutral position, and the notch d is ?open?. • Then, the L.H. and R.H. travel actuator circuits are interconnected with the junction circuit. When any difference occurs in the flows to the L.H and R.H. travel motors, this valve will compensate them and will reduce occurrence of travel deviations.
PC130-7
10-65
STRUCTURE AND FUNCTION
CLSS
2. When operating travel steering
10-66
PC130-7
STRUCTURE AND FUNCTION
CLSS
OPERATION • When the L.H. travel spool (L.H. 1) is returned to the neutral side from the straight traveling state and the steering is operated, there will occur any difference in the load pressures in the L.H. and R.H. travel actuator circuits PA (R.H. A > L.H. A). The LS pressure PLS will become the same as the R.H. A on the higher load pressure side. • Therefore, the flow control valve on the L.H. travel side is pressed to the left side with the LS pressure PLS, i.e., the load pressure on the R.H. travel side, and the notch a closes to interrupt the L.H. and R.H. travel circuits. Also, since the pressures in the spring chambers on the both ends of the travel junction valve spool (4) become different and P1 becomes higher than P2, the spool (4) moves to the P1 side and the notch d closes. Then, the steering can be operated. • The damper is provided to relax the transition characteristics of the junction circuit at the time of abrupt operation.
PC130-7
10-67
STRUCTURE AND FUNCTION
CLSS
TRAVEL LS BYPASS CIRCUIT 1. At normal operation
10-68
PC130-7
STRUCTURE AND FUNCTION
CLSS
FUNCTION • When an actuator is operated during travel, this circuit will increase the discarded throttled flow of the LS circuit PLS, loosen the pressure compensation accuracy of the travel circuit and limits reduction of the travel speed to small extent. • The bypass circuit is closed in case of independent travel or independent operation of an actuator. OPERATION • When the boom spool (1) is operated, the LS circuit PLS will come to the same pressure as the boom circuit pressure A1. • At the same time, the LS circuit pressure PLS is led to the spring chamber PLS1 of the pressure reducing valve (2) of the travel valve. • Since the travel spool is not operated, the travel actuator circuit PA is closed and the check valve (4) inside the flow control valve (3) is also closed. • Therefore, the travel LS bypass circuit is closed in case of independent operation of the boom.
PC130-7
10-69
STRUCTURE AND FUNCTION
CLSS
2. At operation of travel + other actuator
10-70
PC130-7
STRUCTURE AND FUNCTION
CLSS
OPERATION • When the boom spool (1) is operated, the LS circuit PLS will come to the same pressure as the boom circuit pressure A1. • Since the actuator circuit pressure is generally higher at boom RAISE than during travel (A1 > A2), the pressure in the spring chamber PLS1 of the flow control valve (3) on the travel side is higher than the travel circuit pressure PA. • So, the pressure reducing valve (2) moves to the left side, and the LS pressure of the spring chamber PLS1 pushes the check valve (4) from the orifice a to open it and flows to the travel circuit PA through the passages b and c. • Therefore, when the LS circuit pressure PLS, which has been as high as the boom circuit pressure A1, flows to the travel circuit A2, the pressure will drop.
PC130-7
10-71
STRUCTURE AND FUNCTION
CLSS
3. At simultaneous operation of boom + swing FUNCTION • When the boom is raised at the time of swinging, the swing pool stroke will be controlled and the flow to the boom will be distributed more to raise the boom more. 1) When the boom is not raised
OPERATION • Since the SA and SB ports are interconnected to the drain and no force is given to the piston (2), the stroke of the spool (1) is not controlled. So, the spool (1) comes to the cases (4) and (5) and the stroke increases by ST1. This increases the filtering oil flow.
10-72
1. 2. 3. 4. 5.
Spool (swing) Piston Plug Case Case
ST1 : Spool stroke
PC130-7
STRUCTURE AND FUNCTION
CLSS
2) At simultaneous operation of boom RAISE
OPERATION • When the boom RAISE PPC pressure is led to the piston (2) as the stroke control pilot pressure PS through the SA and SB ports, the piston (2) will be pressed in the inner direction. • At the time, the maximum stroke of the spool (1) will shorten (by ST0) due to control of the piston (2). Boom RAISE OFF ST1 > Boom RAISE ON ST0 • The spool (1) stroke is controlled and shortens. If the boom is raised at the time of swing (hoist swing), the notch a opening area will decrease. So, the flow distribution to the boom will increase and the boom will rise higher at the time of hoist swing.
PC130-7
10-73
STRUCTURE AND FUNCTION
CLSS
SWING BLEED VALVE FUNCTION • For swing operation, a bleed valve is provided to the pressure reducing valve to raise the LS pressure slowly and to smooth the swing operation. 1. Swing at neutral position
OPERATION • Since the notch a of the pressure reducing valve (1) and the LS circuit are closed and the bleedoff circuit and the LS circuit are also closed, the LS pressure PLS is not affected by operation of other work equipment. • The pump discharge pressure PP is also interrupted from the bleed-off circuit with the piston (2) and is not affected. • The notch b of the bleed spool (3) and the bleedoff circuit are interconnected each other.
10-74
PC130-7
STRUCTURE AND FUNCTION
CLSS
2. At swing fine control
OPERATION • The pressure reducing valve moves in the right direction, and the notch a and the LS circuit interconnect each other. Also, the pump circuit PP, the bleed-off circuit and the LS circuit interconnect each other through the piston (2). • The bleed spool (3) moves in the left direction in proportion to raise of the swing PPC pressure PA. But the notch b throttles and interconnect to the bleed-off circuit in the fine control region and determines the intermediate pressure before the pump discharge pressure PP is reduced and applied to the LS pressure PLS. • Therefore, the intermediate pressure is set lower than the pump discharge pressure PP and rises as the bleed spool (3) moves . So, the LS pressure PLS rises slowly.
PC130-7
10-75
STRUCTURE AND FUNCTION
CLSS
3. At full swing operation
OPERATION • When the swing PPC pressure PA comes to the maximum, the notch b of the bleed spool (3) interrupt the bleed-off circuit. The intermediate pressure becomes equal to the pump discharge pressure PP, and the LS pressure PLS becomes equal to the actuator circuit pressure.
10-76
PC130-7
STRUCTURE AND FUNCTION
CLSS
LS SELECT VALVE FUNCTION • At the time of simultaneous operation of swing + boom RAISE, this valve prevents high swing LS pressure from entering the LS circuit PLS and also prevents the boom RAISE speed from reducing by securing the pump flow at the time of swing drive. 1. During normal operation
OPERATION • The pilot pressure is not generally applied to the pilot port BP except for boom RAISE operation. • In this state, the pump discharge pressure PP pushes the valve (1) to open it and is led to the pressure reducing valve (4) of the swing valve. At the time of swing operation, there occurs the LS pressure PLS suitable for the load pressure, and the pressure is led to the pump LS valve.
PC130-7
10-77
STRUCTURE AND FUNCTION
CLSS
2. At simultaneous operation of swing + boom RAISE
OPERATION • At the simultaneous operation of swing + boom RAISE, the signal pressure of the PPC circuit is led to the pilot port BP. • When this pilot pressure BP is applied to the piston (2) and reaches a pressure that is stronger than the spring (3), the piston (2) will be pushed to the left side, the valve (1) will close and the pump discharge pressure PP will not come to flow to the pressure reducing valve (4) of the swing valve. • Then, the swing pressure does not cause LS pressure PLS, but the LS pressure PLS cause the boom RAISE pressure is led to the pump LS valve, and the pump delivery is controlled with the boom RAISE LS pressure. • The pilot pressure BP depends on the control lever stroke.
10-78
PC130-7
STRUCTURE AND FUNCTION
SELF PRESSURE REDUCING VALVE
SELF PRESSURE REDUCING VALVE
P1 : From pump PR : Supply to solenoid valve, PPC valve and EPC valve. T : To hydraulic tank
PC130-7
10-79
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5. 6.
Control valve block Valve (sequence valve) Spring Screw Poppet Spring (pressure reducing valve pilot)
10-80
SELF PRESSURE REDUCING VALVE
7. 8. 9. 10. 11.
Spring (pressure reducing valve main) Valve (pressure reducing valve) Spring (safety valve) Ball Filter
PC130-7
STRUCTURE AND FUNCTION
SELF PRESSURE REDUCING VALVE
FUNCTION • The self pressure reducing valves reduces the discharge pressure of the main pump and supplies it to the solenoid valve, the PPC valve, etc. as the control pressure.
PC130-7
10-81
STRUCTURE AND FUNCTION
SELF PRESSURE REDUCING VALVE
1. At engine stop (total low pressure)
OPERATION • The spring (6) pushes the poppet (5) t the seat, and the circuit between the ports PR and T is closed. • The spring (7) pushes the valve (8) to the left side, and the circuit between the ports P1 and PR is open. • The spring (3) pushes the valve (2) to the left side, and the circuit between the ports P1 and P2 is closed.
10-82
PC130-7
STRUCTURE AND FUNCTION
SELF PRESSURE REDUCING VALVE
2. At neutral and reduction of load pressure P2 (at own weight fall in boom LOWER and arm IN) Note : When the load pressure P2 is lower than the output pressure PR of the self pressure reducing valve.
OPERATION • The spring (3) and the PR pressure (0 MPa {0 kg/cm2} at the time of engine stop) pushes the valve (2) in the direction to close the circuit between the ports P1 and P2. When the hydraulic oil enters the P1 port, the expression (P1 pressure Spring (7) force + ( d area x PR pressure)) holds, and the self pressure reducing valve will adjust the openings of the ports P1 and P2 so that the P1 pressure can be maintained higher than the PR pressure. • When the PR pressure rises above the set pressure, the poppet (5) will open and the hydraulic oil flows through the route from the PR port, the hole a in the spool (8), the poppet (5) opening to the tank port T.
PC130-7
•
Therefore, there will occur a differential pressure around the hold a in the spool (8) and the spool will move in the direction to close the port P1 and the PR opening. Then, the P1 pressure is reduced and adjusted to a certain pressure (set pressure) with the opening and is supplied as the PR pressure.
10-83
STRUCTURE AND FUNCTION
SELF PRESSURE REDUCING VALVE
3. At raise of load pressure P2
OPERATION • When the load pressure P2 rises due to digging or other operations, the pump delivery will increase and the P1 pressure will rise. Then, the expression (P1 pressure > Spring (7) force + ( d area x PR pressure)) will hold, and the valve (2) will move to the right side till the stroke end. As a result, the opening between the ports P1 and P2 will increase, the passage resistance will become smaller to reduce engine loss horsepower. • When the PR pressure rises above the set pressure, the poppet (5) will open and the hydraulic oil will flow through the route from the PR port, the hole a in the spool (8), the poppet (5) opening to the tank port T.
10-84
•
Therefore, there will occur a differential pressure around the hold a in the spool (8) and the spool will move in the direction to close the port P1 and the PR opening. Then, the P1 pressure is reduced and adjusted to a certain pressure (set pressure) with the opening and is supplied as the PR pressure.
PC130-7
STRUCTURE AND FUNCTION
SELF PRESSURE REDUCING VALVE
4. At occurrence of abnormal high pressure
OPERATION • When the PR pressure of the self pressure reducing valve rises abnormally high, the ball (10) will separate from the seat against the spring (9) force to flow the hydraulic oil to the output ports PR T so as to reduce the PR pressure. Then, the equipment (PPC valve, solenoid valve, etc.), to which the oil pressure is supplied, is protected from the abnormal high pressure.
o
PC130-7
10-85
STRUCTURE AND FUNCTION
CENTER SWIVEL JOINT
CENTER SWIVEL JOINT
1. 2. 3. 4. 5.
Cover Body Slipper seal O-ring Shaft
10-86
A1 : A2 : B1 : B2 : C1 : C2 : D1 : D2 : E1 : E2 : DR1 : DR2 :
From control valve (R.H. travel Forward) To R.H. travel motor B From control valve (L.H. travel Forward) To L.H. travel motor A From control valve (R.H. travel Reverse) To R.H. travel motor A From control valve (L.H. travel Reverse) To L.H. travel motor B 2-stage travel selection solenoid valve To L.H./R.H. travel motor D To hydraulic tank From L.H. travel motor C1 and R.H. travel motor C2
PC130-7
STRUCTURE AND FUNCTION
TRAVEL MOTOR
TRAVEL MOTOR (FINAL DRIVE)
A : From control valve (L.H./R.H. travel) B : From control valve (L.H./R.H. travel) C1 : To hydraulic tank (L.H. travel motor) Plug (R.H. travel motor) C2 : Plug (L.H. travel motor) To hydraulic tank (R.H. travel motor) D : From travel 2nd speed selector solenoid valve
PC130-7
10-87
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Plug Check valve spring Check valve Return spring Counterbalance valve Safety valve Safety valve spring End cover Regulator valve Spring Brake piston Cylinder Spring Swash plate Pivot Crankshaft RV gear A
10-88
TRAVEL MOTOR
18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.
RV gear B Cover Driven gear Drive gear Drain plug Hub Regulator piston Spindle Piston Floating seal Plate Disc Valve plate Spring Piston Plug Check valve
PC130-7
STRUCTURE AND FUNCTION
TRAVEL MOTOR
SPECIFICATION Type Theoretical delivery (cm3/rev{cc/rev}) Rated speed (rpm)
GM18VL3 Hi
33.2 {33.2}
Lo
52.7 {52.7}
Hi
3,562
Lo
2,291
Brake releasing pressure (MPa{kg/cm2})
0.68 {6.94}
Hi-Lo switching pressure (MPa{kg/cm2})
2.94 {30}
Final drive reduction ratio
66
OUTLINE Travel speed selection
• •
Swash plate (14) has 2 faces (x, y) behind it, and is supported by pivot(15). When pressure of comtrol chamber a rises, it pushes regulator piston (24), them swash plate angle becomes minimum, then travel speed goes high.
PC130-7
10-89
STRUCTURE AND FUNCTION
TRAVEL MOTOR
OPERATION Operation of motor At slow speed (the motor swash plate angle is maximized.)
•
• •
•
•
Since the travel 2nd speed selector solenoid valve is demagnetized, the pressurized oil from the main pump does not flow to the D port. Therefore, the spring (10) has pressed the regulator valve (9) to the left side. So, the regulator valve (9) stops the main pressurized oil led from the control valve to the end cover by pushing the check valve (34). The pressurized oil in the control chamber drains in the motor case through the passage b of the regulator valve (9). Then, the main pressurized oil from the cylinder c chamber pushes the swash plate (14) in the direction to maximize the swash plate angle and the motor capacity is increased to the maximum for slow speed travel.
10-90
PC130-7
STRUCTURE AND FUNCTION
TRAVEL MOTOR
At high speed (the motor swash plate angle is minimized.)
•
•
•
When the travel 2nd speed selector solenoid valve is energized, the pilot pressure from the main pump will flow in the D port and push the regulator valve (9) in the right direction. Therefore, the main pressurized oil from the control valve passes through the passage b of the regulator valve (9), flows in the control chamber a and pushed the regulator piston (24) in the left direction. Then, the swash plate (14) is pressed in the direction to minimize the swash plate angle, and the motor capacity is minimized for high speed travel.
PC130-7
10-91
STRUCTURE AND FUNCTION
TRAVEL MOTOR
Operation of brake valve • The brake valve consists of the check valves (3a) and (3b), the counterbalance valve (5) and the safety valve (6), and the circuit configuration is as per the right figure. • Functions and operations of these components are as follows :
Counterbalance valve, check valve Function • When traveling down a slope, the own weight falling force will make the machine travel faster than the motor rotation. So, traveling with reduced engine speed is very dangerous because the motor idles and runs away. These valves let the machine travel at a speed appropriate for the engine speed (pump delivery) to prevent this danger. Operation at oil supply • When the travel lever is operated, the pressurized oil from the control valve will be supplied to the PA port, push and open the check valve (3a) and flow from the MA port on the motor inlet side to the MB port on the motor outlet side. Since the motor outlet circuit is closed with the check valve (3b) and the counterbalance valve (5), however, the supply-side pressure will rise.
10-92
PC130-7
STRUCTURE AND FUNCTION
•
TRAVEL MOTOR
The pressurized oil on the supply side flows in the S1 chamber from the orifice E1 of the counterbalance valve (5). When the pressure in the S1 chamber rises above the switching pressure of the counterbalance valve, the counterbalance valve (5) will be pressed in the right direction. So, the circuit between the outlet side MB port and the PB port will open, the motor outlet circuit will open, and the motor will start rotating.
Brake operation at traveling downhill • If the machine is going to run away when traveling downhill, the motor will idle to reduce the oil pressure on the motor inlet side and the pressure in the S1 chamber through the orifice E1. When the pressure in the S1 chamber drops below the switching pressure of the counterbalance valve, the counterbalance valve (5) will be returned in the left direction with the return spring (4), and the outlet side MB port will be throttled. Then, the pressure on the outlet side will rise and rotation resistance will occur to the motor to prevent the machine from running away. This means that the counterbalance valve (5) moves to a position where the machine own weight and the inlet side pressure balance with the pressure at the outlet side MB port, and the outlet circuit is throttled to control the speed to the pump delivery.
PC130-7
10-93
STRUCTURE AND FUNCTION
TRAVEL MOTOR
Safety valve Function • When stopping a travel (or traveling downhill), the counterbalance valve (5) will close the inlet and outlet circuits of the motor. Since the motor keeps rotating by inertia, however, the pressure on the outlet side of the motor will rise abnormally and the motor and pipes may be damaged. Then, the safety valve leads the abnormally high pressure to the inlet side of the motor to prevent the equipment from being damaged. Operation • When the pressurized oil being supplied from the PA port is stopped flowing at the time of travel stop, the return spring (4) will return the counterbalance valve (5) from the right side to the left side (the neutral position). • Though the counterbalance valve (5) closes the a chamber on the outlet side circuit, the inertia lets the motor rotate and the pressure in the a chamber rises. • The highly pressurized oil in the a chamber passes through the throttle b of the safety valve (6a) and enters in the d chamber from the c chamber. The pressurized oil entered in the d chamber moves the piston (32) to the left side. Meantime, the safety valve (6a) is pushed to open by the pressurized oil in the a chamber, and the pressurized oil in the a chamber flows in the f chamber through the e port. Therefore, the pressurized oil in the a chamber flows in the f chamber at a comparatively slow speed to control the pressure in the a chamber and also to prevent cavitation in the f chamber at the same time. • When the piston (32) reaches the stroke end, the pressures in the d and c chambers will rise, the safety valve (6a) will be closed again and the pressure in the a chamber will rise further. • Then, the safety valve (6b) will open and the pressurized oil in the a chamber will flow in the f chamber from the g chamber. The pressure in the a chamber can be controlled in two stage as mentioned above, and the hydraulic motor can be smoothly braked to stop.
10-94
PC130-7
STRUCTURE AND FUNCTION
TRAVEL MOTOR
Operation of parking brake When operating travel • When the travel lever is operated, the pressurized oil from the pump will work on the counterbalance valve (5), open the circuit a to the parking brake and flow in the b chamber of the brake piston (11). • The pressure in the b chamber overcomes the spring (31) and pushed the brake piston (11) in the left direction. • This will eliminate the press force to the plate (28) and the disc (29), and the plate (28) and the disc (29) will separate, and the brake force will be released.
When positioning travel neutral • When the travel lever is brought to the neutral position, the counterbalance valve (5) will return to the neutral position and the circuit a to the parking brake will be closed. • The pressurized oil in the b chamber of the brake piston (11) will be drained in the case, and the spring (31) will push the brake piston in the right direction. • Therefore, the plate (28) and the disc (19) will be pushed to each other, and the brake will come to work.
PC130-7
10-95
STRUCTURE AND FUNCTION
SWING MOTOR
SWING MOTOR TYPE : KMF40ABE-3
B S T MA MB
: : : : :
From swing brake solenoid valve From control valve To tank From control valve From control valve
10-96
SPECIFICATION Type : KMF40ABE-3 Theoretical delivery : 40.2 cc/rev Safety valve set pressure : 27.5 MPa {280 kg/cm2} Rated speed : 2,413 rpm Brake releasing pressure :1.77 MPa{18.0 kg/cm2}
PC130-7
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Drive shaft Spacer Case Disc Plate Brake ring Brake piston Housing Reverse prevention valve Center spring
PC130-7
SWING MOTOR
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Cylinder Valve plate Piston Center shaft Safety valve Check valve Check valve spring Shuttle valve Shuttle valve spring Brake spring
10-97
STRUCTURE AND FUNCTION
SWING MOTOR
SWING BRAKE 1. When solenoid valve is demagnetized Operation • When the solenoid valve of the swing brake is demagnetized, the pressurized oil from the control pump will be interrupted and the B port will be connected to the tank circuit. • Then, the brake piston (7) will be pressed downward with the brake spring (8) and will push the disc (4) and the plate (5) to work the brake.
2. When solenoid valve is energized Operation • When the solenoid valve of the swing brake is energized, the valve will be changed over and the pressurized oil from the control pump will enter the B port and will flow in the brake chamber A. • The pressurized oil in the A chamber will push the brake spring (8) and the brake piston (7) will move upward. Then, the disc (4) and the plate (5) will separate to release the brake.
10-98
PC130-7
STRUCTURE AND FUNCTION
SWING MOTOR
REVERSE PREVENTION VALVE
1. 2. 3. 4. 5. 6. 7.
Valve body Spool (MA side) Spring (MA side) Plug (MA side) Spool (MB side) Spring (MB side) Plug (MB side)
MA : Port MB : Port T1 : Port T2 : Port
PC130-7
10-99
STRUCTURE AND FUNCTION
SWING MOTOR
Effect explanation drawing
10-100
PC130-7
STRUCTURE AND FUNCTION
SWING MOTOR
FUNCTION • This function is used for reducing swing back generated on a swing body that can result from factors such as inertia of the swing body, backlash and rigidity of the machinery system and compressibility of hydraulic oil. • This function helps preventing loose loads at the end of swing or cutting lead time (better positioning performance allows you to proceed to the next operation within a shorter time).
1. When MB port pressure is generated Operation • MB pressure is conducted to d room via the cutout. Utilizing difference of space (D1>D2), the pressure compresses the spring (6) and drives the spool (5) leftward to interconnect MB e. • Since MA pressure at this time is lower than the pressure set on the spring (3), the spool (2) is not moved and pressurized oil remains closed. Thus, the braking force is maintained.
o
2. When the motor is once stopped Operation • The motor is reverse rotated by charging pressure generated on the MB port (1st reverse rotation). • At this time, reversing pressure is generated on the MA port. MA pressure conducted to a room interconnects MA b by compressing the spring (3) and driving the spool (2) rightward. • The pressure is then conducted through drilled hole on the spool (5) to interconnect b f. Reversing pressure on the MA port is bypassed to the T port to disable the 2nd reverse rotation.
o
o
PC130-7
10-101
STRUCTURE AND FUNCTION
SOLENOID VALVE
SOLENOID VALVE FOR PPC LOCK, 2ND TRAVEL SPEED SELECT, SWING HOLD BRAKE AND 2-STAGE RELIEF SOLENOID VALVE.
1. 2. 3. 4.
PPC lock solenoid valve 2nd travel speed select solenoid valve Swing hold brake solenoid valve 2-stage relief solenoid valve
Solenoid valve 5. Push pin 6. Coil 7. Gauge 8. Spool 9. Block 10. Spring
A1 : To PPC valve A2 : To 2-stage relief valve A3 : To swing hold brake A4 : To 2nd travel speed select valve ACC : To accumulator P1 : From self-pressure reducing valve T : To hydraulic oil tank
Check valve 11. Plug 12. Spring 13. Plunger
10-102
PC130-7
STRUCTURE AND FUNCTION
SOLENOID VALVE
OPERATION When solenoid is "demagnetized" • The coil (6) remains demagnetized as long as signal current to it is stopped.. • Thus, the spool (8) is pushed leftward by the spring (10). • Since ports P to A are closed by this spool, flow of pilot oil pressure to the actuator is blocked. At the same time, oil from the actuator is lead from A port to T port, then drained to the hydraulic oil tank.
When solenoid is "magnetized" • The coil (6) is magnetized by signal current conducted to it. • Thus, the spool (8) is pushed rightward by the push pin (5). • As the result, pilot oil pressure is conducted from P port through the cage (7) and A port up the actuator. At the same time, T port is closed, thereby blocking flow of oil to the hydraulic oil tank.
PC130-7
10-103
STRUCTURE AND FUNCTION
PPC ACCUMULATOR
PPC ACCUMULATOR 1. 2. 3. 4. 5. 6.
Gas plug Shell Poppet Holder Bladder Oil port
SPECIFICATIONS Gas used : Nitrogen gas Gas capacity : 0.3 Charged gas pressure : 1.18 MPa (12 kg/cm2) at 80°C Maximum operating pressure : 6.86 MPa (70 kg/cm2)
l
10-104
PC130-7
STRUCTURE AND FUNCTION
PPC VALVE
PPC VALVE FOR SWING, WORK EQUIPMENT
P : From main pump P1 : Left : Arm OUT/Right : Boom LOWER P2 : Left : Arm IN/Right : Boom RAISE
PC130-7
P3 : Left : Swing RIGHT/Right : Bucket CURL P4 : Left : Swing LEFT/Right : Bucket DUMP T : To tank
10-105
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5.
Spool Metering spring Centering spring Piston Disk
10-106
PPC VALVE
6. 7. 8. 9. 10.
Nut (for linking the lever) Joint Plate Retainer Body
PC130-7
STRUCTURE AND FUNCTION
PPC VALVE
OPERATION 1) At neutral • Ports A and B of the control valve and ports P1 and P2 of the PPC valve are connected to drain chamber D through fine control hole f in spool (1). (Fig. 1)
o
2) During fine control (neutral fine control) When piston (4) starts to be pushed by disc (5), retainer (9) is pushed; spool (1) is also pushed by metering spring (2), and moves down. When this happens, fine control hole f is shut off from drain chamber D, and at almost the same time, it is connected to pump pressure chamber PP, so pilot pressure oil from the main pump passes through fine control hole f and goes from port P1 to port A. When the pressure at port P1 becomes higher, spool (1) is pushed back and fine control hole f is shut off from pump pressure chamber PP. At almost the same time, it is connected to drain chamber D to release the pressure at port P1. When this happens, spool (1) moves up or down so that force of metering spring (2) is balanced with the pressure at port P1. The relationship in the position of spool (1) and body (10) (fine control hole f is at a point midway between drain hole D and pump pressure chamber PP) does not change until retainer (9) contacts spool (1). Therefore, metering spring (2) is compressed proportionally to the amount of movement of the control lever, so the pressure at port P1 also rises in proportion to the travel of the control lever. In this way, the control valve spool moves to a position where the pressure in chamber A (the same as the pressure at port P1) and the force of the control valve spool return spring are balanced. (Fig. 2)
PC130-7
10-107
STRUCTURE AND FUNCTION
PPC VALVE
3) During fine control (when control lever is returned) When disc (5) starts to be returned, spool (1) is pushed up by the force of centering spring (3) and the pressure at port P1. When this happens, fine control hole f is connected to drain chamber D and the pressure oil at port P1 is released. If the pressure at port P1 drops too far, spool (1) is pushed down by metering spring (2), and fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, and the pump pressure is supplied until the pressure at port P1 recovers to a pressure that corresponds to the lever position. When the spool of the control valve returns, oil in drain chamber D flows fine control hole f' in the valve on the side that is not working. The oil passes through port P2 and enters chamber B to fill the chamber with oil. (Fig. 3)
4) At full stroke When disc (5) pushes down piston (4), and retainer (9) pushes down spool (1), fine control hole f is shut off from drain chamber D, and is connected with pump pressure chamber PP. Therefore, the pilot pressure oil from the main pump passes through fine control hole f and flows to chamber A from port P1, and pushes the control valve spool. The oil returning from chamber B passes from port P2 through fine control hole f' and flows to drain chamber D. (Fig. 4)
10-108
PC130-7
STRUCTURE AND FUNCTION
PPC VALVE
FOR TRAVEL
P T P1 P2
: : : :
From main pump To tank L.H reverse L.H forward
PC130-7
P3 : R.H reverse P4 : R.H forward P5 : Travel signal
10-109
STRUCTURE AND FUNCTION
1. 2. 3. 4.
Plate Body Piston Collar
10-110
PPC VALVE
5. 6. 7. 8.
Metering spring Centering spring Valve Pin
PC130-7
STRUCTURE AND FUNCTION
PPC VALVE
OPERATION 1. In the neutral mode • P1 and P2 ports of the operation valves A, B and PPC valve are connected to the drain room D via the fine control hole f on the spool (1).
2. In the fine control mode (neutral fine control) • As the piston (4) is pushed by the disk (5), the retainer (9) is pushed, too. At the same time, the spool (1) is also pushed down via the metering spring (2). • By this move, connection of the fine control hole f is switched from the drain room D to the pump pressure room PP, and pilot pressurized oil for the main pump is conducted from P1 port to A port. • As P1 port pressure increases, the spool (1) is pushed back. By this move, connection of the fine control hole f is switched from the pump pressure room PP to the drain room D, thereby relieving P1 port pressure. • As the result, the spool (1) moves up and down so that force of the metering spring (2) and P1 port pressure may be balanced. Positional relationship between the spool (1) and body (10) (fine control hole f is situated at mid point between the drain room D and pump pressure room PP) remains unchanged until the retainer (9) is contacted against the spool (1). • The metering spring (2) is, therefore, compressed in proportion to strokes of the operation lever. Thus, the P1 port pressure, too, increases in proportion to strokes of the operation lever. • As the result, the operation valve spool moves to the position where pressure of A room (the same as P1 port pressure) is balanced against force of the operation valve spool return spring.
o
PC130-7
10-111
STRUCTURE AND FUNCTION
PPC VALVE
3. In the fine control mode (when operation lever is shifted back to its original position) • As the disk (5) starts returning, the spool (1) is pushed up by force of the centering spring (3) and P1 port pressure. • By this move, the fine control hole f is connected to the drain room D and relieves pressurized oil of P1 port to it. • If P1 port pressure goes excessively low, the spool (1) is pushed down by the metering spring (2) and passage between the fine control hole f and the drain room D is shut down. And, almost at the same time, the hole is connected to the pump pressure room PP and starts supplying pump the pressure. This supply continues until the P1 port pressure is recovered to the level equivalent to the lever position. • When the operation valve spool returns, oil in the drain room D flows in through the fine control hole f' on the not moving side valve. Oil is then conducted via P2 port to the room B to fill it up.
4. In the full stroke mode • When the disk (5) pushes down the piston (4) and the retainer (9) pushes down the spool (1), connection of the fine control hole f is switched from the drain room D to the pump pressure room PP. • Thus, pilot pressurized oil from the control pump passes through the fine control hole f and conducted to A room via P1 port to push the operation valve spool. • Return oil from B room is conducted from P2 port to the drain room D via the fine control hole f'.
10-112
PC130-7
STRUCTURE AND FUNCTION
PPC VALVE
FOR SERVICE
1. 2. 3. 4. 5. 6. 7. 8. 9.
Spool Metering spring Centering spring Piston Lever Plate Retainer Body Filter
PC130-7
P T P1 P
: From self pressure reducing valve : To tank : To blade or service valve : To blade or service valve
10-113
STRUCTURE AND FUNCTION
PPC VALVE
OPERATION 1. In the neutral mode • P1 and P2 ports of the operation valves A, B and PPC valve are connected to the drain room D via the fine control hole f on the spool (1).
2. In the fine control mode (Neutral fine control) • As the piston (4) is pushed by the disk (5), the retainer (7) is pushed, too. At the same time, the spool (1) is also pushed down via the metering spring (2). • By this move, connection of the fine control hole f is switched from the drain room D to the pump pressure room PP, and pilot pressurized oil for the control pump is conducted from P1 port to A port. • As P1 port pressure increases, the spool (1) is pushed back. By this move, connection of the fine control hole f is switched from the pump pressure room PP to the drain room D, thereby relieving P1 port pressure. • As the result, the spool (1) moves up and down so that force of the metering spring (2) and P1 port pressure may be balanced. • Positional relationship between the spool (1) and body (8) (fine control hole f is situated at mid point between the drain room D and pump pressure room PP) remains unchanged until the retainer (7) is contacted against the spool (1). • The metering spring (2) is, therefore, compressed in proportion to strokes of the operation lever. Thus, the P1 port pressure, too, increases in proportion to strokes of the operation lever. • As the result, the operation valve spool moves to the position where pressure of A room (the same as P1 port pressure) is balanced against force of the operation valve spool return spring.
o
10-114
PC130-7
STRUCTURE AND FUNCTION
PPC VALVE
3. In the fine control mode (when the operation lever is shifted back to its original position) • As the lever (5) starts returning, the spool (1) is pushed up by force of the centering spring (3) and P1 port pressure. By this move, the fine control hole f is connected to the drain room D and relieves pressurized oil of P1 port to it. • If P1 port pressure goes excessively low, the spool (1) is pushed down by the metering spring (2) and passage between the fine control hole f and the drain room D is shut down. And, almost at the same time, the hole is connected to the pump pressure room PP and starts supplying pump the pressure. This supply continues until the P1 port pressure is recovered to the level equivalent to the lever position. • When the operation valve spool returns, oil in the drain room D flows in through the fine control hole f' on the not moving side valve. Oil is then conducted via P2 port to the room B to fill it up.
4. In the full stroke mode • When the disk (5) pushes down the piston (4) and the retainer (7) pushes down the spool (1), connection of the fine control hole f is switched from the drain room D to the pump pressure room PP. • Thus, pilot pressurized oil from the control pump passes through the fine control hole f and conducted to A room via P1 port to push the operation valve spool. • Return oil from B room is conducted from P2 port to the drain room D via the fine control hole f'.
PC130-7
10-115
STRUCTURE AND FUNCTION
WORK EQUIPMENT
WORK EQUIPMENT
1. 2. 3. 4. 5. 6. 7.
Bucket Link Bucket cylinder Arm Arm cylinder Boom Boom cylinder
10-116
PC130-7
STRUCTURE AND FUNCTION
AIR CONDITIONER PIPING
AIR CONDITIONER PIPING
A: B: C: D:
Hot air/cold air spurting port Internal air circulation port External air inlet Refrigerant checking port
1. 2. 3. 4.
Hot water inport piping Air conditioner compressor Condenser Refrigerant piping
PC130-7
5. 6. 7. 8.
Receiver tank Hot water return piping Air conditioner unit Duct
10-117
STRUCTURE AND FUNCTION
ENGINE CONTROL
ENGINE CONTROL
1. 2. 3. 4. 5. 6. 7. 8. 9.
Starting switch Fuel control dial Governor motor Starting motor Linkage Battery relay Battery Engine throttle and pump controller Fuel injection pump
10-118
OUTLINE • The engine can be started and stopped with only starting switch (1). • The engine throttle and pump controller(8) reveives the signal of fuel control dial (2) and transmits the drive signal to governor motor (3) to control the governor lever angle of fuel injection pump (9) and control the engine speed.
PC130-7
STRUCTURE AND FUNCTION
ENGINE CONTROL
1. OPERATION OF SYSTEM Starting engine • When the starting switch is turned to the START position, the starting signal flows to the starting motor, and the starting motor turns to start the engine. When this happens, the engine throttle and pump controller checks the signal from the fuel control dial and sets the engine speed to the speed set by the fuel control dial.
Engine speed control • The fuel control dial sends a signal to the engine throttle and pump controller according to the position of the dial. The engine throttle and pump controller calculates the angle of the governor motor according to this signal, and sends a signal to drive the governor motor so that it is at that angle. When this happens, the operating angle of the governor motor is detected by the potentiometer, and feedback is sent to the engine throttle and pump controller, so that it can observe the operation of the governor motor.
Stopping engine • When the starting switch is turned to the STOP position, the engine throttle and pump controller drives the governor motor so that the governor lever is set to the NO INJECTION position. • When this happens, to maintain the electric power in the system until the engine stops completely, the engine throttle and pump controller itself drives the battery relay.
PC130-7
10-119
STRUCTURE AND FUNCTION
ENGINE CONTROL
2. COMPONENT Fuel control dial 1. 2. 3. 4. 5. 6.
Knob Dial Spring Ball Potentiometer Connector
FUNCTION • The fuel control dial is installed under the monitor panel, and a potentiometer is installed under the knob. The potentiometer shaft is turned by turning the knob. • As the potentiometer shaft is turned, the resistance of the variable resistor in the potentiometer changes and a throttle signal is sent to the engine throttle and pump controller. The hatched area in the graph shown at right is the abnormality detection area.
10-120
PC130-7
STRUCTURE AND FUNCTION
ENGINE CONTROL
GOVERNOR MOTOR
1. 2. 3. 4. 5. 6. 7. 8.
Potentiometer Cover Shaft Dust seal Bearing Motor Gear Connector
OPERATION While motor is stopped • Electric power is applied to both phases A and B of the motor. While motor is running • The engine throttle and pump controller supplies a pulse current to phases A and B, and the motor revolves, synchronizing to the pulse.
FUNCTION • The motor is turned according to the drive signal from the engine throttle and pump controller to control the governor lever of the fuel injection pump. This motor used as the motive power source is a stepping motor. • A potentiometer for feedback is installed to monitor the operation of the motor. • Revolution of the motor is transmitted through the gear to the potentiometer. PC130-7
10-121
STRUCTURE AND FUNCTION
ELECTRIC CONTROL SYSTEM
ELECTRIC CONTROL SYSTEM CONTROL FUNCTION
1 Engine/Pump composite control function
2 Pump/Valve control function
3 One-touch power maximizing function
4 Auto-deceleration function
5 Electric control system
Auto-warm-up/Overheat prevention function
6 Swing control function
7 Travel control function
8 ATT flow control, circuit selector function (if equipped)
Self-diagnosis function
10-122
PC130-7
STRUCTURE AND FUNCTION
ELECTRIC CONTROL SYSTEM
MACHINE CONTROL SYSTEM DIAGRAM
10-124
PC130-7
STRUCTURE AND FUNCTION
PC130-7
ELECTRIC CONTROL SYSTEM
10-125
STRUCTURE AND FUNCTION
ELECTRIC CONTROL SYSTEM
1. ENGINE AND PUMP CONTROL FUNCTION
10-126
PC130-7
STRUCTURE AND FUNCTION
ELECTRIC CONTROL SYSTEM
FUNCTION • This function is for selecting any of the three working modes "A," "B", "E" and "L" with the working mode selector switch on the monitor panel. The controller can select optimum engine torques or pump absorption torques for works to be expected. •
The controller detects the engine governor speed set with the fuel control dial depending on the pump absorption torque set in each mode and detects actual engine speeds. Then, the controller controls all torques at each output point of the engine so that the pump can absorb them.
•
When an engine speed was lowered, the controller prevents the engine from stopping by throttling the pump absorption toque.
PC130-7
10-127
STRUCTURE AND FUNCTION
1. CONTROL METHOD IN EACH MODE Mode A • Matching point in Mode A • When a load to the pump increases and the pressure rises and the engine speed lowers. At the time, the controller reduces the pump delivery so that the speed lowers to the speed at the full output point or so. If the pressure drops on the contrary, the controller increases the pump delivery so that the speed comes to the speed at the full output point or so. The controller repeats these controls so that the engine can always be used at speeds at the full output point or so.
10-128
ELECTRIC CONTROL SYSTEM
A Travel (A1)
66.2 kW/2,200 rpm {88.7 HP/2,200 rpm}
A Work (A2)
65.5 kW/2,200 rpm {87.8 HP/2,200 rpm}
PC130-7
STRUCTURE AND FUNCTION
ELECTRIC CONTROL SYSTEM
Mode E / Mode B / Mode L Mode Partial output point
Model
E
B
L
90%
90%
56%
PC130-7
Mode E
58.8 kW/2,000 rpm {78.9 HP/2,000 rpm}
Mode B
58.8 kW/2,000 rpm {78.9 HP/2,000 rpm}
Mode L
36.8 kW/1,500 rpm {70 HP/1,500 rtpm}
•
•
At this time, the controller keeps the pump absorption torque along the constant horsepower curve and lower the engine speed by the composite control of the engine and pump. By this method, the engine is used in the low fuel consumption area.
PC130-7
10-129
STRUCTURE AND FUNCTION
ELECTRIC CONTROL SYSTEM
2. FUNCTION TO CONTROL PUMP DURING TRAVEL • If the machine travels in mode work A, B, E, or L, the working mode does not change, but the pump absorption torque and engine speed rise to travel A mode.
3. PUMP DRIVE IN AN EMERGENCY • Even if controllers and sensors get out of order, the emergency pump drive switch (S) will enable to maintain functions of the machine with absorption torques quite similar to those in the Mode E. In this case, a constant current flows from the battery to the PC-EPC valve, and the valve detects the oil pressure only. (1) Normal (2) Emergency
a
The emergency pump drive switch (S) is of the alternative type. If the machine is operated after the switch is set to "Emergency (2)" even though the machine is normal, the user code "E02" will be shown on the display.
10-130
PC130-7
STRUCTURE AND FUNCTION
ELECTRIC CONTROL SYSTEM
2. PUMP/VALVE CONTROL FUNCTION
FUNCTION • The machine is matched to various types of work properly with the 2-stage relief function to increase the digging force, etc.
PC130-7
10-131
STRUCTURE AND FUNCTION
ELECTRIC CONTROL SYSTEM
1) Cut-off function • When the cut-off function is turned on, the PC-EPC current is increased to near the maximum value. By this operation, the flow rate in the relief state is lowered to reduce fuel consumption. • Operating condition for turning on cut-off function. Condition •
The average value of the front and rear pressure sensors is above 27.9 MPa {285 kg/cm 2} and the one-touch power maximizing function is not turned on
The cut-off function does not work, however, while the machine is traveling in mode A, the lock switch is turned on. 2) 2-stage relief function • The relief pressure in the normal work is 31.9 MPa {325 kg/cm2}. If the 2-stage relief function is turned on, however, the relief pressure rises to about 34.8 MPa {355 kg/cm 2}. By this operation, the hydraulic force is increased further. • Operating condition for turning on 2-stage relief function Condition • • • •
During travel When swing lock switch is turned on When one-touch power maximizing function is turned on When L mode is operated
10-132
Relief pressure 31.9 MPa {325 kg/cm2}
⇓
34.8 MPa {355 kg/cm2}
PC130-7
STRUCTURE AND FUNCTION
ELECTRIC CONTROL SYSTEM
3. ONE-TOUCH POWER MAXIMIZING FUNCTION
FUNCTION • Power can be increased for about 8.5 sec. by operating the left knob switch.
PC130-7
10-133
STRUCTURE AND FUNCTION
ELECTRIC CONTROL SYSTEM
1) One-touch power maximizing function • When the operator needs more digging force to dig up a large rock, etc., if the left knob switch is pressed, the hydraulic force is increased about 9% to increase the digging force. • If the left knob switch is turned on in working mode "A" or "E", each function is set automatically as shown below.
⇓ Software cut-off function Working mode
Engine/Pump control
A, E
Matching at rated output point
10-134
2-stage relief function 31.9 MPa {325 kg/cm2}
⇓
34.8 MPa {355 kg/cm2}
Operation time Automatically Cancel reset at 8.5 sec
PC130-7
STRUCTURE AND FUNCTION
ELECTRIC CONTROL SYSTEM
4. AUTO-DECELERATION FUNCTION
FUNCTION • If the all control levers are set in NEUTRAL while waiting for a dump truck or work, the engine speed is lowered to the medium level automatically to reduce the fuel consumption and noise. • If any lever is operated, the engine speed rises to the set level instantly.
PC130-7
10-135
STRUCTURE AND FUNCTION
ELECTRIC CONTROL SYSTEM
OPERATION When control levers are set in neutral • If all the control levers are set in NEUTRAL while the engine speed is above the decelerator operation level (about 1,400 rpm), the engine speed lowers instantly to the first deceleration level about 100 rpm lower than the set speed. • If 4 more seconds pass, the engine speed lowers to the second deceleration level (about 1,400 rpm) and keeps at that level until any lever is operated again. When any control lever is operated • If any control lever is operated while the engine speed is kept at the second deceleration level, the engine speed rises instantly to the level set with the fuel control dial.
10-136
PC130-7
STRUCTURE AND FUNCTION
ELECTRIC CONTROL SYSTEM
5. AUTO-WARM-UP/OVERHEAT PREVENTION FUNCTION
FUNCTION • After the engine is started, if the engine cooling water temperature is low, the engine speed is raised automatically to warm up the engine. If the engine cooling water temperature rises too high during work, the pump load is reduced to prevent overheating.
PC130-7
10-137
STRUCTURE AND FUNCTION
ELECTRIC CONTROL SYSTEM
1) Auto-warm-up function • After the engine is started, if the engine cooling water temperature is low, the engine speed is raised automatically to warm up the engine. Operating condition (All)
Operated
⇒
Water temperature: Below 30°C. Engine speed: Max. 1,200 rpm
Engine speed: Max. 1,200 rpm
⇓ Resetting condition (Any one) Auto Manual
Water temperature: Above 30°C Auto-warm-up operation time: Min. 10 minutes
⇒
Engine speed: Any level
Fuel control dial: Kept at 70% of full level for 3 sec. or longer
Operating condition
Water and oil temperature: Above 105°C
Operation/Remedy
⇒
Operating condition
Water and oil temperature: Above 102°C
Water and oil temperature: Above 98°C
⇒
Water and oil temperature: Below 105?C
⇒
Work mode: Mode A, E, OR B Engine speed: Keep as is. Monitor alarm lamp: Lights up. Lower pump discharge.
⇒
Work mode: Mode A Engine speed: Keep as is. Lower pump discharge.
⇒
Work mode: Travel Engine speed: Keep as is. Lower travel speed.
• Under above condition, controller is set to condition before operation of function. (Manual reset)
Water and oil temperature: Below 102°C • Under above condition, controller is set to condition before operation of function. (Automatic reset) Resetting condition
⇒
Operation/Remedy
⇒
Fuel control dial: Return to low idle position once.
Resetting condition
Operation/Remedy
Operating condition
Water and oil temperature: Above 95°C
Work mode: Any mode Engine speed: Low idle Monitor alarm lamp: Lights up Alarm buzzer: Sounds
Resetting condition
Operation/Remedy
Operating condition
10-138
Reset
Water and oil temperature: Below 98°C • Under above condition, controller is set to condition before operation of function. (Automatic reset) Resetting condition
⇒
Water and oil temperature: Below 95°C • Under above condition, controller is set to condition before operation of function. (Automatic reset)
PC130-7
STRUCTURE AND FUNCTION
ELECTRIC CONTROL SYSTEM
6. SWING CONTROL FUNCTION
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Battery Battery relay Fusible link Starting switch Fuse box Controller Swing holding brake release switch Swing lock switch Monitor panel Swing holding brake solenoid valve
Input/Output Signals a. Controller power supply b. Solenoid power supply c. Monitor panel power supply d. S-NET signal
PC130-7
11. 12. 13. 14. 15. 16. 17. 18.
PPC lock solenoid valve Swing motor L.H. work equipment PPC valve Arm IN PPC oil pressure switch Swing PPC oil pressure switch Engine Hydraulic pump Control valve 18a. Self pressure reducing valve 18b. Main relief valve
e. Solenoid valve drive signal f. Swing PPC oil pressure switch signal g. Arm IN PPC oil pressure switch signal
10-139
STRUCTURE AND FUNCTION
FUNCTION Swing lock and swing holding brake • The swing lock (manual type) is for locking swing at optional positions. The swing holding brake (automatic type) interlocks with swing and prevents hydraulic drift from occurring after stop of swing. When the swing lock is released, only the hydraulic brake with the safety valve is effective for swing. So, note that, when a swing stops on a slope, a hydraulic drift may occur sometimes. Even during arm IN operation, release the swing holding brake.
ELECTRIC CONTROL SYSTEM
Swing lock switch
a
OFF
Swing lock monitor
Function
The lamp Swing holding goes brake OUT.
• When the swing control lever is set to NEUTRAL, the swing holding brake works 4 sec. later. • When the swing control lever or the arm IN lever is operated, the swing holding brake is released and free swing becomes possible.
The lamp Swing turns ON. lock
• The swing holding brake works, and the swing is locked. • Even if the swing control lever is operated, the swing holding brake cannot be released, and no swing is possible.
a
ON
Release of swing holding brake • If the controller gets out of order and no swing is possible because the swing holding brake does not work normally, use the swing holding brake release switch (S), and the swing holding brake will be released and swing will become possible. (1) Normal (2) Release
a
Even if the swing holding brake release switch is set to "ON," the swing holding brake is not be released while the swing lock switch is set to "ON."
Operation
Swing ON holding (when the controller brake reis out of order) lease switch Swing lock switch
Swing brake
OFF (when the controller is in order)
ON
OFF
ON
OFF
The swing lock works.
The swing lock is released.
The swing lock works.
The swing holding brake works.
Input/Output signal time chart
10-140
PC130-7
STRUCTURE AND FUNCTION
ELECTRIC CONTROL SYSTEM
7. TRAVEL CONTROL FUNCTION
1. 2. 3. 4. 5. 6. 7. 8. 9.
Battery Battery relay Fusible link Starting switch Fuse box Controller Monitor panel Travel speed selector solenoid valve L.H. travel motor
Input/Output signals a. Controller power supply b. Solenoid power supply c. Monitor panel power supply d. S-NET signal
PC130-7
10. 11. 12. 13. 14. 15.
R.H. travel motor Engine speed sensor Pump pressure sensor Engine Hydraulic pump Control valve 15a. Self pressure reducing valve 15b. Main relief valve
e. Solenoid valve drive signal f. Engine speed signal g. Pump pressure signal
10-141
STRUCTURE AND FUNCTION
FUNCTION Travel Speed Selection 1. Travel Speed "Manual" Change • When the travel speed selector switch is set to LOW or HIGH, the motor capacity changes and travel speeds can be selected.
ELECTRIC CONTROL SYSTEM
Travel speed selector switch
LOW (low speed)
HIGH (high speed)
Motor capacity (cc/rev)
52.7
33.2
Travel speed (km/h)
2.7
5.5
Maximum
Minimum
ravel motor swash plate angle
2. "Automatic"change of travel speed 1) Automatic selection corresponding to engine speed • If engine speed drops to 1,500 rpm or less when travel speed selector switch is in HIGH and travel speed is HIGH, travel speed changes to LOW automatically. • If engine speed becomes 1,700 rpm or less when travel speed selector switch is in HIGH and travel speed is LOW, travel speed changes to HIGH automatically. If travel speed selector switch is in LOW, travel speed is not changed automatically.
a
2) Automatic selection corresponding to discharge pressure of pump • If travel pressure of 30.4MPa {310 kg/ cm 2} or higher continues for 0.2 seconds or more when travel speed selector switch is in HIGH, travel speed changes to LOW automatically. • If travel pressure of 16.7MPa {170 kg/ cm 2} or lower continues for 0.2 seconds or more when travel speed selector switch is in HIGH, travel speed changes to HIGH automatically. If travel speed selector switch is in LOW, travel speed is not changed automatically.
a
10-142
PC130-7
STRUCTURE AND FUNCTION
ELECTRIC CONTROL SYSTEM
8. PPC LOCK FUNCTION
1. 2. 3. 4. 5. 6. 7. 8. 9.
Battery Battery relay Fusible link Starting switch Fuse box Controller Safety lock lever PPC lock switch PPC lock solenoid valve
10. 11. 12. 13. 14. 15. 16.
Left work equipment PPC valve Right work equipment PPC valve Traveling PPC valve Blade PPC valve (Blade specification) Engine Hydraulic pump Operation valve 16a. Self pressure reducing valve 16b. Man relief valve
Input/Output signals a. Power supply of controller b. Power supply of solenoids c. Solenoid valve driving signals
Function • PPC lock switch works with safety lock lever. Setting safety lock lever to "Lock", PPC lock switch turns to "OFF". • Turning PPC lock switch to "OFF" shuts off current to PPC lock solenoid valve, making operation lever on the work equipment disabled.
PC130-7
10-143
STRUCTURE AND FUNCTION
ELECTRIC CONTROL SYSTEM
SELF DIAGNOSIS FUNCTION 1. Error code display/Alarm functions • Controller always watches electronic devices which constitutes the system, including controller itself, each potentiometer which issues input signals, each solenoid valve which receives output signals, and EPC valves, to check for they normal operation. • If an abnormality occurred in any of these devices, the controller diagnoses it and display the results on display (1) of monitor panel as a "USER CODE" or "SERVICE CODE", sounding alarm buzzer at the same time to notify the abnormality to operator. Refer to the "TROUBLESHOOTING" section as for the details of display and measures to be taken.
a
2. Error code memory function • Controller takes in memory the error code diagnosed about an abnormality which occurred in advanced system. Refer to the "TESTING AND ADJUSTING" section as for the details of display and how to reset.
a
10-144
PC130-7
STRUCTURE AND FUNCTION
ELECTRIC CONTROL SYSTEM
SYSTEM COMPONENTS ENGINE SPEED SENSOR
FUNCTION • The engine speed sensor is installed on the ring gear of the engine flywheel. It electrically counts number of gear teeth that pass its front side and sends the counting to the controller.
1. 2. 3. 4. 5.
Magnet Terminal Case Boots Connector
Remarks : Number of ring gear teeth is 127. •
For the count, a magnet is used which generates current every time a gear tooth passes its front side.
PC130-7
10-145
STRUCTURE AND FUNCTION
ELECTRIC CONTROL SYSTEM
PPC HYDRAULIC SWITCH
SPECIFICATION Contact structre : Normally opened Operating (ON) pressure : 490 ± 98.1 kPa {5.0 ± 1.0 kg/cm2} Resetting (OFF) pressure : 294 ± 49.0 kPa {3.0 ± 0.5 kg/cm2}
1. Plug 2. Switch 3. Connector
FUNCTION • 8 switches installed to junction block sense operating condetion of each actuator, and send it to controller. • 1 switch installed to travel PPC valve sense travel operating condition, and send it to controller.
10-146
PC130-7
STRUCTURE AND FUNCTION
ELECTRIC CONTROL SYSTEM
CONTROLLER
PC130-7
10-147
STRUCTURE AND FUNCTION
ELECTRIC CONTROL SYSTEM
Input/output signals CN-1
CN-2
Pin No.
Signal name
Input/ output
Pin No.
CN-3 Signal name NC
Input/ output
Pin No.
Output
1
Control power supply
Input Input
Signal name
1
NC
Input
1
2
NC
Input
2
Swing prolix switch
Input
2
Solenoid power supply
3
NC
Input
3
NC
Input
3
SOL_COM
4
Signal GND
5
NC
6 7 8
Input/ output
—
—
4
232C_RxD
Input
4
Battery relay drive
Output
Input
5
NC
Input
5
Motor drive a (+)
Output
NC
Input
6
6
LS_EPC
Output
Input
Over load caution enable switch
Input
Overload pressure sensor
Input
Output
Input
Machine select 4
NC
Pump pressure sensor
7
7
NC
Output
8
NC
Output
Input
8 9
NC
Output
10
NC
Input
11
NC
Output
12
CAN shield
13
Machine select 5
14
232C_TxD
15
NC
16
NC
Input
17
Machine select 3
Input
18
NC
Output
19
NC
Output
20
NC
Input
21
S_NET
22
CANO_L
23
CAN1_L
9
NC
10
Signal GND
—
11
Knob switch
Input
12
NC
Input
13
Feed back signal
Input
14
NC
Input
15
NC
Input
16
SENS_PWR
17
Start switch (C)
Input
18
NC
Input
19
Fuel dial
Input
20
NC
Input
21
Analog GND
Output
—
22
POT_PWR
23
Start switch (Acc)
Input
24
NC
Input
10-148
Output
— Input Output Input
Input/ Output Input/ Output Input/ Output
9
Bucket curl switch
Input
10
Boom ralse switch
Input
11
Control power supply
Input
12
Solenoid power supply
Input
13
SOL_COM
—
14
Key signal
Input
15
Motor drive a (-)
Output
16
PC-EPC
Output
17
NC
Output
18
Heater relay solenoid
Output
19
Bucket dump switch
Input
20
Boom lower switch
Input
21
GND
22
Solenoid power supply
23
SOL_COM
24
Key signal
25
Motor drive b (+)
— Input — Input Output
24
Flash memory write enable signal
Input
26
NC
Output
25
NC
Input
27
Travel speed solenoid
Output
26
NC
Input
28
2-stage rellef solenoid
Output
27
Machine select 2
Input
29
Swing switch
Input
28
NC
Input
30
Arm curl switch
Input
29
Puls GND
—
31
GND
—
30
NC
Input
32
GND
—
31
GND (S_NET GND)
—
33
GND
—
32
CAN0_H
34
NC
33
CAN1_H
Input/ Output Input/ Output
35
Motor drive b (-)
Output
34
GND (232C GND)
—
36
NC
Output
35
Service switch
—
37
Swing brake solenoid
Output
36
NC
Input
38
NC
Output
37
Machine select 1
Input
39
Travel switch
Input
38
Swing lock switch
Input
40
Arm dump switch
Input
39
Puls GND
40
Eng. speed
— Input
PC130-7
STRUCTURE AND FUNCTION
ELECTRIC CONTROL SYSTEM
PUMP PRESSURE SENSOR
1. Plug 2. Sensor 3. Connector
FUNCTION • Mounted on the inlet circuit of control valve, this sensor changes discharging pressure of pump into voltage, and send it to automatic travel speed change controller.
Monitor panel Refer to the section describing the "Monitor System".
a
PC valve LS valve PC-EPC valve Refer to the section describing the "Hydraulic Pump (Piston pump)". LS-EPC valve Refer to the section describing the "Hydraulic Pump (Piston pump)".
a a
PPC lock solenoid valve 2nd speed select solenoid valve Swing hold brake solenoid valve 2-stage relief solenoid valve Refer to the section describing the "Solenoid Valve".
a
PC130-7
10-149
STRUCTURE AND FUNCTION
MONITOR SYSTEM
MONITOR SYSTEM
1. 2. 3. 4. 5.
Monitor panel Battery Controller Sensors and switches Wiper motor, window washer motor
Description • The monitor system monitors conditions of the machine with sensors mounted on its each section, processes promptly the information obtained, and displays it on panel to let operator know the conditions of the machine.
Input/Output signals a. Power supply b. Switch signal c. Caution signal d. Sensor/switch signal e. Sensor/switch signal f. Output for driving
10-150
PC130-7
STRUCTURE AND FUNCTION
MONITOR SYSTEM
MONITOR PANEL
OUTLINE • The monitor panel has the functions to display a monitor, gauge, service meter and electric system. It has also an alarm buzzer built in. • A CPU (Central Processing Unit) mounted inside processes, displays and outputs information.
Input/Output signals AMP070-12P [CN-P01] Pin No. 1 2 3 4 5 6 7 8 9 10 11 12
PC130-7
Signal name Starting switch (battery) Starting switch (battery) Window washer motor output Starting switch (C-terminal) Wiper W-contact GND GND VB + (24V) Wiper motor (+) Wiper motor (–) Alarm buzzer ON signal Wiper P-contact
•
•
The monitor's switch section consists of three flat type sheet switches. Pressing any of these switches changes the conditions of the machine, which are shown by LEDs located above the switches turned ON. The monitor does not give correct display if any of the monitor panel unit, controller, or the wiring between monitor-panel and controller is in abnormal condition.
AMP040-20P [CN-P02] I/O signal Input Input Output Input Input — — Input Output Output Input Input
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Signal name Engine coolant temperature Fuel level Radiator coolant level NC Air cleaner clogging NC Engine oil pressure Engine oil level S-NET signal S-NET signal Battery charge level Hydraulic oil level GND (analog signal) NC Pull-up window limit switch Alarm buzzer cancel Swing lock Preheating Lamp switch GND (S-NET)
I/O signal Input Input Input Input Input Input Input Input Input/Output Input/Output Input Input — — Input Input Input Input Input —
10-151
STRUCTURE AND FUNCTION
MONITOR SYSTEM
METER DISPLAY
No. 1
Display category
Display item
Service meter
[*1] Display 2 3a Gauge 3b Caution
Coolant temperature
4a Gauge 4b Caution 5
6
Pilot
8 9
Caution
11 12
Display method
Time counting while engine is in operation (alternator is generating) (Always lit even if starting switch is OFF) Count time during engine operates. Alphanumerics in 2 Displays 2 digit alphanumerics (user code or digits service code) if electric control system is in abnormal condition. See picture above All the segments of the corresponding level and lower are turned ON. Specified tempera- (Level 8 (102°C or higher):Monitor lamp blinks. ture (102°C) or Level 9: Monitor lamp blinks and alarm buzzer higher sounds.) See picture above All the segments of the corresponding level and lower are turned on. (Level 1 (42 l or less): Specified level Monitor lamp blinks.) (42 l) or lower
Display Remarks color
0 – 99999.9 h
Blue
LCD
Red
LED
Blue
LCD
Red
LED
Turned on for about 30 seconds after starting switch was turned to "HEAT". It blinks (for about 10 seconds) after preheating was over to notify it to operator, and then it is turned off. • Turned on when the swing lock function is acWhen swing-lock is tive. Swing lock in operation • Blinks when swing holding brake release Green switch was turn on. • Turned ON when specified oil maintenance periods (125h, 250, and 500h) elapsed. (Also, When specified oilOil elapsed time and telephone No. of your dealmaintenance perimaintenance er are shown on service meter.) ods elapsed • Not turned on if no oil maintenance period has been specified. Engine oil level Max. low level Battery charge Charge in fault (charge voltage < level battery voltage) Turned ON when starting switch was turned on; Air cleaner turned off after engine started running. At clogging clogging In normal condition : turned OFF Red In abnormal condition : turned ON Lower than the Engine oil specified pressure (As for engine oil pressure, charge and over pressure 49 kPa {0.5 kg/cm2} load alarm buzzer sounds if the pressure became abnormal when engine was running.) Min. specified presOver load sure 16.7 MPa {170 kg/cm2} Preheating
[*2] 7
10
Fuel level
Display area
During preheating
Lamp
[*1] As for display and operation, refer to the "Self Diagnosis Function" section. [*2] As for display and operation, refer to the "Troubleshooting" chapter.
10-152
PC130-7
STRUCTURE AND FUNCTION
MONITOR SYSTEM
MONITOR SWITCH
No. 1
2
3
4
* 5
*
a
Name
Function
Operation
Used to select a travel speed from two of them. "Lo" is lit: Travel in low speed. Travel speed selector switch "Hi" is lit: Travel in high speed. Lo Hi Activates the function to reduce fuel consumption. Turned ON: The function is active. ON OFF Auto-deceleration switch Turned OFF: The function is not active. (Lit) Activates wiper of front glass. "ON" is lit: Wiper works continuously. OFF INT ON Wiper switch "INT" is lit: Wiper works intermittently. (Not lit) (Intermittent) (Continuous) Not lit: Wiper is not working. [When wiper is not working] ON : Washer fluid is sprayed and wiper works continuously. OFF : Wiper works twice and stops after the switch was released. [When wiper is working intermitWind washer switch Sprays washer fluid onto front glass. tently] ON : Washer fluid is sprayed and wiper works continuously. OFF : Wiper works twice and returns to intermittent operation after the switch was released. Sets the movement and force of the working equipment. "A" is lit: A mode (for heavy duty work) Operation mode selector A E L B "E" is lit: E mode (for fuel economical operation) switch "L" is lit: L mode (for fine control work) "B" is lit: B mode (for breaker work)
You can change the default settings which become active when starting switch is turned on. Refer to the "TROUBLESHOOTING" chapter. Signs written in bold fonts in the "Operation" column above represent the positions switches default to when starting switched is turned on.
PC130-7
10-153
STRUCTURE AND FUNCTION
MONITOR SYSTEM
SENSORS • • •
Signal from a sensor is directly entered to the panel. There are two types of sensors, contact type and resistance type. One end of a contact type sensor is connected to the ground on the machine body. Display class Caution Gauge
Sensor type Engine oil pressure Coolant temperature Fuel level Hydraulic oil temperature
Sensing approach Contact Resistance Resistance Resistance
When normal OFF (open) — — —
When failed ON (closed) — — —
ENGINE OIL PRESSURE SENSOR
1. Plug 2. Contact ring 3. Contact
4. Diaphragm 5. Spring 6. Terminal
COOLANT TEMPERATURE SENSOR HYDRAULIC OIL TEMPERATURE SENSOR
1. Connector 2. Plug 3. Thermistor
10-154
PC130-7
STRUCTURE AND FUNCTION
MONITOR SYSTEM
FUEL LEVEL SENSOR
1. 2. 3. 4.
Float Connector Cover Variable resisto
PC130-7
10-155
40 MAINTENANCE STANDARD
SWING MACHINERY .............................................................. 40- 2 SWING CIRCLE ...................................................................... 40- 4 TRACK FRAME, IDLER CUSHION......................................... 40- 5 IDLER ...................................................................................... 40- 6 CARRIER ROLLER ................................................................. 40- 7 TRACK ROLLER ..................................................................... 40- 8 SPROCKET ............................................................................. 40- 9 TRACK SHOE ......................................................................... 40-10 HYDRAULIC PUMP................................................................. 40-14 CONTROL VALVE ................................................................... 40-15 SUCTION SAFETY VALVE ..................................................... 40-24 SELF PRESSURE REDUCTION VALVE ................................ 40-25 TRAVEL MOTOR..................................................................... 40-26 SWING MOTOR ...................................................................... 40-27 SOLENOID VALVE .................................................................. 40-28 CENTER SWIVEL JOINT ........................................................ 40-29 PPC VALVE ............................................................................. 40-30 HYDRAULIC CYLINDER ......................................................... 40-34 WORK EQUIPMENT ............................................................... 40-36 DIMENSION OF WORK EQUIPMENT.................................... 40-38
PC130-7
40-1
MAINTENANCE STANDARD
SWING MACHINERY
SWING MACHINERY
40-2
PC130-7
MAINTENANCE STANDARD
SWING MACHINERY
Unit: mm No.
Check item
Criteria
Remedy
Standard clearance
Clearance limit
0.07 – 0.18
0.4
Backlash between No.1 sun gear and No.1 planetary gear.
0.13 – 0.31
0.6
3
Backlash between No.1 planetary gear and ring gear.
0.15 – 0.34
0.7
4
Backlash between No.1 planetary carrier and No.2 sun gear.
0.14 – 0.34
0.7
5
Backlash between No.2 sun gear and No.2 planetary gear.
0.13 – 0.31
0.6
6
Backlash between No.2 planetary gear and ring gear.
0.15 – 0.34
0.7
7
Backlash between No.2 planetary carrier and swing pinion.
0.08 – 0.19
0.4
8
Backlash between swing pinion and swing circle.
0.13 – 1.16
2.3
Standard size
Repair limit
9
Wear of swing pinion surface contacting with oil seal.
0
144.8
1
Backlash between swing motor shaft and No.1 sun gear.
2
PC130-7
145 - 0.1000
Replace
Apply hardchrome plating recondition, or replace
40-3
MAINTENANCE STANDARD
SWING CIRCLE
SWING CIRCLE
Unit: mm No.
1
40-4
Check item
Axial clearance of bearing
Criteria
Remedy
Standard clearance
Clearance limit
0.10 – 0.25
0.9
Replace
PC130-7
MAINTENANCE STANDARD
TRACK FRAME, IDLER CUSHION
TRACK FRAME, IDLER CUSHION
Unit: mm No.
1
2
Check item
Idler guide top and bottom width
Idler guide left and right width
Criteria Standard size
Clearance limit
Track frame
84
89
Idler support
82
77
Rebuild or replace
Track frame
185
193
Rebuild
Idler support
183
175
Rebuild or replace
Standard size 3
Recoil spring
PC130-7
Remedy
Rebuild
Repair limit
Free length
Installed length
Installed load
Free length
Installed load
502
390
84.3 kN {8,600 kg}
490
75.0 kN {7,650 kg}
Replace
40-5
MAINTENANCE STANDARD
IDLER
IDLER
Unit: mm No.
Check item
Criteria
Remedy
Standard size
Repair limit
527
—
Outer diameter of tread
489
477
3
Depth of protruding portion
19
25
4
Width of protruding portion
52
42
5
Total width
115
107
6
Width of tread
31.5
36.5
1
Outer diameter of protruding portion
2
7
Clearance between idler shaft and bushing
Standard size 54
8
Interference between idler and bushing
Standard size 61
9
Side clearance of idler (on one side)
10
Tread wall thickness (at center of tread)
40-6
Tolerance
Rebuild or replace
Shaft
Hole
Standard clearance
Clearance limit
– 0.250 – 0.280
+ 0.074 0
0.250 – 0.354
1.5
Tolerance Shaft
Hole
+ 0.117 + 0.087
+ 0.030 0
Standard in- Interference terference Replace limit 0.057 – 0.117
Standard clearance
Clearance limit
0.18 – 0.38
1.5
Standard size
Repair limit
15
9
—
Rebuild or replace
PC130-7
MAINTENANCE STANDARD
CARRIER ROLLER
CARRIER ROLLER
Unit: mm No.
Check item
1
Outer diameter of tread
2
Width of tread
3
Clearance between shaft and bushing
Criteria Standard size
Repair limit
116
106
123
—
Standard size 40
4
Interference between collar and bushing
Standard size 47
5
Play on carrier roller in axial direction
6
Tread wall thickness (at 10 mm away from end face roller)
PC130-7
Remedy
Tolerance Shaft
Hole
Standard clearance
+ 0.055 – 0.035
+ 0.261 + 0.200
-0.145 – 0.226
Tolerance Shaft
Hole
+ 0.061 – 0.036
+ 0.025 0
Rebuild or replace —
Clearance limit — Replace
Standard in- Interference terference limit 0.011 – 0.061
Standard size
Repair limit
0.363 – 0.537
1.5
17.7
12.7
—
Rebuild or replace
40-7
MAINTENANCE STANDARD
TRACK ROLLER
TRACK ROLLER
Unit: mm No.
1
Check item
Criteria
Diameter of flange (outside)
Remedy
Standard size
Repair limit
158
—
2
Outer diameter of tread
130
120
3
Flange width
26.5
—
4
Total width
176
—
5
Width of tread
35
—
6
Clearance between shaft and bushing
Standard size 48
7
Interference between roller and bushing
Standard size 55
8
Track roller side clearance (on one side)
9
Tread wall thickness (at center of width)
40-8
Tolerance
Rebuild or replace
— Rebuild or replace
Shaft
Hole
Standard clearance
Clearance limit
– 0.250 – 0.350
+ 0.186 – 0.025
0.225 – 0.536
1.5
Tolerance Shaft
Hole
+ 0.190 + 0.110
+ 0.093 + 0.063
Standard in- Interference terference Replace limit 0.017 – 0.127
Standard clearance
Clearance limit
0.160 – 0.345
1.5
Standard size
Repair limit
37.5
32.5
—
Rebuild or replace
PC130-7
MAINTENANCE STANDARD
SPROCKET
SPROCKET
Unit: mm No.
Check item
Criteria
Remedy
Standard size
Tolerance
Repair limit
547.4
+ 1.0 – 2.0
535
Wear on addendum diameter
607
—
595
3
Wear on addendum width
27
—
22
4
Wear on tooth bottom width
42
± 1.5
39
5
Tooth bottom wall thickness
111.7
+ 0.465 – 1.160
105.5
1
Wear on tooth bottom diameter
2
PC130-7
Rebuild or replace
40-9
MAINTENANCE STANDARD
TRACK SHOE
TRACK SHOE TRIPLE SHOE, ROAD LINER, CITY PAD SHOE
a
1 Triple shoe and city pad shoe 2 Road liner P portion shows the link of bushing press fitting end.
40-10
PC130-7
MAINTENANCE STANDARD
TRACK SHOE
Unit: mm No.
1
Check item
Criteria
Link pitch
Standard size
Repair limit
175.25
178.25
Bushing outside diameter 46.3
3
Link height
4
Thickness of link metal (bushing pressfitting portion)
Turn of replace
When turned
Standard size 2
Remedy
Normal road
Impact road
—
42.3
Standard size
Repair limit
86
81
24
19
5
Rebuild or replace
102.4 Replace
6
Shoe bolt pitch
86.4
7
57
8 9
Inside diameter Link
10
52.4
Overall width
35
Tread width
30.1
11
Protrusion of pin
5.5
12
Protrusion of regular bushing
3.75
13
Overall length of pin
173
14
Overall length of bushing
86.7
15
Thickness of bushing metal
16
Thickness of spacer
17 18
Press fitting force
*19
Rebuild or replace
Adjust of replace
Standard size
Repair limit
7.8
3.8 —
Bushing
39.2 –137.2 kN {4 – 14 ton}
Regular pin
78.4 –186.3 kN {8 – 19 ton}
Master pin
39.2 – 98.1 kN {4 – 10 ton}
—
a The items marked * are for dry type track. PC130-7
40-11
MAINTENANCE STANDARD
TRACK SHOE
Unit: mm No.
Check item
Criteria
Remedy
Tightening torque (Nm {kgm}) Additional tightening angle (deg) a. Regular link Shoe bolt 20 b. Master link
Triple shoe City pad shoe
196 ± 20 {20 ± 2}
90 ± 10
Road liner
147 ± 10 {15 ± 1}
50 ± 5
Tightening torque (Nm {kgm})
Additional tightening angle (deg)
Lower limit torque (Nm {kgm})
—
—
—
No. of shoe (each side)
21
22
23
Interference between bushing and link
Interference between regular pin and link
Clearance between regular pin and bushing
43 Standard size
*24
*25
a
Height of grouser
Standard interference
46
+ 0.387 + 0.347
+ 0.062 0
0.285 – 0.387
30
+ 0.150 0
– 0.198 – 0.250
0.198 – 0.400
Standard size
Standard size
Standard size 30
26
Tolerance Hole
30
Clearance between master pin and bushing
—
Shaft
30
Interference between master pin and link
Retighten
a. Road liner
Tolerance
Standard clearance
Shaft
Hole
+ 0.150 0
– 0.830 – 0.330
0.180 – 0.830 Adjust or replace
Tolerance Shaft
Hole
Standard interference
+ 0.020 – 0.020
– 0.198 – 0.250
0.178 – 0.270
Tolerance
Standard interference
Shaft
Hole
– 0.200 – 0.300
+ 0.630 + 0.230
0.430 – 0.930
Standard size
Repair limit
58
21
Replace
The items marked * are for dry type track.
40-12
PC130-7
MAINTENANCE STANDARD
TRACK SHOE
RIPLE SHOE, CITY PAD SHOE
Unit: mm No.
Check item
1
Height of grouser
2
Overall height of shoe
3
Thickness
4 5
Criteria Standard size
Repair limit
20
10
29.5
19.5 9.5 14
Length of grouser top
6
PC130-7
Remedy
Repair by build-up welding or replace
13 15
40-13
MAINTENANCE STANDARD
HYDRAULIC PUMP
HYDRAULIC PUMP
40-14
PC130-7
MAINTENANCE STANDARD
CONTROL VALVE
CONTROL VALVE (1/9)
PC130-7
40-15
MAINTENANCE STANDARD
CONTROL VALVE
(2/9)
Unit: mm No.
Check item
Criteria Standard size
1
Suction valve spring
Remedy Repair limit
Free length x O.D.
Installed length
Installed load
Free length
Installed load
46.8 x 7.50
40.6
5.50±0.40N {0.56±0.04kg}
—
4.40 N {0.45 kg}
2
Suction valve spring
16.0 x 16.0
12.0
5.70 N {0.58 kg}
—
4.50 N {0.46 kg}
3
Piston spring
20.0 x 7.0
14.0
1.20 N {0.12 kg}
—
0.98 N {0.10 kg}
40-16
Replace spring if any damages or deformations are found
PC130-7
MAINTENANCE STANDARD
CONTROL VALVE
(3/9)
Unit: mm No.
Check item
Criteria Standard size
1
Spool return spring
Remedy Repair limit
Free length x O.D.
Installed length
Installed load
Free length
Installed load
—
45.0
53.5 N {5.46 kg}
—
—
2
Spool return spring
—
45.0
55.9 N {5.70 kg}
—
—
3
Spool return spring
—
41.0
92.2 N {9.4 kg}
—
—
PC130-7
Replace spring if any damages or deformations are found
40-17
MAINTENANCE STANDARD
CONTROL VALVE
(4/9)
Unit: mm No.
Check item
Criteria Standard size
1
Flow control valve spring
Remedy Repair limit
Free length x O.D.
Installed length
Installed load
Free length
Installed load
—
23.5
29.4 N {3 kg}
—
—
2
Pressure reduction valve spring
27.5 x 14.2
18.0
17.7±0.98N {1.80±0.10kg}
—
13.7 N {1.40 kg}
3
Pressure reduction valve spring
28.2 x 14.5
26.0
29.4±2.94N {3.0±0.30kg}
—
23.5 N {2.40 kg}
4
Pressure reduction valve spring
32.5 x 14.2
23
17.6 N {1.8 kg}
—
14.1 N {1.44 kg}
40-18
Replace spring if any damages or deformations are found
PC130-7
MAINTENANCE STANDARD
CONTROL VALVE
(5/9)
Unit: mm No.
Check item
Criteria Standard size
1
Check valve spring
PC130-7
Remedy Repair limit
Free length x O.D.
Installed length
Installed load
Free length
Installed load
41.5 x 8.50
31.5
5.88 N {0.60 kg}
—
4.71 N {0.48 kg}
Replace spring if any damages or deformations are found
40-19
MAINTENANCE STANDARD
CONTROL VALVE
(6/9)
Unit: mm No.
Check item
Criteria Standard size
1
Lift check valve spring Cooler bypass valve spring
Remedy Repair limit
Free length x O.D.
Installed length
Installed load
Free length
Installed load
72.7 x 20.6
42.5
135±4.90N {13.8±0.50kg}
—
113 N {11.5 kg}
2
Lift check valve spring
72.7 x 20.6
42.5
67.7 N {6.9 kg}
—
—
3
Bleed spool return spring
23.3 x 12.5
23.0
3.92±0.98N {0.40±0.10kg}
—
2.94 N {0.30 kg}
40-20
Replace spring if any damages or deformations are found
PC130-7
MAINTENANCE STANDARD
CONTROL VALVE
(7/9)
Unit: mm No.
Check item
Criteria Standard size
1
Travel junction spool
PC130-7
Remedy Repair limit
Free length x O.D.
Installed length
Installed load
Free length
Installed load
17.7 x 8.20
13.0
13.7±0.10N {1.40±0.10kg}
—
10.1 N {1.10 kg}
Replace spring if any damages or deformations are found
40-21
MAINTENANCE STANDARD
CONTROL VALVE
(8/9)
Unit: mm No.
Check item
Criteria Standard size
1
Check valve spring
40-22
Remedy Repair limit
Free length x O.D.
Installed length
Installed load
Free length
Installed load
41.5 x 8.50
31.5
5.88 N {0.60 kg}
—
4.71 N {0.48 kg}
Replace spring if any damages or deformations are found
PC130-7
MAINTENANCE STANDARD
CONTROL VALVE
(9/9)
PC130-7
40-23
MAINTENANCE STANDARD
SUCTION SAFETY VALVE
SUCTION SAFETY VALVE FOR SERVICE VALVE
Unit: mm No.
Check item
Criteria Standard size
1
2
Suction valve spring
Piston spring
40-24
Free length x O.D.
Remedy Repair limit
Installed length
Installed load
Free length
Installed load
9.50
2.06 N {0.21 kg}
—
1.57 N {0.16 kg}
16.3 x 21.3 20.0 x 7.0
14.0
2.06 N {0.21 kg}
—
1.57 N {0.16 kg}
Replace spring if any damages or deformations are found
PC130-7
MAINTENANCE STANDARD
SELF PRESSURE REDUCTION VALVE
SELF PRESSURE REDUCTION VALVE
Unit: mm No.
Check item
Criteria Standard size
1
Spring (pressure reduction main)
Remedy Repair limit
Free length x O.D.
Installed length
Installed load
Free length
Installed load
19.2 x 7.20
16.1
19.6 N {2.0 kg}
—
17.7 N {1.80 kg}
2
Spring (pressure reduction valve pilot)
16.5 x 7.20
12.7
20.6 N {2.10 kg}
—
18.6 N {1.90 kg}
3
Spring
71.0 x 18.0
59.0
200 N {20.4 kg}
—
186 N {19.0 kg}
4
Spring (safety valve)
16.1 x 7.80
13.4
61.7 N {6.30 kg}
—
58.8 N {6.0 kg}
PC130-7
Replace spring if any damages or deformations are found
40-25
MAINTENANCE STANDARD
TRAVEL MOTOR
TRAVEL MOTOR GM18VL-3
40-26
PC130-7
MAINTENANCE STANDARD
SWING MOTOR
SWING MOTOR KMF40ABE-3
Unit: mm No.
Check item
Criteria Standard size
1
2
Check valve spring
Shuttle valve spring
PC130-7
Free length x O.D.
Remedy Repair limit
Installed length
Installed load
Free length
Installed load
23.0
1.28 N {0.13 kg}
—
0.98 N {0.10 kg}
33.0 x 13.8 16.4 x 8.90
11.5
13.7 N {1.40 kg}
—
10.8 N {1.10 kg}
Replace spring if any damages or deformations are found
40-27
MAINTENANCE STANDARD
SOLENOID VALVE
SOLENOID VALVE FOR PPC LOCK, 2ND TRAVEL SPEED SELECTOR, SWING AND PARK BRAKE, AND 2STAGE RELIEF SOLENOID VALVE
40-28
PC130-7
MAINTENANCE STANDARD
CENTER SWIVEL JOINT
CENTER SWIVEL JOINT
Unit: mm No.
1
Check item Clearance between rotor and shaft
PC130-7
Criteria
Remedy
Standard size
Standard clearance
Clearance limit
80
0.056 – 0.105
0.111
Replace
40-29
MAINTENANCE STANDARD
PPC VALVE
PPC VALVE FOR SWING, WORK EQUIPMENT
Unit: mm No.
Check item
Criteria Standard size
1
Centering spring (for P3 and P4 ports)
Remedy Repair limit
Free length x O.D.
Installed length
Installed load
Free length
Installed load
44.45 x 15.5
34.0
29.4 N {3.0 kg}
—
23.5 N {2.40 kg}
2
Centering spring (for P1 and P2 ports)
47.93 x 15.5
34.0
39.2 N {4.0 kg}
—
31.4 N {3.20 kg}
3
Metering spring
26.53 x 8.15
34.0
16.7 N {1.70 kg}
—
13.7 N {1.40 kg}
40-30
Replace spring if any damages or deformations are found
PC130-7
MAINTENANCE STANDARD
PPC VALVE
FOR TRAVEL
Unit: mm No.
Check item
Criteria Standard size
1
2
Metering spring
Centering spring
PC130-7
Remedy Repair limit
Free length x O.D.
Installed length
Installed load
Free length
Installed load
6.5 x 8.15
24.9
16.7 N {1.70 kg}
—
13.7 N {1.40 kg}
48.1 x 15.5
32.5
108 N {11.0 kg}
—
86.3 N {8.80 kg}
Replace spring if any damages or deformations are found
40-31
MAINTENANCE STANDARD
PPC VALVE
FOR SERVICE
Unit: mm No.
Check item
Criteria Standard size
1
2
Centering spring
Metering spring
40-32
Remedy Repair limit
Free length x O.D.
Installed length
Installed load
Free length
Installed load
42.4 x 15.5
28.4
207.8 N {21.2 kg}
—
167 N {17.0 kg}
2.7 x 8.10
22.0
16.7 N {1.70 kg}
—
13.3 N {1.36 kg}
Replace spring if any damages or deformations are found
PC130-7
MAINTENANCE STANDARD
HYDRAULIC CYLINDER
HYDRAULIC CYLINDER BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
40-34
PC130-7
MAINTENANCE STANDARD
HYDRAULIC CYLINDER
Unit: mm No.
Check item Cylinder
1
2
3
Clearance between piston rod and bushing
Clearance between piston rod support shaft and bushing
5
6
Cylinder piston tightening torque
Cylinder piston lock screw tightening torque
PC130-7
Tolerance Shaft Hole
Standard clearance
Clearance limit
70
– 0.030 – 0.076
+ 0.259 + 0.063
0.093 – 0.335
0.435
Arm
75
– 0.030 – 0.076
+ 0.279 + 0.065
0.095 – 0.355
0.455
Bucket
65
– 0.030 – 0.076
+ 0.250 + 0.055
0.085 – 0.326
0.426
Boom
70
– 0.030 – 0.100
+ 0.190 + 0.070
0.100 – 0.290
1.0
Arm
70
– 0.030 – 0.100
+ 0.190 + 0.070
0.100 – 0.290
1.0
Bucket
65
– 0.030 – 0.080
+ 0.170 + 0.070
0.100 – 0.250
1.0
Boom
70
– 0.030 – 0.100
+ 0.190 + 0.070
0.100 – 0.290
1.0
70
– 0.030 – 0.100
+ 0.190 + 0.070
0.100 – 0.290
1.0
65
– 0.030 – 0.080
+ 0.170 + 0.070
0.100 – 0.250
1.0
Clearance between cylinder bottom supArm port shaft and bushing Bucket
Cylinder head tightening torque
Standard size
Remedy
Boom
Boom 4
Criteria
Arm
Replace bushing
172 ± 24.5 Nm {17.5 ± 2.5 kgm} 270 ± 39 Nm {27.5 ± 4.0 kgm}
Bucket
172 ± 24.5 Nm {17.5 ± 2.5 kgm}
Boom
294 ± 29.4 Nm {30.0 ± 3.0 kgm}
Arm
294 ± 29.4 Nm {30.0 ± 3.0 kgm}
Bucket
294 ± 29.4 Nm {30.0 ± 3.0 kgm}
Boom
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
Arm
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
Bucket
30.9 ± 3.4 Nm {3.15 ± 0.35 kgm}
Re-tightening
40-35
MAINTENANCE STANDARD
WORK EQUIPMENT
WORK EQUIPMENT
40-36
PC130-7
MAINTENANCE STANDARD
WORK EQUIPMENT
Unit: mm No.
1
Check item
Clearance between connecting pin and bushing of revolving frame and boom.
Criteria Tolerance
Remedy
Shaft
Hole
Standard clearance
Clearance limit
70
– 0.030 – 0.100
+ 0.130 + 0.065
0.095 – 0.230
0.8
Standard size
2
Clearance between connecting pin and bushing of boom and arm.
70
– 0.030 – 0.100
+ 0.141 + 0.074
0.104 – 0.241
0.8
3
Clearance between connecting pin and bushing of arm and link.
60
– 0.030 – 0.080
+ 0.129 + 0.074
0.104 – 0.209
0.8
60
– 0.030 – 0.080
+ 0.135 + 0.074
0.104 – 0.215
0.8
65
– 0.030 – 0.080
+ 0.133 + 0.074
0.104 – 0.213
0.8
4 5
Clearance between connecting pin and bushing of arm and bucket. Clearance between connecting pin and bushing of link and bucket.
Replace
6
Clearance between connecting pin and bushing of link and link.
60
– 0.030 – 0.080
+ 0.130 + 0.074
0.104 – 0.210
0.8
7
Clearance between the blade and track frame mounting pin and bushing
70
– 0.030 – 0.100
+ 0.198 + 0.124
0.154 – 0.298
1.5
PC130-7
40-37
MAINTENANCE STANDARD
DIMENSION OF WORK EQUIPMENT
DIMENSION OF WORK EQUIPMENT ARM
40-38
PC130-7
MAINTENANCE STANDARD
DIMENSION OF WORK EQUIPMENT
Unit: mm No.
Measuring position
1
—
Standard size 70
Tolerance Shaft
Hole
– 0.030 – 0.100
+ 0.100 0
81.5
+ 1.0 0
Cylinder head side
80
± 1.2
Boom side
226
+ 0.5 0
Arm side
226
– 0.2 – 0.7
Arm side 2
3 – 0.030 – 0.100
+ 0.100 0
4
—
70
5
—
264
± 2.0
6
—
213.5
± 1.0
7
—
640.6
± 0.5
8
—
2,491
—
9
—
2,101.9
± 1.5
10
—
290.4
± 0.5
11
—
493
± 0.2
12
—
422
± 0.5
13
—
374.9
—
14
—
1,175.1
—
15
—
60
– 0.030 – 0.080
+ 0.200 0
Link side
259
0 – 0.1
Bucket side
261
± 1.0
16
17
—
60
– 0.030 – 0.080
+ 0.200 0
Arm side
226
0 – 0.5
Bucket side
274
—
Min.
1,378
—
Max.
2,263
—
18
19
PC130-7
40-39
MAINTENANCE STANDARD
DIMENSION OF WORK EQUIPMENT
BUCKET
40-40
PC130-7
MAINTENANCE STANDARD
DIMENSION OF WORK EQUIPMENT
Unit: mm No.
Measuring position
Standard size
Tolerance
1
—
371.3
± 0.5
2
—
51.6
± 0.5
3
—
97.9°
—
4
—
374.9
—
5
—
1241.6
—
6
—
190.2
—
7
—
5°
—
8
—
0°
—
9
—
60
+ 0.2 0
10
—
64
—
11
—
80
12
—
261
± 1.0
13
—
50
—
14
—
85
—
15
—
380
+ 1.0 0
16
—
18
—
17
—
110
—
18
—
130
—
19
—
132
—
20
—
108
—
21
—
274
—
22
—
51
—
23
—
34
—
24
—
104.2
—
25
—
119.6
—
26
—
74
—
27
—
65
—
PC130-7
+ 0.25 0
40-41
90 OTHERS
HYDRAULIC CIRCUIT DIAGRAM........................................... 90- 3 ELECTRICAL CIRCUIT DIAGRAM (1/4)................................. 90- 5 ELECTRICAL CIRCUIT DIAGRAM (2/4)................................. 90- 7 ELECTRICAL CIRCUIT DIAGRAM (3/4)................................. 90- 9 ELECTRICAL CIRCUIT DIAGRAM (4/4)..................................90-11
PC130-7
90-1
HYDRAULIC CIRCUIT DIAGRAM
PC130-7
90-3
ELECTRICAL CIRCUIT DIAGRAM (1/4)
PC130-7
90-5
ELECTRICAL CIRCUIT DIAGRAM (2/4)
PC130-7
90-7
ELECTRICAL CIRCUIT DIAGRAM (3/4)
PC130-7
90-9
ELECTRICAL CIRCUIT DIAGRAM (4/4)
PC130-7
90-11
View more...
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