Hitachi EX1200-7 Hydraulic Excavator FCO Cummins engine Operational Technical Manual TOKAA90-EN-01 (

PART NO.

TOKAA90-EN-01

EX1200-7 HYDRAULIC EXCAVATOR TECHNICAL MANUAL OPERATIONAL PRINCIPLE TOKAA90-EN-01

PRINTED IN JAPAN (K) 2019, 10

Technical Manual Operational Principle

EX1200-7

Hydraulic Excavator FCO Cummins engine

Service Manual consists of the following separate Part No. Technical Manual (Operational Principle) : Vol. No.TOKAA90-EN Technical Manual (Troubleshooting) : Vol. No.TTKAA90-EN Workshop Manual : Vol. No.WKAA90-EN

INTRODUCTION To The Reader This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.

The machine specification and description according to destination may be explained on this manual.

 If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual. (Note: Do not tear off the form. Copy it for usage.):  Service Material Development Center Hitachi Construction Machinery Co., Ltd.  TEL: 81-29-832-7233  FAX: 81-29-831-1162  E-mail: HCM-TIC-GES@hitachi-kenki.com

 Be sure to thoroughly read this manual for correct product information and service procedures.

Additional References Please refer to the other materials (operator’s manual, parts catalog, engine technical material and Hitachi training material etc.) in addition to this manual.

Manual Composition This manual consists the Technical Manual and the Workshop Manual.

 Information included in the Workshop Manual: Technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and assemble / disassemble procedures.

 Information included in the Technical Manual: Technical information needed for redelivery and delivery, operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures.

Page Number Each page has a number, located on the center lower part of the page, and each number contains the following information: Example:  Technical Manual: T 1-3-5 T 1 3 5

 Workshop Manual: W 1-3-2-5 W 1 3 2 5

Technical Manual Section Number Group Number Consecutive Page Number for Each Group

IN-1

Workshop Manual Section Number Group Number Sub Group Number Consecutive Page Number for Each Group

INTRODUCTION Safety Alert Symbol and Headline Notations In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage.

dCAUTION: Indicates potentially hazardous situation which could, if not avoided, result in personal injury or death.

d This is the safety alert symbol. When you see this

symbol, be alert to the potential for personal injury.

Never fail to follow the safety instructions prescribed along with the safety alert symbol.

The safety alert symbol is also used to draw attention to component/part weights.

To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.

IMPORTANT: Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.

fNOTE: Indicates supplementary technical information or knowhow.

Units Used SI Units (International System of Units) are used in this manual.

A table for conversion from SI units to other system units is shown below for reference purposes.

Quantity

To Convert From

Into

Multiply By

Length

mm

in

0.03937

mm

ft

0.003281

L

US gal

0.2642

L

US qt

1.057

m3

yd3

1.308

Weight

kg

lb

2.205

Force

N

kgf

0.10197

N

lbf

0.2248

Torque

N·m

kgf·m

Pressure

MPa

kgf/cm

10.197

MPa

psi

145.0

kW

PS

1.360

kW

HP

1.341

Temperature

°C

°F

°C×1.8+32

Velocity

km/h

mph

0.6214

min

rpm

1.0

L/min

US gpm

0.2642

mL/rev

cc/rev

1.0

Volume

Power

-1

Flow rate

0.10197 2

IN-2

SYMBOL AND ABBREVIATION Symbol / Abbreviation TO TT T/M W, W/M FCO MC1 MC2 ECM DLU GSM

BPU CSU

FMU ODR RPU

WIU GPS CAN

Name

Explanation

Technical manual (Operational principle) Technical manual (Troubleshooting) Technical manual Workshop manual

Technical manual (Operational Principle).

Technical manual (Troubleshooting).

Technical manual.

Workshop manual (Removal and Installation, Disassembly and Assembly).

Fuel Consumption/Combustion The engine maker designs to specifically optimize for the Optimization Combustion/Consumption of the diesel fuel.

Main Controller 1 Main controller 1. MC1 controls the engine, pump, and valve according to the machine operating condition.

Main Controller 2 Main controller 2. MC2 controls the lights, wiper, washer, and sliding fold-in ladder alarm.

Engine Control Module Engine controller. ECM controls fuel injection amount according to the machine operating condition.

Data Logging Unit Data logging unit. DLU records the information from each controller.

Global System for Mobile communications Communication controller. GSM is a type of wireless controller communication system, is used in more than on 100 countries around Europe and Asia, and becomes the factual global standards of the mobile telephone.

Basic Performance Monitoring Unit Basic performance monitoring unit. BPU semiautomatically measures the basic performance.

Contamination Sensing Unit Contamination sensing unit. CSU senses contaminants in the drain circuits of the main pump, swing motor, and travel motor.

Fatigue Monitoring Unit Mechanical fatigue monitoring unit. FMU monitors mechanical fatigue of the structures.

Operation Data Recorder Operation data recorder. ODR automatically records the data related to the detected information which has been set.

Radiation Performance monitoring Unit RPU monitors the oil cooler state and the engine cooling system including the radiator by using each temperature sensor.

Wireless Interface Unit WIU outputs the machine operation data to PC via wireless LAN. Global Positioning System Global positioning system.

Controller Area Network CAN communication. CAN is a serial communications protocol internationally-standardized by ISO (International Organization for Standardization).

SY-1

SYMBOL AND ABBREVIATION Symbol / Name Abbreviation OP, OPT Option MPDr. Maintenance Pro Dr. A/I WU Li ATT

Auto-Idle Warming-Up Low (Slow) Idle Attachment

HI, Hi LO, Lo LD BH

High Low LOADING SHOVEL BACKHOE

Explanation Optional component.

MPDr. is software that troubleshooting, monitoring, and adjustment.

Auto-idle.

Warming-up.

Slow idle engine speed.

Attachment. Attachment is optional parts such as breaker, crusher, and pulverizer in this manual.

Travel fast position.

Travel slow position.

SY-2

SECTION AND GROUP SECTION 1 GENERAL Group 1 Specifications CONTENTS Group 2 Component Layout Group 3 Component Specifications

SECTION 2 SYSTEM Group 1 Controller TECHNICAL MANUAL

Group 2 Control System

(Operational Principle)

Group 3 ECM System Group 4 Hydraulic System Group 5 Electrical System Group 6 Air Conditioning System

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Group 2 Swing Device Group 3 Control Valve Group 4 Pilot Valve Group 5 Travel Device Group 6 Signal Control Valve Group 7 Others (Upperstructure) Group 8 Others (Undercarriage)

All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.

COPYRIGHT(C)2012 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved

TECHNICAL MANUAL (Troubleshooting)

WORKSHOP MANUAL

SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction Group 2 Standard Group 3 Engine Test Group 4 Excavator Test Group 5 Component Test Group 6 Adjustment SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Group 2 Monitor Group 3 e-Service Group 4 Component Layout Group 5 Troubleshooting A Group 6 Troubleshooting B Group 7 Air Conditioner

SECTION 1 GENERAL INFORMATION Group 1 Precautions for Disassembling and Assembling Group 2 Tightening Torque Group 3 Painting Group 4 Bleeding Air from Hydraulic Oil Tank Group 5 Hydraulic Circuit Pressure Release Procedure Group 6 Preparation SECTION 2 MAINTENANCE STANDARD Group 1 Upperstructure Group 2 Undercarriage Group 3 Front Attachment SECTION 3 UPPERSTRUCTURE Group 1 Cab Group 2 Counterweight Group 3 Main Frame Group 4 Engine Group 5 Radiator Assembly Group 6 Hydraulic Oil Tank Group 7 Fuel Tank Group 8 Pump Device Group 9 Control Valve Group 10 Swing Device Group 11 Pilot Valve Group 12 Solenoid Valve Group 13 Signal Control Valve Group 14 Muffler Filter SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing Group 2 Travel Device Group 3 Center Joint Group 4 Track Adjuster Group 5 Front Idler Group 6 Upper and Lower Roller Group 7 Track SECTION 5 ATTACHMENT Group 1 Front Attachment Group 2 Cylinder Group 3 Hose Rupture Valve

SECTION 1

GENERAL CONTENTS Group 1 Specifications

Specifications (Backhoe)................................................... T1-1-1 Specifications (Loading Shovel)..................................... T1-1-2 Working Range (Backhoe)................................................ T1-1-3 Working Range (Be Backhoe).......................................... T1-1-4 Working Range (Loading Shovel).................................. T1-1-5

Group 2 Component Layout

Main Component................................................................. T1-2-1 Front Attachment ............................................................... T1-2-2 Electrical System (Overview)........................................... T1-2-3 Electrical System (In Cab).................................................. T1-2-4 Electrical System (Switch Panel)..................................... T1-2-5 Electrical System (Electrical Equipment Box)............. T1-2-6 Electrical System (Rear Tray) ........................................... T1-2-7 Electrical System (Battery Box)........................................ T1-2-8 Around Air Cleaner.............................................................. T1-2-9 Around Engine Compartment ....................................... T1-2-9 Pressure Sensor (Main Control Valve 4-Spool Side)/Pressure Sensor (Main Control Valve 5-Spool Side)..........................T1-2-10 Around Pump Device ......................................................T1-2-11 Pump Device.......................................................................T1-2-12 Control Valve.......................................................................T1-2-13 Signal Control Valve..........................................................T1-2-14 Solenoid Valve.....................................................................T1-2-15 Fan Valve (Oil Cooler, Radiator).....................................T1-2-15 Engine....................................................................................T1-2-16 Around Oil Cooler..............................................................T1-2-17 Around Radiator.................................................................T1-2-17 Auto-Lubrication Device.................................................T1-2-18 Swing Device and Pressure Sensors for Front Attachment..................................................T1-2-19 Hydraulic Oil Tank..............................................................T1-2-20 Fuel Tank...............................................................................T1-2-20 Sliding Fold-In Ladder......................................................T1-2-21 Layout of Fuse.....................................................................T1-2-22

Group 3 Component Specifications

Engine...................................................................................... T1-3-1 Engine Accessories.............................................................. T1-3-5 Hydraulic Component........................................................ T1-3-6 Backhoe................................................................................... T1-3-8 Loading Shovel..................................................................... T1-3-8 Electrical Component.......................................................T1-3-10

KAA90T-1-1

(Blank)

KAA90T-1-2

SECTION 1 GENERAL Group 1 Specifications Specifications (Backhoe)

C

A

B

E D I

H F

G

Model Type of Front-End Attachment

Bucket Capacity (Heaped) Operating Weight Engine Engine Power A: Overall Width B: Cab Height C: Rear End Swing Radius D: Minimum Ground Clearance E: Counterweight Clearance F: Undercarriage Length G: Undercarriage Width H: Sprocket Center to Idle Center I: Track Shoe Width Ground Pressure Swing Speed Travel Speed (fast/slow) Gradeability

-

m3 kg (lb) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) kPa (kgf/cm2) (psi) min-1 (rpm) km/h % (Degree)

fNOTE: *The dimensions do not include the height of the shoe lug.

T1-1-1

MKAA-12-001

EX1200-7 Hydraulic Excavator Backhoe BE Backhoe [9.0 m (29’ 6”) boom, [7.55 m (24’ 9”) BE-boom, 3.6 m (11’ 10”) arm] 3.4 m (11’ 2”) BE-arm] 5.2 7.0 115000 (253600) 117000 (258000) Cummins QSK23 567 kW/1800 min ¹ (770 PS/1800 rpm) 5470 (17’ 9”) 4350 (14’ 3”) 4900 (16’ 1”) *1020 (3’ 4”) 1820 (6’ 0”) 6500 (21’ 4”) 4600 (15’ 1”) 5090 (16’ 8”) 700 (28”) (Grouser shoe) 145 (1.48) (21.1) 148 (1.51) (21.5) 5.2 3.5/2.4 70 (35)

SECTION 1 GENERAL Group 1 Specifications Specifications (Loading Shovel) C

A

B E

D I

H G

F TKAA90-01-01-001

Model Type of Front-End Attachment

-

EX1200-7 Hydraulic Excavator Loading Shovel

Bucket Capacity (Heaped)

m3

PCSA 6.5 (8.5 yd3)

Operating Weight kg (lb) Engine -1 Engine Power kW/min (PS/rpm) A: Overall Width mm (ft·in) B: Cab Height mm (ft·in) C: Rear End Swing Radius mm (ft·in) D: Minimum Ground Clearance mm (ft·in) E: Counterweight Clearance mm (ft·in) F: Undercarriage Length mm (ft·in) G: Undercarriage Width mm (ft·in) H: Sprocket Center to Idle Center mm (ft·in) mm (ft·in) I: Track Shoe Width kPa (kgf/cm2) (psi) Ground Pressure Swing Speed Travel Speed (fast/slow) Gradeability

118000 (260200) Cummins QSK23 567 /1800 (770 /1800) 5470 (17’ 11”) *5440 (17’ 10”) 4900 (16’ 1”) 1020 (3’ 4”) (Excluding shoe lug) 1820 (6’ 0”) 6500 (21’ 4”) 4600 (15’ 1”) 5090 (16’ 8”) 700 (28 in) (Grouser shoe) 149 (1.5) (21.6) 5.8 3.5/2.4 (2.2/1.5 mph) 70 (35)

min-1 (rpm) km/h % (Degree)

fNOTE: *The standard specification loading shovel is equipped with an elevated cab.

T1-1-2

SECTION 1 GENERAL Group 1 Specifications Working Range (Backhoe)

C

D

E B

A' A

Boom Length Arm Length A : Maximum Digging Reach A’ : Maximum Digging Reach (on ground) B : Maximum Digging Depth C : Maximum Cutting Height D : Maximum Dumping Height E : Maximum Vertical Wall

MKAA-12-002

9.00 m (29’ 6”) 3.60 m (11’ 10”) 15350 mm (50’ 4”) 15010 mm (49’ 3”) 9380 mm (30’ 9”) 13460 mm (44’ 2”) 9080 mm (29’ 10”) 6450 mm (21’ 2”)

T1-1-3

SECTION 1 GENERAL Group 1 Specifications Working Range (Be Backhoe)

C

D

E

B

A' A

Boom Length Arm Length A : Maximum Digging Reach A’ : Maximum Digging Reach (on ground) B : Maximum Digging Depth C : Maximum Cutting Height D : Maximum Dumping Height E : Maximum Vertical Wall

MKAA-12-003

7.55 m (24’ 9”) BE-boom 3.40 m (11’ 2”) BE-arm 13790 mm (45’ 2”) 13410 mm (44’ 0”) 8100 mm (26’ 6”) 12340 mm (40’ 5”) 8010 mm (26’ 3”) 4440 mm (14’ 6”)

T1-1-4

SECTION 1 GENERAL Group 1 Specifications Working Range (Loading Shovel)

H

G

E

E'

F

A C

B D TKAA90-01-01-002

A: B: C: D: E: E': F: G: H:

Minimum Digging Distance Minimum Level Crowding Distance Level Crowding Distance Maximum Digging Reach Maximum Cutting Height Maximum Dumping Height Maximum Digging Depth Working Radius at Maximum Dumping Height Maximum Bucket Opening Width

T1-1-5

mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in) mm (ft·in)

4510 (14’ 10”) 6580 (21’ 7”) 4450 (14’ 7”) 11500 (37’ 9”) 12410 (40’ 9”) 8750 (28’ 9”) 4780 (15’ 8”) 6140 (20’ 2”) 1880 (6’ 2”)

SECTION 1 GENERAL Group 1 Specifications (Blank)

T1-1-6

SECTION 1 GENERAL Group 2 Component Layout Main Component

34 30

9 33

6

32

31

Detail A

27

7

11

10

8

5

12

4

13

3 2

14 15 16

36

17

35

29

18

19 20 21 23

28

22

24

A

25 26

2345-

Auto-Lubrication Device Tool Box Fuel Tank (Refer to T1-2-20.)

Swing Device (Refer to T1-219) 6- Signal Control Valve 7- Main Control Valve 8- 2-Spool Solenoid Valve Unit 9- Radiator 10- 4-Spool Solenoid Valve Unit 11- Muffer

12- Engine 13- Air Cleaner (Refer to T1-2-9) 14- Around Pump Device (Refer to T1-2-11.)

15- Pump Transmission 16- Hydraulic Oil Tank (Refer to T1-2-20.)

17- Swing Control Valve 18- Travel Device 19- Sliding Fold-In Ladder 20- Lower Roller

21222324252627282930-

T1-2-1

Battery Upper Roller Accumulator Track Adjuster Front Attachment/Swing Pilot Valve Front Idler Travel Pilot Valve Swing Bearing Center Joint Oil Cooler

TKAA90-01-02-008

31- Fuel Cooler 32- Air Conditioner Condenser 33- Pump Transmission Oil Cooler 34- Intercooler 35- Pilot Shut-Off Solenoid Valve 36- Bucket Open/Close Pilot Valve (only LD)

SECTION 1 GENERAL Group 2 Component Layout Front Attachment Backhoe 4 3

2 1

5 6

TKAB-01-02-002

Loading Shovel 4 8 3 6

1

5

7

2

7 TKAA90-01-02-009

12-

Bucket Bucket Cylinder

34-

Arm Cylinder Boom

56-

T1-2-2

Boom Cylinder Arm

78-

Dump Cylinder (only LD) Level Cylinder (only LD)

SECTION 1 GENERAL Group 2 Component Layout Electrical System (Overview)

11 10 13

9

8 7

14 6 5 3

1

15 16 18

32 19 21 22 20 24

31 26 25 28 29 13-

5678-

Work Light (Right) Components Related with Auto-Lubrication Device (Refer to T1-2-18.)

Satellite Communication Antenna WIU Antenna Around Oil Cooler (Refer to T1-2-17.)

Components Related with Signal Control Valve (Refer to T1-2-14.)

9-

1011131415-

Components Related with Main Control Valve (Refer to T1-2-13.)

Around Radiator (Refer to T12-17.)

Components Related with Engine (Refer to T1-2-17.)

Rear View Camera Rear Light Engine Stop Switch 2

16- Components Related with Pump Device (Refer to T1-212.)

18- Around Engine Compartment (Refer to T1-2-9.)

19- Components Related with Swing Control Valve (Refer to T1-2-13.)

20- Pressure Sensor (4-Spool Side)/Pressure Sensor (5-Spool Side) (Refer to T1-2-10.)

21- 4-Spool Solenoid Valve Unit

T1-2-3

TKAA90-01-02-002 22- 2-Spool Solenoid Valve Unit 24- Cab Rear Light (Option) 25- Electrical System (Battery Box) (Refer to T1-2-8.)

26- Step Light 28- Electrical System (In Cab) (Refer to T1-2-4.)

29- Work Light (Left) 31- Work Light (Cab Upper) 32- Horn

SECTION 1 GENERAL Group 2 Component Layout Electrical System (In Cab)

1

2

4

3

View A (Illustration viewed in the cab toward the cab door )

7

8

9

10

A

TKAB-01-02-051

6

5 TKAB-01-02-004

123-

Aerial Angle Monitor (Option) Monitor Electrical System (Switch Panel) (Refer to T1-2-5.)

4-

Electrical System (Electrical Equipment Box) (Refer to T1-2-6.)

56-

T1-2-4

Electrical System (Rear Tray) (Refer to T1-2-7.)

Electrical System (Switch Panel) (Refer to T1-2-5.)

78910-

Step Light Switch Engine Stop Indicator Engine Stop Switch 1 Cab Door

SECTION 1 GENERAL Group 2 Component Layout Electrical System (Switch Panel) Switch Panel (Left)

Switch Panel (Right) 8

1

9

10

11 12

13 14 15 24 23

2 3 4

16 17 18 19

5 22 6

20

7

21

TKAB-01-02-005

123456-

Horn Switch Travel Alarm Deactivation Switch (Option) Seat Heater Switch (Option)/ Cab Rear Light Switch (Option) Boom Mode Switch Fan Reverse Rotation Switch Lubrication Mode Selection Switch

789-

Buzzer Deactivation Switch Power Digging Switch AUTO/OFF Switch/Fan Switch (Air Conditioner) 10- Temperature Control Switch/ MODE Switch (Air Conditioner) 11- Return to Previous Screen Switch (Monitor)

TKAB-01-02-006

12- Return to Basic Screen Switch (Monitor) 13- Selector/Set Switch (Monitor) 14- AM/FM Selector/Tuning Switch (Radio) 15- Power Switch/Volume Control Switch (Radio) 16- Engine Control Dial 17- Auto-Idle Switch

T1-2-5

18- Travel Mode Switch 19- Work Light Switch 20- Screen Changeover Switch (for Aerial Angle) (Option) 21- Power Mode Switch 22- Numeric Keypad 23- Wiper/Washer Switch 24- Key Switch

SECTION 1 GENERAL Group 2 Component Layout Electrical System (Electrical Equipment Box)

A

1 2 3 4 5 11

10 9

8 7

Detail A

12

13

14

15

6

26

TKAB-01-02-007

16

17 18

25 24

23

123456-

Fault Code Selection Switch Engine Troubleshooting Switch Engine Stop Indicator Lamp Engine Warning Indicator Lamp Engine Maintenance Indicator Lamp Connector for DLU

7891011121314-

22

21

Connector for PC (Cummins) CSU (Option) MC1 DLU MC2 Unused (R6) Wiper Relay Low (R7) Work Light Relay 2 (Boom Light) (R12)

20

19

15- Wiper Relay High 2 (R8) 16- Work Light Relay 1 (Work Light) (R11) 17- Wiper Relay High 1 (R9) 18- Washer Relay (R10) 19- Unused (R5) 20- Unused (R4) 21- Auto-Lubrication Relay 1 (R13) 22- Unused (R3)

T1-2-6

TKAB-01-02-008 23- Sliding Fold-In Ladder Relay (R14) 24- Pump Transmission Oil Level Switch Relay (R2) 25- Step Light Relay (R1) 26- Auto-Lubrication Relay 2 (R31)

SECTION 1 GENERAL Group 2 Component Layout Electrical System (Rear Tray)

1 2 3

12

11

View A

4

A

10

B

9

18

Detail B

13 14 15 16

8

7

19

TKAB-01-02-009

6 5

20

21

22

29 28

27 17 1234567-

WIU (Option) Cigar Lighter 12V Socket Pump Regulator Pressure Learning Switch Fuse Box 3 (Option) (Refer to T1-2-24) Fuse Box 2 (Refer to T1-2-23) Fuse Box 1 (Refer to T1-2-22)

26

89101112131415-

12 V Power Unit Aerial Angle Controller (Option) Air Conditioner Controller GSM Monitor Controller Alternator Signal Relay (R33) Alternator Relay (R32) Pilot Shut-Off Relay (R26)

25

24

23 TKAB-01-02-011

TKAB-01-02-010 161718192021222324-

T1-2-7

Seat Heater Relay (Option) Radio Controller Security Horn Relay (R20) Horn Relay (R21) Load Dump Relay (R22) Starter Cut Relay (R23) Security Relay (R24) ACC ON Relay 1 (R19) ACC ON Relay 2 (R18)

25- Work Light Relay 3 (Work Light (Cab Upper)) (R28) 26- Auto Shut-Down Relay (R17) 27- Back Light Relay (R27) 28- ACC Cut Relay (R16) 29- Key Switch ON Cut Relay (R15)

SECTION 1 GENERAL Group 2 Component Layout Electrical System (Battery Box) Detail A

6

7

8

1 4

2

A

20 19 18 17

12-

Isolation Switch (Battery Circuit) Isolation Switch (Starter Circuit)

16

TKAB-01-02-012

3 3467-

Battery Washer Tank Battery Relay 1 Diode 1

8161718-

T1-2-8

Battery Relay 2 Slow Blow Fuse 4 (200 A) Slow Blow Fuse 1 (45 A) Slow Blow Fuse 3 (75 A)

TKAA90-01-02-007

19- Slow Blow Fuse 2 (75 A) 20- Fuse 3 (20 A)

SECTION 1 GENERAL Group 2 Component Layout Around Air Cleaner 1

4 1-

Air Cleaner

2-

3

Drain Filter

2 3-

Pump Transmission Oil Filter

TKAB-01-02-016 4-

Pilot Filter

Around Engine Compartment 6

5

TKAB-01-02-053 TKAA90-01-02-003

5-

Engine Oil Filter

6-

Fuel Filter (Stage 1)

T1-2-9

SECTION 1 GENERAL Group 2 Component Layout Pressure Sensor (Main Control Valve 4-Spool Side)/Pressure Sensor (Main Control Valve 5-Spool Side)

View A

A

2 TKAB-01-02-014

1-

Pressure Sensor (4-Spool Side)

2-

Pressure Sensor (5-Spool Side)

T1-2-10

1 TKAB-01-02-015

SECTION 1 GENERAL Group 2 Component Layout Around Pump Device

1

2

3

6

12-

Pump 3 Pump 2

34-

5

4

Engine Stop Switch 2 3-Unit Pump

56-

T1-2-11

TKAB-01-02-018

Pump 1 Fan Pump

SECTION 1 GENERAL Group 2 Component Layout Pump Device 1

2

3

A

B

7

D

C

6 12-

Pump 3 Regulator Pressure Sensor Pump Transmission Oil Level Switch

34-

5

4

Pump 2 Regulator Pressure Sensor Pump 2 Delivery Pressure Sensor

Views A, B, C

TKAB-01-02-019 5-

Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

6-

7-

Pump 1 Regulator Pressure Sensor

View D (3-Unit Pump)

8

9

10

11

12

14

TKAB-01-02-020

89-

Pump Regulator (Pumps 1, 2, 3) Pump Control Solenoid Valve (Pumps 1, 2, 3)

10- Transmission Lubrication Pump 11- Pilot Pump 12- Fan Pump

13- Fan Pump Regulator 14- Fan Pump Control Solenoid Valve

T1-2-12

13

TKAB-01-02-052

SECTION 1 GENERAL Group 2 Component Layout Control Valve Main Control Valve View A

1

2 3

9

4

5

6

7

A

TKAB-01-02-021

8

TKAB-01-02-022 12-

Press Sensor (Arm Roll-Out) Pressure Sensor (Boom Raise)

34-

Pressure Sensor (Bucket RollOut) Main Relief Valve

56-

Pressure Sensor (Bucket Roll-In) Pressure Sensor (Boom Lower)

789-

Press Sensor (Arm Roll-In) High-Pressure Filter High-Pressure Filter

Swing Control Valve 10

11

TKAB-01-02-023 10- High-Pressure Filter

11- Main Relief Valve

T1-2-13

SECTION 1 GENERAL Group 2 Component Layout Signal Control Valve Detail A B

C

C

A

1

2 3 TKAB-01-02-059

4

5

TKAB-01-02-025

View B Section C-C

8 14

9

13

10

12

11

T178-03-06-002

6

1234-

Signal Control Valve Pressure Sensor (SA) Pressure Sensor (SB) Pressure Sensor (SA) Mounting Part

7

5678-

TKAB-01-02-057

Pressure Sensor (SB) Mounting Part Pressure Sensor (Travel) Pressure Sensor (Swing) Boom Raise Shockless Valve

9- Auxiliary 10- Auxiliary 11- Flow Combiner Valve Control Spool

T1-2-14

12- Swing Parking Brake Release Spool 13- Auxiliary 14- Auxiliary

SECTION 1 GENERAL Group 2 Component Layout Solenoid Valve 2-Spool Solenoid Valve Unit

4-Spool Solenoid Valve Unit

5 1

2

3

TKAB-01-02-027

TKAB-01-02-058 12-

4-Spool Solenoid Valve Unit (SC) 4-Spool Solenoid Valve Unit (SF)

34-

4-Spool Solenoid Valve Unit (SI) 4-Spool Solenoid Valve Unit (SG)

56-

Fan Valve (Oil Cooler, Radiator)

7

8

9 TKAB-01-02-055 7-

Fan Reverse Rotation Control Solenoid Valve

89-

6

4

Fan Valve Relief Valve

T1-2-15

2-Spool Solenoid Valve Unit (SC) 2-Spool Solenoid Valve Unit (SI)

SECTION 1 GENERAL Group 2 Component Layout Engine 2

1

4

5

3

TKAA90-01-02-005

7

10 11

12 TKAA90-01-02-004

9

8

TKAA90-01-02-006 123-

Air Conditioner Compressor Boost Pressure Sensor ECM

457-

Coolant Filter Alternator Coolant Temperature Sensor

8- Starter 1 9- Starter 2 10- Engine Speed Sensor

T1-2-16

11- Engine Protection Relay 1 12- Engine Protection Relay 2

SECTION 1 GENERAL Group 2 Component Layout Around Oil Cooler 1

3 12-

4

View A

A

Fuel Filter (Stage 1) Oil Cooler Fan Valve

34-

Oil Cooler Fan Motor Oil Cooler

5

4

TKAB-01-02-035

2

5-

TKAB-01-02-036

Fuel Cooler

Around Radiator View B

10

11

7 B

9

78-

Coolant Level Sensor Radiator Fan Motor

8

14

TKAB-01-02-037

9- Radiator Fan Valve 10- Radiator

11- Intercooler 12- Air Conditioner Condenser

T1-2-17

13

12

TKAB-01-02-038

13- Receiver Tank 14- Pump Transmission Oil Cooler

SECTION 1 GENERAL Group 2 Component Layout Auto-Lubrication Device Quicklub Lubrication System (Standard) 1

2

3

4

5 6

TKAB-01-02-056 1-

Auto/Manual Selector Valve Lever Proximity Switch

2-

345-

Distribution Valve Grease Pump Diode 23

6-

Pail

Centro Matic Lubrication System (Option) 7

8

View A

9

10 A

11 13 12

TKAB-01-02-039

78-

Grease Pump Air Breather

9-

Auto-Lubrication Solenoid Valve 10- Diode 22

15 11- Diode 3 12- Grease Tank 13- Grease Pressure Gauge

T1-2-18

14

TKAB-01-02-040

14- Auto/Manual Selector Valve Lever 15- Pressure Switch

SECTION 1 GENERAL Group 2 Component Layout Swing Device and Pressure Sensors for Front Attachment 1 B C

1 2 A

TKAB-01-02-041

2 View B

View A

3

5

1234-

Swing Motor Relief Valve Arm Bottom Pressure Sensor Boom Bottom Pressure Sensor

567-

Bucket Bottom Pressure Sensor Arm Rod Pressure Sensor Bucket Rod Pressure Sensor

TKAB-01-02-043

6

TKAB-01-02-042

4

View C

7

T1-2-19

TKAB-01-02-044

SECTION 1 GENERAL Group 2 Component Layout Hydraulic Oil Tank View A

3

2

4

A

1 1-

Hydraulic Oil Level Check Switch

2-

TKAB-01-02-046

TKAB-01-02-045

Hydraulic Oil Level Gauge

3-

Hydraulic Oil Temperature Sensor

4-

Valve Limit Switch

Fuel Tank

6

5

7

TKAB-01-02-048

TKAB-01-02-047 5-

Fuel Level Gauge

6-

Fuel Level Switch

7-

T1-2-20

Fuel Level Sensor

SECTION 1 GENERAL Group 2 Component Layout Sliding Fold-In Ladder View A

1

2

B

TKAB-01-02-050

TKAB-01-02-049

A

View B

3 TKAA90-01-02-010

1-

Sliding Fold-In Ladder

2-

Sliding Fold-In Ladder Limit Switch

3-

T1-2-21

Step Light Switch

SECTION 1 GENERAL Group 2 Component Layout Layout of Fuse Fuse Box 1

Fuse Box 1

10 9 8 7 6

20 19 18 17 16

5 4 3 2 1

15 14 13 12 11

M178-07-034

Fuse No. Capacity Connected to 1 20 A Pilot Shut-Off Relay (Power), Pilot Shut-Off Solenoid Valve (Power), Sliding Fold-In Ladder Relay (Power), Security Relay (Power), MC1 (Solenoid Valve Power), Charge Signal Relay 2 15 A 12 V Power Supply 3 20 A Air Conditioner Unit 4 10 A Work Light Relay 3 5 15 A Auto-Lubrication Relay 1, Auto-Lubrication Relay 2 6 20 A Work Light Relay 2 7 20 A Work Light Relay 1 8 10 A Back Light Relay 9 20 A Washer Relay, Wiper Relay High 1, Wiper Relay Low (Power) 10 5A 11 5A 12 13 14 10 A 15 20 A 16 20 A Fuel Level Switch, Pump Transmission Oil Level Switch 17 10 A Seat Heater (Option) 18 20 A Seat Compressor (Option) 19 20 A Travel Alarm Device (Fender Side) (Option), Travel Alarm Device (Rear Side) (Option) 20 20 A Beacon Light (Option)

T1-2-22

SECTION 1 GENERAL Group 2 Component Layout Fuse Box 2 Fuse Box 2 30 29 28 27 26

40 39 38 37 36

25 24 23 22 21

35 34 33 32 31

M178-07-034

Fuse No. Capacity Connected to 21 5A Starter Cut Relay (Power), Auto Shut-Down Relay (Power), ACC Cut Relay (Power), Key Switch ON Cut Relay (Power) 22 23 5A Radio 24 10 A Horn Relay (Power) 25 5A Buzzer, Air Conditioner Unit, GSM (Key Switch ON Signal) 26 5A MC1 (Power) 27 5A MC1 (Key Switch ON Signal) 28 5A Engine Stop Switch 1 29 5A Step Light Relay (Power) 30 5A MC2 (Power) 31 5A DLU (Power) 32 5A Battery Relay 1, Battery Relay 2, Load Dump Relay 33 5A Monitor Controller (Key Switch START Signal), DLU (Key Switch START Signal) 34 5A Monitor Controller (Key Switch ON Signal), DLU (Key Switch ON Signal), MC2 (Key Switch ON Signal), THIRD PARTY INTERFACE (Key Switch ON Signal) 35 10 A Monitor Controller (Backup Power), GSM (Power), Switch Panel, Cab Light, Security Horn (Power), Security Horn Relay (Power), Radio (Backup Power) 36 5A Monitor Controller (Power) 37 10 A Auxiliary 3 (Option) 38 10 A Auxiliary 1 (Option), THIRD PARTY INTERFACE (Power) 39 15 A ACC ON Relay 2 (Power) 40 15 A ACC ON Relay 1 (Power)

T1-2-23

SECTION 1 GENERAL Group 2 Component Layout Fuse Box 3 (Option)

41 42 43 44 45 46 47 48 49 50

TKEB-05-01-001

Fuse No. 41 42 43 44 45 46 47 48 49 50

Capacity Connected to 5A Engine START Signal (Option) 5A Key Switch ON Signal (Option) 5A CSU (Power) (Option) 5A WIU (Power) (Option) 5A Auxiliary 5A Auxiliary 5A Auxiliary 5A Auxiliary -

fNOTE: CSU: Contamination Sensing Unit WIU: Wireless Interface Unit

T1-2-24

SECTION 1 GENERAL Group 3 Component Specifications Engine Manufacturer

Cummins Inc.

Model

QSK23-C

Type

Diesel, 4-Cycle, Water-cooled, Direct Injection Type, Exhaust Turbo Charged Type

Cyl. No.- Bore × Stroke

6-170 mm×170 mm (6-6.7×6.7 in)

Piston Displacement

23.15 L (6 US gal)

Rated Output

567 kW/1800 min-1 (771 PS/1800 rpm)

Compression Ratio

16:1

Dry Weight

2600 kg (5740 lb)

Firing Order

1-5-3-6-2-4

Rotation Direction Dimension Overall length × width × height

Counter clockwise (Viewed from flywheel side) 1859×940×1656 mm (6 ft×3 ft×5 ft 5 in)

T1-3-1

SECTION 1 GENERAL Group 3 Component Specifications COOLING SYSTEM

Thermostat

Cracking Temperature at Atmospheric Pressure: 77 °C Full Open: 90 °C

LUBRICATION SYSTEM

Water Pump

Centrifugal Type

Lubrication Pump Type

Gear Pump

Oil Filter

Full-Flow Paper Element Type with Bypass

STARTING SYSTEM Voltage/Output STARTING ASSIST SYSTEM Type ENGINE STOP SYSTEM Stop Method

24 V/7.5 kW×2 (24 V/10 PS×2) Ether Injection Type Electronic Control

ALTERNATOR

Type

Regulator Integrated AC Type

Voltage/Output

24 V/140 A

SUPERCHARGING SYSTEM

Type

Exhaust-Turbocharger Type with Lubrication, Water-Cooled Type

FUEL SYSTEM

Type

Cummins HPI

Governor

Electronic All Speed Control

T1-3-2

SECTION 1 GENERAL Group 3 Component Specifications IMPORTANT: This list shows design specifications, which are not servicing standards.

Performance Fuel Consumption (When rated, Gross) Maximum Output Torque (Gross) No Load Speed Fast: Slow:

SAEJ1995 206 g/kW·h (151 g/PS·h) 3468 N·m at 1350 min-1 (2560 lbf·ft at 1350 rpm) 1950 ± 30 min-1 (rpm) 850 ± 30 min-1 (rpm)

T1-3-3

SECTION 1 GENERAL Group 3 Component Specifications Engine Performance Curve (QSK23-C) Test Condition: The engine operating with fuel system, not included are alternator and fan. Curves shown above represent gross engine performance capabilities obtained and corrected in accordance with SAE J1995 conditions of 100 kPa (14.5 psi) barometric pressure [91 m (300 ft) altitude] 25 °C (77 °F) inlet air temperature, and 1 kPa (0.1 psi) water vapor pressure with SAE No.2 diesel fuel.

N·m

T

kW

P

min-1

N

TKAB-01-03-001

P:

Output

T:

Torque

N:

T1-3-4

Engine Speed

SECTION 1 GENERAL Group 3 Component Specifications Engine Accessories Core Dimension (height × width × depth) Core Rows Fin Pitch Fin Type Radiation Area

Core Dimension (height × width × depth) Core Rows Fin Pitch Fin Type Radiation Area BATTERY

Radiator 1300×1285×100 mm (4 ft 3 in×4 ft 3 in×4 in) 1 row (3 used) 3.5/2 mm (0.1/2 in) ALW-4 202.65 m2 (242.4 yd2)

Oil Cooler 1190×1540.6×93 mm (3 ft 11 in×5 ft×4 in) 3 rows (6 used) 3.5/2 mm (0.1/2 in) CF40-1 167.15 m2 (200 yd2)

Intercooler 980×904×65 mm (3 ft 3 in×2 ft 12 in×3 in) 1 row (1 used) 4.0/2 mm (0.2/2 in) CFT 10-Hole Pipe 43.46 m2 (52 yd2)

Fuel Cooler 419.4×765×31 mm (1 ft 5 in×2 ft 6 in×1 in)

Pump Transmission Oil Cooler 284.4×312×40 mm (11 in×1 ft×2 in)

1 row (1 used) 3.5/2 mm (0.1/2 in) CF40-1 9.62 m2 (11.5 yd2)

1 row (1 used) 3.5 mm (0.1 in) Corrugated 3.34 m2 (4 yd2)

Type Nominal Voltage Capacity CCA Discharge Characteristics (-15 °C/500 A)

245H52 12 V 176 Ah (5-Hour Rate), 185 Ah (20-Hour Rate) 1170 A Duration 7.8 min 30-Second Voltage at Discharge 9.9 V Dimension (height × width 266×518×276 mm (11 in×1 ft 8 in×11 in) × length)

T1-3-5

SECTION 1 GENERAL Group 3 Component Specifications Hydraulic Component PUMP DEVICE

Drive Gear Ratio

Main Pump: 1.041 3-Unit Pump: 1.063

MAIN PUMP

Type

Swash-Plate Type Variable Displacement Plunger Pump

Theoretical Displacement (SetCapacity)

280 cm3/rev (17.1 in3/rev)

Rated Pressure

34.3 MPa (4970 psi)

Type

Hydraulic Pressure Operated Type

REGULATOR 3-UNIT PUMP

MAIN CONTROL VALVE

Fan Pump

Pilot Pump

Transmission Oil Circulation Pump

Type

Swash-Plate Type Fixed Displacement Variable Displacement Type Gear Pump Plunger Pump

Theoretical Displacement

80 cm3/rev (4.9 in3/rev) 28 cm3/rev (1.7 in3/rev) 14.8 cm3/rev (0.9 in3/ rev)

Maximum Flow Rate (Theoretical Value)

125 L/min (33 US gpm)

Type

Pilot Pressure Operated Type (4-Spools + 5-Spools)

Main Relief SetPressure

Normal: 31.9 MPa at 250 L/min (4630 psi at 66 US gpm)

51.4 L/min (13.6 US gpm)

Fixed Displacement Type Gear Pump

27.1 L/min (7.2 US gpm)

Increases Pressure: 34.3 MPa at 230 L/min (4970 psi at 60.8 US gpm) Overload Relief SetPressure

SWING CONTROL VALVE Type

35.3 MPa at 110 L/min (5120 psi at 29 US gpm) (Boom, Arm, Bucket) 11.8 MPa at 110 L/min (1710 psi at 29 US gpm) (Boom Lower (Boom Mode Switch: ON) 17.7 MPa at 500 L/min (2570 psi at 132 US gpm) (Bucket Open (LD)) 33.3 MPa at 110 L/min (4830 psi at 29 US gpm) (Bucket Close (LD)) Pilot Pressure Operated Type (4-Spools)

Main Relief SetPressure

31.9 MPa at 250 L/min (4630 psi at 66.1 US gpm)

Overload Relief SetPressure

35.3 MPa at 110 L/min (Arm)

T1-3-6

SECTION 1 GENERAL Group 3 Component Specifications SWING DEVICE

Type

Two-Stage Reduction Planetary Gear

Reduction Gear Ratio

28.235

Type

Swash-Plate Type, Fixed Displacement Axial Plunger Motor

Theoretical Displacement

210.1 cm3/rev (12.8 in3/rev)

Type

Non Counterbalance Valve Type

Relief Set-Pressure

27.4 MPa at 110 L/min (3970 psi at 29.1 US gpm)

Type

Wet-Type Spring Set Hydraulic Released Multi-Disc Brake

Release Pressure

2.0 to 2.5 MPa (290 to 365 psi)

Type

Three-Stage Reduction Planetary Gear

Reduction Gear Ratio

137.204

Type

Swash-Plate Type Variable Displacement Axial Plunger Motor

Theoretical Displacement (Fast/Slow)

228.6/337.2 cm3/rev (13.9/20.6 in3/rev)

Type

Counterbalance Valve Type

Relief Set-Pressure

36.8 MPa at 120 L/min (5340 psi at 31.7 US gpm)

TRAVEL PARKING BRAKE

Type

Wet-Type Spring Set Hydraulic Released Multi-Disc Brake

RADIATOR FAN MOTOR OIL COOLER FAN MOTOR

Release Starting Pressure Theoretical Displacement Theoretical Displacement

1.37 MPa (200 psi) 48.0 cm3/rev (2.9 in3/rev) 48.0 cm3/rev (2.9 in3/rev)

SWING MOTOR VALVE UNIT SWING PARKING BRAKE TRAVEL DEVICE TRAVEL MOTOR

TRAVEL BRAKE VALVE

T1-3-7

SECTION 1 GENERAL Group 3 Component Specifications Backhoe CYLINDER Rod Diameter

Boom 160 mm (6.3 in)

Arm 180 mm (7.1 in)

Bucket 170 mm (6.7 in)

Cylinder Bore

230 mm (9.1 in)

260 mm (10.2 in)

240 mm (9.5 in)

Stroke

2210 mm (7 ft 3 in)

2425 mm (7 ft 12 in)

1790 mm (5 ft 11 in)

Fully Retracted Length 3200 mm (10 ft 6 in)

3605 mm (11 ft 10 in)

2895 mm (9 ft 6 in)

Boom 160 mm (6.3 in) 230 mm (9.1 in) 2075 mm (6 ft 10 in) 3170 mm (10 ft 5 in)

Arm 150 mm (5.9 in) 215 mm (8.5 in) 1835 mm (6 ft 0 in) 2785 mm (9 ft 2 in)

Bucket 150 mm (5.9 in) 200 mm (7.9 in) 1600 mm (5 ft 3 in) 3405 mm (11 ft 2 in)

Level Rod Diameter 160 mm (6.3 in) Cylinder Bore 230 mm (9.1 in) Stroke 790 mm (2 ft 7 in) Fully Retracted Length 1815 mm (5 ft 11 in)

Dump 85 mm (3.5 in) 140 mm (5.5 in) 475 mm (1ft 7 in) 1090 mm (3 ft 7 in)

Loading Shovel CYLINDER Rod Diameter Cylinder Bore Stroke Fully Retracted Length CYLINDER

T1-3-8

SECTION 1 GENERAL Group 3 Component Specifications FRONT ATTACHMENT PILOT VALVE

Plunger Stroke

TRAVEL PILOT VALVE

Plunger Stroke

Ports 1, 2, 3, 4: 4.6 mm (0.18 in)

BUCKET OPEN/CLOSE PILOT VALVE (LD)

Plunger Stroke

4.5 mm (0.17 in)

5-SPOOL SOLENOID VALVE UNIT

Type

5-Spool Proportional Solenoid Valve

Rated Voltage

DC 24 V

Coil Resistance

22 Ω

Type

2-Spool Proportional Solenoid Valve

Rated Voltage

DC 24 V

Coil Resistance

22 Ω

SIGNAL CONTROL VALVE

Rated Pressure

3.72 MPa

PILOT SHUT-OFF SOLENOID VALVE

Type

ON/OFF Solenoid Valve

Rated Voltage

DC 24 V

Coil Resistance Relief Set-Pressure Relief Set-Pressure Cracking Pressure

48 Ω 21.6 kPa at 44.5 L/min (3.1 psi at 11.8 US gpm) 21.6 kPa at 44.5 L/min (3.1 psi at 11.8 US gpm) 343 kPa at 40 L/min (49.7 psi at 10.6 US gpm)

Full-Flow Filter Suction Filter Pilot Filter Fuel Filter (Stage 1) Pump Transmission Oil Filter Drain Filter

β10>2.0 177 μm (80 mesh) β10≥1.4 5 μm 105 μm 10 μm

2-SPOOL SOLENOID VALVE UNIT

OIL COOLER FAN VALVE RADIATOR FAN VALVE OIL COOLER BYPASS CHECK VALVE FILTER (FILTRATION GRAIN SIZE)

Ports 1, 3: 6.5 mm (0.26 in) Ports 2, 4: 8.0 mm (0.32 in)

T1-3-9

SECTION 1 GENERAL Group 3 Component Specifications Electrical Component BATTERY RELAYS 1, 2

Voltage/Current

24 V/120 A

ENGINE PROTECTION RELAYS 1, 2

Voltage/Current

24 V/180 A

HYDRAULIC OIL TEMPERATURE SENSOR

Operating Temperature

-30 to 120 °C (-22 to 248 °F)

AIR FILTER RESTRICTION SWITCH

Operating Pressure

6.2±0.6 kPa (900±87 psi)

HORN

Voltage/Current

26 V/2.3 A

Sound Pressure

115±5 dB (A) at 2 m

Boom Light

24 V/70 W

Work Light (Left)

24 V/50 W

Work Light (Right)

24 V/50 W

Work Light (Cab Upper)

24 V/50 W

Cab Light

24 V/30 mA

Step Light

24 V/70 W

Cab Rear Light

24 V/70 W

Rear Light

24 V/70 W

Refrigerant

R134 a

Cooling Ability

4.5 kW (6.1 PS) or More

Cool Air Volume

550 m3/h (720 yd3) or More

Heating Ability

5.8 kW (7.9 PS) or More

Warm Air Volume

390 m3/h (510 yd3) or More

Temperature Adjusting System

Electronic Type

Refrigerant Quantity

1250±50 g (3±0.1 lb)

Compressor Oil Quantity

160 cm3 (9.8 in3)

ILLUMINATION

AIR CONDITIONER

T1-3-10

MEMO

MEMO

SECTION 2

SYSTEM CONTENTS Group 1 Controller

Outline..................................................................................... T2-1-1 DLU: Data Logging Unit..................................................... T2-1-3

Group 2 Control System

Outline..................................................................................... T2-2-1 Engine Control...................................................................... T2-2-6 Pump Control......................................................................T2-2-26 Valve Control (Standard).................................................T2-2-52 Other Control......................................................................T2-2-70

Group 6 Air Conditioning System

Outline..................................................................................... T2-6-1 Electrical Circuit Diagram.................................................. T2-6-4 Functions of Main Parts..................................................... T2-6-5 Functions of Main Components...................................T2-6-10

Group 3 Engine System

ECM System........................................................................... T2-3-1

Group 4 Hydraulic System

Outline..................................................................................... T2-4-1 Pilot Circuit............................................................................. T2-4-2 Main Circuit..........................................................................T2-4-12 Transmission Oil Cooling Circuit...................................T2-4-32 Fan Motor Circuit...............................................................T2-4-33

Group 5 Electrical System

Outline..................................................................................... T2-5-1 Main Circuit............................................................................ T2-5-2 Electric Power Circuit (Key Switch: OFF)...................... T2-5-4 Electric Power Circuit (Key Switch: ACC)...................... T2-5-6 Electric Power Circuit (Key Switch: ON)........................ T2-5-8 Starting Circuit (Key Switch: START)............................T2-5-16 Charging Circuit (Key Switch: ON)...............................T2-5-18 Pilot Shut-Off Circuit (Key Switch: ON).......................T2-5-20 Auto Shut-Down Circuit..................................................T2-5-22 Engine Stop Circuit............................................................T2-5-24 Surge Voltage Prevention Circuit.................................T2-5-26 Monitor Circuit....................................................................T2-5-29 Security Circuit....................................................................T2-5-30 Radio Circuit........................................................................T2-5-32 Air Conditioner Circuit.....................................................T2-5-32 Accessory Circuit................................................................T2-5-35 Work Light Circuit..............................................................T2-5-36 Step Light Circuit (Serial No. 7002 to 7043).............T2-5-38 Step Light Circuit (Serial No. 7045 and up)..............T2-5-40 Wiper/Washer Circuit........................................................T2-5-42 Cab Light Circuit.................................................................T2-5-46 Sliding Fold-In Ladder Alarm Circuit...........................T2-5-48

KAA90T-2-1

(Blank)

KAA90T-2-2

SECTION 2 SYSTEM Group 1 Controller Outline

fNOTE: DLU: Data Logging Unit

The following controllers are provided in this machine for the control, monitoring, display, and log data communication. Each controller excluding communication controller (9) communicates by using the CAN circuit and sends or receives the required signal.

WIU: Wireless Interface Unit CSU: Contamination Sensing Unit

Controller

Control

MC1(4) MC2(8) ECM(5) Monitor Controller (2)

MC1 (4) controls the engine, pumps, and valves.

MC2 (8) controls the lights, wiper, washer, and sliding fold-in ladder alarm.

ECM (5) controls the actual engine speed.

Monitor controller (2) displays the operating information and alarms on the monitor.

Air conditioner controller (7) controls the air conditioner.

Air Conditioner Controller (7) Radio Controller (6) Radio controller (6) controls the radio.

Communication Controller Communication controller (9) sends the mails and operating information.

(9) DLU(11) DLU (11) controls for the communication status monitoring and operating information maintenance.

WIU (12) (Option) WIU (12) downloads log data from DLU (11) and records them in its built-in memory.

CSU (13) (Option) CSU (13) monitors the amount of contaminant (metal particles) with the contamination sensors (option) in the drain circuits.

Comment on Control T2-2 T2-5 T2-3 T5-2 T2-6, T5-8 T2-5 T5-9 T2-1 -

fNOTE: Refer to the corresponding group for details of each controller control.

3. MPDr.

5.ECM

a. Power CAN

10 8. MC2

1 2

4. MC1

11. DLU

12. WIU

9 13.CSU

6

7

b. Body CAN

c. Monitoring CAN d. DLU-CAN TKAB-02-01-005

a-

Power CAN

b-

Body CAN

c-

Monitoring CAN

d-

1234-

Monitor Monitor Controller MPDr. MC1

5678-

ECM Radio Controller Air Conditioner Controller MC2

9101112-

Communication Controller GPS Antenna DLU WIU(OP)

13- CSU(OP)

T2-1-1

DLU-CAN

SECTION 2 SYSTEM Group 1 Controller CAN Circuit CAN (Controller Area Network) is ISO Standards of the serial communication protocol.

Four networks (CAN bus (3)) in the following are equipped for this machine.  Power CAN (4) is mainly used for the engine control.  Body CAN (5) is mainly used for the accessories.  Monitoring CAN (7) is mainly used for display and log data communication.  DLU-CAN (8) is used for communication between DLU (17) and WIU (15) (option).

CAN bus (3) consists of two wire harnesses, CAN-H (High) (1) and CAN-L (Low) (2).

Each controller judges the CAN bus (3) level due to the potential difference between CAN-H (High) (1) and CAN-L (Low) (2).

Each controller arranges potential difference of CAN bus (3) and sends the signal and data to other controllers.

Termination resistors (120 Ω) (9) are installed to both ends of CAN bus (3).

1

3

2 TKEB-02-05-017

12-

CAN-H (High) CAN-L (Low)

3-

CAN Bus

9. MPDr. 14

10

4. Power CAN

14

22. ECM

12 11

5. Body CAN 13

21. MC1 14 14 8. DLU-CAN

14 15.WIU

20. MC2

19

17. DLU

18

16.CSU 7. Monitoring CAN

45789-

Power CAN Body CAN Monitoring CAN DLU CAN MPDr.

1011121314-

Monitor Controller Monitor Monitor Control Unit Information Control Unit Termination Resistor (120 Ω)

1516171819-

T2-1-2

WIU (OP) CSU (OP) DLU Radio Controller Air Conditioner Controller

20- MC2 21- MC1 22- ECM

TKAA90-02-01-001

SECTION 2 SYSTEM Group 1 Controller DLU: Data Logging Unit Outline  Monitor System Monitoring DLU (11) monitors communication status with the connected units and records abnormality if any.

 FMS Communication (Option) DLU (11) communicates with FMS (Fleet Management System).

DLU (11) sends alarm information to FMS simultaneously when warning.

 Operating Hour Control DLU (11) incorporates the built-in clock. The built-in clock is corrected by using the GPS receiving part of communication controller (9).

 Satellite Communication Terminal (Option)/Mobile Communication Terminal (Option) DLU (11) sends the log data recorded in DLU (11) to the satellite communication terminal or mobile communication terminal.

 Taking-in Basic data DLU (11) takes in the data related to ECM from Power CAN (a).  Warning Detection DLU (11) records warning information with stamped time.  Operating Condition Detection DLU (11) processes the data every 30 minutes.

3. MPDr.

5. ECM

a. Power CAN

10 8. MC2

1 2

4. MC1

11. DLU

12. WIU

9 13.CSU

6

7

b. Body CAN

c. Monitoring CAN d. DLU-CAN TKAB-02-01-005

a-

Power CAN

b-

Body CAN

c-

Monitoring CAN

d-

1234-

Monitor Monitor Controller MPDr. MC1

5678-

ECM Radio Controller Air Conditioner Controller MC2

9101112-

Communication Controller GPS Antenna DLU WIU(OP)

13- CSU(OP)

T2-1-3

DLU-CAN

SECTION 2 SYSTEM Group 1 Controller (Blank)

T2-1-4

SECTION 2 SYSTEM Group 2 Control System Outline MC1 (main controller 1) is used in order to control the machine operations. Signals from the engine control dial, various sensors, and various switches are sent to MC1 and processed in the logic circuit.

MC1 sends the signal equivalent to the target engine speed to ECM by using CAN communication in order to control the engine. (Refer to SYSTEM/Controller.)

In addition, MC1 drives the solenoid valve units and pump control solenoid valves in order to control the pump and valve.

T2-2-1

SECTION 2 SYSTEM Group 2 Control System Engine Control Input Signal Engine Control Dial Power Mode Switch Auto-Idle Switch Travel Mode Switch Key Switch Pilot Shut-Off Switch Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor Pump 1 Regulator Pressure Sensor Pump 2 Regulator Pressure Sensor Pump 3 Regulator Pressure Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Pressure Sensor (LD: Arm Extend/BH: Roll-In) Pressure Sensor (LD: Arm Retract/BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing)

                  

Pressure Sensor (Travel) Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) Hydraulic Oil Temperature Sensor

  

Coolant Temperature Sensor Engine Speed Sensor Boost Pressure Sensor

  

ECM CAN0

MPDr. Work Mode

 

Monitor Controller

fNOTE: OP: Option

T2-2-2

Output Signal Engine Control (ECM) Engine Control Dial Control Power Mode Switch Control ECO Mode Control PWR Mode Control HP Mode Control ECO Control Travel Mode Control Auto-Idle Control Engine Speed Slow Down Control

MC1

SECTION 2 SYSTEM Group 2 Control System Pump Control Input Signal Engine Control Dial Power Mode Switch Auto-Idle Switch Travel Mode Switch Key Switch Pilot Shut-Off Switch Pump Regulator Pressure Learning Switch Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor Pump 1 Regulator Pressure Sensor Pump 2 Regulator Pressure Sensor Pump 3 Regulator Pressure Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Pressure Sensor (LD: Arm Extend/BH: Roll-In) Pressure Sensor (LD: Arm Retract/BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing) Pressure Sensor (Travel)

                   MC1  

Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP)  Hydraulic Oil Temperature Sensor  Boost Temperature Sensor  Fuel Temperature Sensor Coolant Temperature Sensor Engine Speed Sensor

 

ECM

 CAN0

MPDr. Work Mode

 

Monitor Controller CAN1

Ambient Temperature Sensor



Air Conditioner Controller

fNOTE: OP: Option *: This control is for only the machine with the optional parts equipped.

T2-2-3

Output Signal Pump Control (Pump Control Solenoid Valve) Speed Sensing Control Output Power Control Engine Protection Control Swing High Pressure Power Decrease Control Overheat Prevention Control * Attachment Operation Pump Control Fan Pump Flow Rate Control Pump Learning Control Pump 1 Flow Rate Control Pump 2 Flow Rate Control Pump 3 Flow Rate Control

SECTION 2 SYSTEM Group 2 Control System Valve Control, Other Control Input Signal Engine Control Dial Power Mode Switch Auto-Idle Switch Travel Mode Switch Key Switch Pilot Shut-Off Switch Power Digging Switch Boom Mode Switch Fan Reverse Rotation Switch Pump 1 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor Pump 1 Regulator Pressure Sensor Pump 2 Regulator Pressure Sensor Pump 3 Regulator Pressure Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Pressure Sensor (LD: Arm Extend/BH: Roll-In) Pressure Sensor (LD: Arm Retract/BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing) Pressure Sensor (Travel) Pressure Sensor (4-Spool Side) Pressure Sensor (5-Spool Side) Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) Lubrication Mode Selection Switch Hydraulic Oil Temperature Sensor Boom Bottom Pressure Sensor Overload Alarm Switch (OP) Coolant Temperature Sensor

                         

Output Signal Valve Control (Standard) (4-Spool/2-Spool Solenoid Valve Units) Power Digging Control Auto-Power Lift Control Travel Motor Displacement Angle Control Pressure Rising Selection Control When Traveling Boom Mode Control Bypass Cut Valve Control During Boom Lowering Arm 2 Flow Rate Control Fan Reverse Rotation Control Other Control Work Mode Control Auto Shut-Down Control Auto-Lubrication Control (Quicklub Lubrication System) * Auto-Lubrication Control (Centro Matic System) Hydraulic Oil Overheat Alarm Control * Swing Alarm Control * Travel Alarm Control * Overload Alarm Control

MC1

   

 ECM

CAN0 MPDr. Work Mode

 

Monitor Controller

fNOTE: OP: Option *: This control is for only the machine with the optional parts equipped.

T2-2-4

SECTION 2 SYSTEM Group 2 Control System (Blank)

T2-2-5

SECTION 2 SYSTEM Group 2 Control System Engine Control The engine control consists of the followings.  Engine Control Dial Control  Power Mode Switch Control  ECO Mode Control  PWR Mode Control  HP Mode Control  ECO Control  Travel Mode Control  Auto-Idle Control  Engine Speed Slow Down Control

T2-2-6

SECTION 2 SYSTEM Group 2 Control System Engine Control System Layout 2 3 4 5 6 7 8 9 12

1

40

14. MPDr.

16

15

39 38

42

17 41. MC2

37 13. MC1 36

18. ECM 35 19 21 22

34 33 20

32

31 30 29

28 27 26

25 24 23 TKAA90-02-02-001

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Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing)

9- Pressure Sensor (Travel) 12- Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) 13- MC1 14- MPDr. 15- Monitor Controller 16- Monitor 17- CAN 18- ECM 19- Coolant Temperature Sensor 20- Engine 21- Boost Pressure Sensor 22- Engine Speed Sensor

23- Pump 2 Regulator Pressure Sensor 24- Pump 2 Control Solenoid Valve 25- Pump 2 Delivery Pressure Sensor 26- Pump 1 Regulator Pressure Sensor 27- Pump 1 Control Solenoid Valve 28- Pump 1 Delivery Pressure Sensor 29- Pump 3 Regulator Pressure Sensor 30- Pump 3 Control Solenoid Valve

T2-2-7

31- Pump 3 Delivery Pressure Sensor 32- Auto Shut-Down Signal 33- Travel Mode Switch 34- Slow Speed Position 35- Fast Speed Position 36- Auto-Idle Switch 37- Power Mode Switch 38- Engine Control Dial 39- Key Switch 40- Pilot Shut-Off Switch 41- MC2 42- Sliding Fold-In Ladder Relay

SECTION 2 SYSTEM Group 2 Control System Engine Control Dial Control A

Purpose: The engine control dial control controls the engine speed according to the rotation angle of engine control dial (38).

E

Operation: 1. MC1 (13) receives the signals of the rotation angle (the required engine speed) of engine control dial (38). MC1 (13) sends the signal equivalent to the target engine speed according to the received signals to ECM (18) by using CAN communication (17).

2. ECM (18) controls the engine speed according to the received signal by using CAN communication (17).

F C ABC-

T2-2-8

Engine Speed Engine Control Dial Position Slow Idle Position

D DEF-

B

Fast Idle Position Fast Idle Speed Slow Idle Speed

SECTION 2 SYSTEM Group 2 Control System

2 3 4 5 6 7 8 9 12

1

40

14. MPDr.

16

15

39 38

42

17 41. MC2

37 13. MC1 36

180. ECM 35 19 21 22

34 33 20

32

31 30 29

28 27 26

25 24 23 TKAA90-02-02-002

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Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing)

9- Pressure Sensor (Travel) 12- Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) 13- MC1 14- MPDr. 15- Monitor Controller 16- Monitor 17- CAN 18- ECM 19- Coolant Temperature Sensor 20- Engine 21- Boost Pressure Sensor 22- Engine Speed Sensor

23- Pump 2 Regulator Pressure Sensor 24- Pump 2 Control Solenoid Valve 25- Pump 2 Delivery Pressure Sensor 26- Pump 1 Regulator Pressure Sensor 27- Pump 1 Control Solenoid Valve 28- Pump 1 Delivery Pressure Sensor 29- Pump 3 Regulator Pressure Sensor 30- Pump 3 Control Solenoid Valve

T2-2-9

31- Pump 3 Delivery Pressure Sensor 32- Auto Shut-Down Signal 33- Travel Mode Switch 34- Slow Speed Position 35- Fast Speed Position 36- Auto-Idle Switch 37- Power Mode Switch 38- Engine Control Dial 39- Key Switch 40- Pilot Shut-Off Switch 41- MC2 42- Sliding Fold-In Ladder Relay

SECTION 2 SYSTEM Group 2 Control System Power Mode Switch Control Purpose: The power mode switch control shifts the power mode (ECO/PWR/HP mode) by operating power mode switch (37).

Operation: 1. MC1 (13) receives the signal from power mode switch (37).

2. MC1 (13) shifts the power mode according to the setting of “Power Mode Selection“ and ”Power Mode Memory Selection” on MPDr. (14) by pushing power mode switch (37). (Refer to the table.)

3. According to the power mode, MC1 (13) sends the signal equivalent to the target engine speed to ECM (18) by using CAN communication (17).

4. ECM (18) controls the engine speed according to the received signal by using CAN communication (17).

5. At the same time, MC1 (13) sends the control mode of power mode to monitor controller (15) by using CAN communication (17).

6. Monitor controller (15) displays the control mode of power mode on monitor (16).

Power Mode ON/OFF Setting

Power mode at the moment when key switch is turned OFF

0

ECO, PWR Mode Selection

1 2 3

ECO Mode Keeping PWR Mode Keeping ECO, PWR, HP Mode Selection (Default)

4

HP Mode Keeping

ECO PWR ECO PWR HP -

T2-2-10

Power mode when key switch is ON next time Power Mode Memory Power Mode Memory Selection: ON (Default) Selection: OFF ECO ECO PWR PWR ECO ECO PWR PWR ECO ECO PWR PWR PWR HP HP HP

SECTION 2 SYSTEM Group 2 Control System

2 3 4 5 6 7 8 9 12

1

40

14. MPDr.

16

15

39 38

42

17 41. MC2

37 13. MC1 36

18. ECM

35 19

21 22

34 33 20

32

31 30 29

28 27 26

25 24 23 TKAA90-02-02-004

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Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing)

9- Pressure Sensor (Travel) 12- Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) 13- MC1 14- MPDr. 15- Monitor Controller 16- Monitor 17- CAN 18- ECM 19- Coolant Temperature Sensor 20- Engine 21- Boost Pressure Sensor 22- Engine Speed Sensor

23- Pump 2 Regulator Pressure Sensor 24- Pump 2 Control Solenoid Valve 25- Pump 2 Delivery Pressure Sensor 26- Pump 1 Regulator Pressure Sensor 27- Pump 1 Control Solenoid Valve 28- Pump 1 Delivery Pressure Sensor 29- Pump 3 Regulator Pressure Sensor 30- Pump 3 Control Solenoid Valve

T2-2-11

31- Pump 3 Delivery Pressure Sensor 32- Auto Shut-Down Signal 33- Travel Mode Switch 34- Slow Speed Position 35- Fast Speed Position 36- Auto-Idle Switch 37- Power Mode Switch 38- Engine Control Dial 39- Key Switch 40- Pilot Shut-Off Switch 41- MC2 42- Sliding Fold-In Ladder Relay

SECTION 2 SYSTEM Group 2 Control System ECO Mode Control A

Purpose: The ECO (Economy) mode control lowers the engine speed in order to reduce fuel consumption.

E F

Operation: 1. When all following conditions exist, the ECO mode control is activated.  Required engine speed signal from engine control dial (38): The engine speed is faster than the ECO mode speed.  Power mode switch (37): ECO mode position

G C

2. When the ECO mode control is activated, MC1 (13) sends the signal equivalent to the ECO mode speed to ECM (18) by using CAN communication (17).

ABCD-

3. ECM (18) sets the engine speed to the ECO mode speed (1700 min-1)

T2-2-12

Engine Speed Engine Control Dial Position Slow Idle Position Fast Idle Position

D EFG-

B

Fast Idle Speed (1950 min-1) ECO Mode Speed (1700 min-1) Slow Idle Speed

SECTION 2 SYSTEM Group 2 Control System

2 3 4 5 6 7 8 9 12

1

40

14. MPDr.

16

15

39 38

42

17 41. MC2

37 13. MC1 36

18. ECM

35 19

21 22

34 33 20

32

31 30 29

28 27 26

25 24 23 TKAA90-02-02-005

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Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing)

9- Pressure Sensor (Travel) 12- Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) 13- MC1 14- MPDr. 15- Monitor Controller 16- Monitor 17- CAN 18- ECM 19- Coolant Temperature Sensor 20- Engine 21- Boost Pressure Sensor 22- Engine Speed Sensor

23- Pump 2 Regulator Pressure Sensor 24- Pump 2 Control Solenoid Valve 25- Pump 2 Delivery Pressure Sensor 26- Pump 1 Regulator Pressure Sensor 27- Pump 1 Control Solenoid Valve 28- Pump 1 Delivery Pressure Sensor 29- Pump 3 Regulator Pressure Sensor 30- Pump 3 Control Solenoid Valve

T2-2-13

31- Pump 3 Delivery Pressure Sensor 32- Auto Shut-Down Signal 33- Travel Mode Switch 34- Slow Speed Position 35- Fast Speed Position 36- Auto-Idle Switch 37- Power Mode Switch 38- Engine Control Dial 39- Key Switch 40- Pilot Shut-Off Switch 41- MC2 42- Sliding Fold-In Ladder Relay

SECTION 2 SYSTEM Group 2 Control System PWR Mode Control Purpose: The PWR (Power) mode control is used during normal operation and sets the fast idle engine speed to 1800 min-1.

A E F

Operation: 1. When all following conditions exist, the PWR mode is activated.  Work Mode: Digging Mode  Required engine speed signal from engine control dial (38): The engine speed is set faster than the PWR mode speed.  Power mode switch (37): PWR mode position 2. When the PWR mode is activated, MC1 (13) sends the signal equivalent to the PWR mode speed to ECM (18) by using CAN communication (17).

G C ABCDE-

3. ECM (18) sets the engine speed to the PWR mode speed (1800 min-1).

fNOTE: The PWR mode control can be made operable or inoperable by MPDr. (14).

T2-2-14

Engine Speed Engine Control Dial Position Slow Idle Position Fast Idle Position Fast Idle Speed (1950 min-1)

D F-

PWR Mode Speed (1800 min) Slow Idle Speed

1

G-

B

SECTION 2 SYSTEM Group 2 Control System

2 3 4 5 6 7 8 9 12

1

40

14. MPDr.

16

15

39 38

42

17 41. MC2

37 13. MC1 36

18. ECM

35 19

21 22

34 33 20

32

31 30 29

28 27 26

25 24 23 TKAA90-02-02-006

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Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing)

9- Pressure Sensor (Travel) 12- Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) 13- MC1 14- MPDr. 15- Monitor Controller 16- Monitor 17- CAN 18- ECM 19- Coolant Temperature Sensor 20- Engine 21- Boost Pressure Sensor 22- Engine Speed Sensor

23- Pump 2 Regulator Pressure Sensor 24- Pump 2 Control Solenoid Valve 25- Pump 2 Delivery Pressure Sensor 26- Pump 1 Regulator Pressure Sensor 27- Pump 1 Control Solenoid Valve 28- Pump 1 Delivery Pressure Sensor 29- Pump 3 Regulator Pressure Sensor 30- Pump 3 Control Solenoid Valve

T2-2-15

31- Pump 3 Delivery Pressure Sensor 32- Auto Shut-Down Signal 33- Travel Mode Switch 34- Slow Speed Position 35- Fast Speed Position 36- Auto-Idle Switch 37- Power Mode Switch 38- Engine Control Dial 39- Key Switch 40- Pilot Shut-Off Switch 41- MC2 42- Sliding Fold-In Ladder Relay

SECTION 2 SYSTEM Group 2 Control System HP Mode Control Purpose: The HP (High Power) mode control does not limit the engine speed. When a little more engine output power is required during arm roll-in operation for deeply digging, the HP mode control is used.

A E F

Operation: 1. When all following conditions exist, the HP mode is activated.  Work Mode: Digging Mode  Power mode switch (37): HP mode position  Required engine speed signal from engine control dial (38): The engine speed is set faster than the PWR mode speed (1800 min-1).

2. MC1 (13) does not limit the target engine speed.

MC1 (13) sends the signal equivalent to the engine control dial (38) to ECM (18) by using CAN communication (17).

G C ABCD-

3. ECM (18) controls the engine speed according to the received signal by using CAN communication (17).

4. MC1 (13) controls the pump delivery flow rate according to the target engine speed and the engine load. (Refer to Speed Sensing Control.)

T2-2-16

Engine Speed Engine Control Dial Position Slow Idle Position Fast Idle Position

D EFG-

B

Fast Idle Speed (1950 min-1) PWR Mode Speed (1800 min-1) Slow Idle Speed

SECTION 2 SYSTEM Group 2 Control System

2 3 4 5 6 7 8 9 12

1

40

14. MPDr.

16

15

39 38

42

17 41. MC2

37 13. MC1 36

18. ECM

35 19

21 22

34 33 20

32

31 30 29

28 27 26

25 24 23 TKAA90-02-02-007

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Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing)

9- Pressure Sensor (Travel) 12- Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) 13- MC1 14- MPDr. 15- Monitor Controller 16- Monitor 17- CAN 18- ECM 19- Coolant Temperature Sensor 20- Engine 21- Boost Pressure Sensor 22- Engine Speed Sensor

23- Pump 2 Regulator Pressure Sensor 24- Pump 2 Control Solenoid Valve 25- Pump 2 Delivery Pressure Sensor 26- Pump 1 Regulator Pressure Sensor 27- Pump 1 Control Solenoid Valve 28- Pump 1 Delivery Pressure Sensor 29- Pump 3 Regulator Pressure Sensor 30- Pump 3 Control Solenoid Valve

T2-2-17

31- Pump 3 Delivery Pressure Sensor 32- Auto Shut-Down Signal 33- Travel Mode Switch 34- Slow Speed Position 35- Fast Speed Position 36- Auto-Idle Switch 37- Power Mode Switch 38- Engine Control Dial 39- Key Switch 40- Pilot Shut-Off Switch 41- MC2 42- Sliding Fold-In Ladder Relay

SECTION 2 SYSTEM Group 2 Control System ECO Control A

Purpose: The ECO control reduces the engine speed by 100 min-1 from the fast idle speed when all control levers are in neutral. Therefore, the fuel consumption and noise level can be reduced.

E

Operation: 1. When all following conditions exist and all the control levers are set to the neutral position [all pressure sensors (2 to 9, 12): OFF], MC1 (13) sends the signal to ECM (18) by using CAN communication (17) after one second.

G

 Engine control dial (38): Fast Idle Position  Power mode switch (37): HP or PWR

F

C ABCD-

Engine Speed Engine Control Dial Position Slow Idle Position Fast Idle Position

D EFG-

B

Fast Idle Speed (1950 min-1) ECO Speed Slow Idle Speed

2. ECM (18) reduces the engine speed by 100 min-1 from the fast idle speed.

fNOTE: The ECO control is deactivated by MPDr. (14)

temporarily or completely. The ECO control is activated again when key switch (39) is turned OFF with the ECO control deactivated temporarily. The ECO control is always dectivated with the ECO control deactivated completely. (ECO Control Suspend)

fNOTE: When the engine speed is set slower than the

fast idle speed by 100 min-1 by engine control dial (38), the engine speed does not change. And the ECO control is done regardless of whether the auto-idle control is done or not. The fast idle speed can be corrected by MPDr. (14). (PWR Mode Speed)

T2-2-18

SECTION 2 SYSTEM Group 2 Control System 2 3 4 5 6 7 8 9 12

1

40

14. MPDr.

16

15

39 38

42

17 41. MC2

37 13. MC1 36

18. ECM

35 19

21 22

34 33 20

32

31 30 29

28 27 26

25 24 23 TKAA90-02-02-003

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Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing)

9- Pressure Sensor (Travel) 12- Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) 13- MC1 14- MPDr. 15- Monitor Controller 16- Monitor 17- CAN 18- ECM 19- Coolant Temperature Sensor 20- Engine 21- Boost Pressure Sensor 22- Engine Speed Sensor

23- Pump 2 Regulator Pressure Sensor 24- Pump 2 Control Solenoid Valve 25- Pump 2 Delivery Pressure Sensor 26- Pump 1 Regulator Pressure Sensor 27- Pump 1 Control Solenoid Valve 28- Pump 1 Delivery Pressure Sensor 29- Pump 3 Regulator Pressure Sensor 30- Pump 3 Control Solenoid Valve

T2-2-19

31- Pump 3 Delivery Pressure Sensor 32- Auto Shut-Down Signal 33- Travel Mode Switch 34- Slow Speed Position 35- Fast Speed Position 36- Auto-Idle Switch 37- Power Mode Switch 38- Engine Control Dial 39- Key Switch 40- Pilot Shut-Off Switch 41- MC2 42- Sliding Fold-In Ladder Relay

SECTION 2 SYSTEM Group 2 Control System Travel Mode Control Purpose: The travel mode control decreases the fast idle engine speed to 1800 min-1, when the machine travels at the HP mode. Therefore, this control decreases the travel speed and protects the travel motor.

A E F

Operation: 1. When all following conditions exist, MC1 (13) sends the restricted engine speed signal at 1800 min-1 to ECM (18).

G

 Required engine speed signal from engine control dial (38): over 1800 min-1  Power mode switch (37): HP mode position  Pressure Sensor (Travel) (9): Outputting signal

C

2. ECM (18) sets the engine speed to 1800 min-1.

3. MC1 (13) decreases the travel speed so that the pump delivery flow rate can be set according to the restricted engine speed. (Refer to Speed Sensing Control.)

ABCDE-

T2-2-20

Engine Speed Engine Control Dial Position Slow Idle Position Fast Idle Position Fast Idle Speed

D FG-

1800 min-1 Slow Idle Speed

B

SECTION 2 SYSTEM Group 2 Control System

2 3 4 5 6 7 8 9 12

1

40

14. MPDr.

16

15

39 38

42

17 41. MC2

37 13. MC1 36

18. ECM

35 19

21 22

34 33 20

32

31 30 29

28 27 26

25 24 23 TKAA90-02-02-041

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Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing)

9- Pressure Sensor (Travel) 12- Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) 13- MC1 14- MPDr. 15- Monitor Controller 16- Monitor 17- CAN 18- ECM 19- Coolant Temperature Sensor 20- Engine 21- Boost Pressure Sensor 22- Engine Speed Sensor

23- Pump 2 Regulator Pressure Sensor 24- Pump 2 Control Solenoid Valve 25- Pump 2 Delivery Pressure Sensor 26- Pump 1 Regulator Pressure Sensor 27- Pump 1 Control Solenoid Valve 28- Pump 1 Delivery Pressure Sensor 29- Pump 3 Regulator Pressure Sensor 30- Pump 3 Control Solenoid Valve

T2-2-21

31- Pump 3 Delivery Pressure Sensor 32- Auto Shut-Down Signal 33- Travel Mode Switch 34- Slow Speed Position 35- Fast Speed Position 36- Auto-Idle Switch 37- Power Mode Switch 38- Engine Control Dial 39- Key Switch 40- Pilot Shut-Off Switch 41- MC2 42- Sliding Fold-In Ladder Relay

SECTION 2 SYSTEM Group 2 Control System Auto-Idle Control A

Purpose: The auto-idle control reduces the engine speed when all control levers are in neutral. Therefore, the fuel consumption and noise level can be reduced.

E

Operation: 1. When all following conditions exist, the auto-idle control is activated.

F

 Auto-idle switch (36): ON position  Control lever: All control levers are held in the neutral position [pressure sensors (2 to 9, 12): OFF] beyond 3.5 seconds 2. When the auto-idle control is activated, MC1 (13) sends the signal equivalent to the auto-idle speed to ECM (18) by using CAN communication (17).

G C ABCD-

3. ECM (18) changes the engine speed into the autoidle speed.

4. When any one of the following condition exists, the auto-idle control is deactivated.  Control lever: Any control lever is operated [pressure sensors (2 to 9, 12): ON]  When power mode switch (37) is operated  When engine control dial (38) is operated 5. MC1 (13) returns the signal sending to ECM (18) into the signal equivalent to the target engine speed set by engine control dial (38) immediately.

fNOTE: The auto-idle speed can be adjusted by MPDr. (14). (AI Speed)

T2-2-22

Engine Speed Engine Control Dial Position Slow Idle Position Fast Idle Position

D EFG-

Fast Idle Speed Auto-Idle Speed Slow Idle Speed

B

SECTION 2 SYSTEM Group 2 Control System

2 3 4 5 6 7 8 9 12

1

40

14. MPDr.

16

15

39 38

42

17 41. MC2

37 13. MC1 36

18. ECM

35 19

21 22

34 33 20

32

31 30 29

28 27 26

25 24 23 TKAA90-02-02-008

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Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing)

9- Pressure Sensor (Travel) 12- Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) 13- MC1 14- MPDr. 15- Monitor Controller 16- Monitor 17- CAN 18- ECM 19- Coolant Temperature Sensor 20- Engine 21- Boost Pressure Sensor 22- Engine Speed Sensor

23- Pump 2 Regulator Pressure Sensor 24- Pump 2 Control Solenoid Valve 25- Pump 2 Delivery Pressure Sensor 26- Pump 1 Regulator Pressure Sensor 27- Pump 1 Control Solenoid Valve 28- Pump 1 Delivery Pressure Sensor 29- Pump 3 Regulator Pressure Sensor 30- Pump 3 Control Solenoid Valve

T2-2-23

31- Pump 3 Delivery Pressure Sensor 32- Auto Shut-Down Signal 33- Travel Mode Switch 34- Slow Speed Position 35- Fast Speed Position 36- Auto-Idle Switch 37- Power Mode Switch 38- Engine Control Dial 39- Key Switch 40- Pilot Shut-Off Switch 41- MC2 42- Sliding Fold-In Ladder Relay

SECTION 2 SYSTEM Group 2 Control System Engine Speed Slow Down Control Purpose: The engine speed slow down control gradually reduces the engine speed to the slow idle speed when the auto shut-down control is performed. Therefore, the loads of the engine and hydraulic actuator can be reduced.

A

Operation: 1. MC1 (13) saves the engine speed at the moment when the auto shut-down control is performed.

2. MC1 (13) sends the signal that the engine speed gradually reduces from the saved engine speed to ECM (18) by using CAN communication (17).

C

B

3. ECM (18) reduces the engine speed to the slow idle speed according to CAN communication (17).

4. Then, the auto shut-down control stops the engine.

(Refer to Auto Shut-Down Control.)

AB-

T2-2-24

Engine Speed Time

C-

Slow Idle Speed

SECTION 2 SYSTEM Group 2 Control System

2 3 4 5 6 7 8 9 12

1

40

14. MPDr.

16

15

39 38

42

17 41. MC2

37 13. MC1 36

18. ECM

35 19

21 22

34 33 20

32

31 30 29

28 27 26

25 24 23 TKAA90-02-02-010

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Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing)

9- Pressure Sensor (Travel) 12- Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) 13- MC1 14- MPDr. 15- Monitor Controller 16- Monitor 17- CAN 18- ECM 19- Coolant Temperature Sensor 20- Engine 21- Boost Pressure Sensor 22- Engine Speed Sensor

23- Pump 2 Regulator Pressure Sensor 24- Pump 2 Control Solenoid Valve 25- Pump 2 Delivery Pressure Sensor 26- Pump 1 Regulator Pressure Sensor 27- Pump 1 Control Solenoid Valve 28- Pump 1 Delivery Pressure Sensor 29- Pump 3 Regulator Pressure Sensor 30- Pump 3 Control Solenoid Valve

T2-2-25

31- Pump 3 Delivery Pressure Sensor 32- Auto Shut-Down Signal 33- Travel Mode Switch 34- Slow Speed Position 35- Fast Speed Position 36- Auto-Idle Switch 37- Power Mode Switch 38- Engine Control Dial 39- Key Switch 40- Pilot Shut-Off Switch 41- MC2 42- Sliding Fold-In Ladder Relay

SECTION 2 SYSTEM Group 2 Control System Pump Control The pump control consists of the followings.  Speed Sensing Control  Output Power Control  Engine Protection Control  Swing High Pressure Power Decrease Control  Overheat Prevention Control  * Attachment Operation Pump Control  Fan Pump Flow Rate Control  Pump Learning Control  Pump 1 Flow Rate Control  Pump 2 Flow Rate Control  Pump 3 Flow Rate Control

fNOTE: * This control is for only the machine with the optional parts equipped.

T2-2-26

SECTION 2 SYSTEM Group 2 Control System Pump Control System Layout 2 3 4 5 6 7 8 9 12

1

41

14. MPDr.

16

15

40 39

17 38

37 36

18. ECM

13. MC1

35 19

21

22

42

34 23 20

33

32 31 30

29 28 27

26 25 24 TKAB-02-02-011

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Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing) Pressure Sensor (Travel)

12- Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) 13- MC1 14- MPDr. 15- Monitor Controller 16- Monitor 17- CAN 18- ECM 19- Coolant Temperature Sensor 20- Boost Temperature Sensor 21- Fuel Temperature Sensor 22- Engine Speed Sensor 23- Engine

24- Pump 2 Regulator Pressure Sensor 25- Pump 2 Control Solenoid Valve 26- Pump 2 Delivery Pressure Sensor 27- Pump 1 Regulator Pressure Sensor 28- Pump 1 Control Solenoid Valve 29- Pump 1 Delivery Pressure Sensor 30- Pump 3 Regulator Pressure Sensor 31- Pump 3 Control Solenoid Valve

T2-2-27

32- Pump 3 Delivery Pressure Sensor 33- Fan Pump Control Solenoid Valve 34- Air Conditioner Controller 35- Ambient Temperature Sensor 36- Pump Regulator Pressure Learning Switch 37- Auto-Idle Switch 38- Power Mode Switch 39- Engine Control Dial 40- Key Switch 41- Pilot Shut-Off Switch 42- Fan Pump

SECTION 2 SYSTEM Group 2 Control System Speed Sensing Control Purpose: The speed sensing control controls the main pump delivery flow rate in response to the engine speed changes according to the variations in the load so that the engine output power can be utilized more efficiently.

HP Mode Q

Operation: 1. The target engine speed can be set by engine control dial (39).

2. ECM (18) receives the signal from engine speed sensor (22).

3. ECM (18) calculates it and sends the actual engine speed to MC1 (13) by using CAN communication (17).

P

4. MC1 (13) calculates the difference in the speed between the target engine speed and actual engine speed that is recieved through CAN communication (17) from ECM (18).

T111-05-02-004

PWR/ECO Mode Q

5. If the actual engine speed is faster than the target engine speed, MC1 (18) judges that the load to the engine is light. MC1 (18) performs the control so that the pump delivery flow rate can increase according to the difference between the actual engine speed and the target engine speed. When the power mode switch is in the PWR or ECO position, the control to increase the pump delivery flow rate is not performed.

6. MC1 (13) sends the signals to the pump control solenoid valves (28, 25, 31).

P

7. The pump control solenoid valves (28, 25, 31) deliver the pilot pressure according to the signals to the regulators, and controls the pump delivery flow rate.

T166-02-01-014 P-

8. On the contrary, if the engine load is heavy and the actual engine speed is slower than the target engine speed, the pump displacement angle is reduced so that the pump flow rate will be reduced.

Therefore, the engine load is reduced and the engine stall is prevented.

T2-2-28

Pressure

Q-

Flow Rate

SECTION 2 SYSTEM Group 2 Control System

2 3 4 5 6 7 8 9 12

1

41

14. MPDr.

16

15

40 39

17 38

37 36

18. ECM

13. MC1

35 19

21

22

42

34 23 20

33

32 31 30

29 28 27

26 25 24 TKAB-02-02-012

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Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing) Pressure Sensor (Travel)

12- Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) 13- MC1 14- MPDr. 15- Monitor Controller 16- Monitor 17- CAN 18- ECM 19- Coolant Temperature Sensor 20- Boost Temperature Sensor 21- Fuel Temperature Sensor 22- Engine Speed Sensor 23- Engine

24- Pump 2 Regulator Pressure Sensor 25- Pump 2 Control Solenoid Valve 26- Pump 2 Delivery Pressure Sensor 27- Pump 1 Regulator Pressure Sensor 28- Pump 1 Control Solenoid Valve 29- Pump 1 Delivery Pressure Sensor 30- Pump 3 Regulator Pressure Sensor 31- Pump 3 Control Solenoid Valve

T2-2-29

32- Pump 3 Delivery Pressure Sensor 33- Fan Pump Control Solenoid Valve 34- Air Conditioner Controller 35- Ambient Temperature Sensor 36- Pump Regulator Pressure Learning Switch 37- Auto-Idle Switch 38- Power Mode Switch 39- Engine Control Dial 40- Key Switch 41- Pilot Shut-Off Switch 42- Fan Pump

SECTION 2 SYSTEM Group 2 Control System Output Power Control Purpose: The output power control effectively utilizes the engine output power by controlling the delivery flow rate of pumps 1, 2, 3 so that allocated sum of pumps 1, 2, 3 driving torque does not exceed the engine output torque.

Operation: 1. Normally, when pumps 1, 2, and 3 are operated, the delivery pressure is not same.

2. A pump of higher delivery pressure carries higher load and a pump of lower delivery pressure carries lower load.

3. The pump delivery pressure sensors (29, 26, 32) and pump regulator pressure sensors (27, 24, 30) detect this state and send the signals to MC1 (13).

4. MC1 (13) calculates the target displacement angles of pumps 1, 2, and 3 so that allocated sum of pumps 1, 2, 3, and fan pump driving torque does not exceed the engine output torque by using the signals from the pump delivery pressure sensors (29, 26, 32) and pump regulator pressure sensors (27, 24, 30).

5. MC1 (13) compares the pump displacement angle calculated by the pump regulator pressure sensors (27, 24, 30) with the target pump displacement angle.

6. MC1 (13) monitors the actual pump displacement angle at the larger load side for comparison with the target pump displacement angle, and drives the pump control solenoid valve of the pump at the larger load side for the difference with the target angle. Then, MC1 (13) increases the pump delivery flow rate at the larger load side.

fNOTE: The delivery flow rate of the fan pump is

controlled by the fan pump flow rate control regardless of the engine output torque. (Refer to T2-2-50.)

T2-2-30

SECTION 2 SYSTEM Group 2 Control System

2 3 4 5 6 7 8 9 12

1

41

14. MPDr.

16

15

40 39

17 38

37 36

18. ECM

13. MC1

35 19

21

22

42

34 23 20

33

32 31 30

29 28 27

26 25 24 TKAB-02-02-013

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Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing) Pressure Sensor (Travel)

12- Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) 13- MC1 14- MPDr. 15- Monitor Controller 16- Monitor 17- CAN 18- ECM 19- Coolant Temperature Sensor 20- Boost Temperature Sensor 21- Fuel Temperature Sensor 22- Engine Speed Sensor 23- Engine

24- Pump 2 Regulator Pressure Sensor 25- Pump 2 Control Solenoid Valve 26- Pump 2 Delivery Pressure Sensor 27- Pump 1 Regulator Pressure Sensor 28- Pump 1 Control Solenoid Valve 29- Pump 1 Delivery Pressure Sensor 30- Pump 3 Regulator Pressure Sensor 31- Pump 3 Control Solenoid Valve

T2-2-31

32- Pump 3 Delivery Pressure Sensor 33- Fan Pump Control Solenoid Valve 34- Air Conditioner Controller 35- Ambient Temperature Sensor 36- Pump Regulator Pressure Learning Switch 37- Auto-Idle Switch 38- Power Mode Switch 39- Engine Control Dial 40- Key Switch 41- Pilot Shut-Off Switch 42- Fan Pump

SECTION 2 SYSTEM Group 2 Control System Engine Protection Control Purpose: When ECM (18) detects abnormality, the engine protection control decreases the pump delivery flow rate and pump driving torque. Then, the engine is prevented from damage.

1. When any one of the following conditions exists, ECM (18) sends the abnormal signal to MC1 (13) by using CAN communication (17).  Coolant Temperature: High  Intake Manifold Temperature: High  Engine Oil Pressure: Low  Coolant Level: Low 2. When MC1 (13) receives the abnormal signal, MC1 (13) sends the pump driving torque reduction request signal to the pump control solenoid valves (28, 25, 31).

3. The pump control solenoid valves (28, 25, 31) decreases the displacement angle of each pump, and decreases the pump delivery flow rate and pump driving torque. Then, the engine load is reduced.

4. At the same time, MC1 (13) sends the signal to monitor controller (15). Monitor controller (15) displays the alarm on monitor (16) and sounds the buzzer.

T2-2-32

SECTION 2 SYSTEM Group 2 Control System

2 3 4 5 6 7 8 9 12

1

41

14. MPDr.

16

15

40 39

17 38

37 43 36

44

18. ECM

13. MC1

45

35 19

21

22

42

34 23 20

33

32 31 30

29 28 27

26 25 24 TKAB-02-02-045

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Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing) Pressure Sensor (Travel)

12- Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) 13- MC1 14- MPDr. 15- Monitor Controller 16- Monitor 17- CAN 18- ECM 19- Coolant Temperature Sensor 20- Boost Temperature Sensor 21- Fuel Temperature Sensor 22- Engine Speed Sensor 23- Engine 24- Pump 2 Regulator Pressure Sensor

25- Pump 2 Control Solenoid Valve 26- Pump 2 Delivery Pressure Sensor 27- Pump 1 Regulator Pressure Sensor 28- Pump 1 Control Solenoid Valve 29- Pump 1 Delivery Pressure Sensor 30- Pump 3 Regulator Pressure Sensor 31- Pump 3 Control Solenoid Valve 32- Pump 3 Delivery Pressure Sensor 33- Fan Pump Control Solenoid Valve

T2-2-33

34- Air Conditioner Controller 35- Ambient Temperature Sensor 36- Pump Regulator Pressure Learning Switch 37- Auto-Idle Switch 38- Power Mode Switch 39- Engine Control Dial 40- Key Switch 41- Pilot Shut-Off Switch 42- Fan Pump 43- Intake Manifold Temperature Sensor 44- Engine Oil Pressure Sensor 45- Coolant Level Sensor

SECTION 2 SYSTEM Group 2 Control System Swing High Pressure Power Decrease Control Purpose: The swing high pressure power decrease control reduces the pump 3 delivery flow rate when performing the swing single operation or combined operation of boom lower and swing, and reduces fuel consumption.

Operation: 1. When all following conditions exist, MC1 (13) activates the pump 3 control solenoid valve (31).  Swing pilot pressure: High  Outputting signal from pressure sensor (swing) (8) or outputting signal from both pressure sensor (boom lower) (3) and pressure sensor (swing) (8) are detected.  Pump 3 delivery pressure: High 2. The pump 3 control solenoid valve (31) delivers the pilot pressure according to the signal to the regulator and reduces the pump 3 delivery flow rate.

T2-2-34

SECTION 2 SYSTEM Group 2 Control System

2 3 4 5 6 7 8 9 12

1

41

14. MPDr.

16

15

40 39

17 38

37 36

18. ECM

13. MC1

35 19

21

22

42

34 23 20

33

32 31 30

29 28 27

26 25 24 TKAB-02-02-015

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Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing) Pressure Sensor (Travel)

12- Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) 13- MC1 14- MPDr. 15- Monitor Controller 16- Monitor 17- CAN 18- ECM 19- Coolant Temperature Sensor 20- Boost Temperature Sensor 21- Fuel Temperature Sensor 22- Engine Speed Sensor 23- Engine

24- Pump 2 Regulator Pressure Sensor 25- Pump 2 Control Solenoid Valve 26- Pump 2 Delivery Pressure Sensor 27- Pump 1 Regulator Pressure Sensor 28- Pump 1 Control Solenoid Valve 29- Pump 1 Delivery Pressure Sensor 30- Pump 3 Regulator Pressure Sensor 31- Pump 3 Control Solenoid Valve

T2-2-35

32- Pump 3 Delivery Pressure Sensor 33- Fan Pump Control Solenoid Valve 34- Air Conditioner Controller 35- Ambient Temperature Sensor 36- Pump Regulator Pressure Learning Switch 37- Auto-Idle Switch 38- Power Mode Switch 39- Engine Control Dial 40- Key Switch 41- Pilot Shut-Off Switch 42- Fan Pump

SECTION 2 SYSTEM Group 2 Control System Overheat Prevention Control Purpose: The overheat prevention control prevents engine overheating by reducing the pump maximum flow rate and pump driving torque when the coolant or hydraulic oil temperature exceeds the specified value.

Operation:  Control by Coolant Temperature 1. ECM (18) sends the signal of coolant temperature sensor (19) to MC1 (13) by using CAN communication (17).

Control by Coolant Temperature Q

2. MC1 (13) calculates the target pump displacement angle, which reduces the pump driving torque by 7%, by using the signals from the pump delivery pressure sensors (29, 26, 23) when the coolant temperature becomes 99 °C or higher.

3. MC1 (13) compares the pump displacement angle calculated by the signal of the pump regulator pressure sensors (27, 24, 30) with the target pump displacement angle.

P Control by Hydraulic Oil Temperature

4. MC1 (13) monitors the actual pump displacement angle for comparison with the target pump displacement angle, and activates the pump control solenoid valves (28, 25, 31), decreases the pump displacement angle, and decreases the pump driving torque.

Q

 Control by Hydraulic Oil Temperature 1. MC1 (13) receives the signal from the hydraulic oil temperature sensor (1).

P

2. MC1 (13) calculates the target pump displacement angle, which reduces the pump driving torque by 7%, by using the signals from the pump delivery pressure sensors (29, 26, 23) when the hydraulic oil temperature becomes 100 °C or higher.

P-

3. MC1 (13) compares the pump displacement angle calculated by the signal of the pump regulator pressure sensors (27, 24, 30) with the target pump displacement angle.

4. MC1 (13) monitors the actual pump displacement angle for comparison with the target pump displacement angle, and activates the pump control solenoid valves (28, 25, 31), decreases the pump displacement angle, and decreases the pump maximum flow rate and pump driving torque.

fNOTE: When the following conditions are met, the overheat prevention control is terminated.

 Coolant Temperature: 95 °C or less  Hydraulic Oil Temperature: 95 °C or less

T2-2-36

Pressure

Q-

Flow Rate

SECTION 2 SYSTEM Group 2 Control System

2 3 4 5 6 7 8 9 12

1

41

14. MPDr.

16

15

40 39

17 38

37 36

18. ECM

13. MC1

35 19

21

22

42

34 23 20

33

32 31 30

29 28 27

26 25 24 TKAB-02-02-016

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Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing) Pressure Sensor (Travel)

12- Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) 13- MC1 14- MPDr. 15- Monitor Controller 16- Monitor 17- CAN 18- ECM 19- Coolant Temperature Sensor 20- Boost Temperature Sensor 21- Fuel Temperature Sensor 22- Engine Speed Sensor 23- Engine

24- Pump 2 Regulator Pressure Sensor 25- Pump 2 Control Solenoid Valve 26- Pump 2 Delivery Pressure Sensor 27- Pump 1 Regulator Pressure Sensor 28- Pump 1 Control Solenoid Valve 29- Pump 1 Delivery Pressure Sensor 30- Pump 3 Regulator Pressure Sensor 31- Pump 3 Control Solenoid Valve

T2-2-37

32- Pump 3 Delivery Pressure Sensor 33- Fan Pump Control Solenoid Valve 34- Air Conditioner Controller 35- Ambient Temperature Sensor 36- Pump Regulator Pressure Learning Switch 37- Auto-Idle Switch 38- Power Mode Switch 39- Engine Control Dial 40- Key Switch 41- Pilot Shut-Off Switch 42- Fan Pump

SECTION 2 SYSTEM Group 2 Control System Attachment Operation Pump Control (Option) Purpose: The attachment operation pump control limits the upper limit of the maximum pump 2 flow rate when operating the attachment. Therefore, this control controls the optimum flow rate for the attachment.

Operation: 1. Select ATT Mode of Work Mode on the monitor.

2. When the breaker (attachment pilot valve) is operated, pressure sensor (LD: bucket open/close/ BH: auxiliary) (12) (option) detects the attachment pilot pressure and sends the signal to MC1 (13).

3. MC1 (13) activates the pump 2 control solenoid valve (25) until the pump 2 displacement angle decreases to the pump maximum flow rate displacement position commanded by the attachment mode. Then, MC1 (13) keeps the displacement angle.

fNOTE: As the attachment is controlled by the auxiliary

spool at the 5-spool in the control valve, only the pump 2 maximum flow rate is controlled.

fNOTE: As returning oil from the breaker does not flow

through the oil cooler but directly flows to the hydraulic oil tank, the hydraulic oil temperature increases. In order to prevent the hydraulic oil temperature from increasing, MC1 (13) activates the pump 1 flow rate control solenoid valve (28) and increases delivery flow rate of pump 1 when operating the breaker. Consequently, as oil amount flowing to the oil cooler increases, increase of the hydraulic oil temperature is controlled, and the engine overheating is prevented when operating the breaker.

T2-2-38

SECTION 2 SYSTEM Group 2 Control System 2 3 4 5 6 7 8 9 12

1

41

14. MPDr.

16

15

40 39

17 38

37 36

18. ECM

13. MC1

35 19

21

22

42

34 23 20

33

32 31 30

29 28 27

26 25 24 TKAB-02-02-017

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Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing) Pressure Sensor (Travel)

12- Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) 13- MC1 14- MPDr. 15- Monitor Controller 16- Monitor 17- CAN 18- ECM 19- Coolant Temperature Sensor 20- Boost Temperature Sensor 21- Fuel Temperature Sensor 22- Engine Speed Sensor 23- Engine

24- Pump 2 Regulator Pressure Sensor 25- Pump 2 Control Solenoid Valve 26- Pump 2 Delivery Pressure Sensor 27- Pump 1 Regulator Pressure Sensor 28- Pump 1 Control Solenoid Valve 29- Pump 1 Delivery Pressure Sensor 30- Pump 3 Regulator Pressure Sensor 31- Pump 3 Control Solenoid Valve

T2-2-39

32- Pump 3 Delivery Pressure Sensor 33- Fan Pump Control Solenoid Valve 34- Air Conditioner Controller 35- Ambient Temperature Sensor 36- Pump Regulator Pressure Learning Switch 37- Auto-Idle Switch 38- Power Mode Switch 39- Engine Control Dial 40- Key Switch 41- Pilot Shut-Off Switch 42- Fan Pump

SECTION 2 SYSTEM Group 2 Control System Fan Pump Flow Rate Control Purpose: The fan pump flow rate control controls the fan pump delivery flow rate according to the boost temperature, coolant temperature, hydraulic oil temperature, fuel temperature, and ambient temperature. The fan pump flow rate control prevents the fan pump delivery flow rate from decreasing when the engine speed is low while the air conditioner is ON. Therefore, the fan rotation speed is controlled to the optimum temperature for oil cooler, radiator, intercooler, and air conditioner condenser.

Operation:  Air Conditioner Switch: OFF 1. ECM (18) sends the signals of fuel temperature sensor (21) and coolant temperature sensor (19) to MC1 (13) by using CAN communication (17).

2. The hydraulic oil temperature sensor (1) and boost temperature sensor (20) send the signals to MC1 (13).

3. MC1 (13) calculates the fan rotation speed by using the received signals.

4. MC1 (13) sends the highest output signal in the calculated fan rotation speed to the fan pump control solenoid valve (33) and controls the fan pump delivery flow rate.

5. Therefore, the fan rotation speed is properly controlled.

T2-2-40

SECTION 2 SYSTEM Group 2 Control System 2 3 4 5 6 7 8 9 12

1

41

14. MPDr.

16

15

40 39

17 38

37 36

18. ECM

13. MC1

35 19

21

22

42

34 23 20

33

32 31 30

29 28 27

26 25 24 TKAB-02-02-018

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Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing) Pressure Sensor (Travel)

12- Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) 13- MC1 14- MPDr. 15- Monitor Controller 16- Monitor 17- CAN 18- ECM 19- Coolant Temperature Sensor 20- Boost Temperature Sensor 21- Fuel Temperature Sensor 22- Engine Speed Sensor 23- Engine

24- Pump 2 Regulator Pressure Sensor 25- Pump 2 Control Solenoid Valve 26- Pump 2 Delivery Pressure Sensor 27- Pump 1 Regulator Pressure Sensor 28- Pump 1 Control Solenoid Valve 29- Pump 1 Delivery Pressure Sensor 30- Pump 3 Regulator Pressure Sensor 31- Pump 3 Control Solenoid Valve

T2-2-41

32- Pump 3 Delivery Pressure Sensor 33- Fan Pump Control Solenoid Valve 34- Air Conditioner Controller 35- Ambient Temperature Sensor 36- Pump Regulator Pressure Learning Switch 37- Auto-Idle Switch 38- Power Mode Switch 39- Engine Control Dial 40- Key Switch 41- Pilot Shut-Off Switch 42- Fan Pump

SECTION 2 SYSTEM Group 2 Control System  Air Conditioner Switch: ON 1. ECM (18) sends the signals of fuel temperature sensor (21) and coolant temperature sensor (19) to MC1 (13) by using CAN communication (17).

2. Air conditioner controller (34) sends the signal of ambient temperature sensor (35) to MC1 (13).

3. The hydraulic oil temperature sensor (1) and boost temperature sensor (20) send the signals to MC1 (13).

4. Engine control dial (39) sends the target engine speed signal to MC1 (13).

5. MC1 (13) calculates the fan rotation speed by using the received signals.

6. MC1 (13) sends the highest output signal in the calculated fan rotation speed to the fan pump control solenoid valve (33) and controls the fan pump delivery flow rate.

7. The fan rotation speed is properly controlled regardless of the engine speed.

T2-2-42

SECTION 2 SYSTEM Group 2 Control System 2 3 4 5 6 7 8 9 12

1

41

14. MPDr.

16

15

40 39

17 38

37 36

18. ECM

13. MC1

35 19

21

22

42

34 23 20

33

32 31 30

29 28 27

26 25 24 TKAB-02-02-019

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Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing) Pressure Sensor (Travel)

12- Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) 13- MC1 14- MPDr. 15- Monitor Controller 16- Monitor 17- CAN 18- ECM 19- Coolant Temperature Sensor 20- Boost Temperature Sensor 21- Fuel Temperature Sensor 22- Engine Speed Sensor 23- Engine

24- Pump 2 Regulator Pressure Sensor 25- Pump 2 Control Solenoid Valve 26- Pump 2 Delivery Pressure Sensor 27- Pump 1 Regulator Pressure Sensor 28- Pump 1 Control Solenoid Valve 29- Pump 1 Delivery Pressure Sensor 30- Pump 3 Regulator Pressure Sensor 31- Pump 3 Control Solenoid Valve

T2-2-43

32- Pump 3 Delivery Pressure Sensor 33- Fan Pump Control Solenoid Valve 34- Air Conditioner Controller 35- Ambient Temperature Sensor 36- Pump Regulator Pressure Learning Switch 37- Auto-Idle Switch 38- Power Mode Switch 39- Engine Control Dial 40- Key Switch 41- Pilot Shut-Off Switch 42- Fan Pump

SECTION 2 SYSTEM Group 2 Control System Pump Learning Control Purpose: The pump learning control records the current and control pressure, which are the basic parameters of the pump control when activating the pump control solenoid valves (28, 25, 31). This control controls to sufficient performance of each pump.

Operation: 1. When the following conditions exist and the pump regulator pressure learning switch (36) in the rear console is turned to the pump learning side (opposite side of E), MC1 (13) activates the pump control solenoid valves (28, 25, 31).  Engine (23): Running  Engine control dial (39): Fast Idle speed Position  Auto-idle switch (37): OFF  Power mode switch (38): HP mode  Pressure sensor: No outputting signal (the control lever is in the neutral position)  Hydraulic Oil Temperature: 50±5 °C  Pilot shut-off switch (41): LOCK Position 2. The spools of the pump control solenoid valves (28, 25, 31) are operated.

3. The pump regulator pressure sensors (27, 24, 30) detect control pressure of the pump control solenoid valves (28, 25, 31), and send the signals in response to each pressure to MC1 (13).

4. MC1 (13) records the current and control pressure while activating the pump control solenoid valves (28, 25, 31). Therefore, the pump control is optimized.

IMPORTANT: When the following work has been performed, perform the pump learning. (Refer to Technical Manual/Troubleshooting.)  When the pump, pump regulator, pump control solenoid valves (28, 25, 31) have been replaced  When MC1 (13) has been replaced

fNOTE: The pump learning is not necessary to perform

the pump learning when the battery has been replaced.

T2-2-44

SECTION 2 SYSTEM Group 2 Control System

2 3 4 5 6 7 8 9 12

1

41

14. MPDr.

16

15

40 39

17 38

37 36

18. ECM

13. MC1

35 19

21

22

42

34 23 20

33

32 31 30

29 28 27

26 25 24 TKAB-02-02-020

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Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing) Pressure Sensor (Travel)

12- Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) 13- MC1 14- MPDr. 15- Monitor Controller 16- Monitor 17- CAN 18- ECM 19- Coolant Temperature Sensor 20- Boost Temperature Sensor 21- Fuel Temperature Sensor 22- Engine Speed Sensor 23- Engine

24- Pump 2 Regulator Pressure Sensor 25- Pump 2 Control Solenoid Valve 26- Pump 2 Delivery Pressure Sensor 27- Pump 1 Regulator Pressure Sensor 28- Pump 1 Control Solenoid Valve 29- Pump 1 Delivery Pressure Sensor 30- Pump 3 Regulator Pressure Sensor 31- Pump 3 Control Solenoid Valve

T2-2-45

32- Pump 3 Delivery Pressure Sensor 33- Fan Pump Control Solenoid Valve 34- Air Conditioner Controller 35- Ambient Temperature Sensor 36- Pump Regulator Pressure Learning Switch 37- Auto-Idle Switch 38- Power Mode Switch 39- Engine Control Dial 40- Key Switch 41- Pilot Shut-Off Switch 42- Fan Pump

SECTION 2 SYSTEM Group 2 Control System Pump 1 Flow Rate Control Q

Purpose: The pump 1 flow rate control controls the pump 1 flow rate which is required according to each stroke of the boom, arm, bucket, and travel control levers. Therefore, the fuel consumption is reduced.

Operation: 1. When the control lever is operated, MC1 (13) receives the signals from pressure sensors (boom raise (2), boom lower (3), LD: arm extend/BH: rollout (5), LD: arm retract/BH: roll-in (4), LD: bucket tilt-out/BH: roll-in (6), LD: bucket tilt-in/BH: roll-out (7), and travel (9)).

A A-

2. MC1 (13) activates the pump 1 control solenoid valve (28) according to the control lever stroke and controls the pump 1 flow rate.

T2-2-46

Control Level Operation

Q-

Flow Rate

SECTION 2 SYSTEM Group 2 Control System

2 3 4 5 6 7 8 9 12

1

41

14. MPDr.

16

15

40 39

17 38

37 36

18. ECM

13. MC1

35 19

21

22

42

34 23 20

33

32 31 30

29 28 27

26 25 24 TKAB-02-02-022

123456789-

Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing) Pressure Sensor (Travel)

12- Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) 13- MC1 14- MPDr. 15- Monitor Controller 16- Monitor 17- CAN 18- ECM 19- Coolant Temperature Sensor 20- Boost Temperature Sensor 21- Fuel Temperature Sensor 22- Engine Speed Sensor 23- Engine

24- Pump 2 Regulator Pressure Sensor 25- Pump 2 Control Solenoid Valve 26- Pump 2 Delivery Pressure Sensor 27- Pump 1 Regulator Pressure Sensor 28- Pump 1 Control Solenoid Valve 29- Pump 1 Delivery Pressure Sensor 30- Pump 3 Regulator Pressure Sensor 31- Pump 3 Control Solenoid Valve

T2-2-47

32- Pump 3 Delivery Pressure Sensor 33- Fan Pump Control Solenoid Valve 34- Air Conditioner Controller 35- Ambient Temperature Sensor 36- Pump Regulator Pressure Learning Switch 37- Auto-Idle Switch 38- Power Mode Switch 39- Engine Control Dial 40- Key Switch 41- Pilot Shut-Off Switch 42- Fan Pump

SECTION 2 SYSTEM Group 2 Control System Pump 2 Flow Rate Control Q

Purpose: The pump 2 flow rate control controls the pump 2 flow rate which is required according to each stroke of the levers (or pedal) of the boom, arm, bucket, travel, and LD: bucket open/close/BH: auxiliary (option). Therefore, the fuel consumption is reduced.

Operation: 1. When the control lever is operated, MC1 (13) receives the signals from pressure sensors (boom raise (2), boom lower (3), LD: arm extend/BH: rollout (5), LD: arm retract/BH: roll-in (4), LD: bucket tilt-out/BH: roll-in (6), LD: bucket tilt-in/BH: roll-out (7), travel (9), and auxiliary (12)).

A A-

2. MC1 (13) activates the pump 2 control solenoid valve (25) according to the control lever stroke and controls the pump 2 flow rate.

T2-2-48

Control Level Operation

Q-

Flow Rate

SECTION 2 SYSTEM Group 2 Control System

2 3 4 5 6 7 8 9 12

1

41

14. MPDr.

16

15

40 39

17 38

37 36

18. ECM

13. MC1

35 19

21

22

42

34 23 20

33

32 31 30

29 28 27

26 25 24 TKAB-02-02-023

123456789-

Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing) Pressure Sensor (Travel)

12- Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) 13- MC1 14- MPDr. 15- Monitor Controller 16- Monitor 17- CAN 18- ECM 19- Coolant Temperature Sensor 20- Boost Temperature Sensor 21- Fuel Temperature Sensor 22- Engine Speed Sensor 23- Engine

24- Pump 2 Regulator Pressure Sensor 25- Pump 2 Control Solenoid Valve 26- Pump 2 Delivery Pressure Sensor 27- Pump 1 Regulator Pressure Sensor 28- Pump 1 Control Solenoid Valve 29- Pump 1 Delivery Pressure Sensor 30- Pump 3 Regulator Pressure Sensor 31- Pump 3 Control Solenoid Valve

T2-2-49

32- Pump 3 Delivery Pressure Sensor 33- Fan Pump Control Solenoid Valve 34- Air Conditioner Controller 35- Ambient Temperature Sensor 36- Pump Regulator Pressure Learning Switch 37- Auto-Idle Switch 38- Power Mode Switch 39- Engine Control Dial 40- Key Switch 41- Pilot Shut-Off Switch 42- Fan Pump

SECTION 2 SYSTEM Group 2 Control System Pump 3 Flow Rate Control Q

Purpose: The pump 3 flow rate control controls the pump 3 flow rate which is required according to each stroke of the boom, arm, bucket, and swing control levers. Therefore, the fuel consumption is reduced.

Operation: 1. When the control lever is operated, MC1 (13) receives the signals from pressure sensors (boom raise (2), boom lower (3), LD: arm extend/BH: rollout (5), LD: arm retract/BH: roll-in (4), LD: bucket tilt-out/BH: roll-in (6), LD: bucket tilt-in/BH: roll-out (7), and swing (8)).

A A-

2. MC1 (13) activates the pump 3 control solenoid valve (31) according to the control lever stroke and controls the pump 3 flow rate.

T2-2-50

Control Level Operation

Q-

Flow Rate

SECTION 2 SYSTEM Group 2 Control System 2 3 4 5 6 7 8 9 12

1

41

14. MPDr.

16

15

40 39

17 38

37 36

18. ECM

13. MC1

35 19

21

22

42

34 23 20

33

32 31 30

29 28 27

26 25 24 TKAB-02-02-024

123456789-

Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing) Pressure Sensor (Travel)

12- Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) 13- MC1 14- MPDr. 15- Monitor Controller 16- Monitor 17- CAN 18- ECM 19- Coolant Temperature Sensor 20- Boost Temperature Sensor 21- Fuel Temperature Sensor 22- Engine Speed Sensor 23- Engine

24- Pump 2 Regulator Pressure Sensor 25- Pump 2 Control Solenoid Valve 26- Pump 2 Delivery Pressure Sensor 27- Pump 1 Regulator Pressure Sensor 28- Pump 1 Control Solenoid Valve 29- Pump 1 Delivery Pressure Sensor 30- Pump 3 Regulator Pressure Sensor 31- Pump 3 Control Solenoid Valve

T2-2-51

32- Pump 3 Delivery Pressure Sensor 33- Fan Pump Control Solenoid Valve 34- Air Conditioner Controller 35- Ambient Temperature Sensor 36- Pump Regulator Pressure Learning Switch 37- Auto-Idle Switch 38- Power Mode Switch 39- Engine Control Dial 40- Key Switch 41- Pilot Shut-Off Switch 42- Fan Pump

SECTION 2 SYSTEM Group 2 Control System Valve Control (Standard) The valve control consists of the followings.  Power Digging Control  Auto-Power Lift Control (only BH)  Travel Motor Displacement Angle Control  Pressure Rising Selection Control When Traveling  Boom Mode Control  Bypass Cut Valve Control During Boom Lowering  Arm 2 Flow Rate Control  Fan Reverse Rotation Control

T2-2-52

SECTION 2 SYSTEM Group 2 Control System Valve Control (Standard) System Layout

14. MPDr.

16 20 21

15

17. ECM

1 2 3 4 5 6 7 8 9 10 11 12 51 33

50 49 48 47

22 23 24

19

18

31

28

30

27

32

29

25

13. MC1

46 45 44 43

26

35

42 34

41

36

40

39 52 12345678910111213-

Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing) Pressure Sensor (Travel) Pressure Sensor (4-Spool Side) Pressure Sensor (5-Spool Side) Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) MC1

1415161718192021222324-

2526-

MPDr. Monitor Controller Monitor ECM Engine Radiator Fan Reverse Rotation Spool Radiator Fan Valve Radiator Fan Reverse Rotation Control Solenoid Valve Oil Cooler Fan Reverse Rotation Spool Oil Cooler Fan Valve Oil Cooler Fan Reverse Rotation Control Solenoid Valve Pump 2 Regulator Pressure Sensor Pump 2 Control Solenoid Valve

27- Pump 2 Delivery Pressure Sensor 28- Pump 1 Regulator Pressure Sensor 29- Pump 1 Control Solenoid Valve 30- Pump 1 Delivery Pressure Sensor 31- Pump 3 Regulator Pressure Sensor 32- Pump 3 Control Solenoid Valve 33- Pump 3 Delivery Pressure Sensor 34- 4-Spool Solenoid Valve Unit 35- Main Control Valve 36- Main Relief Valve 37- Boom Overload Relief Selector Valve 38- Bypass Shut-Out Valve (4-Spool Side)

T2-2-53

38

37

TKAB-02-02-025

39- Travel Motor Displacement Angle Control Valve 40- 2-Spool Solenoid Valve Unit 41- Fan Reverse Rotation Switch 42- Boom Mode Switch 43- Power Digging Switch 44- Travel Mode Switch 45- Slow Speed Position 46- Fast Speed Position 47- Power Mode Switch 48- Engine Control Dial 49- Key Switch 50- Pilot Shut-Off Switch 51- Boom Bottom Pressure Sensor 52- Arm 2 Flow Rate Control Valve

SECTION 2 SYSTEM Group 2 Control System Power Digging Control Purpose: The power digging control increases the digging force by temporarily increasing the relief pressure.

Operation: 1. For maximum eight seconds after power digging switch (43) is turned ON, MC1 (13) continuously activates the 4-spool solenoid valve unit (34) (SF).

2. When the 4-spool solenoid valve unit (34) (SF) is activated, the pilot pressure acts on main relief valve (36) and increases the relief pressure. (Refer to COMPONENT OPERATION/Control Valve.)

T2-2-54

SECTION 2 SYSTEM Group 2 Control System 14. MPDr.

16 20 21

15

17. ECM

1 2 3 4 5 6 7 8 9 10 11 12 51 33

50 49 48 47

22 23 24

19

18

31

28

30

27

32

29

25

13. MC1

46 45 44 43

26

35

42 34

41

36

40

39 52 12345678910111213-

Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing) Pressure Sensor (Travel) Pressure Sensor (4-Spool Side) Pressure Sensor (5-Spool Side) Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) MC1

1415161718192021222324-

2526-

MPDr. Monitor Controller Monitor ECM Engine Radiator Fan Reverse Rotation Spool Radiator Fan Valve Radiator Fan Reverse Rotation Control Solenoid Valve Oil Cooler Fan Reverse Rotation Spool Oil Cooler Fan Valve Oil Cooler Fan Reverse Rotation Control Solenoid Valve Pump 2 Regulator Pressure Sensor Pump 2 Control Solenoid Valve

27- Pump 2 Delivery Pressure Sensor 28- Pump 1 Regulator Pressure Sensor 29- Pump 1 Control Solenoid Valve 30- Pump 1 Delivery Pressure Sensor 31- Pump 3 Regulator Pressure Sensor 32- Pump 3 Control Solenoid Valve 33- Pump 3 Delivery Pressure Sensor 34- 4-Spool Solenoid Valve Unit 35- Main Control Valve 36- Main Relief Valve 37- Boom Overload Relief Selector Valve 38- Bypass Shut-Out Valve (4-Spool Side)

T2-2-55

38

37

TKAB-02-02-027

39- Travel Motor Displacement Angle Control Valve 40- 2-Spool Solenoid Valve Unit 41- Fan Reverse Rotation Switch 42- Boom Mode Switch 43- Power Digging Switch 44- Travel Mode Switch 45- Slow Speed Position 46- Fast Speed Position 47- Power Mode Switch 48- Engine Control Dial 49- Key Switch 50- Pilot Shut-Off Switch 51- Boom Bottom Pressure Sensor 52- Arm 2 Flow Rate Control Valve

SECTION 2 SYSTEM Group 2 Control System Auto-Power Lift Control (only BH) Purpose: The auto-power lift control increases the relief pressure when raising the boom.

Operation: 1. When all following conditions exist, MC1 (13) activates the 4-spool solenoid valve unit (34) (SF).  Pressure sensor (boom raise) (2): Outputting signal (The boom pilot pressure must be increased to the specified pressure.)

(Reference: 0.7 MPa)  Pump 1 delivery pressure sensor (30): High (Reference: 29 MPa)  Pressure sensor (arm roll-in) (4): Specified pressure or lower (Reference: 0.7 MPa) 2. When the 4-spool solenoid valve unit (34) (SF) is activated, the pilot pressure acts on main relief valve (36) and increases the relief pressure. (Refer to COMPONENT OPERATION/Control Valve.)

fNOTE: The auto-power lift control is performed when performing combined operation except arm roll-in as well as single operation.

T2-2-56

SECTION 2 SYSTEM Group 2 Control System 14. MPDr.

16 20 21

15

17. ECM

1 2 3 4 5 6 7 8 9 10 11 12 51 33

50 49 48 47

22 23 24

19

18

31

28

30

27

32

29

25

13. MC1

46 45 44 43

26

35

42 34

41

36

40

39 52 12345678910111213-

Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing) Pressure Sensor (Travel) Pressure Sensor (4-Spool Side) Pressure Sensor (5-Spool Side) Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) MC1

1415161718192021222324-

2526-

MPDr. Monitor Controller Monitor ECM Engine Radiator Fan Reverse Rotation Spool Radiator Fan Valve Radiator Fan Reverse Rotation Control Solenoid Valve Oil Cooler Fan Reverse Rotation Spool Oil Cooler Fan Valve Oil Cooler Fan Reverse Rotation Control Solenoid Valve Pump 2 Regulator Pressure Sensor Pump 2 Control Solenoid Valve

27- Pump 2 Delivery Pressure Sensor 28- Pump 1 Regulator Pressure Sensor 29- Pump 1 Control Solenoid Valve 30- Pump 1 Delivery Pressure Sensor 31- Pump 3 Regulator Pressure Sensor 32- Pump 3 Control Solenoid Valve 33- Pump 3 Delivery Pressure Sensor 34- 4-Spool Solenoid Valve Unit 35- Main Control Valve 36- Main Relief Valve 37- Boom Overload Relief Selector Valve 38- Bypass Shut-Out Valve (4-Spool Side)

T2-2-57

38

37

TKAB-02-02-028

39- Travel Motor Displacement Angle Control Valve 40- 2-Spool Solenoid Valve Unit 41- Fan Reverse Rotation Switch 42- Boom Mode Switch 43- Power Digging Switch 44- Travel Mode Switch 45- Slow Speed Position 46- Fast Speed Position 47- Power Mode Switch 48- Engine Control Dial 49- Key Switch 50- Pilot Shut-Off Switch 51- Boom Bottom Pressure Sensor 52- Arm 2 Flow Rate Control Valve

SECTION 2 SYSTEM Group 2 Control System Travel Motor Displacement Angle Control Purpose: The travel motor displacement angle control controls the travel mode.

Operation:  Slow speed 1. When travel mode switch (44) is in slow speed position (45), the travel motor displacement angle is kept in the maximum angle, and the travel speed is slow.  Fast speed 1. When all following conditions exist, MC1 (13) activates the 4-spool solenoid valve unit (34) (SC).  Travel mode switch (44): Fast speed position (46)  Pressure sensor (travel) (9): Outputting signal  Pump 1, 2 delivery pressure sensors (30, 27): The delivery pressure of both pumps is low. (Reference: less than 20.1 MPa)  Pressure sensor (4-spool side) (10) or Pressure sensor (5-spool side) (11): The pilot pressure of either pump or both pumps is high. (Reference: over 3.0 MPa) 2. When the 4-spool solenoid valve unit (34) (SC) is activated, the pilot pressure acts on the travel motor displacement angle control valve (39) and decreases the displacement angle to the minimum so that the travel speed increases.

T2-2-58

SECTION 2 SYSTEM Group 2 Control System 14. MPDr.

16 20 21

15

17. ECM

1 2 3 4 5 6 7 8 9 10 11 12 51 33

50 49 48 47

22 23 24

19

18

31

28

30

27

32

29

25

13. MC1

46 45 44 43

26

35

42 34

41

36

40

39 52 12345678910111213-

Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing) Pressure Sensor (Travel) Pressure Sensor (4-Spool Side) Pressure Sensor (5-Spool Side) Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) MC1

1415161718192021222324-

2526-

MPDr. Monitor Controller Monitor ECM Engine Radiator Fan Reverse Rotation Spool Radiator Fan Valve Radiator Fan Reverse Rotation Control Solenoid Valve Oil Cooler Fan Reverse Rotation Spool Oil Cooler Fan Valve Oil Cooler Fan Reverse Rotation Control Solenoid Valve Pump 2 Regulator Pressure Sensor Pump 2 Control Solenoid Valve

27- Pump 2 Delivery Pressure Sensor 28- Pump 1 Regulator Pressure Sensor 29- Pump 1 Control Solenoid Valve 30- Pump 1 Delivery Pressure Sensor 31- Pump 3 Regulator Pressure Sensor 32- Pump 3 Control Solenoid Valve 33- Pump 3 Delivery Pressure Sensor 34- 4-Spool Solenoid Valve Unit 35- Main Control Valve 36- Main Relief Valve 37- Boom Overload Relief Selector Valve 38- Bypass Shut-Out Valve (4-Spool Side)

T2-2-59

38

37

TKAB-02-02-029

39- Travel Motor Displacement Angle Control Valve 40- 2-Spool Solenoid Valve Unit 41- Fan Reverse Rotation Switch 42- Boom Mode Switch 43- Power Digging Switch 44- Travel Mode Switch 45- Slow Speed Position 46- Fast Speed Position 47- Power Mode Switch 48- Engine Control Dial 49- Key Switch 50- Pilot Shut-Off Switch 51- Boom Bottom Pressure Sensor 52- Arm 2 Flow Rate Control Valve

SECTION 2 SYSTEM Group 2 Control System Pressure Rising Selection Control When Traveling Purpose: The pressure rising selection control when traveling increases the main relief valve pressure when performing travel operation.

Operation: 1. MC1 (13) receives the signal from pressure sensor (travel) (9) when performing travel operation. MC1 (13) activates the 4-spool solenoid valve unit (34) (SF).

2. When the 4-spool solenoid valve unit (34) (SF) is activated, the pilot pressure acts on main relief valve (36) and increases the relief pressure. (Refer to COMPONENT OPERATION/Control Valve.)

T2-2-60

SECTION 2 SYSTEM Group 2 Control System 14. MPDr.

16 20 21

15

17. ECM

1 2 3 4 5 6 7 8 9 10 11 12 51 33

50 49 48 47

22 23 24

19

18

31

28

30

27

32

29

25

13. MC1

46 45 44 43

26

35

42 34

41

36

40

39 52 12345678910111213-

Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing) Pressure Sensor (Travel) Pressure Sensor (4-Spool Side) Pressure Sensor (5-Spool Side) Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) MC1

1415161718192021222324-

2526-

MPDr. Monitor Controller Monitor ECM Engine Radiator Fan Reverse Rotation Spool Radiator Fan Valve Radiator Fan Reverse Rotation Control Solenoid Valve Oil Cooler Fan Reverse Rotation Spool Oil Cooler Fan Valve Oil Cooler Fan Reverse Rotation Control Solenoid Valve Pump 2 Regulator Pressure Sensor Pump 2 Control Solenoid Valve

27- Pump 2 Delivery Pressure Sensor 28- Pump 1 Regulator Pressure Sensor 29- Pump 1 Control Solenoid Valve 30- Pump 1 Delivery Pressure Sensor 31- Pump 3 Regulator Pressure Sensor 32- Pump 3 Control Solenoid Valve 33- Pump 3 Delivery Pressure Sensor 34- 4-Spool Solenoid Valve Unit 35- Main Control Valve 36- Main Relief Valve 37- Boom Overload Relief Selector Valve 38- Bypass Shut-Out Valve (4-Spool Side)

T2-2-61

38

37

TKAB-02-02-026

39- Travel Motor Displacement Angle Control Valve 40- 2-Spool Solenoid Valve Unit 41- Fan Reverse Rotation Switch 42- Boom Mode Switch 43- Power Digging Switch 44- Travel Mode Switch 45- Slow Speed Position 46- Fast Speed Position 47- Power Mode Switch 48- Engine Control Dial 49- Key Switch 50- Pilot Shut-Off Switch 51- Boom Bottom Pressure Sensor 52- Arm 2 Flow Rate Control Valve

SECTION 2 SYSTEM Group 2 Control System Boom Mode Control Purpose: The boom mode control reduces body vibration by decreasing the relief pressure of the overload relief valve during digging and level operation.

Operation: 1. When all following conditions exist, MC1 (13) activates the 4-spool solenoid valve unit (34) (SI).  Boom mode switch (42): ON  Pressure sensor (travel) (9): No outputting signal  Pressure sensor (boom raise (2), boom lower (3), LD: arm extend/BH: roll-in (4), LD: arm retract/BH: roll-out (5), LD: bucket tilt-out/BH: roll-in (6), LD: bucket tilt-in/BH: roll-out (7), LD: bucket open/close/ BH: auxiliary (12) (OP)): Either of pressure sensors: Outputting signal 2. Pressure oil from the pilot pump flows through the 4-spool solenoid valve unit (34) (SI) and acts on the boom overload relief selector valve (37).

3. When the boom overload relief selector valve (37) is shifted, the relief set pressure of the overload relief valve decreases.

4. As the holding pressure at the boom cylinder rod side decreases, body vibration during boom lower operation decreases.

(Refer to COMPONENT OPERATION/Control Valve/ Boom Overload Relief Selector Valve.)

fNOTE: When output of either of pressure sensors (boom

raise (2), boom lower (3), LD: arm extend/BH: roll-in (4), LD: arm retract/BH: roll-out (5), LD: bucket tilt-out/BH: roll-in (6), LD: bucket tilt-in/BH: roll-out (7), LD: bucket open/close/BH: auxiliary (12) (OP)) exceeds 0.7 MPa, MC1 (13) recognizes that the control lever is operated.

T2-2-62

SECTION 2 SYSTEM Group 2 Control System 14. MPDr.

16 20 21

15

17. ECM

1 2 3 4 5 6 7 8 9 10 11 12 51 33

50 49 48 47

22 23 24

19

18

31

28

30

27

32

29

25

13. MC1

46 45 44 43

26

35

42 34

41

36

40

39 52 12345678910111213-

Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing) Pressure Sensor (Travel) Pressure Sensor (4-Spool Side) Pressure Sensor (5-Spool Side) Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) MC1

1415161718192021222324-

2526-

MPDr. Monitor Controller Monitor ECM Engine Radiator Fan Reverse Rotation Spool Radiator Fan Valve Radiator Fan Reverse Rotation Control Solenoid Valve Oil Cooler Fan Reverse Rotation Spool Oil Cooler Fan Valve Oil Cooler Fan Reverse Rotation Control Solenoid Valve Pump 2 Regulator Pressure Sensor Pump 2 Control Solenoid Valve

27- Pump 2 Delivery Pressure Sensor 28- Pump 1 Regulator Pressure Sensor 29- Pump 1 Control Solenoid Valve 30- Pump 1 Delivery Pressure Sensor 31- Pump 3 Regulator Pressure Sensor 32- Pump 3 Control Solenoid Valve 33- Pump 3 Delivery Pressure Sensor 34- 4-Spool Solenoid Valve Unit 35- Main Control Valve 36- Main Relief Valve 37- Boom Overload Relief Selector Valve 38- Bypass Shut-Out Valve (4-Spool Side)

T2-2-63

38

37

TKAB-02-02-030

39- Travel Motor Displacement Angle Control Valve 40- 2-Spool Solenoid Valve Unit 41- Fan Reverse Rotation Switch 42- Boom Mode Switch 43- Power Digging Switch 44- Travel Mode Switch 45- Slow Speed Position 46- Fast Speed Position 47- Power Mode Switch 48- Engine Control Dial 49- Key Switch 50- Pilot Shut-Off Switch 51- Boom Bottom Pressure Sensor 52- Arm 2 Flow Rate Control Valve

SECTION 2 SYSTEM Group 2 Control System Bypass Cut Valve Control During Boom Lowering Purpose: The bypass cut valve control during boom lowering can make the track be raised off the ground, and reduces hunting with the track raised off the ground.

Operation: 1. When all following conditions exist, MC1 (13) activates the 4-spool solenoid valve unit (34) (SG).  Pressure Sensor (Boom Lower) (3): Outputting signal  Boom Bottom Pressure Sensor (51): less than 1 MPa 2. When the 4-spool solenoid valve unit (34) (SG) is activated, the bypass shut-out valve (4-spool side) (38) is shifted by the pilot pressure.

3. Pressure oil from pump 1 flows to boom 1 spool (54) through the boom 1 flow rate control valve (53).

4. Pressure oil from boom 1 spool (54) flows to the boom rod side. Therefore, the jack-up force increases.

T2-2-64

SECTION 2 SYSTEM Group 2 Control System 16

14. MPDr.

20 21 19

15

17. ECM

1 2 3 4 5 6 7 8 9 10 11 12 51 33

50 49 48 47

22 23 24

18

31

28

30

27

32

29

25

13. MC1

46 45 44 43

26

35

42 34

41

36

40

53 54

39 52 12345678910111213-

Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing) Pressure Sensor (Travel) Pressure Sensor (4-Spool Side) Pressure Sensor (5-Spool Side) Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) MC1

1415161718192021222324-

2526-

MPDr. Monitor Controller Monitor ECM Engine Radiator Fan Reverse Rotation Spool Radiator Fan Valve Radiator Fan Reverse Rotation Control Solenoid Valve Oil Cooler Fan Reverse Rotation Spool Oil Cooler Fan Valve Oil Cooler Fan Reverse Rotation Control Solenoid Valve Pump 2 Regulator Pressure Sensor Pump 2 Control Solenoid Valve

27- Pump 2 Delivery Pressure Sensor 28- Pump 1 Regulator Pressure Sensor 29- Pump 1 Control Solenoid Valve 30- Pump 1 Delivery Pressure Sensor 31- Pump 3 Regulator Pressure Sensor 32- Pump 3 Control Solenoid Valve 33- Pump 3 Delivery Pressure Sensor 34- 4-Spool Solenoid Valve Unit 35- Main Control Valve 36- Main Relief Valve 37- Boom Overload Relief Selector Valve 38- Bypass Shut-Out Valve (4-Spool Side)

T2-2-65

38

37

TKAB-02-02-032

39- Travel Motor Displacement Angle Control Valve 40- 2-Spool Solenoid Valve Unit 41- Fan Reverse Rotation Switch 42- Boom Mode Switch 43- Power Digging Switch 44- Travel Mode Switch 45- Slow Speed Position 46- Fast Speed Position 47- Power Mode Switch 48- Engine Control Dial 49- Key Switch 50- Pilot Shut-Off Switch 51- Boom Bottom Pressure Sensor 52- Arm 2 Flow Rate Control Valve 53- Boom 1 Flow Rate Control Valve 54- Boom 1 Spool

SECTION 2 SYSTEM Group 2 Control System Arm 2 Flow Rate Control  Arm Roll-In (BH)/Extend (LD) The procedure for the backhoe is explained as an example.

Purpose: The arm 2 flow rate control increases the boom raise speed during digging operation. The arm 2 flow rate control circuit enables the arm level crowding operation during arm level crowding operation.

Operation:  When performing digging operation 1. When all following conditions exist, MC1 (13) activates the 2-spool solenoid valve unit (40) (SI).

 When performing arm level crowding operation 1. When all following conditions exist, MC1 (13) activates the 2-spool solenoid valve unit (40) (SI).

 Pressure Sensor (Boom Raise) (2): Outputting signal  Pressure Sensor (Arm Roll-In) (4): Outputting signal  Pump 1 Delivery Pressure Sensor (30), Pump 2 Delivery Pressure Sensor (27), Pump 3 Delivery Pressure Sensor (33): The delivery pressure of pumps is high. (Reference: over 22 MPa)

 Pressure Sensor (Boom Raise) (2): Outputting signal  Pressure Sensor (Arm Roll-In) (4): Outputting signal  Pump 1 Delivery Pressure Sensor (30), Pump 2 Delivery Pressure Sensor (27), Pump 3 Delivery Pressure Sensor (33): All delivery pressure of pumps is low. (Reference: less than 22 MPa)

2. The 2-spool solenoid valve unit (40) (SI) is activated.

The output pilot pressure shifts the arm 2 flow rate control valve (52).

2. The 2-spool solenoid valve unit (40) (SI) outputs lower pilot pressure. The pilot pressure acts on the arm 2 flow rate control valve (52).

3. Pressure oil which flows from pump 1 to the arm 2 spool is restricted by the arm 2 flow rate control valve (52).

3. Therefore, pressure oil from pump 1 is restricted by the arm 2 flow rate control valve (52) so that the specified flow rate of pressure oil can flow to the arm 2 spool.

4. As the pressure oil flow rate which flows from pump 1 to the arm 2 spool is reduced, the pressure oil flow rate which flows from pump 1 to the boom 1 spool increases. Then, the boom raise speed increases.

4. Pressure oil from pump 1 flows to the boom 1 spool and arm 2 spool in good balance. This enables the arm level crowding operation.

fNOTE: When all delivery pressure sensors (30, 27, 33) of

pumps 1, 2, 3 are abnormal, the same control as the arm level crowding operation is performed.

fNOTE: The reduced amount of the arm 2 flow rate control valve (52) can be adjusted by MPDr. during arm level crowding operation. (Arm 2 Flw Cont P/S Correction)

T2-2-66

SECTION 2 SYSTEM Group 2 Control System 14. MPDr.

16 20 21

15

17. ECM

1 2 3 4 5 6 7 8 9 10 11 12 51 33

50 49 48 47

22 23 24

19

18

31

28

30

27

32

29

25

13. MC1

46 45 44 43

26

35

42 34

41

36

40

39 52 12345678910111213-

Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing) Pressure Sensor (Travel) Pressure Sensor (4-Spool Side) Pressure Sensor (5-Spool Side) Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) MC1

1415161718192021222324-

2526-

MPDr. Monitor Controller Monitor ECM Engine Radiator Fan Reverse Rotation Spool Radiator Fan Valve Radiator Fan Reverse Rotation Control Solenoid Valve Oil Cooler Fan Reverse Rotation Spool Oil Cooler Fan Valve Oil Cooler Fan Reverse Rotation Control Solenoid Valve Pump 2 Regulator Pressure Sensor Pump 2 Control Solenoid Valve

27- Pump 2 Delivery Pressure Sensor 28- Pump 1 Regulator Pressure Sensor 29- Pump 1 Control Solenoid Valve 30- Pump 1 Delivery Pressure Sensor 31- Pump 3 Regulator Pressure Sensor 32- Pump 3 Control Solenoid Valve 33- Pump 3 Delivery Pressure Sensor 34- 4-Spool Solenoid Valve Unit 35- Main Control Valve 36- Main Relief Valve 37- Boom Overload Relief Selector Valve 38- Bypass Shut-Out Valve (4-Spool Side)

T2-2-67

38

37

TKAB-02-02-049

39- Travel Motor Displacement Angle Control Valve 40- 2-Spool Solenoid Valve Unit 41- Fan Reverse Rotation Switch 42- Boom Mode Switch 43- Power Digging Switch 44- Travel Mode Switch 45- Slow Speed Position 46- Fast Speed Position 47- Power Mode Switch 48- Engine Control Dial 49- Key Switch 50- Pilot Shut-Off Switch 51- Boom Bottom Pressure Sensor 52- Arm 2 Flow Rate Control Valve

SECTION 2 SYSTEM Group 2 Control System Fan Reverse Rotation Control Purpose: The fan reverse rotation control turns the oil cooler fan and radiator fan in reverse, and cleans the oil cooler and radiator.

Operation: 1. When the fan reverse rotation switch is turned ON, MC1 (13) activates the oil cooler fan reverse rotation control solenoid valve (24) and radiator fan reverse rotation control solenoid valve (21).

2. When the oil cooler fan reverse rotation control solenoid valve (24) and radiator fan reverse rotation control solenoid valve (21) are activated, pressure oil from the pilot pump shifts the oil cooler fan reverse rotation spool (22) and radiator fan reverse rotation spool (19).

3. The delivery ports of the oil cooler fan valve (23) and radiator fan valve (20) are shifted. Then, the fan motors turns in reverse. (Refer to SYSTEM/Hydraulic System.)

Therefore, accumulated dirt in the oil cooler and radiator cores is discharged.

T2-2-68

SECTION 2 SYSTEM Group 2 Control System 14. MPDr.

16 20 21

15

17. ECM

1 2 3 4 5 6 7 8 9 10 11 12 51 33

50 49 48 47

22 23 24

19

18

31

28

30

27

32

29

25

13. MC1

46 45 44 43

26

35

42 34

41

36

40

39 52 12345678910111213-

Hydraulic Oil Temperature Sensor Pressure Sensor (Boom Raise) Pressure Sensor (Boom Lower) Press Sensor (LD: Arm Extend/ BH: Roll-In) Press Sensor (LD: Arm Retract/ BH: Roll-Out) Pressure Sensor (LD: Bucket Tilt-Out/BH: Roll-In) Pressure Sensor (LD: Bucket Tilt-In/BH: Roll-Out) Pressure Sensor (Swing) Pressure Sensor (Travel) Pressure Sensor (4-Spool Side) Pressure Sensor (5-Spool Side) Pressure Sensor (LD: Bucket Open/Close/BH: Auxiliary) (OP) MC1

1415161718192021222324-

2526-

MPDr. Monitor Controller Monitor ECM Engine Radiator Fan Reverse Rotation Spool Radiator Fan Valve Radiator Fan Reverse Rotation Control Solenoid Valve Oil Cooler Fan Reverse Rotation Spool Oil Cooler Fan Valve Oil Cooler Fan Reverse Rotation Control Solenoid Valve Pump 2 Regulator Pressure Sensor Pump 2 Control Solenoid Valve

27- Pump 2 Delivery Pressure Sensor 28- Pump 1 Regulator Pressure Sensor 29- Pump 1 Control Solenoid Valve 30- Pump 1 Delivery Pressure Sensor 31- Pump 3 Regulator Pressure Sensor 32- Pump 3 Control Solenoid Valve 33- Pump 3 Delivery Pressure Sensor 34- 4-Spool Solenoid Valve Unit 35- Main Control Valve 36- Main Relief Valve 37- Boom Overload Relief Selector Valve 38- Bypass Shut-Out Valve (4-Spool Side)

T2-2-69

38

37

TKAB-02-02-031

39- Travel Motor Displacement Angle Control Valve 40- 2-Spool Solenoid Valve Unit 41- Fan Reverse Rotation Switch 42- Boom Mode Switch 43- Power Digging Switch 44- Travel Mode Switch 45- Slow Speed Position 46- Fast Speed Position 47- Power Mode Switch 48- Engine Control Dial 49- Key Switch 50- Pilot Shut-Off Switch 51- Boom Bottom Pressure Sensor 52- Arm 2 Flow Rate Control Valve

SECTION 2 SYSTEM Group 2 Control System Other Control The other control consists of the followings.  Work Mode Control  Auto Shut-Down Control  Auto-Lubrication Control (Quicklub Lubrication System)  * Auto-Lubrication Control (Centro Matic System)  Hydraulic Oil Overheat Alarm Control  * Swing Alarm Control  * Travel Alarm Control  * Overload Alarm Control NOTE: *: This control is for only the machine with the optional parts equipped.

f

T2-2-70

SECTION 2 SYSTEM Group 2 Control System Work Mode Control The work mode control consists of digging mode and attachment mode 1 to 11. The mode can be selected by the monitor.  Digging Mode: The normal control is performed.  Attachment Mode: This functions only machine with optional parts equipped.

The upper limit of the maximum pump 2 flow rate is limited according to the kind of attachment. (Refer to T2-2-38 to 39.)

The increasing/decreasing settings are made by MPDr..

NOTE: As the attachment mode, one to eleven attachment modes can be selected by MPDr..  Unset1 to 5  Breaker 1 to 5  Pulverizer 1 to 5  Crusher 1 to 5  Vibrating Hammer 1 to 5  Other 1 to 5  Grapple 1 to 5  Clamshell 1 to 5  Thumb 1 to 5  Tilting Rotator 1 to 5  Tilting Bucket 1 to 5

f

T2-2-71

SECTION 2 SYSTEM Group 2 Control System Auto Shut-Down Control Purpose: The auto shut-down control automatically stops the engine in order to reduce the fuel consumption when the operation is not performed in a specified time.

fNOTE: The auto shut-down ON/OFF can be selected

Operation: 1. When all following conditions exist, MC1 (2) sends the auto shut-down signal to monitor controller (5) by using CAN communication (3).

and reset it to the START position, and the engine can restart.

and the time when the auto shut-down control is activated can be set by monitor (6).

fNOTE: Return the key switch to the OFF or ACC position

 Pilot shut-off switch (15): OFF (Pilot shut-off lever: LOCK position)  Auto shut-down: ON  Overheat alarm: OFF  Coolant temperature: less than 100 °C  Abnormal communication of ECM (8) or monitor controller (5): None  Overload alarm switch (16) (option): OFF 2. Monitor controller (5) displays the auto shut-down notice on monitor (6) and sounds buzzer (7) once before 30 seconds for the auto shut-down enable time set by monitor (6). Monitor controller (5) sounds buzzer (7) continuously before 15 seconds. (intermittent sound) 3. MC1 (2) decreases the engine speed to the slow idle speed after the auto shut-down enable time is over.

(Refer to Engine Speed Slow Down Control.)

4. When the engine speed is decreased to the slow idle speed, MC1 (2) turns ON auto shut-down relay (13).

5. When auto shut-down relay (13) is ON, the battery relay is turned OFF and the engine stops. (Refer to SYSTEM/Electrical System.)

T2-2-72

SECTION 2 SYSTEM Group 2 Control System 4. MPDr.

1

6 5

15

7 3

14 2. MC1 16

8. ECM

11 10

13

TKAB-02-02-033

123-

Hydraulic Oil Temperature Sensor MC1 CAN

4567-

MPDr. Monitor Controller Monitor Buzzer

8- ECM 10- Coolant Temperature Sensor 11- Engine 13- Auto Shut-Down Relay

T2-2-73

14- Engine Control Dial 15- Pilot Shut-Off Switch 16- Overload Alarm Switch (Option)

SECTION 2 SYSTEM Group 2 Control System Auto-Lubrication Control (Quicklub Lubrication System)

13. When the number of times (number of reciprocating motion) reaches to the set value, MC1 (2) disconnects terminal #C17 from the ground.

Purpose: The auto-lubrication control (quicklub lubrication system) controls the auto-lubrication device so that auto-lubrication can be correctly performed. (Refer to COMPONENT OPERATION/Others (Upperstructure)/ Distribution Valve.)

14. As auto-lubrication relay 1 (8) and auto-lubrication relay 2 (13) are turned OFF, no current flows to grease pump (9) and grease pump (9) is stopped.

Operation: 1. When the lubrication mode selection switch (1) is set to the auto position, MC1 (2) connects terminal #C17 to the ground inside.

2. Therefore, auto-lubrication relay 1 (8) and autolubrication relay 2 (13) are excited.

3. Current from fuse #5 (7) flows to grease pump (9) and proximity switch (11).

4. Grease pump (9) is operated and auto-lubrication starts.

5. While auto-lubrication relay 1 (8) and autolubrication relay 2 (13) are ON, grease pump (9) is operated and grease is discharged.

15. When the set interval passed, MC1 (2) connects terminal #C17 to the ground again. Then, grease pump (9) is operated and auto-lubrication is resumed.

16. When the signal from proximity switch (11) is not sent to terminal #E3 in MC1 (2) within 5 minutes after auto-lubrication relay 1 (8) and autolubrication relay 2 (13) were turned ON, MC1 (2) recognizes that malfunction (such as no grease or faulty grease pump) of the auto-lubrication circuit has occurred. MC1 (2) sends the signal to monitor controller (5) by using CAN communication (3).

17. Monitor controller (5) displays the auto-lubrication alarm on monitor (6).

fNOTE: The lubrication time and interval can be set on

6. When grease is discharged from grease pump (9), the piston of distribution valve (10) moves.

monitor (6) or by using MPDr. (4).

7. Proximity switch (11) is installed in distribution valve (10) and is turned ON/OFF in response to the movement of the piston of distribution valve (10).

8. When the piston on distribution valve (10) comes close to proximity switch (11), proximity switch (11) is turned ON and transistor (12) in proximity switch (11) is turned ON. 9. Therefore, terminal #E3 in MC1 (2) is connected to the ground through proximity switch (11).

10. When the piston on distribution valve (10) gets away from proximity switch (11), proximity switch (11) is turned OFF and transistor (12) is turned OFF. 11. Therefore, the signal from terminal #2 in proximity switch (11) is input to terminal #E3 in MC1 (2).

12. MC1 (2) detects the number of distribution valve (10) operating times (number of reciprocating motion) according to the signal input to terminal #E3.

T2-2-74

SECTION 2 SYSTEM Group 2 Control System

4. MPDr.

14 7

6 1

3

5

2. MC1

8 C17

13

E3

9

10

3

2 1

11

12 TKAB-02-02-046

123-

Lubrication Mode Selection Switch MC1 CAN

4567-

MPDr. Monitor Controller Monitor Fuse #5

891011-

T2-2-75

Auto-Lubrication Relay 1 Grease Pump Distribution Valve Proximity Switch

12- Transistor 13- Auto-Lubrication Relay 2 14- Current from Battery

SECTION 2 SYSTEM Group 2 Control System Auto-Lubrication Control (Centro Matic System) (Option)

7. When pressure switch (10) is turned ON, MC1 (2) disconnects terminal #C17 from the ground.

Purpose: The auto-lubrication control (centro matic system) controls the auto-lubrication device so that autolubrication can be correctly performed. (Refer to COMPONENT OPERATION/Others (Upperstructure)/ Distribution Valve.)

8. As auto-lubrication relay 1 (8) and auto-lubrication relay 2 (13) are turned OFF, no current flows to the motor of grease pump (9) and grease pump (9) is stopped.

Operation: 1. When the lubrication mode selection switch (1) is set to the auto position, MC1 (2) connects terminal #C17 to the ground inside.

2. Therefore, auto-lubrication relay 1 (8) and autolubrication relay 2 (13) are excited.

3. Current from fuse #5 (7) flows to the motor of grease pump (9) and the auto-lubrication solenoid valve (11).

4. Grease pump (9) is operated and auto-lubrication starts.

9. When the set interval passed, MC1 (2) connects terminal #C17 to the ground again. Then, grease pump (9) is operated and auto-lubrication is resumed.

10. When the signal from pressure switch (10) is not sent to terminal #E3 in MC1 (2) within 5 minutes after auto-lubrication relay 1 (8) and autolubrication relay 2 (13) were turned ON, MC1 (2) recognizes that malfunction (such as no grease or faulty grease pump) of the auto-lubrication circuit has occurred. MC1 (2) sends the signal to monitor controller (5) by using CAN communication (3).

11. Monitor controller (5) displays the auto-lubrication alarm on monitor (6).

5. While auto-lubrication relay 1 (8) and autolubrication relay 2 (13) are ON, grease pump (9) is operated and grease is discharged.

fNOTE: The lubrication time and interval can be set on

6. Pressure switch (10) is installed in the lubrication circuit. When the lubrication circuit pressure increases over the set pressure, pressure switch (10) is turned ON.

T2-2-76

monitor (6) or by using MPDr. (4).

SECTION 2 SYSTEM Group 2 Control System

4. MPDr.

14 7

6 1

3

5

2. MC1

8 C17

13

E3

9

10

11

TKAB-02-02-042

123-

Lubrication Mode Selection Switch MC1 CAN

4567-

MPDr. Monitor Controller Monitor Fuse #5

8- Auto-Lubrication Relay 1 9- Grease Pump 10- Pressure Switch

T2-2-77

11- Auto-Lubrication Solenoid Valve 13- Auto-Lubrication Relay 2 14- Current from Battery

SECTION 2 SYSTEM Group 2 Control System Hydraulic Oil Overheat Alarm Control

fNOTE: The temperature, judging time, and buzzer

Purpose: When hydraulic oil temperature increases over the specified value, the hydraulic oil overheat alarm control sounds buzzer (7).

ON/OFF operation of the hydraulic oil overheat alarm control can be set by MPDr. (4).

Operation: 1. The signal from the hydraulic oil temperature sensor (1) is sent to MC1 (2).

2. When hydraulic oil temperature is kept high for a specified period of time, MC1 (2) sends the signal to monitor controller (5) by using CAN communication (3).

3. Monitor controller (5) sounds buzzer (7) and displays the hydraulic oil overheat alarm on monitor (6).

4. When hydraulic oil temperature decreases, monitor controller (5) stops buzzer (7) and deletes the hydraulic oil overheat alarm on monitor (6).

1 4. MPDr.

3

6

2. MC1

5

7 TDAA-02-02-010

1-

Hydraulic Oil Temperature Sensor

23-

MC CAN

45-

T2-2-78

MPDr. Monitor Controller

67-

Monitor Buzzer

SECTION 2 SYSTEM Group 2 Control System Swing Alarm Control (Option) Purpose: The swing alarm control sounds buzzer (3) and turns on beacon light (4) when performing the swing operation.

Operation: 1. MC1 (2) receives the signal from pressure sensor (swing) (1) when the swing operation is performed.

2. As long as MC1 (2) receives this signal, MC1 (2) sends the signal, sounds buzzer (3), and turns on beacon light (4).

1

2. MC1

3

4 TKAB-02-02-034

1-

Pressure Sensor (Swing)

2-

MC1

3-

T2-2-79

Buzzer

4-

Beacon Light

SECTION 2 SYSTEM Group 2 Control System Travel Alarm Control (Option) Purpose: The travel alarm control sounds buzzers (6, 7) when performing the travel operation.

Operation: 1. MC1 (2) receives the signal from pressure sensor (travel) (1) when the travel operation is performed.

2. As long as MC1 (2) receives this signal, MC1 (2) sends the signal to travel alarm device (fender side) (3) and travel alarm device (rear side) (4), and sounds buzzers (6, 7).

fNOTE: After traveling continuously for over 13 seconds, buzzers (6, 7) can be deactivated by the travel alarm deactivation switch (5).

1

2. MC1 6 3

5

4 7 TKAB-02-02-043

12-

Pressure Sensor (Travel) MC1

34-

Travel Alarm Device (Fender Side) Travel Alarm Device (Rear Side)

56-

T2-2-80

Travel Alarm Deactivation Switch Buzzer

7-

Buzzer

SECTION 2 SYSTEM Group 2 Control System Overload Alarm Control (Option) Purpose: The overload alarm control sounds buzzer (8) and displays the overload alarm when boom raise operation such as hoisting is overloaded.

fNOTE: The alarm pressure setting (Tipping Threshold Boom CYL Bottom Pressure) of load in MC1 (2) can be adjusted by MPDr. (5).

Operation: 1. When all following conditions exist, MC1 (2) sends the signal to monitor controller (6).  Overload alarm: Enable  Boom bottom pressure sensor (3): Outputting signal beyond the specified pressure  Overload alarm switch (1): ON 2. As long as receiving the signal from MC1 (2), monitor controller (6) connects terminal #D7 to the ground inside.

3. Monitor controller (6) sounds buzzer (8) and displays the overload alarm on monitor (7).

3

5. MPDr.

1

4 7 2. MC1

6 D7

8

TKAB-02-02-044

12-

Overload Alarm Switch MC1

34-

Boom Bottom Pressure Sensor CAN

56-

T2-2-81

MPDr. Monitor Controller

78-

Monitor Buzzer

SECTION 2 SYSTEM Group 2 Control System (Blank)

T2-2-82

SECTION 2 SYSTEM Group 3 Engine System ECM System ECM receives the signals from sensors and MC1. ECM processes and performs the following controls.  Injector Control  Slow Idle Control at Low Temperature  Low Temperature Start Control (Option)  Troubleshooting Control

T2-3-1

SECTION 2 SYSTEM Group 3 Engine System Injector Control ECM (12) activates injector (13) and controls the engine by receiving the signal of target engine speed (Power CAN (11)) and the signals from control sensors such as engine speed sensor (1), the fuel pump delivery pressure sensor (2), the fuel timing pressure sensor (3), and fuel pressure sensor (4).

Slow Idle Control at Low Temperature ECM (12) keeps the engine speed at slow idle speed until temperature of coolant temperature sensor (6), fuel temperature sensor (9), and the intake manifold temperature sensor (7) reaches the specified temperature.

Low Temperature Start Control (Option) ECM (12) excites ether solenoid (18) and improves the engine starting ability when the detected temperature is lower than the specified temperature by the signal from the intake manifold temperature sensor (7).

Troubleshooting Control ECM (12) controls the engine speed, fuel injection amount, and engine stop by receiving the signal of target engine speed (Power CAN (11)) and the erratic data from control sensors such as engine speed sensor (1), the fuel pump delivery pressure sensor (2), the fuel timing pressure sensor (3), fuel pressure sensor (4), fuel temperature sensor (9), engine oil pressure sensor (5), coolant temperature sensor (6), and the intake manifold temperature sensor (7).

ECM (12) indicates trouble information by turning on and blinking engine fault code indicator lights (14, 15, 16). Then, ECM (12) sends the signal that the icon is displayed on the monitor.

T2-3-2

SECTION 2 SYSTEM Group 3 Engine System

13 1 2 3 14

4 5

15

6

16

7

12. ECM

17

18

9

10. MC1 11. Power CAN

TKAA90-02-03-001

12345-

Engine Speed Sensor Fuel Pump Delivery Pressure Sensor Fuel Timing Pressure Sensor Fuel Pressure Sensor Engine Oil Pressure Sensor

67-

Coolant Temperature Sensor Intake Manifold Temperature Sensor 9- Fuel Temperature Sensor 10- MC1 11- Power CAN

12- ECM 13- Injector 14- Engine Maintenance Indicator Lamp 15- Engine Stop Indicator Lamp

T2-3-3

16- Engine Warning Indicator Lamp 17- Monitor 18- Ether Solenoid

SECTION 2 SYSTEM Group 3 Engine System (Blank)

T2-3-4

SECTION 2 SYSTEM Group 4 Hydraulic System Outline The hydraulic system mainly consists of the pilot circuit, main circuit, transmission oil cooling circuit, and fan motor circuit.

Pilot Circuit: Power Source Pilot Pump

Related Device

Supplied to

Pilot Valve

Operation Control Circuit

Pump Regulator

Pump Control Circuit

4-Spool Solenoid Valve Unit

Valve Control Circuit

2-Spool Solenoid Valve Unit

Travel Motor Displacement Angle Control Circuit

Signal Control Valve

Swing Parking Brake Release Circuit Hydraulic Oil Heat Circuit

Main Circuit: Power Source Main Pump

Related Device

Supplied to

Main Control Valve

Motor

Swing Control Valve

Cylinder

Transmission Oil Cooling Circuit: Power Source

Related Device

Supplied to

Transmission Oil Circulation Pump

Pump Transmission Oil Cooler

Pump Transmission

Fan Motor Circuit: Power Source Fan Pump

Related Device

Supplied to

Oil Cooler Fan Valve

Oil Cooler Fan Motor

Radiator Fan Valve

Radiator Fan Motor

T2-4-1

SECTION 2 SYSTEM Group 4 Hydraulic System Pilot Circuit Outline: Pressure oil from the pilot pump is used in order to operate the following circuits.  Operation Control Circuit (A1)  Pump Control Circuit (A2)  Valve Control Circuit (A3)  Travel Motor Displacement Angle Control Circuit (A4)  Swing Parking Brake Release Circuit (A5)  Hydraulic Oil Heat Circuit (A6)

fNOTE: Two accumulators are equipped for the pilot

circuit. The accumulators supply hydraulic oil to the pilot circuit for a period of time after the engine has been stopped.

T2-4-2

SECTION 2 SYSTEM Group 4 Hydraulic System

fNOTE: The figure shows for the loading shovel.

A1 1. Travel Pilot Valve

2. Pilot Valve (Left)

3. Pilot Valve (Right)

35

36

6. Swing Control Valve

5 34. Pilot Shut-Off Solenoid Valve

A5 8. Swing Motor 9. Pump 1 Regulator

33. Signal Control Valve

A6 20. Main Control Valve

31

B1

A2 SC

14

SI

15 28

A3

10. Pump 2 Regulator

29

11. Pump 3 Regulator

16

SG

17

SI

18

SF

19

12. Fan Pump Regulator

21. Hydraulic Oil Tank

SC 22. Suction Filter 24. Pilot Relief Valve

26. Travel Motor

26. Travel Motor

A4

23. Pilot Pump

25. Pilot Filter TKAA90-02-04-012

A1- Operation Control Circuit A2- Pump Control Circuit A3- Valve Control Circuit

A4- Travel Motor Displacement Angle Control Circuit

A5- Swing Parking Brake Release Circuit A6- Hydraulic Oil Heat Circuit

B1- To Main Control Valve Spool

12356891011-

12- Fan Pump Regulator 14- Flow Combiner Valve 15- Bypass Shut-Out Valve (5-Spool Side) 16- Arm 2 Flow Rate Control Valve 17- Bypass Shut-Out Valve (4-Spool Side) 18- Boom Overload Relief Selector Valve

192021222324252628-

2931333435-

Travel Pilot Valve Pilot Valve (Left) Pilot Valve (Right) Boom Lower Shockless Valve Swing Control Valve Swing Motor Pump 1 Regulator Pump 2 Regulator Pump 3 Regulator

T2-4-3

Main Relief Valve Main Control Valve Hydraulic Oil Tank Suction Filter Pilot Pump Pilot Relief Valve Pilot Filter Travel Motor 4-Spool Solenoid Valve Unit

2-Spool Solenoid Valve Unit Accumulator Signal Control Valve Pilot Shut-Off Solenoid Valve Bucket Close Pilot Valve (only LD) 36- Bucket Open Pilot Valve (only LD)

SECTION 2 SYSTEM Group 4 Hydraulic System Operation Control Circuit 1. Pilot valves (B5 to B9) controls pressure oil from pilot pump (B0) and moves the spools in main control valve (A8) and swing control valve (A9).

2. Signal control valve (B3) is provided between pilot valves (B5 to B9) and main control valve (A8). Boom raise shockless valve (B4) is provided in the boom raise circuit in signal control valve (B3).

3. Boom raise shockless valve (B4) restricts returning oil from main control valve (A8) when stopping the boom raise operation and dampens the quick spool movement in main control valve (A8). (Refer to COMPONENT OPERATION/Signal Control Valve.)

4. Boom lower shockless valve (A6) is provided between pilot valve (right) (B7) in the boom lower circuit and signal control valve (B3).

5. Boom lower shockless valve (A6) restricts returning oil from main control valve (A8) and swing control valve (A9) when stopping the boom lower operation, and dampens the quick spool movement in main control valve (A8) and swing control valve (A9). (Refer to COMPONENT OPERATION/Signal Control Valve.)

6. When the pilot shut-off solenoid valve (B2) is in the LOCK position, pressure oil does not flow to pilot valves (B5 to B9). Even if the control lever is operated, the machine is not operated.

7. Accumulators (B1) are equipped so that pressure oil can be supplied to the operation control circuit for a period of time after the engine has been stopped.

Therefore, even when the engine is stopped with the front attachment raised due to troubles, pressure oil can be supplied to the spools in main control valve (A8) and swing control valve (A9) from accumulators (B1). Then, the front attachment can be operated.

T2-4-4

SECTION 2 SYSTEM Group 4 Hydraulic System

fNOTE: The figure shows for the loading shovel.

B5

A0

A1

A2

A3

B6

A4

A5

B7

A10 B8 A11 B9

A6

B2 B3 B4 B1

4 3 782 1 6 5 A7

B0 A9

11

12 9 10 18 17 16 15 14 13

19 20

A8 1

2

6

5

8

7

12

9

11

10 19

18 17

20 13

14

14 4

3

13

16 15

15

17

16 18 TKAA90-02-04-013 12345-

Boom Raise Boom Lower Arm Roll-In Arm Roll-Out Swing Left

A0- Travel (Left) A1- Travel (Right) A2- Swing A3- Arm A4- Boom A5- Bucket

678910-

Swing Right Bucket Roll-In Bucket Roll-Out Travel (Left Forward) Travel (Left Reverse)

1112131415-

Travel (Right Forward) Travel (Right Reverse) Boom Raise Boom Lower Arm Roll-Out

1617181920-

A6- Boom Lower Shockless Valve A7- To Swing Control Valve A8- Main Control Valve A9- Swing Control Valve A10- Bucket Close (only LD) A11- Bucket Open (only LD)

B0B1B2B3B4B5-

Pilot Pump Accumulator Pilot Shut-Off Solenoid Valve Signal Control Valve Boom Raise Shockless Valve Travel Pilot Valve

B6- Pilot Valve (Left) B7- Pilot Valve (Right) B8- Bucket Close Pilot Valve (only LD) B9- Bucket Open Pilot Valve (only LD)

T2-4-5

Arm Roll-In Bucket Roll-Out Bucket Roll-In Bucket Open (only LD) Bucket Close (only LD)

SECTION 2 SYSTEM Group 4 Hydraulic System Pump Control Circuit (Refer to COMPONENT OPERATION/Pump Device.)  Main Pump Control by Pump Control Solenoid Valve 1. MC1 activates pump 1 control solenoid valve (9), pump 2 control solenoid valve (6), and pump 3 control solenoid valve (10) according to each actuator operation. (Refer to SYSTEM/Control System.)

2. Pilot pressure from pilot pump (4) is controlled by the pump 1 control solenoid valve (9), pump 2 control solenoid valve (6), and pump 3 control solenoid valve (10). The controlled pilot pressure is supplied to the regulators in pump 1 (2), pump 2 (5), and pump 3 (1) as the pump displacement angle control pressure.

3. The regulators increase or decrease the pump delivery flow rate according to the pump displacement angle control pressure.  Fan Pump Control by Fan Pump Control Solenoid Valve 1. Pilot pressure from pilot pump (4) is controlled by the fan pump control solenoid valve (8) and is supplied to the regulator in fan pump (3) as the fan pump control pressure.

2. The regulator increases or decreases the fan pump delivery flow rate according to the fan pump control pressure.

T2-4-6

SECTION 2 SYSTEM Group 4 Hydraulic System

1

3

2

4

5

8 10

9

6

TKAB-02-04-003

123-

Pump 3 Pump 1 Fan Pump

456-

Pilot Pump Pump 2 Pump 2 Control Solenoid Valve

89-

T2-4-7

Fan Pump Control Solenoid Valve Pump 1 Control Solenoid Valve

10- Pump 3 Control Solenoid Valve

SECTION 2 SYSTEM Group 4 Hydraulic System Valve Control Circuit (Refer to COMPONENT OPERATION/Control Valve, Travel Device.)  Pilot pressure from pilot pump (14) controls the following valves through the pilot valve, boom 1 spool (8), arm 1 spool (15), 4-spool solenoid valve unit (18) (SG, SI, SF, SC), 2-spool solenoid valve unit (19) (SC, SI), and flow combiner valve control spool (20) in signal control valve (3).  Boom 1 Spool (8): Boom 1 Anti-Drift Valve (9) and Boom 2 Anti-Drift Valve (17)  Arm 1 Spool (15): Arm 1 Anti-Drift Valve (16)  4-Spool Solenoid Valve Unit (18) (SG): Bypass ShutOut Valve (4-Spool Side) (12)  4-Spool Solenoid Valve Unit (18) (SI): Boom Overload Relief Selector Valve (10)  4-Spool Solenoid Valve Unit (18) (SF): Main Relief Valve (7) (increasing the set pressure)  4-Spool Solenoid Valve Unit (18) (SC): Travel Motor Displacement Angle Control Valve (13)  *2-Spool Solenoid Valve Unit (19) (SC): Bypass ShutOut Valve (5-Spool Side) (5)  2-Spool Solenoid Valve Unit (19) (SI): Arm 2 Flow Rate Control Valve (11)  Flow Combiner Valve Control Spool (20) (Travel (Right) Pilot Pressure): Flow Combiner Valve (6) *Option Travel Motor Displacement Angle Control Circuit (Refer to COMPONENT OPERATION/Travel Device.)

Pilot pressure from the 4-spool solenoid valve unit (18) (SC) controls the travel motor displacement angle control valve (13).

T2-4-8

SECTION 2 SYSTEM Group 4 Hydraulic System

fNOTE: The figure shows for the backhoe.

1

2

3

19

20 4

SC SI

18

5

6

7

17 a SG SI SF

8

SC

9

16 a 14

15 10 11

12 TKAA90-02-04-011

13 a-

Pilot Pressure from Boom 1 Spool (8)

12345-

Travel (Right Forward) Travel (Right Reverse) Signal Control Valve Main Control Valve Bypass Shut-Out Valve (5-Spool Side) Flow Combiner Valve

6-

78910-

Main Relief Valve Boom 1 Spool Boom 1 Anti-Drift Valve Boom Overload Relief Selector Valve 11- Arm 2 Flow Rate Control Valve

12- Bypass Shut-Out Valve (4-Spool Side) 13- Travel Motor Displacement Angle Control Valve 14- Pilot Pump 15- Arm 1 Spool 16- Arm 1 Anti-Drift Valve

T2-4-9

17181920-

Boom 2 Anti-Drift Valve 5-Spool Solenoid Valve Unit 2-Spool Solenoid Valve Unit Flow Combiner Valve Control Spool

SECTION 2 SYSTEM Group 4 Hydraulic System Swing Parking Brake Release Circuit (Refer to COMPONENT OPERATION/Swing Device.)

1. When operating the front attachment or swing device, pilot pressure from the pilot valve is selected by shuttle valve (7) in signal control valve (6). And this pilot pressure shifts swing parking brake release spool (8).

2. Pilot pressure SH from pilot pump (10) is supplied to swing motor (9) and releases the swing parking brake.

Hydraulic Oil Heat Circuit 1. When the pilot shut-off solenoid valve (11) is seated, pilot pressure oil is supplied to signal control valve (6). The hydraulic oil temperature increases due to orifice (5) in signal control valve (6).

2. This warmed pressure oil flows to signal control valve (6) and the pilot valves, and warms the pilot system components.

T2-4-10

SECTION 2 SYSTEM Group 4 Hydraulic System

fNOTE: The figure shows for the backhoe.

1

2

3

SH

4

5

11

6

10

8

9

7

TKAB-02-04-005

123-

Swing Arm Boom

456-

Bucket Orifice Signal Control Valve

78-

T2-4-11

Shuttle Valve Swing Parking Brake Release Spool

9- Swing Motor 10- Pilot Pump 11- Pilot Shut-Off Solenoid Valve

SECTION 2 SYSTEM Group 4 Hydraulic System Main Circuit Outline 1. The main pump (pump 1 (20), pump 2 (21), and pump 3 (19)) draws hydraulic oil from hydraulic oil tank (23) and delivers it to main control valve (8) and swing control valve (24).

2. Pressure oil from pump 1 (20) flows to travel (right) spool (14), bucket spool 1 (15), boom 1 spool (16), and arm 2 spool (17) through 4-spool side (A) in main control valve (8).

3. Pressure oil from pump 2 (21) flows to bucket 2 spool (13), arm 1 spool (12), boom 2 spool (11), bucket open/close (LD)/auxiliary (BH) spool (10), and travel (left) spool (9) through 5-spool side (B) in main control valve (8).

4. Pressure oil from pump 3 (19) flows to boom 3 spool (25), swing spool (26), bucket 3 spool (27), and arm 3 spool (28) through in swing control valve (24).

5. Delivered hydraulic oil is supplied to the motors or cylinders in response to the spool operation of main control valve (8) and swing control valve (24).

6. Returning oil from the motors or cylinders returns to hydraulic oil tank (23) through main control valve (8) and oil cooler (3) or swing control valve (24).

7. When the oil temperature is low (high viscosity) and the oil flow resistance increases in oil cooler (3), bypass check valve (4) is opened and hydraulic oil directly returns to hydraulic oil tank (23).

T2-4-12

SECTION 2 SYSTEM Group 4 Hydraulic System

fNOTE: The figure shows for the backhoe.

1. Radiator 2. Oil Cooler Fan Motor Fan Motor

4. Bypass Check Valve

5. Boom Cylinder

3

8. Main Control Valve 32. Travel Motor (Left)

31. Attachments

30. Bucket Cylinder

6. Travel Motor (Right)

A

9 10

14

11

15

12

16

13

17

7. Arm Cylinder

B

29. Swing Motor 18. Fan Pump

25 26

24. Swing Control Valve

27

19.

Pump 3

20.

Pump 1

21.

Pump 2

22. Suction Filter

28 23. Hydraulic Oil Tank TKAB-02-04-007

A-

4-Spool Side

B-

5-Spool Side

123456789-

Radiator Fan Motor Oil Cooler Fan Motor Oil Cooler Bypass Check Valve Boom Cylinder Travel Motor (Right) Arm Cylinder Main Control Valve Travel (Left) Spool

10- Bucket Open/Close (LD)/ Auxiliary (BH) Spool 11- Boom 2 Spool 12- Arm 1 Spool 13- Bucket 2 Spool 14- Travel (Right) Spool 15- Bucket 1 Spool 16- Boom 1 Spool 17- Arm 2 Spool

181920212223242526-

T2-4-13

Fan Pump Pump 3 Pump 1 Pump 2 Suction Filter Hydraulic Oil Tank Swing Control Valve Boom 3 Spool Swing Spool

272829303132-

Bucket 3 Spool Arm 3 Spool Swing Motor Bucket Cylinder Attachments Travel Motor (Left)

SECTION 2 SYSTEM Group 4 Hydraulic System Neutral Circuit 1. When the control lever is in neutral, pressure oil from the main pump (pump 1 (18), pump 2 (17), and pump 3 (19)) returns to hydraulic oil tank (27) through main control valve (1) and swing control valve (26).

2. Parallel circuits (5, 4, 24) are provided in each circuit of pump 1 (18), pump 2 (17), and pump 3 (19). The combined operation becomes possible.

Flow Combiner Circuit 1. When performing boom raise, arm, and bucket rollin operation, pressure oil from three pumps (pump 1 (18), pump 2 (17), pump 3 (19)) is combined.

2. When performing bucket roll-out operation, pressure oil from pump 3 (19) is not combined, but pressure oil from pump 1 (18) and pump 2 (17) is combined.

3. When performing boom lower operation, pressure oil from pump 2 (17) and pump 3 (19) is not combined, but pressure oil from pump 1 (18) and the bottom side of boom cylinder (12) is combined.

(Boom Lower Regenerative Circuit) Relief Circuit 1. Main relief valves (7, 40) are provided in the main circuit.

2. Main relief valves (7, 40) prevent the pressure in main circuit from exceeding the set pressure when the spool is operated (when the control lever is operated).

3. Overload relief valves (10, 14, 33, 35, 37, 41, 42) are provided in the actuator circuits (between the control valve and the actuators, and between swing control valve and the actuators) of boom, arm, bucket, and bucket open/close (LD)/auxiliary (BH).

4. Overload relief valves (10, 14, 33, 35, 37, 41, 42) prevent the pressure caused by external force in the actuator circuit from exceeding the set pressure.

5. Overload relief valves (10, 14, 33, 35, 37, 41, 42) have make-up function. When the pressure in the actuator circuit decreases, overload relief valves (10, 14, 33, 35, 37) draw pressure oil from hydraulic oil tank (27) and prevent cavitation from occurring.

6. Low-pressure relief valve (28) is provided in the return circuit of the main circuit.

7. Low-pressure relief valve (28) keeps the main circuit pressure constant and improves the actuator drawing performance when cavitation occurs.

T2-4-14

SECTION 2 SYSTEM Group 4 Hydraulic System

fNOTE: The figure shows for the backhoe.

1

39

2

3

4

5

6

8

7

38

9 10 37

11

36

12

35 13

34 33 32 31

14 16 15

42

30

40 20

28

21

27

22 29

19

23

18

17

24 25 26 41 27 1234567891011-

Main Control Valve Travel (Left) Spool Neutral Circuit (Pump 2) Parallel Circuit (Pump 2) Parallel Circuit (Pump 1) Travel (Right) Spool Main Relief Valve Travel Motor (Right) Bucket 1 Spool Overload Relief Valve Neutral Circuit (Pump 1)

1213141516171819202122-

Boom Cylinder Boom 1 Spool Overload Relief Valve Arm 2 Spool Arm Cylinder Pump 2 Pump 1 Pump 3 Boom 3 Spool Neutral Circuit (Pump 3) Swing Spool

2324252627282930313233-

T2-4-15

Bucket 3 Spool Parallel Circuit (Pump 3) Arm 3 Spool Swing Control Valve Hydraulic Oil Tank Low-Pressure Relief Valve Swing Motor Bucket 2 Spool Bucket Cylinder Arm 1 Spool Overload Relief Valve

343536373839404142-

TKAA90-02-04-002 Boom 2 Spool Overload Relief Valve Auxiliary Spool Overload Relief Valve Dump Cylinder (only LD)/ Attachments Travel Motor (Left) Main Relief Valve Overload Relief Valve Overload Relief Valve

SECTION 2 SYSTEM Group 4 Hydraulic System Combined Operation Circuit  Swing, Boom Raise 1. When the boom is raised while swinging, pilot pressure shifts swing spool (9), boom 1 spool (2), boom 2 spool (13), and boom 3 spool (7).

2. Pressure oil from pump 1 (5) flows to boom cylinders (3) through parallel circuit (1) and boom 1 spool (2), and raises the boom.

3. Pressure oil from pump 2 (4) flows to boom cylinders (3) through parallel circuit (12) and boom 2 spool (13), and raises the boom.

4. Pressure oil from pump 3 (6) flows to swing motor (11) through parallel circuit (8) and swing spool (9), and swings the machine. At the same time, pressure oil from pump 3 (6) flows through parallel circuit (8) and boom 3 spool (7), is combined with pressure oil from pump 1 (5) and pump 2 (4), and flows to boom cylinders (3). Then, the boom is raised.

T2-4-16

SECTION 2 SYSTEM Group 4 Hydraulic System

fNOTE: The figure shows for the backhoe.

1

13 2

3

12

7 8

10

9

11

6

5

10

1234-

Parallel Circuit (Pump 1) Boom 1 Spool Boom Cylinder Pump 2

5678-

Pump 1 Pump 3 Boom 3 Spool Parallel Circuit (Pump 3)

9101112-

T2-4-17

4

TKAA90-02-04-003

Swing Spool Hydraulic Oil Tank Swing Motor Parallel Circuit (Pump 2)

13- Boom 2 Spool

SECTION 2 SYSTEM Group 4 Hydraulic System Flow Combiner Circuit Purpose: The flow combiner circuit shifts flow combiner valve (4) when performing combined operation of travel and front attachment, and the machine can travel straight.  Travel, Boom Raise 1. When the boom is raised while traveling, pilot pressure shifts travel (right) spool (5), travel (left) spool (2), boom 1 spool (7), boom 2 spool (13), and boom 3 spool (12).

2. At the same time, the travel (right) pilot pressure shifts the flow combiner valve control spool in the signal control valve. Therefore, primary pilot pressure (3) from the pilot pump acts on flow combiner valve (4) through the signal control valve and shifts flow combiner valve (4).

3. Pressure oil from pump 1 (10) flows through travel (right) spool (5) and activates travel motor (right) (6).

4. At the same time, pressure oil from pump 1 (10) flows to travel (left) spool (2) through flow combiner valve (4) and activates travel motor (left) (1).

5. Pressure oil from pump 2 (9) flows to boom cylinder (8) through boom 2 spool (13) and raises the boom.

6. Pressure oil from pump 3 (11) flows through boom 3 spool (12), is combined with pressure oil from pump 2 (9), and raises the boom.

7. Pressure oil from pump 2 (9) and pressure oil from pump 3 (11) is used for the boom. Pressure oil from pump 1 (10) is equally supplied to both right and left travel motors and the machine can travel straight.

fNOTE: As the travel (right) circuit is a tandem circuit,

pressure oil from pump 1 (10) does not flow to boom 1 spool (7).

T2-4-18

SECTION 2 SYSTEM Group 4 Hydraulic System

fNOTE: The figure shows for the backhoe.

1

6 2

3

4

5

13

8 7

12 11 10

9

TKAA90-02-04-004

123-

Travel Motor (Left) Travel (Left) Spool Primary Pilot Pressure from Pilot Pump (From Flow Combiner Valve Control Spool)

45678-

Flow Combiner Valve Travel (Right) Spool Travel Motor (Right) Boom 1 Spool Boom Cylinder

910111213-

T2-4-19

Pump 2 Pump 1 Pump 3 Boom 3 Spool Boom 2 Spool

SECTION 2 SYSTEM Group 4 Hydraulic System Arm 2 Flow Rate Control Circuit Purpose: The arm 2 flow rate control circuit increases the boom raise speed when performing combined operation of boom raise and arm roll-in. The arm 2 flow rate control circuit stabilizes the arm level crowding operation during arm level crowding operation.  When performing digging operation 1. When performing the combined operation of boom raise and arm roll-in, pilot pressure shifts boom 1 spool (2), boo 2 spool (18), boom 3 spool (14), arm 1 spool (17), arm 2 spool (8), and arm 3 spool (15).

2. At this time, MC1 activates the 2-spool solenoid valve unit (SI). (Refer to SYSTEM/Control System.)

7. At the same time, pressure oil from pump 1 (10) flows to the arm 2 flow rate control valve (poppet valve) (7) through parallel circuit (1).

8. Pressure oil from pump 1 (10) is restricted by the arm 2 flow rate control valve (poppet valve) (7) which is pushed by pressure oil from the arm 2 flow rate control valve (selector valve) (5).

9. Pressure oil from pump 1 (10) preferentially flows to boom cylinder (3) and the boom raise speed increases.

3. Pilot pressure (6) from the 2-spool solenoid valve unit (SI) shifts the arm 2 flow rate control valve (selector valve) (5).

4. Pressure oil from pump 2 (9) flows to boom cylinder (3) and arm cylinder (4) through parallel circuit (12), arm 1 spool (17), and boom 2 spool (18). Then, pressure oil raises the boom and roll in the arm.

5. Pressure oil from pump 3 (11) flows to boom cylinder (3) and arm cylinder (4) through boom 3 spool (14) and arm 3 spool (15). Then, pressure oil raises the boom and roll in the arm.

6. Pressure oil from pump 1 (10) flows to boom cylinder (3) through parallel circuit (1) and boom 1 spool (2). Then, pressure oil raises the boom.

T2-4-20

SECTION 2 SYSTEM Group 4 Hydraulic System

fNOTE: The figure shows for the backhoe.

1

18

3

17 2

5 4

6 7

8

13 12 16

14 11

10

9

15

TKAA90-02-04-005

16 12345-

Parallel Circuit (Pump 1) Boom 1 Spool Boom Cylinder Arm Cylinder Arm 2 Flow Rate Control Valve (Selector Valve)

6-

Pilot Pressure from 2-Spool Solenoid Valve Unit (SI) 7- Arm 2 Flow Rate Control Valve (Poppet Valve) 8- Arm 2 Spool 9- Pump 2 10- Pump 1

11121314151617-

T2-4-21

Pump 3 Parallel Circuit (Pump 2) Parallel Circuit (Pump 3) Boom 3 Spool Arm 3 Spool Hydraulic Oil Tank Arm 1 Spool

18- Boom 2 Spool

SECTION 2 SYSTEM Group 4 Hydraulic System  When performing arm level crowding operation 1. When performing the combined operation of boom raise and arm roll-in, pilot pressure shifts boom 1 spool (2), boo 2 spool (18), boom 3 spool (14), arm 1 spool (17), arm 2 spool (8), and arm 3 spool (15).

2. At this time, MC1 activates the 2-spool solenoid valve unit (SI). (Refer to SYSTEM/Control System.)

3. The 2-spool solenoid valve unit (SI) reduces pilot pressure. Reduced pilot pressure (6) is supplied to the arm 2 flow rate control valve (selector valve) (5).

4. The arm 2 flow rate control valve (selector valve) (5) balances the reduced pilot pressure with the spring force.

5. Pressure oil from pump 2 (9) flows to boom cylinder (3) and arm cylinder (4) through parallel circuit (12), arm 1 spool (17), and boom 2 spool (18). Then, pressure oil raises the boom and roll in the arm.

9. Pressure oil from pump 1 (10) is restricted to the specified amount by the arm 2 flow rate control valve (poppet valve) (7) which is pushed by pressure oil from the arm 2 flow rate control valve (selector valve) (5).

10. Therefore, pressure oil from pump 1 (10) appropriately flows to boom cylinder (3) and arm cylinder (4). This stabilizes the arm level crowding operation.

fNOTE: When all delivery pressure sensors of pump 1 (10), pump 2 (9), and pump 3 (11) are abnormal, the same control as the arm level crowding operation is performed.

fNOTE: The reduced amount of the arm 2 flow rate

control valve can be adjusted by MPDr.. (Arm 2 Flow Rate Control P/S Adjustment)

6. Pressure oil from pump 3 (11) flows to boom cylinder (3) and arm cylinder (4) through boom 3 spool (14) and arm 3 spool (15). Then, pressure oil raises the boom and roll in the arm.

7. Pressure oil from pump 1 (10) flows to boom cylinder (3) through parallel circuit (1) and boom 1 spool (2). Then, pressure oil raises the boom.

For LD Front

8. At the same time, pressure oil from pump 1 (10) flows to the arm 2 flow rate control valve (poppet valve) (7) through parallel circuit (1).

T2-4-22

SECTION 2 SYSTEM Group 4 Hydraulic System

fNOTE: The figure shows for the backhoe.

1

18

3

17 2

5 4

6 7

8

13 12 16

14 11

10

9

15

TKAA90-02-04-006

16

12345-

Parallel Circuit (Pump 1) Boom 1 Spool Boom Cylinder Arm Cylinder Arm 2 Flow Rate Control Valve (Selector Valve)

6-

Pilot Pressure from 2-Spool Solenoid Valve Unit (SI) 7- Arm 2 Flow Rate Control Valve (Poppet Valve) 8- Arm 2 Spool 9- Pump 2 10- Pump 1

11121314151617-

T2-4-23

Pump 3 Parallel Circuit (Pump 2) Parallel Circuit (Pump 3) Boom 3 Spool Arm 3 Spool Hydraulic Oil Tank Arm 1 Spool

18- Boom 2 Spool

SECTION 2 SYSTEM Group 4 Hydraulic System Arm Regenerative Cut Circuit  Arm Roll-In (BH)/Extend (LD) The procedure for the backhoe is explained as an example.

Purpose: When the load is high at arm roll-in operation, the arm regenerative cut circuit flows back pressure oil at the arm cylinder (2) rod side to hydraulic oil tank (8) without regeneration for the bottom side. Therefore, pressure oil from pump 1 (4) is supplied to the arm and the digging force is improved.

 Regeneration Cut (Pump 1 (4) delivery pressure: High) 1. When the load becomes heavy at arm roll-in operation, the arm regeneration cut valve (6) is shifted by pressure oil from pump 1 (4).

 Regeneration (Pump 1 (4) delivery pressure: Low) 1. Pressure oil from pump 1 (4) acts on the arm regeneration cut valve (6).

2. Returning oil from the cylinder rod side flows to hydraulic oil tank (8) through arm 2 spool (1) and the arm regeneration cut valve (6).

2. When the load is light at arm roll-in operation, the arm regeneration cut valve (6) is not shifted.

3. As returning oil from the cylinder rod side is restricted by the arm regeneration cut valve (6), the pressure at the cylinder rod side is higher than the pressure at the cylinder bottom side.

4. Pressure oil from the cylinder rod side pushes to open the check valve in arm 1 spool (9) and flows to the cylinder bottom side.

5. The regeneration is done like this and the cylinder speed increases.

T2-4-24

3. The pressure at the arm cylinder (2) rod side decreases and the digging force is improved.

SECTION 2 SYSTEM Group 4 Hydraulic System

fNOTE: The figure shows for the backhoe.

9

1

2

6 8 5

4

3

7 TKAA90-02-04-007

123-

Arm 2 Spool Arm Cylinder Pump 2

456-

Pump 1 Pump 3 Arm Regeneration Cut Valve

789-

T2-4-25

Arm 3 Spool Hydraulic Oil Tank Arm 1 Spool

SECTION 2 SYSTEM Group 4 Hydraulic System Bucket Regenerative Cut Circuit Purpose: When the load is high at bucket roll-in operation, the bucket regenerative cut circuit flows back pressure oil at the bucket cylinder (8) rod side to hydraulic oil tank (7) without regeneration for the bottom side. Therefore, the pressure at the bucket cylinder (8) rod side decreases and the digging force is improved.  Regeneration (Pump 1 (4) delivery pressure: Low) 1. Pressure oil from pump 1 (4) acts on the bucket regeneration cut valve (1).

2. When the load is light at bucket roll-in operation, the bucket regeneration cut valve (1) is not shifted.

 Regeneration Cut (Pump 1 (4) delivery pressure: High) 1. When the load becomes heavy at bucket roll-in operation, the bucket regeneration cut valve (1) is shifted by pressure oil from pump 1 (4).

3. As returning oil from the cylinder rod side is restricted by the bucket regeneration cut valve (1), the pressure at the cylinder rod side is higher than the pressure at the cylinder bottom side.

4. Pressure oil from the cylinder rod side pushes to open the check valve in bucket 1 spool (2) and flows to the cylinder bottom side.

5. The regeneration is done like this and the cylinder speed increases.

T2-4-26

2. Returning oil from the cylinder rod side flows to hydraulic oil tank (7) through bucket 1 spool (2) and the bucket regeneration cut valve (1).

3. The pressure at the bucket cylinder (8) rod side decreases and the digging force is improved.

SECTION 2 SYSTEM Group 4 Hydraulic System

fNOTE: The figure shows for the backhoe.

1 2

9

8

7 5

4

3

6

TKAA90-02-04-008

123-

Bucket Regeneration Cut Valve Bucket 1 Spool Pump 2

456-

Pump 1 Pump 3 Bucket 3 Spool

789-

T2-4-27

Hydraulic Oil Tank Bucket Cylinder Bucket 2 Spool

SECTION 2 SYSTEM Group 4 Hydraulic System Boom Lower Meter-In Cut Control Purpose: When performing the boom lower operation with the front attachment above the ground, the boom lower meter-in cut control restricts pressure oil which flows to boom cylinder (6) from the pump. The boom falls due to the own weight by the boom regenerative circuit and pressure oil from the pump is used for other actuators.

Therefore, other actuators are preferentially operated. The meter-in cut control is deactivated with the track raised off the ground. Therefore, the boom is given priority to operate and the force to raise the track increases.

fNOTE: As an example, the combined operation of

boom lower and arm roll-out (BH) is explained here.

 Boom cylinder (6) bottom pressure: High (with the front attachment above the ground) 1. When performing combined operation of boom lower and arm roll-out, the arm roll-out pilot pressure shifts arm 1 spool (16), arm 2 spool (9), arm 3 spool (14), boom 1 spool (8), boom 2 spool (17), and boom 3 spool (13).

2. When boom lower operation is done, the boom lower meter-in cut valve (4) is shifted by the boom cylinder (6) bottom pressure.

3. Boom lower pilot pressure (5) shifts the boom flow rate control valve (selector valve) (2) through the boom lower meter-in cut valve (4).

4. Pressure oil from pump 1 (11) acts on the boom flow rate control valve (poppet valve) (1) through parallel circuit (3) and the boom flow rate control valve (selector valve) (2).

5. As the back pressure of the boom flow rate control valve (poppet valve) (1) increases and the boom flow rate control valve (poppet valve) (1) is closed, pressure oil which flows from pump 1 (11) to boom 1 spool (8) is restricted by poppet valve (1).

6. Pressure oil in the boom cylinder (6) bottom side flows to the boom cylinder (6) rod side through boom 2 spool (17) due to boom own weight.

7. As pressure oil from pump 1 (11), pump 2 (10), and pump 3 (12) is used for the arm preferentially, arm roll-out speed increases.

T2-4-28

SECTION 2 SYSTEM Group 4 Hydraulic System

fNOTE: The figure shows for the backhoe. fNOTE: The illustration shows during combined operation of boom lower and arm roll-out.

1

2

3

4

17

5

6

7

8

16

9

13 15 12

11

10

14

15 TKAA90-02-04-009

123-

Boom Flow Rate Control Valve (Poppet Valve) Boom Flow Rate Control Valve (Selector Valve) Parallel Circuit (Pump 1)

4567-

Boom Lower Meter-In Cut Valve Boom Lower Pilot Pressure Boom Cylinder Arm Cylinder

89101112-

T2-4-29

Boom 1 Spool Arm 2 Spool Pump 2 Pump 1 Pump 3

1314151617-

Boom 3 Spool Arm 3 Spool Hydraulic Oil Tank Arm 1 Spool Boom 2 Spool

SECTION 2 SYSTEM Group 4 Hydraulic System  Boom cylinder (3) bottom pressure: Low (with the track raised off the ground) 1. When the boom lower operation is done with the bucket set on the ground, the boom cylinder (3) bottom pressure becomes low and the boom lower meter-in cut valve (2) is not shifted.

2. MC1 activates the 4-spool solenoid valve unit (SG) according to the boom cylinder (3) bottom pressure. (Refer to SYSTEM/Control System.)

3. Pressure oil from the pilot pump flows through the 4-spool solenoid valve unit (SG) and shifts the bypass shut-out valve (4-spool side) (9).

4. When the bypass shut-out valve (4-spool side) (9) is shifted, neutral circuit (1) of pump 1 (8) is blocked.

5. As the boom lower pilot pressure does not act on the boom flow rate control valve (selector valve) (4), the boom flow rate control valve (poppet valve) (5) is opened.

6. Pressure oil from pump 1 (8) flows to boom 1 spool (6).

7. Pressure oil in the boom cylinder (3) bottom side flows through boom 2 spool (12), is combined with pressure oil from boom 1 spool (6), and flows to the boom cylinder (3) rod side.

T2-4-30

SECTION 2 SYSTEM Group 4 Hydraulic System

fNOTE: The figure shows for the backhoe.

1 2 12 3 4 5

6

7

9

11 10

8

11 TKAA90-02-04-010

1234-

Neutral Circuit (Pump 1) Boom Lower Meter-In Cut Valve Boom Cylinder Boom Flow Rate Control Valve (Selector Valve)

5678-

Boom Flow Rate Control Valve (Poppet Valve) Boom 1 Spool Pilot Pressure from 4-Spool Solenoid Valve Unit (SG) Pump 1

9-

Bypass Shut-Out Valve (4-Spool Side) 10- Boom 3 Spool 11- Hydraulic Oil Tank 12- Boom 2 Spool

T2-4-31

SECTION 2 SYSTEM Group 4 Hydraulic System Transmission Oil Cooling Circuit 1. The transmission oil circulation pump (3) draws transmission oil from pump transmission (1) and supplies it to pump transmission oil cooler (6).

2. Transmission oil cooled by the pump transmission oil cooler (6) flows back to pump transmission (1).

3. When oil temperature is low (high viscosity) and oil flow resistance increases in the pump transmission oil cooler (6), check valve (4) is opened and transmission oil directly returns to pump transmission (1).

4. Therefore, transmission oil is prevented transmission oil temperature from rising, foreign matter is removed by the pump transmission oil filter (5), and the parts of pump transmission (1) are lubricated.

1

2

6

5

4

12-

Pump Transmission Manifold

3-

3

Transmission Oil Circulation Pump

45-

T2-4-32

Check Valve Pump Transmission Oil Filter

TKAB-02-04-020

6-

Pump Transmission Oil Cooler

SECTION 2 SYSTEM Group 4 Hydraulic System Fan Motor Circuit 1. Pressure oil from fan pump (6) flows to the oil cooler fan motor (1) and radiator fan motor (2) through ports M1 of the oil cooler fan valve (9) and radiator fan valve (4).

2. Hydraulic oil turns the oil cooler fan motor (1) and radiator fan motor (2), is combined with pressure oil returning from the main control, and returns to hydraulic oil tank (7).

M2

M1

1

M2

M1

2

3 4

9

12-

Oil Cooler Fan Motor Radiator Fan Motor

8

34-

7

Radiator Fan Reverse Rotation Spool Radiator Fan Valve

567-

T2-4-33

6

Pilot Pump Fan Pump Hydraulic Oil Tank

TKAB-02-04-017

5

89-

Oil Cooler Fan Reverse Rotation Spool Oil Cooler Fan Valve

SECTION 2 SYSTEM Group 4 Hydraulic System Fan Reverse Rotation Control Circuit Purpose: The fan reverse rotation control circuit turns the radiator fan and oil cooler fan in reverse, removes dirt and dust on the radiator and oil cooler, and recovers the cooling performance.

1. MC1 activates the radiator fan reverse rotation control solenoid valve (9) and oil cooler fan reverse rotation control solenoid valve (4) according to the signal from the fan reverse rotation switch. (Refer to SYSTEM/Control System.)

2. Pressure oil from pilot pump (6) flows through the radiator fan reverse rotation control solenoid valve (9) and oil cooler fan reverse rotation control solenoid valve (4), and shifts the radiator fan reverse rotation spool (10) and oil cooler fan reverse rotation spool (3).

3. Pressure oil from fan pump (7) flows to radiator fan motor (1) and the oil cooler fan motor (2) through ports M2 of radiator fan valve (11) and the oil cooler fan valve (5). Then, radiator fan motor (1) and the oil cooler fan motor (2) turn in reverse.

T2-4-34

SECTION 2 SYSTEM Group 4 Hydraulic System

M2

1

M1

M2

2

M1

11

3 4

5

10

9 8 7

123-

Radiator Fan Motor Oil Cooler Fan Motor Oil Cooler Fan Reverse Rotation Spool

4-

56-

Oil Cooler Fan Reverse Rotation Control Solenoid Valve Oil Cooler Fan Valve Pilot Pump

789-

T2-4-35

6

Fan Pump Hydraulic Oil Tank Radiator Fan Reverse Rotation Control Solenoid Valve

TKAB-02-04-015

10- Radiator Fan Reverse Rotation Spool 11- Radiator Fan Valve

SECTION 2 SYSTEM Group 4 Hydraulic System (Blank)

T2-4-36

SECTION 2 SYSTEM Group 5 Electrical System Outline The electrical circuit is broadly divided into the main circuit, monitor circuit, accessory circuit, and control circuit.  The main circuit consists of the engine and the accessory related circuits.  The monitor circuit displays the machine operating conditions. The monitor circuit consists of the monitor controller, monitor, relays, and switches.  The accessory circuit controls the various lights, the wiper, the washer, and the sliding fold-in ladder alarm. The accessory circuit consists of MC2, the relays, and switches.  The control circuit controls the engine, pump, and valve. The control circuit consists of the actuators such as solenoid valves, MC1, ECM, sensors, and switches.

(Refer to SYSTEM/Control System.)

T2-5-1

SECTION 2 SYSTEM Group 5 Electrical System Main Circuit The major functions and circuits in the main circuit are as follows.  The electric power circuit supplies all electric power to all electrical systems on the machine. {Key Switch, Battery, Fuses (Fuse Box, Slow Blow Fuse)}  The CAN circuit performs communication between each controller.  The starting circuit starts the engine.

(Key Switch, Starter 1, Starter 2, Engine Protection Relay 1, Engine Protection Relay 2)  The charging circuit supplies electric power to the batteries and charges them. {Alternator, (Regulator)}  The pilot shut-off circuit controls the pilot shut-off solenoid valve according to the pilot shut-off lever position. The pilot shut-off solenoid valve controls the pilot pressure oil that flows from the pilot pump to the pilot valve.

(Pilot Shut-Off Solenoid Valve, Pilot Shut-Off Lever)  The auto shut-down circuit automatically stops the engine when the specified conditions exist.

(MC1, Auto Shut-Down Relay, ACC Cut Relay, Key Switch ON Cut Relay)  The engine stop circuit (key switch: OFF) stops the engine by using ECM. (ECM)  The surge voltage prevention circuit prevents the occurrence of serge voltage developed when stopping the engine.

(Load Dump Relay)

T2-5-2

SECTION 2 SYSTEM Group 5 Electrical System (Blank)

T2-5-3

SECTION 2 SYSTEM Group 5 Electrical System Electric Power Circuit (Key Switch: OFF) The battery (1) negative terminal is grounded to the body. The circuit from the battery (1) positive terminal is connected as shown below when key switch (8) is in the OFF position.

Battery (1)

Slow Blow Fuse 1 (5)

Fuse 1 (25)

Key Switch (8) Terminal B Load Dump Relay (6) Fuse Box 2 (23) Terminal Horn Relay (Power) (22) #24 Terminal MC1 (Power) (21) #26 Terminal Step Light Relay (Power) (20) #29 Terminal MC2 (Power) (19) #30 Terminal DLU (Power) (18) #31 Terminal Monitor Controller (Backup Power) (11) #35 GSM (Power) (12) Switch Panel (13) Cab Light (14) Security Horn (Power) (15) Security Horn Relay (Power) (16) Radio (Backup Power) (17) Terminal ACC ON Relay 2 (Power) (10) #39 Terminal ACC ON Relay 1 (Power) (9) #40 Fuse Box 3 (7) (Option) ECM (Power) (4)

T2-5-4

SECTION 2 SYSTEM Group 5 Electrical System

7 8

4

5 9 6

1

10

25 23

31 35 39 40

24

22

11 12 13 14 15 16 17

21

18

26 29 30

20 19 TKAA90-02-05-001

1456789-

Battery ECM (Power) Slow Blow Fuse 1 Load Dump Relay Fuse Box 3 (OP) Key Switch ACC ON Relay 1 (Power)

10- ACC ON Relay 2 (Power) 11- Monitor Controller (Backup Power) 12- GSM (Power) 13- Switch Panel 14- Cab Light 15- Security Horn (Power)

16171819202122-

T2-5-5

Security Horn Relay (Power) Radio (Backup Power) DLU (Power) MC2 (Power) Step Light Relay (Power) MC1 (Power) Horn Relay (Power)

23- Fuse Box 2 25- Fuse 1

SECTION 2 SYSTEM Group 5 Electrical System Electric Power Circuit (Key Switch: ACC) 1. When key switch (3) is set to the ACC position, terminal B is connected to terminal ACC (4) in key switch (3).

2. The circuits from the battery (1) positive terminal and terminal ACC (4) in key switch (3) are connected as shown below and makes each accessory operation possible.

Battery (1)

Slow Blow Fuse 1 (2)

Fuse Box 2 (6)

Terminal #39 Terminal #40 Terminal #23 Terminal #36

Key Switch ACC Cut Relay (5) Terminal ACC (4) ACC ON Relay 1 (10) ACC ON Relay 2 (9)

fNOTE: When key switch (3) is set to the ON position, the operation of the lights, the wiper, the washer, and the sliding fold-in ladder alarm becomes possible.

T2-5-6

ACC ON Relay 2 (9) Option (8) ACC ON Relay 1 (10) Cigar Lighter (7) Radio (12) Monitor Controller (Power) (11)

SECTION 2 SYSTEM Group 5 Electrical System 4 3 5

6

2

7

8

23

1

36 39 40

12

10

9

11

TKAA90-02-05-002

123-

Battery Slow Blow Fuse 1 Key Switch

456-

Terminal ACC ACC Cut Relay Fuse Box 2

789-

T2-5-7

Cigar Lighter Option ACC ON Relay 2

10- ACC ON Relay 1 11- Monitor Controller (Power) 12- Radio

SECTION 2 SYSTEM Group 5 Electrical System Electric Power Circuit (Key Switch: ON) 1. When key switch (5) is in the ON position (or the engine is running), terminal B is connected to terminals ACC (6) and M (7) in key switch (5).

fNOTE: The alternator supplies power when the engine is running.

2. The circuit from the battery (1) positive terminal and terminal M (7) in key switch (5) are connected as shown below.

Battery (1)

Battery Relay (11)

Slow Blow Fuse 3 (2)

Fuse Box 1 (4)

Slow Blow Fuse 2 (16)

Fuse Box 2 (9) Key Switch Terminal M (7) Slow Blow Key Switch Terminal M (7) Fuse 1 (3)

Fuse Box 2 (9) Key Switch ON Cut Relay (8)

T2-5-8

Fuse Box 2 (9)

#1 #2 #3 #4 #5 #6 #7 #8 #9 #10 #11 #14 #15 #16 #17 #18 #19 #20 #37 #38 #21 #25 #27 #28 #32 #34

Refer to T2-510.

Refer to T2-512.

SECTION 2 SYSTEM Group 5 Electrical System

6

7

5

8

4 2

3 9

1 16

A

11

B

10 TKAA90-02-05-003

A-

Refer to T2-5-11.

B-

Refer to T2-5-13.

123-

Battery Slow Blow Fuse 3 Slow Blow Fuse 1

456-

Fuse Box 1 Key Switch Terminal ACC

789-

T2-5-9

Terminal M Key Switch ON Cut Relay Fuse Box 2

10- Battery Relay 2 11- Battery Relay 1 16- Slow Blow Fuse 2

SECTION 2 SYSTEM Group 5 Electrical System Fuse Box 1 (1)

#1

#2 #3 #4 #5

Pilot Shut-Off Relay (Power) Pilot Shut-Off Solenoid Valve Sliding Fold-In Ladder Relay (Power) Security Relay (Power) Alternator Signal Relay MC1 (Solenoid Valve Power) 12V Power Unit Air Conditioner Unit Work Light Relay 3 Auto-Lubrication Relay 1

#6

Auto-Lubrication Relay 2 Work Light Relay 2

#7

Work Light Relay 1

#8 #9

Back Light Relay Washer Relay Wiper Relay High 1 Wiper Relay Low (Power) Fuel Level Switch Pump Transmission Oil Level Switch Seat Heater (Option) Seat Compressor (Option) Travel Alarm Device (Fender Side) (Option) Travel Alarm Device (Rear Side) (Option) Beacon Light (Option)

#16 #17 #18 #19 #20

T2-5-10

Work Light (Cab Upper) Auto-Lubrication Relay 2 (Power) Proximity Switch Grease Pump Work Light Relay 3 (Power) Boom Light Back Light Relay (Power) Work Light (Right) Work Light (Left) Rear Light Washer Motor

SECTION 2 SYSTEM Group 5 Electrical System

A

B

C

1

TKAB-02-05-004

A-

Refer to T2-5-9.

1-

Fuse Box 1

B-

From Slow Blow Fuse 3

C-

T2-5-11

From Slow Blow Fuse 2

SECTION 2 SYSTEM Group 5 Electrical System Fuse Box 2 (2)

#37 #38 #21

#25

#27 #28 #32

#34

Auxiliary 3 (Option) Auxiliary 1 (Option) Starter Cut Relay (Power) Auto Shut-Down Relay (Power) ACC Cut Relay (Power) Key Switch ON Cut Relay (Power) Buzzer Air Conditioner Unit GSM MC1 Engine Stop Switch 1 Battery Relay 1 Battery Relay 2 Load Dump Relay Monitor Controller Alternator (Terminal L) DLU MC2

T2-5-12

SECTION 2 SYSTEM Group 5 Electrical System

A

B

C

D

1

TKAA90-02-05-005

A-

Refer to T2-5-9.

1-

Fuse Box 2

B-

From Key Switch Terminal M

C-

T2-5-13

From Key Switch ON Cut Relay

D-

From Slow Blow Fuse 2

SECTION 2 SYSTEM Group 5 Electrical System CAN Circuit CAN (Controller Area Network) is ISO Standards of the serial communication protocol.

Four networks (CAN bus (3)) in the following are equipped for this machine.  Power CAN (4) is mainly used for the engine control.  Body CAN (5) is mainly used for the accessory control.  Monitoring CAN (7) is mainly used for display and log data communication.  DLU-CAN (8) is used for communication between DLU (17) and WIU (15) (option).

CAN bus (3) consists of two wire harnesses, CAN-H (High) (1) and CAN-L (Low) (2).

Each controller judges the CAN bus (3) level due to the potential difference between CAN-H (High) (1) and CAN-L (Low) (2).

Each controller arranges the CAN bus (3) level and sends the signal and data to other controllers.

Termination resistors (120 Ω) (14) are installed to both ends of CAN bus (3).

1

3

2 TKEB-02-05-017

12-

CAN-H (High) CAN-L (Low)

3-

CAN Bus

9.MPDr. 14

10

4.Power CAN

14

22.ECM

12 11

5.Body CAN 13

21.MC1 14 14

8.DLU-CAN

14

15.WIU 20.MC2

19

17.DLU

18

16.CSU 7.Monitoring CAN

45789-

Power CAN Body CAN Monitoring CAN DLU CAN MPDr.

1011121314-

Monitor Controller Monitor Monitor Control Unit Information Control Unit Termination Resistor (120 Ω)

1516171819-

T2-5-14

WIU (OP) CSU (OP) DLU Radio Controller Air Conditioner Controller

20- MC2 21- MC1 22- ECM

TKAA90-02-01-001

SECTION 2 SYSTEM Group 5 Electrical System (Blank)

T2-5-15

SECTION 2 SYSTEM Group 5 Electrical System Starting Circuit (Key Switch: START) 1. When key switch (6) is set to START position (5), terminal B is connected to terminals M (7) and ST (8) in key switch (6).

2. Current from terminal M (7) flows through the key switch ON cut relay (9) and fuse #32 and excites battery relay 1 (2) and battery relay 2 (3). Current from batteries (1) flows to terminals B in starter 1 (17) and starter 2 (16).

3. Current from terminal ST (8) flows to terminals C in starter 1 (17) and starter 2 (16) through starter cut relay (4), Engine Protection relay 1 (18), and Engine Protection relay 2 (19).

4. The coils of starter 1 (17) and starter 2 (16) are excited and the main contactor is attracted. For starter 1 (17) and starter 2 (16), terminals B are connected to terminals M. At the same time, the pinion gears are projected and meshed with the ring gear of the engine.

5. As terminals B are connected to terminals M of starter 1 (17) and starter 2 (16), current from battery relay 1 (2) and battery relay 2 (3) flows to each starter motor through terminals B of starter 1 (17) and starter 2 (16). Then, each starter motor turns.

6. And, current from terminal M (7) in key switch (6) flows to fuses #25, #27, #28, and #34 through the key switch ON cut relay (9).

7. Current from fuses #25, #27, #28, and #34 flows to GSM (13), MC1 (14), ECM (15), Monitor Controller (10), MC2 (11), DLU (12), and Alternator (20) as a signal indicating that key switch (6) is in the START position (5).

T2-5-16

SECTION 2 SYSTEM Group 5 Electrical System

7 8 6 9 5

2

3

4

1

25

20

M

B

M C

14.MC1

B

34 32 28

27

13.GSM

10

C

18 19 17

16 12.DLU

15.ECM

11.MC2 TKAA90-02-05-006

12345-

Battery Battery Relay 1 Battery Relay 2 Starter Cut Relay START Position

678910-

Key Switch Terminal M Terminal ST Key Switch ON Cut Relay Monitor Controller

1112131415-

T2-5-17

MC2 DLU GSM MC1 ECM

1617181920-

Starter 2 Starter 1 Engine Protection Relay 1 Engine Protection Relay 2 Alternator

SECTION 2 SYSTEM Group 5 Electrical System Charging Circuit (Key Switch: ON) 1. After the engine starts and key switch (4) is released, key switch (4) is returned to ON position (3).

2. Terminal B is connected to terminals ACC (5) and M (6) in key switch (4) with key switch (4) set in the ON position (3).

3. While current flows to terminal L in alternator (8), alternator (8) starts generating electricity with the engine running. Current from terminal B in alternator (8) flows to batteries (1) through battery relay 1 (2) and charges batteries (1).

4. Current from terminal AC in alternator (8) excites alternator relay (10).

5. Current from terminal B in alternator (8) flows through battery relay 1 (2), slow blow fuse 3 (9), and fuse #1, excites alternator signal relay (11), and flows to monitor controller (7).

6. Monitor controller (7) detects the alternator (8) generating electricity by the current from alternator (8) and deletes the alternator alarm on the monitor.

T2-5-18

SECTION 2 SYSTEM Group 5 Electrical System

5 6 4 3 10 2 9 11

1 AC

L

8 B

7

TKAA90-02-05-007

123-

Battery Battery Relay 1 ON Position

456-

Key Switch Terminal ACC Terminal M

789-

T2-5-19

Monitor Controller Alternator Slow Blow Fuse 3

10- Alternator Relay 11- Alternator Signal Relay

SECTION 2 SYSTEM Group 5 Electrical System Pilot Shut-Off Circuit (Key Switch: ON) 1. When the pilot shut-off lever is set to the UNLOCK position, pilot shut-off switch (13) is turned ON. 2. Current from fuse #1 flows to the ground through pilot shut-off relay (3) and pilot shut-off switch (13) and pilot shut-off relay (3) is excited.

3. When pilot shut-off relay (3) is excited, the ground circuit in the pilot shut-off solenoid valve (4) is connected to the ground through pilot shut-off relay (3), the sliding fold-in ladder relay (5), and security relay (6).

4. Therefore, the pilot shut-off solenoid valve (4) is turned ON and pressure oil from the pilot pump is supplied to the pilot valve.

fNOTE: When the pilot shut-off lever is set to the

UNLOCK position, terminal #B10 in monitor controller (11) is connected to the ground. Therefore, monitor controller (11) recognizes that the pilot shut-off lever is in the UNLOCK position and displays the image of the rear view camera on the monitor.

 Neutral Engine Start Circuit 1. When the pilot shut-off lever is set to the UNLOCK position, the coil of starter cut relay (7) is connected to the ground.

2. Therefore, starter cut relay (7) is excited.

3. Starter cut relay (7) disconnects, the circuits between terminal ST (9) in key switch (8) and terminals C of starter 1 (15) and starter 2 (14).

4. Therefore, when the pilot shut-off lever is in the UNLOCK position, even if key switch (8) is set to the START position, the starter does not rotate and the engine does not start.

fNOTE: When the pilot shut-off lever is set to the

UNLOCK position, terminal #F13 of MC1 (12) is connected to the ground. Therefore, MC1 (12) recognizes that the pilot shut-off lever is in the UNLOCK position.

T2-5-20

SECTION 2 SYSTEM Group 5 Electrical System

9 8

3

4

5

6 7

1

2

C

F13

C

15

2345-

B10 12.MC1

13

11

TKAA90-02-05-008

14

Battery Pilot Shut-Off Relay Pilot Shut-Off Solenoid Valve Sliding Fold-In Ladder Relay

10

21

6789-

Security Relay Starter Cut Relay Key Switch Terminal ST

10- Fuse Box 2 11- Monitor Controller 12- MC1

T2-5-21

13- Pilot Shut-Off Switch (Pilot Shut-Off Lever) 14- Starter 2 15- Starter 1

SECTION 2 SYSTEM Group 5 Electrical System Auto Shut-Down Circuit

fNOTE: When restarting the engine, return the key

switch to the OFF or ACC position and then reset it to the START position.

1. Current from terminal M (6) excites battery relay 1 (2) and battery relay 2 (3) through the key switch ON cut relay (9) with key switch (5) set in the ON position.

2. The circuits from terminal M (6) are connected to the coils of auto shut-down relay (7), ACC cut relay (8), the key switch ON cut relay (9), and starter cut relay (4) through fuse #21.

3. When all following conditions exist, MC1 (11) connects terminal #C5 to the ground inside. (Refer to SYSTEM/Control System.)

Condition for Auto Shut-Down:  Pilot shut-off lever: LOCK position  Auto shut-down switch: ON  Overheat alarm: OFF  Coolant temperature: 60 to 100 °C  Abnormal communication of ECM and monitor controller: Void 4. Therefore, auto shut-down relay (7) is turned ON. ACC cut relay (8) and the key switch ON cut relay (9) are also turned ON at the same time.

5. The current which indicates key switch (5) is in the ON position, stops flowing from fuse #28 to the 31 pin connector terminal 1 of ECM (12).

6. At the same time, battery relay 1 (2) and battery relay 2 (3) are turned OFF. 7. Therefore, this is the same situation when key switch (5) is set to the OFF position. ECM (12) stops the fuel injection of the injector and stops the engine.

T2-5-22

SECTION 2 SYSTEM Group 5 Electrical System 6 5 7

3

8

9

4

2

21

1

28 32 10

C5 12.ECM

EC311 a

11.MC1

TKAA90-02-05-009

a-

31 pin Connector Terminal 1

1234-

Battery Battery Relay 1 Battery Relay 2 Starter Cut Relay

5678-

Key Switch Terminal M Auto Shut-Down Relay ACC Cut Relay

9101112-

T2-5-23

Key Switch ON Cut Relay Fuse Box 2 MC1 ECM

SECTION 2 SYSTEM Group 5 Electrical System Engine Stop Circuit

7

5

1. When key switch (1) is set from the ON position to OFF position, current from terminal M (3) in key switch (1) stops flowing to the 31 pin connector terminal 1 (a) of ECM (8).

2. ECM (8) stops the fuel injection of the injector and stops the engine.

3. When the engine stops, ECM (8) is turned OFF. Engine Stopping by using Engine Stop Switches 1 and 2 When safety for the persons during inspection must be secured or when the engine does not stop due to some troubles that the machine is failed or damaged with key switch (1) set in the OFF position, push engine stop switch 1 (5) or engine stop switch 2 (6). Engine stop indicator (7) is turned on and the engine stops.

After that, turn engine stop switch 1 (5) or engine stop switch 2 (6) clockwise and return it to the original position. Check that engine stop indicator (7) is turned off.

TKAB-02-05-010

6

1. If the engine does not stop after key switch (1) is set to the OFF position, terminal B (2) continues to be connected to terminal M (3) in key switch (1).

2. At this time, push engine stop switch 1 (5) or engine stop switch 2 (6). Then, the circuit between fuse #28 and the 31 pin connector terminal 1 (a) is disconnected.

TKAB-02-05-011

3. ECM (8) stops the fuel injection of the injector and stops the engine.

fNOTE: Even if the starter rotates with engine stop

switch 1 (5) or engine stop switch 2 (6) set in the ON position, the engine does not start.

Do not use engine stop switch 1 (5) dCAUTION: and engine stop switch 2 (6) unless absolutely necessary. When the machine stops due to the machine failure, do not start the machine until the repair is completed.

T2-5-24

SECTION 2 SYSTEM Group 5 Electrical System

2 3 1

4 28

7 5

8.ECM

EC311 a

6

TKAA90-02-05-012 a-

31 pin Connector Terminal 1

12-

Key Switch Terminal B

34-

Terminal M Fuse Box 2

56-

T2-5-25

Engine Stop Switch 1 Engine Stop Switch 2

78-

Engine Stop Indicator ECM

SECTION 2 SYSTEM Group 5 Electrical System Surge Voltage Prevention Circuit 1. When the engine is stopped (key switch (5): OFF), current from terminal M in key switch (5) disappears and battery relay 1 (2) and battery relay 2 (3) are turned OFF. 2. The engine continues to rotate due to the inertia force just after key switch (5) is turned OFF and alternator (7) continues to generate electricity.

3. As the generating current cannot flow to battery (1), surge voltage arises in the circuit and failures of the electronic components, such as controller, possibly cause. In order to prevent the occurrence of surge voltage, the surge voltage prevention circuit is provided.

4. When alternator (7) is generating electricity, the generating current from terminal AC in alternator (7) excites alternator relay (8). Current from terminal B in alternator (7) excites alternator signal relay (9) and flows to terminal #A15 in monitor controller (6).

Monitor controller (6) connects terminal #D8 to the ground.

5. Therefore, current flows to the exciting circuit in load dump relay (4) and load dump relay (4) is turned ON. 6. Consequently, even if key switch (5) is set to the OFF position with the engine running, current from battery (1) continues to excite battery relay 1 (2) and battery relay 2 (3) through load dump relay (4).

7. In addition, when a specified time has passed since alternator (7) stops generating electricity, monitor controller (6) disconnects terminal #D8 from the ground. Therefore, battery relay 1 (2) and battery relay 2 (3) are turned OFF.

T2-5-26

SECTION 2 SYSTEM Group 5 Electrical System

5

8 4

3 2 9

1 AC 7 B D8

A15 6

TKAA90-02-05-013

123-

Battery Battery Relay 1 Battery Relay 2

456-

Load Dump Relay Key Switch Monitor Controller

789-

T2-5-27

Alternator Alternator Relay Alternator Signal Relay

SECTION 2 SYSTEM Group 5 Electrical System (Blank)

T2-5-28

SECTION 2 SYSTEM Group 5 Electrical System Monitor Circuit The major functions and components in the monitor circuit are as follows.  The security circuit disconnects current for engine starting from the key switch according to the signals from the external alarm system or monitor controller.

At the same time, the security circuit turns OFF the pilot shut-off solenoid valve and disconnects the pilot circuit. The security circuit sounds the security horn at this time.

(Monitor Controller, Security Relay, Security Horn Relay)  The radio circuit operates the radio.

(Monitor Controller, Switch Panel, Radio)  The air conditioner circuit operates the air conditioner.

(Monitor Controller, Switch Panel, Air Conditioner Unit)

T2-5-29

SECTION 2 SYSTEM Group 5 Electrical System Security Circuit 1. When any one of the following condition exists, monitor controller (11) connects terminals #D15 and #D16 to the ground inside.  External alarm signal from e-Service: Exist  Numerical keypad password input error signal: Exist 2. Therefore, security horn relay (10), security relay (3), and starter cut relay (4) are excited.

3. When security horn relay (10) is excited, current from fuse #35 activates security horn (9).

4. When security relay (3) is excited, the ground circuit in the pilot shut-off solenoid valve (2) is disconnected and the pilot shut-off solenoid valve (2) is turned OFF. 5. Therefore, pressure oil which flows to the pilot valve from the pilot pump is blocked by the pilot shut-off solenoid valve (2).

6. When starter cut relay (4) is excited, the circuits between terminal ST (7) in key switch (6) and terminals C of starter 1 (13) and starter 2 (12) are disconnected.

7. Therefore, even if key switch (4) is set to the START position, the engine does not start.

T2-5-30

SECTION 2 SYSTEM Group 5 Electrical System

7 6

2

3

4

5

8

1

21 32

C

35

C 9 10

13

12

D16

D15 11

TKAA90-02-05-014

234-

Pilot Shut-Off Solenoid Valve Security Relay Starter Cut Relay

567-

Fuse Box 1 Key Switch Terminal ST

8- Fuse Box 2 9- Security Horn 10- Security Horn Relay

T2-5-31

11- Monitor Controller 12- Starter 2 13- Starter 1

SECTION 2 SYSTEM Group 5 Electrical System Radio Circuit 1. The operation on switch panel (2) is displayed on monitor (1) through monitor controller (4).

2. When radio (6) is operated on switch panel (2), the signal is sent to monitor controller (4).

3. Monitor controller (4) sends the signal to radio (6) by using the CAN communication and radio (6) is operated.

Air Conditioner Circuit 1. The operation on switch panel (2) is displayed on monitor (1) through monitor controller (4).

2. When the air conditioner is operated on switch panel (2), the signal is sent to monitor controller (4).

3. Monitor controller (4) sends the signal to air conditioner unit (7) by using the CAN communication and the air conditioner is operated.

T2-5-32

SECTION 2 SYSTEM Group 5 Electrical System

1

2

8

3

25 35 36

5

21

4

23

7

124-

Monitor Switch Panel Monitor Controller

6

567-

Fuse Box 2 Radio Air Conditioner Unit

8-

T2-5-33

Fuse Box 1

TKAA90-02-05-015

SECTION 2 SYSTEM Group 5 Electrical System (Blank)

T2-5-34

SECTION 2 SYSTEM Group 5 Electrical System Accessory Circuit The major functions and components in the accessory circuit are as follows.  The work light circuit turns on the work lights (left, right, cab upper), rear light, and boom light.

(MC2, Switch Panel, Work Light Relay 1, Work Light Relay 2, Work Light Relay 3, Back Light Relay)  The step light circuit turns on the step light.

Serial No. 7002 to 7043 (MC2, Key Switch, Step Light Switch, Step Light Relay) Serial No. 7045 and up (Step Light Switch, Step Light Relay)  The wiper/washer circuit operates the wiper including intermittent operation and the washer.

(MC2, Switch Panel, Wiper Relay Low, Wiper Relay High 1, Wiper Relay High 2, Washer Relay)  The cab light circuit turns on/off the cab light by shifting the switch or by opening/closing the door.

(Cab Light Switch, Door Open/Close Switch)  The sliding fold-in ladder alarm circuit disables the machine operation while lowering the sliding foldin ladder. When the pilot shut-off lever is in the UNLOCK position, the buzzer sounds.

(MC2, Sliding Fold-In Ladder Limit Switch, Sliding Fold-In Ladder Relay, Pilot Shut-Off Solenoid Valve, Pilot Shut-Off Lever)

T2-5-35

SECTION 2 SYSTEM Group 5 Electrical System Work Light Circuit Work light (left) (15), work light (right) (16), rear light (9): ON 1. When work light switch (11) is set to the 1 position, current from fuse #7 flows to terminal #B1 of MC2 (14) and switch panel (10), and connects to the ground in switch panel (10).

2. Therefore, work light relay 1 (3) and back light relay (4) are turned ON. Current from fuses #7 and #8 turns on work light (left) (15), work light (right) (16), and rear light (9).

11

TDC1-02-05-013

3. MC2 (14) sends the signal to monitor controller (13) by using the CAN communication.

4. Monitor controller (13) displays operating condition (19) of work light switch (11) on monitor (12).

Work light (left) (15), work light (right) (16), work light (cab upper) (18), rear light (9), boom light (17): ON 1. When work light switch (11) is set to the 2 position, current from fuse #6 flows to terminal #B3 of MC2 (14) and switch panel (10), and connects to the ground in switch panel (10).

12

2. Current from fuse #7 flows to terminals #B1 of MC2 (14) and switch panel (10), and connects to the ground in switch panel (10).

3. Therefore, work light relay 1 (3), work light relay 2 (2), work light relay 3 (1), and back light relay (4) are turned ON. Current from fuses #4, #6, #7, and #8 turns on work light (left) (15), work light (right) (16), work light (cab upper) (18), rear light (9), and boom light (17).

4. MC2 (14) sends the signal to monitor controller (13) by using the CAN communication.

5. Monitor controller (13) displays operating condition (19) of work light switch (11) on monitor (12) and changes the monitor (12) screen into the nighttime mode screen.

fNOTE: When the monitor (12) screen is the nighttime mode screen, push 0 on the numerical keypad switch for a few seconds, and then the monitor (12) screen is changed into the daytime mode screen.

T2-5-36

19

MDAA-01-222

SECTION 2 SYSTEM Group 5 Electrical System 1

2

3

4

5 6 7 8

18

9

17

10 11

16 15

B3

B1 C1 C7

12

14.MC2 13

TKAB-02-05-016

12345-

Work Light Relay 3 Work Light Relay 2 Work Light Relay 1 Back Light Relay From Fuse #4

678910-

From Fuse #6 From Fuse #7 From Fuse #8 Rear Light Switch Panel

1112131415-

T2-5-37

Work Light Switch Monitor Monitor Controller MC2 Work Light (Left)

16- Work Light (Right) 17- Boom Light 18- Work Light (Cab Upper)

SECTION 2 SYSTEM Group 5 Electrical System Step Light Circuit (Serial No. 7002 to 7043) Purpose: The step light circuit turns on/off the step light according to the operation of the key switch and step light switch.

Operation: 1. When all following conditions exist, MC2 (1) connects terminal #B9 to the ground inside.  Key Switch (10): ON  Step Light Switch (9): ON 2. Therefore, step light relay (7) is turned ON. Current from fuse #29 turns on step light (6).

3. After key switch (10) is turned OFF and 60 seconds pass, MC2 (1) disconnect terminal #B9 from the ground. Then, step light (6) is turned off.

fNOTE: When key switch (10) is turned OFF, 15 seconds do not pass, and step light switch (9) is turned ON, step light (6) is turned on for 60 seconds.

T2-5-38

SECTION 2 SYSTEM Group 5 Electrical System

3.MPDr.

5 2 10 4

9 1.MC2

B9

8 7

6 TKAB-02-05-017

123-

MC2 CAN MPDr.

456-

Monitor Controller Monitor Step Light

789-

T2-5-39

Step Light Relay From Fuse #29 Step Light Switch

10- Key Switch

SECTION 2 SYSTEM Group 5 Electrical System Step Light Circuit (Serial No. 7045 and up)

Cab Inside

Purpose: The step light circuit turns on/off the step light according to the operation of step light switch.

4

Operation: 1. When step light switch (4 or 5) is turned ON or OFF, current from fuse # 29 flows to the ground inside and step light relay (2) is excited.

2. Therefore, step light relay (2) is turned ON. Current from fuse #29 turns on step light (3).

TKAB-02-05-010

Sliding Fold-In Ladder Side

5 TKAA90-01-02-010

T2-5-40

SECTION 2 SYSTEM Group 5 Electrical System

#30 #29

4

1.MC2 2

5

3

TKAA90-02-05-022

12-

MC2 Step Light Relay

34-

Step Light Step Light Switch (Cab Inside)

5-

T2-5-41

Step Light Switch (Sliding Fold-In Ladder Side)

SECTION 2 SYSTEM Group 5 Electrical System Wiper/Washer Circuit Wiper Circuit  Wiper/washer switch: INT. position 1. When wiper/washer switch (1) is set to INT. positions (a, b, c), the signal according to the set interval is sent to MC2 (2).

b a

c

2. MC2 (2) connects terminal #B2 to the ground in MC2 (2) according to the input interval.

3. Therefore, wiper relay Low (7) is turned ON and OFF repeatedly.

1

4. When wiper relay Low (7) is ON, current from fuse #9 flows to wiper motor (9) and the wiper is operated.

5. MC2 (2) sends the signal to monitor controller (4) by using the CAN communication.

6. Monitor controller (4) displays operating condition (13) of wiper/washer switch (1) on monitor (5).

TDC1-02-05-014

No. a b c

INT. Position Set Time Slow 8 seconds Middle 6 seconds Fast 3 seconds

 Wiper/washer switch: ON position 1. When wiper/washer switch (1) is set to the ON position, MC2 (2) connects terminal #B12 to the ground in MC2 (2).

2. Therefore, wiper relay High 1 (10) is turned ON.

5

3. Current from fuse #9 flows to wiper motor (9) and the wiper is continuously operated at fast speed.

4. MC2 (2) sends the signal to monitor controller (4) by using the CAN communication.

5. Monitor controller (4) displays operating condition (13) of wiper/washer switch (1) on monitor (5).

13 MDAA-01-222

T2-5-42

SECTION 2 SYSTEM Group 5 Electrical System  Wiper/washer switch: INT. position 1

3

5

4 2.MC2 B2 6 12

7

10 11

8

9

TKAB-02-05-018

 Wiper/washer switch: ON position 1

3

5

4 2.MC2 B12

6

12

7

10 11

8

9

TKAB-02-05-019

123-

Wiper/Washer Switch MC2 CAN

456-

Monitor Controller Monitor From Fuse #9

789-

T2-5-43

Wiper Relay Low Wiper Relay High 2 Wiper Motor

10- Wiper Relay High 1 11- Washer Motor 12- Washer Relay

SECTION 2 SYSTEM Group 5 Electrical System Washer Circuit 1. While pushing wiper/washer switch (1), MC2 (2) receives the signals from wiper/washer switch (1).

2. MC2 (2) connects terminal #B11 to the ground inside and washer relay (12) is excited.

3. Current from fuse #9 flows to washer motor (11) and washer liquid is jetted.

4. When pushing wiper/washer switch (1) for 2 seconds or more, MC2 (2) turns ON washer relay (12) and wiper relay High 1 (10).

1

5. Therefore, the washer and wiper are operated at the same time.

TDC1-02-05-014

T2-5-44

SECTION 2 SYSTEM Group 5 Electrical System 1

3

5

4 2.MC2

B11 6 12

7

10 8 11 9

TKAB-02-05-020

123-

Wiper/Washer Switch MC2 CAN

456-

Monitor Controller Monitor From Fuse #9

789-

T2-5-45

Wiper Relay Low Wiper Relay High 2 Wiper Motor

10- Wiper Relay High 1 11- Washer Motor 12- Washer Relay

SECTION 2 SYSTEM Group 5 Electrical System Cab Light Circuit Cab light switch (4): Door interlocking position (5)

Cab light switch (4): ON position

1. When cab light switch (4) is set to door interlocking position (5), current from fuse #35 flows to door open/close switch (7) through cab light switch (4).

1. When cab light switch (4) is set to ON position (6), current from fuse #35 flows to the ground of cab light switch (4).

2. When the cab door is closed, door open/close switch (7) is turned OFF and cab light switch (4) is disconnected from the ground.

2. Consequently, when cab light switch (4) is in ON position (6), cab light (3) is always turned on.

3. Therefore, cab light (3) is not turned on.

4. When the cab door is opened, door open/close switch (7) is turned ON and cab light switch (4) is connected to the ground.

5. Therefore, cab light (3) is turned on.

T2-5-46

SECTION 2 SYSTEM Group 5 Electrical System

1

2

32

35

3 4

6

5

7

TKAA90-02-05-021

12-

Key Switch Fuse Box 2

34-

Cab Light Cab Light Switch

56-

T2-5-47

Door Interlocking Position ON Position

7-

Door Open/Close Switch

SECTION 2 SYSTEM Group 5 Electrical System Sliding Fold-In Ladder Alarm Circuit Purpose: The sliding fold-in ladder alarm circuit disables the machine operation while lowering the sliding fold-in ladder. When the pilot shut-off lever is in the UNLOCK position, the sliding fold-in ladder alarm circuit sounds the buzzer and displays the sliding fold-in ladder alarm.

Operation: 1. When all following conditions exist, MC2 (1) disconnects terminal #B24 from the ground in MC2 (1).  Key Switch (16): ON  Sliding Fold-In Ladder Limit Switch (15): OFF (While lowering the sliding fold-in ladder) 2. As the sliding fold-in ladder relay (9) is turned OFF and the pilot shut-off solenoid valve (14) is disconnected from the ground, the pilot shut-off solenoid valve (14) is turned OFF. 3. Therefore, pressure oil which is supplied from pilot pump (12) to pilot valve (13) is blocked by the pilot shut-off solenoid valve (14).

4. When all following conditions exist, MC1 (6) and MC2 (1) send the signal to monitor controller (3) by using CAN communication (2).  Key Switch (16): ON  Sliding Fold-In Ladder Limit Switch (15): OFF (While lowering the sliding fold-in ladder)  Pilot Shut-Off Switch (10): ON (Pilot Shut-Off Lever: UNLOCK Position) 5. As long as the signal from MC2 (1) is input, the sliding fold-in ladder alarm is displayed on monitor (5).

6. As long as the signal from MC1 (6) is input, monitor controller (3) connects terminal #D7 to the ground.

7. Monitor controller (3) sounds buzzer (4).

T2-5-48

SECTION 2 SYSTEM Group 5 Electrical System

4 2

5

16 D7 15

3 1.MC2

D16

B24

13

6.MC1

14 F13

7 12

9

11

8

10 TKAB-02-05-023

12345-

MC2 CAN Monitor Controller Buzzer Monitor

678910-

MC1 From Fuse #1 Security Relay Sliding Fold-In Ladder Relay Pilot Shut-Off Switch

11121314-

T2-5-49

Pilot Shut-Off Relay Pilot Pump To Pilot Valve Pilot Shut-Off Solenoid Valve

15- Sliding Fold-In Ladder Limit Switch 16- Key Switch

SECTION 2 SYSTEM Group 5 Electrical System (Blank)

T2-5-50

SECTION 2 SYSTEM Group 6 Air Conditioning System Outline Configuration layout of the air conditioning system is illustrated below.

Either fresh or re-circulated air is induced into the air conditioner unit by operating the fresh/re-circulated air damper servo motor (6).

The induced air flows out of the vents through evaporator (5) or heater core (15) by blower motor (11). Evaporator (5) is a device used to cool the air. Heater core (15) is a device used to warm the air. In the air conditioning system, after the refrigerant is compressed by the compressor, it is sent to evaporator (5) in which the refrigerant expands to cool the air. Heater core (15) warms air by absorbing heat from warmed engine coolant. The temperature is kept at the set temperature by adjusting evaporator (5) and heater core (15).

The vents (operator’s front/rear vent, foot vent, and the front window) can be simultaneously or independently selected by the air vent damper servo motor (1) in accordance with the set-ventilation mode.

The front widow and operator’s front vents are manually selectable. The air conditioning controller controls the air conditioning system. The air conditioner controller controls the damper operation by corresponding to the job site conditions such as atmospheric and cab inside air temperatures, coolant temperature, operator’s set temperature, and the set ventilation mode. In addition, the air conditioning controller displays the air conditioner system operation status on the monitor.

fNOTE: Refer to “AIR CONDITIONER ELECTRICAL CIRCUIT DIAGRAM” attached to the separated Manual, Technical Manual (Troubleshooting). (Publication number: TTKAA90-EN-01_Circuit) 8

7 6. Fresh/Re-circulated Air Damper Servo Motor

1

5. Evaporator

2

9

10

3

4

16

15. Heater Core

14

13

12

11. Blower Motor TDAA-05-07-001

12345-

Air Vent Damper Servo Motor Defroster Vent Rear Vent Front Vent Evaporator

678-

Fresh/Re-circulated Air Damper Servo Motor Re-circulated Air Temperature Sensor Fresh Air Induction Port

9- Re-circulated Air Filter 10- Re-circulated Air Induction Port 11- Blower Motor 12- Power Transistor

T2-6-1

13141516-

Frost Sensor Air Mix Damper Servo Motor Heater Core Foot Vent

SECTION 2 SYSTEM Group 6 Air Conditioning System Component Layout 1

2 3

4 5

6 7

10

8

9

TKAB-02-06-001

11

12

123-

14

13

Solar Radiation Sensor Monitor Temperature Control Switch/ Mode Switch

4567-

27

TKAB-02-06-002

AUTO/OFF Switch/Blower Switch Engine Control Dial Key Switch Monitor Controller

89101112-

T2-6-2

Air Conditioner Unit Fresh Air Filter Air Conditioner Controller Ambient Temperature Sensor High/Low Pressure Switch

TKAB-02-06-003

13- Air Conditioner Condenser 14- Receiver Tank 27- Compressor

SECTION 2 SYSTEM Group 6 Air Conditioning System

19

17

18

16 15

20 21

22

28

23 24 25

TDAA-05-07-028

26

15- Re-circulated Air Filter 16- Compressor Relay 17- Re-circulated Air Temperature Sensor

18- Fresh/Re-circulated Air Damper Servo Motor 19- Frost Sensor 20- Evaporator

21222324-

T2-6-3

Heater Core Air Mix Damper Servo Motor Air Vent Damper Servo Motor Blower Motor Relay

25- Power Transistor 26- Blower Motor 28- Expansion Valve

SECTION 2 SYSTEM Group 6 Air Conditioning System Electrical Circuit Diagram 1. Controller

2. Air Vent Damper Servo Motor 18. Compressor Relay

3. Air Mix Damper Servo Motor

17. Blower Motor Relay

4. Fresh/Re-circulated Air Damper Servo Motor

16. Solar Radiation Sensor

15. Ambient Temperature Sensor 5. Re-circulated Air temperature Sensor 14. High/Low Pressure Switch 6. Frost Sensor 13. Compressor

12

11

10

8. Monitor Controller 9. Blower Motor

7. Power Transistor

TKAA90-02-06-001 1234-

Controller Air Vent Damper Servo Motor Air Mix Damper Servo Motor Fresh/Re-circulated Air Damper Servo Motor

5678-

Re-circulated Air temperature Sensor Frost Sensor Power Transistor Monitor Controller

910111213-

T2-6-4

Blower Motor From fuse #3 From fuse #34 From fuse #25 Compressor

1415161718-

High/Low Pressure Switch Ambient Temperature Sensor Solar Radiation Sensor Blower Motor Relay Compressor Relay

SECTION 2 SYSTEM Group 6 Air Conditioning System Functions of Main Parts

fNOTE: Refer to “AIR CONDITIONER ELECTRICAL CIRCUIT DIAGRAM” attached to the separated Manual, Technical Manual (Troubleshooting). (Publication number: TTKAA90-EN-01_Circuit)

The functions of the main parts for the air conditioner are described below. The connector No. is shown in the parentheses after the part name.  Controller The controller controls the air conditioning system. The controller has the following functions.  The operator’s instructions are input by the switches.  The air and coolant temperature are detected by the sensors.  Input the air conditioner unit conditions.  The blower motor and compressor are controlled by operating the relays.  The air conditioner operating conditions are displayed on the monitor panel.

TDC1-05-07-002

 Power Transistor (CN7) The power transistor is an electric switch to control blower motor voltage.

TDC1-05-07-003

 Blower Motor Relay (CN3) The blower motor relay supplies 24 volts power to the blower motor when the air conditioner is operated. The blower motor relay is turned ON when excited by the current from terminal #30B in controller.

TDC1-05-07-004

 Compressor Relay (CN4) The compressor relay supplies 24 volts power to the compressor clutch when the air conditioner is operated.

The compressor relay is turned ON when excited by the current from terminal #29B in controller.

TDC1-05-07-005

T2-6-5

SECTION 2 SYSTEM Group 6 Air Conditioning System  Frost Sensor (CN12) The frost sensor detects the fin temperature which is cooled by the evaporator. When the temperature is higher than 3 °C (approx. 4.2 kΩ), the controller turns the compressor relay ON. When the temperature is 2 °C (approx. 4.5 kΩ) or less, the controller turns OFF the compressor relay. Therefore, the evaporator in the air conditioner unit is prevented from freezing. The electrical resistance in the frost sensor is 100 Ω to 115 kΩ.

 High/Low Pressure Switch (CN14) The high/low pressure switch controls the compressor clutch solenoid while detecting the compressor circuit pressure. The high/low pressure switch consists of a pressure gauge and a switch. The pressure gauge detects the low pressure range (0.196 MPa to 0.216 MPa) and the surge pressure range (2.55 MPa to 3.14 MPa). When the circuit pressure decreases to the low pressure range or increases to the surge pressure range, the pressure gauge turns OFF the switch. Therefore, the compressor operation stops. If the pressure decreases to the low range, a lack of refrigerant is suspected. Therefore, damage to the compressor due to a lack of refrigerant is prevented.

When the pressure increases to the surge range, damage to the air conditioner circuit parts due to excessively high circuit pressure is prevented.

 Re-circulated Air Temperature Sensor (CN11) The re-circulated air temperature sensor detects the temperatures (0 to 25 °C) around the re-circulated air inlet as the interior air temperatures and converts them to the electrical resistance values. The temperatures 0 °C to 25 °C corresponds to a resistance of 1.645 kΩ (0 °C) to 5 kΩ (25 °C) respectively.

The electrical resistance in the re-circulated air temperature sensor is 300 Ω to 430 kΩ.

 Ambient Temperature Sensor (CN15) The ambient temperature sensor detects the temperature at the side of the air conditioner condenser as the outdoor air temperature, and converts the temperature to the electrical resistance value. The electrical resistance in the ambient temperature sensor is 100 Ω to 210 kΩ.

T2-6-6

TDC1-05-07-006

TDC1-05-07-007

TDAA-05-07-014

TDC1-05-07-008

TDC1-05-07-009

SECTION 2 SYSTEM Group 6 Air Conditioning System  Solar Radiation Sensor (CN16) The solar radiation sensor converts the amount of solar radiation (illumination intensity) at the cab front to the current values.

TDC1-05-07-010

 Fresh/Re-circulated Air Damper Servo Motor (CN10) The fresh/re-circulated air damper servo motor opens or closes the fresh/re-circulated air selection louvers. The damper consists of a motor, link mechanism, and position sensing switch. The motor opens or closes the fresh/recirculated air selection louvers via the link mechanism.

TDC1-05-07-011

T2-6-7

SECTION 2 SYSTEM Group 6 Air Conditioning System  Air Mix Damper Servo Motor (CN9) The air mix damper servo motor controls opening/closing of the air mixing door in response to the set temperature.

This servo motor consists of a motor, link mechanism, and potentiometer. The motor opens or closes the air mix door via the link mechanism. The potentiometer converts the link movements (the mix door strokes) to the voltage.

Both ends of the potentiometer are energized by 5 V from terminals #7D (+) and #25E (-) in controller. The voltage (0.5 to 4.5 V) corresponding to the link movement is output from the center terminal of the potentiometer, and is input to terminal #19B in controller. The set temperature is determined by temperature UP/DOWN signal from the controller. The controller calculates voltage (Vr) corresponding the link position for the set temperature.

Further more, the controller checks the air mix door position by voltage (Vf ) from the potentiometer. Then, after the controller decides the motor rotational direction (polarity of motor) based on the differential voltage between Vr and Vf, the controller sends out the current from terminals #15B and #16B. The controller drives the motor until voltage (Vf ) becomes equal to voltage (Vr).

T2-6-8

TDC1-05-07-012

SECTION 2 SYSTEM Group 6 Air Conditioning System  Air Vent Damper Servo Motor (CN8) The air vent damper servo motor opens or closes the front and rear air vent, foot vent, and defroster vent louvers.

The damper consists of a motor, link mechanism, and potentiometer. The motor opens or closes vent louvers via the link mechanism. The potentiometer converts the link movements (vent louvers strokes) to the voltage.

Both ends of the potentiometer are energized by 5 V from terminals #7C (+) and #25D (-) in controller. The voltage (0.5 to 4.5 V) corresponding to the link movement is output from the center terminal of the potentiometer, and is input to terminal #20B in controller. Depending on the MODE switch set position, vent louvers are operated as shown below:  Front Air Vent: Open, Rear Air Vent: Close, Foot Air Vent: Close  Front Air Vent: Open, Rear Air Vent: Open, Foot Air Vent: Close  Front Air Vent: Open, Rear Air Vent: Open, Foot Air Vent: Open  Front Air Vent: Close, Rear Air Vent: Close, Foot Air Vent: Open The controller calculates the louvers position of front and rear vent that are corresponding to selected switch position as the voltage (Vr) of potentiometer.

Furthermore, the controller checks the vent louvers positions by receiving voltage (Vf ) from the potentiometer. Then, after the controller decides the motor rotational direction (polarity of motor) based on the differential voltage between Vr and Vf. The controller sends out the current from terminals #31B and #32B. The controller drives the motor until voltage (Vf ) becomes equal to voltage (Vr).

T2-6-9

TDC1-05-07-013

SECTION 2 SYSTEM Group 6 Air Conditioning System Functions of Main Components The functions of the main components for the air conditioning system are described below.  Air Conditioner Compressor The air conditioner compressor draws refrigerant from the low-pressure circuit (between evaporator and compressor), compresses refrigerant, and sends the compressed refrigerant to the air conditioner condenser. (Refrigerant generates heat when compressed.)  Air Conditioner Condenser The air conditioner condenser cools hot and highpressure refrigerant.  Receiver Tank The receiver tank removes moisture from high-pressure refrigerant and stores refrigerant.  Expansion Valve The expansion valve atomizes high-pressure liquid refrigerant into low-pressure gas through an orifice.

Then, the expansion valve adjusts the refrigerant flow rate.  Evaporator The evaporator vaporizes refrigerant and absorbs heat from atmosphere.  Heater Core The heater core circulates hot engine coolant and emits heat to atmosphere.  Blower Motor The blower motor sends air to the evaporator.

T2-6-10

MEMO

MEMO