1. Hydraulic System Full

Middle Excavator Main Pump & Main Control Valve

Hyundai Training Center Aug. 2019

19ECG12 1

1.Main Pump

2

Specification

R220LC-9S

1. Main Pump

2. Gear Pump

3

View of Pump Assembly Pi1=Neg. Control

Regulator 1

Regulator 2

Pi2=Neg. Control

Pilot Pump P1 Front

P2 Rear

4

Type of Pump

DT

DP

DPH

DP/DPH

Tandem

Tandem with PTO unit

Tandem with a a built-in centrifugal Pump

Parallel

Parallel with a built-in centrifugal Pump

Parallel with PTO unit

36

--

--

--

--

--

--

63

●

●

--

--

--

--

112

●

●

--

●

--

--

140

●

●

●

--

--

--

180

●

●

●

--

--

--

280

--

--

●

--

--

--

80

●

●

--

--

--

--

140

●

●

--

--

--

--

200

●

●

●

●

●

▲

Arrangement of cylinders

K3V Series

K5V Series

DTP

DTH

5

K3V Series Pump Characteristic 1. High power density 2. High efficiency and large self-priming capability 3. Long life 4. Low noise 5. Wide range of control

Type

K3V63

K3V112

K3V140

K3V180

K3V280

Displacement

63 cm3

112 cm3

140 cm3

180 cm3

280 cm3

Rated

34.3 MPa

Peak

39.2 MPa

Pressure

Speed

Max. Self-Priming

2,650 min-1

2,360 min-1

2,150 min-1

1,950 min-1

1,600 min-1

Max.

3,250 min-1

2,700 min-1

2,500 min-1

2,300 min-1

2,000 min-1

6

Pump Code

K3V

112

DTP

-

1 H9

R

-

9P

K3V : K3V Series K5V : K5V Series K7V : K7V Series

Design Code of Regulator

Size(Displacement) 63 : 63 cc /rev 112 : 112 cc /rev 140 : 140 cc /rev 180 : 180 cc /rev

DT : Tandem Type/ Double Pump S : Single Type / Single Pump DTP : Tandem with PTO

- : Standard H : Booster with Centrifugal Pump

12

Regulator Code

Direction of Rotation (Viewed from Shaft end) R : Clockwise L : Counterclockwise

Design Code

7

Type and control of regulator

KR3

G

-

9

N

1

A Regulator Design Series No. Type of Flow Control C : Negacon Flow Control + Qmax Cut N : Negacon Flow Control P : Posicon Flow Control

Size(Displacement) 6 : K3V63 Pump G : K3V112 Pump H : K3V140/180 Pump 8 : K5V80 Pump S : K5V140 Pump

Type of Horse Power Control 2 : Total Horse Power Control 9 : Power Shift Control

K3V Series Regulator

8

Structure of Pump

Servo Piston

Shoe

Piston

Swash Plate Gear Pump Ass`y

Drive Shaft

Support

Cylinder Block

Valve Plate

9

View & Main Components of Pump

Support Drive Shaft

Servo Piston

Shoe

Piston Swash Plate

Cylinder Block Valve Plate

10

View of Regulator

The Portion of Horse Power Control

The Portion of Flow Control

11

Type and Circuit of Regulator

①

X

①

Y ⑤

⑦

② ④

② X ③

⑥

Y ⑥ Section Y-Y

⑥

Section X-X ** ①~⑦ Regulator Parts Name **

① ③

⑦

⑥

① ② ③ ④ ⑤ ⑥ ⑦

: : : : : : :

Lever 1 Lever 2 Compensator Piston Pilot Piston Adjust Screw(QMC) Feed Back Lever Spool

⑤ ④

②

12

Regulator

Pilot piston Feed back lever

13

Regulator

Lever 1

Lever 2 Spool

Lever 1

Spring 1

Spring 2

Compensator piston Section A-A

Lever 2

Feed back lever Pilot piston

14

Flow Control Flow Increasing Function Spool Pilot piston

Pilot piston Spool

Pilot piston

Spool

Pilot piston

15

Flow Control Flow Reducing Function Compensator piston

Spool Pilot piston

Spool Pilot piston

Pilot piston

Spool

Pilot piston

16

Total Horsepower Control Overload Preventive Function Pilot piston

Pilot piston P1

CL

Spool

Compensator piston

Pilot piston

17

Total Horsepower Control Flow Reset Function Pilot piston Spool

P1

CL

Pilot piston

Spool

Pilot piston

18

Control and Adjustment of Regulator - Flow Control Max. Flow Adjust.Screw(①)

Pilot Flow Adjust. screw(③)

Min. Flow Adjust.Screw(②) Flow Cut Off Adjust. Screw(④) Q

* Pilot Flow Adjust. Screw(③) * Screw Tighten(Flow ↑)

* Max Flow Screw Adjustment(①) * Q

Screw Loosen(Flow ↓)

Screw Loosen (Flow ↑) Screw Tighten (Flow ↓)

※Gradient is not changed * Min Flow Screw Adjustment(②) * Screw Tighten (Flow ↑) Screw Loosen (Flow ↓) Pilot P

Pilot P

* Flow Cut Off Adjustment Screw(④) * Screw Tighten(Flow ↑) Screw Loosen(Flow ↓)

19

Control and Adjustment of Regulator Minimum flow

Maximum flow REGULATOR

REGULATOR

max

20

Control and Adjustment of Regulator - Flow Control

Foot Relief Valve 1

Foot Relief Valve 2

EPPR Valve

0...35 bar

21

Negative Flow Control Flow decrease by Pi pressure increase

Pi increase

Q

Pi 22

Control & Adjustment of Regulator - Horsepower Control

First Horse Power Adjust. Screw(⑤) Second Horse Power Adjust. Screw(⑥)

Q

Second Horse Power Adjust. First Horse Power Adjust. Screw(⑤) Screw(⑥)

* First Horse Power Adjust.Screw(⑤) Screw Tighten (Flow ↑) Screw Loosen(Flow ↓) * Second Horse Power Adjust. Screw(⑥) * Screw Tighten (Flow ↑) Screw Loosen (Flow ↓) ※Gradient is not changed Pd

23

Control & Adjustment of Regulator - Horsepower Control

②

①

HP ∝ P X Q

Screw clockwise (Flow ↑) Screw Counterclockwise (Flow ↓)

① Adjustment of 1st power - Release lock nut of 36mm - Adjust screw of 24mm Screw clockwise (Flow ↑)

② Adjustment of 2nd power - Release lock nut of 13mm - Adjust rectangle screw

Screw counter clockwise (Flow ↓) Pressure

24

Flow Pressure Chart (Sample) The following is a reference value for Training. It's not the same as the real value of the machine. Drain

Pf (EPPR)

Version 1 p

10

S

12

E

12

118K 206L

2100rpm 2000rpm

Drain

P1

P2

25

Pump Regulator Function 1. Horse power control

2. Flow control

Pilot piston

Compensation piston 26

Pump-regulator Adjustment The following is a reference value for Training. Adjustment of max. flow control

Adjustment of min. flow control

Adjustment of outer spring

rpm

Tightening amount of adjusting screw (954)

Flow change amount

Tightening amount of adjusting screw (953)

Flow change amount

Tightening amount of adjusting screw (628)

Compensating control starting pressure change amount

Input torque change amount

min-1

Turn

L/min

Turn

L/min

Turn

Kgf/cm2

Kgf.m

R140LC-9S K5V80DT

1,900

+1/4

-3.0

+1/4

+3.0

+1/4

+19.2

+3.4

R140W-9S K5V80DTP

2,100

+1/4

-3.4

+1/4

+3.4

+1/4

+20.0

+3.47

R160/180LC-9S K5V80DT

2,000

+1/4

-3.2

+1/4

+3.2

+1/4

+17.7

+3.5

R170W-9S K5V80DTP

2,100

+1/4

-3.4

+1/4

+3.4

+1/4

+17.7

+4.2

R220LC-9S K3V112DT

1,900

+1/4

-5.5

+1/4

+4.4

+1/4

+16.5

+4.0

R260LC-9S K3V112DT

1,900

+1/4

-5.5

+1/4

+4.4

+1/4

+16.5

+4.0

HX300 K5V140DTP

1,800

+1/4

-5.6

+1/4

+4.5

+1/4

+19.0

+5.6

R380LC K3V180DTP

1,750

+1/4

-6.7

+1/4

+6.7

+1/4

+19.2

+8.9

HX480 K5V200DTH

1,800

+1/4

-6.9

+1/4

+6.9

+1/4

+17.8

+9.7

Model/type

27

Pump-regulator Adjustment The following is a reference value for Training. Adjustment of inner spring

Adjustment of flow control characteristic

Flow change amount

Input torque change amount

Tightening amount of adjusting screw (924)

Flow control starting pressure change amount

Flow change amount

Turn

L/min

Nᆞm

Turn

MPa

L/min

1,900

+1/4

+8.6

+4.3

+1/4

+1.6

+9.0

R140W-9S K5V80DTP

2,100

+1/4

+9.5

+4.3

+1/4

+1.8

+12.0

R160/180LC-9S K5V80DT

2,000

+1/4

+8.4

+3.8

+1/4

+1.5

+9.5

R170W-9S K5V80DTP

2,100

+1/4

+8.8

+4.5

+1/4

+1.53

+12.0

R220LC-9S K3V112DT

1,900

+1/4

+11.3

+4.7

+1/4

+1.5

+14.8

R260LC-9S K3V112DT

1,900

+1/4

+11.3

+4.7

+1/4

+1.5

+14.8

HX300 K5V140DTP

1,800

+1/4

+12.6

+5.7

+1/4

+0.7

+14.6

R380LC K3V180DTP

1,750

+1/4

+15.9

+9.1

+1/4

+1.6

+18.4

HX480 K5V200DTH

1,800

+1/4

+18.6

+10.4

+1/4

+1.02

+21.0

rpm

Tightening amount of adjusting screw (627)

min-1 R140LC-9S K5V80DT

Model/type

28

Electro Proportional Pressure Reducing

P

A

T

1. 2. 3. 4. 5. 6. 7.

P : Pilot Oil Supply Line (Pilot Pressure) T : Return to Tank A : Secondary Pressure to Flow Regulator at Hydraulic Pump

Sleeve Spring Spool O-ring O-ring Solenoid valve Connector

P A

T

29

Power Mode control [ CAPO System features ]

1. Quick responsibility. 2. Reliable control.

Note] 1. Condition : Arm in / out 2. Colors (Unit of Axis : Bar) (1) RED : P1(Main pump) pressure (2) BLUE: P3(Pilot pump) pressure (3) GREEN: EPPR V/V 2nd pressure

S Mode

‘ P Mode

S Mode

■ Power Mode setting

30

Tools for Disassembling and Reassembling of the Main Pump

The tools necessary to disassemble / reassemble the K3V/K5V pump are shown in the follow list. The size of the bolts and plugs depend on the pump type. B Tool Name & size Name

Allen wrench

Necessary tool(Marking with ○)

Part name

Pump type Hexagon socket head bolt

PT plug (R thread)

PO plug (G thread)

Hexagon socket Head setscrew

2

-

-

-

M4

2.5

-

-

-

M5

3

-

-

-

M6

B

K3V63 K5V80

K3V112 K5V140

K3V140/180 K5V200

4

○

○

○

M5

BP-1/16

-

M8

5

○

○

○

M6

BP-1/8

-

M10

6

○

○

○

M8

BP-1/4

PO-1/4

M12 M14

8

○

○

○

M10

BP-3/8

PO-3/8

M16 M18

10

M12

BP-1/2

PO-1/2

M20

12

M14

-

-

-

M16 M18

BP-3/4

PO-3/4

-

M20 M22

BP-1

PO-1,1 1/4,1 1/2

-

19

M24 M27

-

-

-

21

-

-

-

-

22

M30

-

PO-2

-

14 17

○ ○

○

31

Tools for Disassembling and Reassembling of the Main Pump Necessary tool(Marking with ○)

Tool Name & Size Name

- Double ring Spanner

B

K3V63 K5V80

K3V112 K5V140

K3V140/180 K5V200

Hexagon head bolt

Hexagon nut

VP plug (G thread)

19

○

○

○

M12

M12

VP-1/4

-

-

VP-3/8

○

M16

M16

-

○

M18

M18

VP-1/2

22

○

24

○

27 - Socket wrench

- Double(single) open end Spanner

Part name

Pump type

○

30

○

○

M20

M20

-

36

○

○

-

-

VP-3/4

41

-

-

VP-1

50

-

-

VP-1 1/4

55

-

-

VP-1 1/2

Adjustable angle wrench

-

○

○

○

Medium size, 1set

Screwdriver

-

○

○

○

Minus type screwdriver, medium size, 2 sets

Hammer

-

○

○

○

Plastic hammer, 1 set

Pliers

-

○

○

○

For snap ring, TSR-160

Steel bar

-

○

○

○

Steel bar key material approx.

-

○

○

○

Capable of tightening with specified torques

-

○

○

○

Torque wrench

Vernier Calipers

32

Pump maintenance criteria Worn Part Replacement Criteria When a part exceeds any of the following criteria, replace or readjust it. However, when a part is damaged seriously in appearance, replace it without fail. Standard dimension / Recommended replacement value Part name & inspection

Pump type

Countermeasures

K3V63

K3V112

K5V140

K5V200

Clearance between Piston & cylinder bore (D-d)

0.028 / 0.056

0.039 / 0.067

0.043 / 0.070

0.0375/0.078

Replace piston or cylinder

Play between piston & shoecalking section(δ)

0~0.1 / 0.3

0~0.1 / 0.3

0~0.1 / 0.3

0~0.1 / 0.35

Replace assembly of piston & shoe

Thickness of shoe(t)

3.9 / 3.7

4.9 / 4.7

5.4 / 5.0

5.4 / 5.0

Replace assembly of piston & shoe

Free height of cylinder spring(L)

31.3 / 30.2

41.1 / 40.3

47.9 / 47.1

40.9 / 40.1

Replace cylinder spring

Combined height of set plate & spherical bush

19.0 / 18.2

23.0 / 22.0

23.8 / 22.8

23.8 / 22.8

Replace set plate or spherical bush

Clearance between Piston & cylinder bore(D-d)

Free height of cylinder spring : L

Play between piston & shoe : δ Thickness of shoe : t

Combined height of set plate & spherical bush : H-h

33

Pump maintenance criteria Correction criteria for cylinder, valve plate and swash plate (shoe plate) Surface roughness for valve plate(sliding face), swash plate(shoe plate area) & cylinder(sliding face)

Surface roughness Necessary to be corrected

3-Z

Standard surface roughness (Corrected valve)

0.4-Z or lower (Lapping)

Tightening Torques Part name

Hexagon socket head cap screw (Material : SCM435)

R plug (Material : S45C) Wind a seal tape 1 1/2 to 2 Turns round the plug.

G plug (Material : S45C)

Size

Tightening Torque(Nᆞm)

Tool name

M5

6.9

B=4

M6

12

5

M8

29

6

M10

57

8

M12

98

10

M14

160

12

M16

230

14

M18

330

14

M20

430

17

M22

630

17

NPTF 1/16

8.8

4

R 1/8

12

5

R 1/4

22

6

R 3/8

44

8

R 1/2

65

10

G 1/4

36

6

G 1/2

110

10

G 3/4

170

14

G1

220

17

G 1 1/4

270

17

G 1 1/2

280

17

Allen wrench

Do.

Do.

34

Main Pump Parts

35

Main Pump Parts

111 113 114 123 124 127 NS141 NS151 NS152 153 156 157 211 NS212 S214 251 261 271

XJBN-00077 XJBN-00078 XJBN-00351 XJBN-00950 XJBN-00786 XJBN-00081 XJBN-00067 XJBN-01032 XJBN-01214 XJBN-00945 XJBN-00083 XJBN-00084 XJBN-00085 XJBN-00070 XJBN-00071 XJBN-00086 XJBN-00087 XJBN-01034

Shaft-Drive,Fr Shaft-Drive,Rr Coupling-Spline Bearing-Roller Bearing-Needle Spacer-Bearing Block-Cylinder Piston Shoe Plate-Set Bushing-Spherical Spring-Cylinder Plate-Shoe Plate-Swash Bushing-Tilting Support Cover(F)-Seal Casing-Pump

312 NS313 NS314 401 406 466 468 490 NS531 532 534 535 NS541 NS543 NS544 S545 NS548 K702

XJBN-00089 XJBN-01035 XJBN-01036 XJBN-00090 XJBN-00355 XJBN-00030 XJBN-00031 XJBN-00032 XJBN-00358 XJBN-00955 XJBN-01037 XJBN-00093 XJBN-00859 XJBN-00860 XJBN-00861 XJBN-00038 XJBN-00360 XJBN-00918

Block-Valve Plate-Valve(R) Plate-Valve(L) Screw-Hex Soc Hd Screw-Hex Soc Hd Plug Plug Plug Pin-Tilting Piston-Servo Stopper(L) Stopper(S) Seat Stopper 1 Stopper 2 Ball-Steel Pin-Feed Back O-Ring

K710/717/724

XJBN-00095

O-Ring

K725/728/732

XJBN-00361

O-Ring

774

XJBN-01579

Oil Seal

K789/792

XJBN-00099

Ring-Back Up

806/808

XJBN-00101

Nut-Hex

824

XJBN-00102

Ring-Snap

885

XJBN-00103

Pin-Valve Plate

886

XJBN-00054

Pin-Spring

901

XJBN-00104

Bolt-Eye

953/954

XJBN-00105

Screw-Set

N981

XJBN-00156

Name Plate

983

XJBN-00455

Pin

K

31Q6-10050-BK O-Ring Kit-Main Pump

36

Gear Pump Parts S307

XJBN-00521

Poppet

S308

XJBN-00522

Seat

309

XJBN-00523

Ring

310

XJBN-00524

Spring

311

XJBN-00525

Screw-Adjust

312

XJBN-00334

Nut-Lock

S351

XJBN-00526

Case-Gear

S353

XJBN-00332

Gear-Drive

S354

XJBN-00331

Gear-Driven

355

XJBN-00330

Filter-Return

S361

XJBN-00329

Case-Front

433

XJBN-00328

Socket-Flange

434

XJBN-00327

Socket-Flange

435

XJBN-00326

Socket-Flange

466

XJBN-00356

Plug-Vp

700

XJBN-00325

Ring

K710

XJBN-00095

O-Ring

K725

XJBN-00045

O-Ring

K732

XJBN-00283

O-Ring

850

XJBN-00324

Ring-Snap

887

XJBN-00795

Pin

S

B3

Gear Case Sub Assy

K

XJBN-00974

Gear Pump Seal Kit

37

Regulator Parts 412/413 XJBN-00321 436/438 XJBN-00319 496 XJBN-00032 601 XJBN-00317 611 XJBN-00347 612 XJBN-00315 613 XJBN-00314 614 XJBN-00313 615 XJBN-00312 621 XJBN-00311 622 XJBN-00346 623 XJBN-01202 624 XJBN-01203 625 XJBN-00345 626 XJBN-00306 627 XJBN-01031 628 XJBN-01025 629 XJBN-00303 630 XJBN-00302 631 XJBN-00301 641 XJBN-00871 643 XJBN-01205 644 XJBN-01206 645 XJBN-00793 646 XJBN-00295 651 XJBN-00292 652 XJBN-00291 653 XJBN-00290 654 XJBN-00289 655 XJBN-00288 656 XJBN-00287 K708/722/724 XJBN-00286 K725/728/730 XJBN-00231 K732/733/734 XJBN-00820 K733/734/735 XJBN-00282 K753/755/756 XJBN-01026 K763 XJBN-00094 801/802 XJBN-00278 814/836/858 XJBN-00277 874/875/876 XJBN-00344 887/897/898 XJBN-00272 924 XJBN-00269 K : 31Q6-10050-RK

Screw-Hex Screw-Hex Plug Casing Lever-Feedback Lever 1 Lever 2 Plug-Center Plug-Adjust Piston-Compensator Case-Piston Rod-Compensator Seat(C)-Spring Spring-Outer Spring-Inner Stem(C)-Adjust Screw(C)-Adjust Cover(C) Nut-Lock Sleeve Cover-Pilot Piston-Pilot Seat(Q)-Spring Stem(Q)-Adjust Spring-Pilot Sleeve Spool Seat-Spring Spring-Return Spring-Set Cover-Block O-Ring O-Ring O-Ring O-Ring O-Ring O-Ring Nut Ring-Snap Pin Pin Screw-Set O-Ring Kit-Regulator

38

2.Main Control Valve

39

Specification

1. Main Control Valve

2. Remote Control Valve

40

Port Names of MCV Mark A1 A2 A5 B1 B2 B4 B5 C1 C2 C4 C5 Ck1 Ck2 D1 D2 D4 D5 Dr0 Dr1 Dr2 Dr3 Dr4 Dr5 P01 P02 P03 P04 P05 P06 P1 P2 Pa1 Pa20 Pa21

Port Name Travel motor port-LH (FW) Boom up port Bucket in port Travel motor port-LH (BW) Boom down port Option A port (breaker) Bucket out port Travel motor port-RH (BW) Swing motor port (LH) Arm in port Option B port Bucket confluence Bucket confluence Travel motor port-RH (FW) Swing motor port (RH) Arm out port Option B port Drain port Drain port Drain port Drain port Drain port Drain port Pilot signal port Pilot signal port Swing logic pilot port Bucket parallel orifice pilot port Option B confluence pilot port Option B 2 stage relief valve pilot port Pump port (A2 side) Pump port (A1 side) Travel pilot port-LH (FW) Boom up pilot port Boom up confluence pilot port

Mark Pa4 Pa5 Patt Pb1 Pb20 Pb21 Pb3 Pb4 Pb5 Pc1 Pc2 Pc3 Pc40 Pc41 Pc42 Pc5 Pcb Pd1 Pd2 Pd40 Pd41 Pd5 Pn1 Pn2 Ptr Pu Rs T1 V1 V3 V4

Port Name Option A pilot port (breaker) Bucket in pilot port Auto idle signal-attachment Travel pilot port-LH (BW) Boom down pilot port Lock valve pilot port (boom) Arm in confluence pilot port Arm in regeneration cut port Bucket out pilot port Travel pilot port-RH (BW) Swing pilot port (LH) Swing priority pilot port Arm in pilot port Lock valve pilot port (arm) Arm in regen-cut signal selector port Option B pilot port Bucket in confluence pilot port Travel pilot port-RH (FW) Swing pilot port (RH) Arm out pilot port Arm out confluence pilot port Option B pilot port Negative control signal port (A2 port side) Negative control signal port (A1 port side) Auto idle signal-travel Power boost Make up for swing motor Return port Carry-over port (for option) Carry-over P port (for option) Carry-over port (for option)

41

Structure

Straight Travel Travel Right Swing Logic Valve

Swing

Boom2

Arm1 Option Logic Valve Option

2 stage Overload Relief Valve

Arm Holding Valve

Pcb

Bucket in confluence pilot port

Patt

Auto idle signal-attachment

42

Structure

Main Relief Valve Travel Left

Boom1

Arm2

Arm Regeneration

Bucket

Negative Relief Valve

Bucket Confluence (ck2)

Rs

Make up for swing motor

V4

Carry-over port

Pu

Power boost

43

Structure

P2 Port

Ptr Port

P1 Port

V1

Swing Priority

Arm Regeneration Valve

Negative Relief Valve

44

Check Valve Position

CK1 is included OPTION

Ck2

Pb21 Dr1

V4 RH

LH

45

Boom Up Operation

BK

Boom Up has priority over swing/bucket operation - swing logic v/v

Bucket limited

- bucket-in stroke limiter

붐2

P1

P2

46

Swing Logic Valve Function (Boom Priority Function) When Boom up & Swing are operated simultaneously, it increases Boom up speed. The swing logic valve does not work in single swing operation. Manual : Boom up speed depends on the speed level you select Auto : Boom up speed is automatically adjusted according to the pilot pressures of boom up & swing.

Boom1 spool

Swing priority Boom priority EPPR valve

Boom 2

Swing Logic P2

47

Electric Circuit for Boom Priority

Boom MCU

XAb2

XAb1

CN 53-9

CN 512 CN 52-23 CN 51-5

CN 52-24

XBs

XAs

Boom Priority EPPR + Boom Priority EPPR -

CN 53-19

Battery Power 24V

Boom Up Pressure GND. Pressure

P03 (MCV)

Swing Pressure

Swing

▲

Psp

P3

48

Swing Logic Valve Operation To/From cylinder

Swing spool

To tank

P03 Bypass passage

Swing spool

P2

P2 bypass passage P2 parallel passage

From boom priority EPPR v/v

49

Boom-2 Spool, Swing Priority Spool When swing is operated, the pilot pressure is applied to “Pc3” and the pump flow is supplied to the swing motor preferentially. When boom up is operated, the pilot pressure is applied to “Pa2” and Boom flow confluence is performed.

Pc3 Pa2

Swing motor

P2

50

Boom-2 Spool & Swing Priority Spool Operation Boom summation passage

P1 Swing priority spool Arm2 spool

Boom up Pilot pressure

Swing pilot pressure

P2

P2 parallel passage (to arm1, option spool)

Boom2 spool

P2 parallel

P2

51

Boom Down Operation When boom down is operated, the pressure in the return line can be higher than that of supply line and this allows the make-up function by pushing the check valve.

P1

P2

52

Make-up Function in Boom-1 Spool Boom moves down fast

P1

Boom down Pilot pressure

P1

Boom down Pilot pressure Check valve

53

Bucket-in Operation

●

Pcb

●

CK2

Pa5

●

54

Bucket-in Confluence When bucket in is operated, the pilot pressure is applied to center bypass v/v through port “PCB”, then P2 flow is summated with P1 flow. Pcb Center bypass v/v

NRV1

Pcb

NRV2

Negative control v/v(NRV2)

P2 P1 P2 oil goes to Ck2 port Main Relief V/V

Pa5 Pcb

NRV2

55

Boom Priority Function : Bucket Stroke Limiter During the combined operation of boom-up and bucket-in, boom-up pilot pressure moves the bucket spool to half stroke, not full stroke.

BK stroke limiter

BK

②P2

Flow to bucket cylinder is reduced and P2 pump oil is supplied to boom cylinder preferentially.

BM up pilot

BM1

①P1

Boom up pilot

(Pb5) Bucketin pilot

Stroke limiter spool

56

Arm-in Operation

BK

버켓감속

(암재생해제sol)

AM1

선회우선

AM2

P2

P1

57

Arm Regeneration Since Arm regeneration spool blocks return line, return oil opens check valve and flows to supply line.

(Low pressure)

Arm-in

Arm Regeneration Arm-in

58

Arm Regeneration Completion Arm regeneration would be finished when the angle of Arm IN operation is over 90˚

Arm In flow

Arm-in

ARM Regeneration Arm-in

59

Arm Regeneration Cut

ON

(Low pressure)

ARM In flow

Arm-in

Arm Regeneration Arm-in

60

Optional Attachment Breaker Mode

At breaker mode, CPU sends the current to ATT’ Flow Control EPPR V/V and reduce the oil flow with 7 steps.

Max 7 step, reduced 10 lpm each step

61

Breaker Circuit

When selecting ‘Breaker’ mode and turning on breaker sw (on RH RCV), Breaker sol is activated and MCU sends the current to breaker EPPR valve.

P2

Breaker sol

Att’ flow control v/v

Safety sol

P3

62

Crusher Mode

At crusher mode, CPU sends the current to ATT’ Flow Control EPPR V/V and reduces the oil flow with 4 steps.

210 bar → 280 bar

Max 4 step, reduced 20 lpm each step

63

Option Circuit (Breaker/Crusher)

210 bar → 280 bar

⑧

P2

⑦

⑥ P1

①

① Option Att’ Safety sol. ② Option Att’ pressure sol.

②

⑤

Arm 2

③

④

③ Option Att’ conflux sol. ④ Option Att’ flow control v/v ⑤ Safety sol. ⑥ Pilot selector v/v ⑦ Option conflux ON/OFF v/v ⑧ 2-Stage option relief v/v

P3

① ② ③ ④

64

Option Confluence On/Off Valve If the operator selects ‘crusher’ mode on the cluster, the attachment conflux solenoid will be activated. So, pilot pressure affects “P05” and 1P, 2P will be summated.

P2

P1

P05 Option Confluence Pilot Port

P1 parallel line

P05

65

2 Stage Option Relief Valve Structure

66

Circuit for Straight Travel Function

BM work

X

X

TL

(P3)

TR

Swing parking Brake release Pilot pressure

travel

P1

P2

Check v/v ●

● ● ●

●

P2

Orifice

P1

67

Holding Valve Boom Holding Condition - Applied when Boom down and Arm in - Prevent Boom & Arm drop

When RCV lever is in neutral condition, the return oil from Boom cyl. is blocked by the check valve. So it can not flow to the Boom spool section. Neutrality

P3 Holding Check V/V

Boom Spool

68

Boom Holding Released When Boom down operation, Pilot pressure acts on Pb20(Boom1 spool), Pal(Holding release port). Then Boom goes down.

P3

Pb20 → Boom down

69

Auto Deceleration System Hyd. Circuit of Auto Deceleration (Neutral) 1150 rpm 1000 rpm

Arm regen, Arm1, Arm2, Option, Swing Spool

BM work

TL

(P3)

TR

S/parking release Pilot pressure

travel

P1

P2

70

Pressure sensor operation during Travel, Work

BM work

TL

(P3)

TR

S/parking release Pilot pressure

travel

P1

P2

71

Main Relief Valve Structure

Pu

72

Main relief V/V operation Main relief closed

Line pressure(P) (350bar)

Main relief valve set pressure

Pu

73

Main relief V/V operation Main relief open

Line pressure(P) (350bar)

Main relief valve set pressure

Pu

74

Main relief V/V operation Power boost on When power boost switch is ON, the pilot pressure enters through hole (A). Then piston(B) is pushed to the left and that causes to increase the spring force.

350 bar → 380 bar Pu

(A) (B)

75

Main relief V/V operation Adjustment of Main relief valve pressure 1) Power booster pressure setting ① Loosen lock nut “A” and tighten adjustment screw “B” clockwise securely. ② Loosen lock nut “C” and adjust adjustment. ③ After the pressure is set, tighten lock nut “C”. Pu

Ⓐ 19mm Lock Nut • Ⓑ 4mm Adjust screw • • • Ⓑ 22mm Adjust screw Ⓑ 27mm Lock Nut ※ Adjust screw(D) changes about 130bar per 1 rotation 2) Main pressure setting ① After high pressure is set, loosen adjustment screw “B” counterclockwise to set main pressure. ② After the pressure is set to 330~335bar, tighten lock nut “A”. 76

Overload Relief Valve

Line pressure(P)

Relief valve set pressure (400bar)

Line pressure(P)

Relief valve set pressure (400bar)

77