Sumitomo SH80-3B Hydraulic Excavator Service Text Manual WLST0803B-00W - PDF DOWNLOAD

Table of Contents

SH80

Table of Contents Main body Section Specifications ...................................................................................................... 1 Overall ........................................................................................................................ 1 1. Main Data ......................................................................................................... 1 2. Performance ..................................................................................................... 1 3. Main Body Dimensions..................................................................................... 1 4. Engine .............................................................................................................. 2 5. Cooling System ................................................................................................ 2 6. Upper Side Work System ................................................................................. 3 7. Operating Device.............................................................................................. 4 8. Swing Units ...................................................................................................... 5 9. Travel Lower Body ............................................................................................ 5 10. Dozer Blade...................................................................................................... 5

AL

Hydraulic Equipment................................................................................................... 6 1. Hydraulic Device............................................................................................... 6 2. Control Valve, Cylinder ..................................................................................... 6

RN

Capacities, Filters ....................................................................................................... 7 1. Coolant and Oil Capacities ............................................................................... 7

TE

2. Hydraulic Oil Filters .......................................................................................... 7

IN

3. Fuel Filter ......................................................................................................... 7

Overall View ........................................................................................................ 8

E

Overall View (SH80-3B).............................................................................................. 8

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

1. Standard Arm (1.71 m)..................................................................................... 8 2. Long Arm (2.12 m) ........................................................................................... 8

Work Range Diagram.......................................................................................... 9 Work Range Diagram (SH80-3B) ............................................................................... 9 1. Standard Arm (1.71 m)..................................................................................... 9 2. Long Arm (2.12 m) ......................................................................................... 10

Optional Components ....................................................................................... 11 List of Optional Components .................................................................................... 11

Major Equipment ............................................................................................... 12 Equipment Configuration .......................................................................................... 12 Overall.................................................................................................................. 12 Operator’s Cab..................................................................................................... 13

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AST-15-00-002EN 1

Table of Contents Main Equipment Table....................................................................................... 14 Lower Mechanism..................................................................................................... 14 Assembly Diagrams (with blade).......................................................................... 14 Lower Component .................................................................................................... 15 1. Travel Unit....................................................................................................... 15 2. Take-up Roller ................................................................................................ 15 3. Upper-roller .................................................................................................... 15 4. Lower-roller..................................................................................................... 15 5. Recoil Spring .................................................................................................. 16 6. Shoes ............................................................................................................. 16 Upper Component .................................................................................................... 17 1. Swing Unit ...................................................................................................... 17 Engine-related .......................................................................................................... 18 1. Engine ............................................................................................................ 18

AL

2. Muffler ............................................................................................................ 18 3. Air Cleaner (double element).......................................................................... 19

RN

4. Radiator.......................................................................................................... 19 Hydraulic Device....................................................................................................... 20

TE

1. Hydraulic pump .............................................................................................. 20 Control-related .......................................................................................................... 21

IN

1. Control Valve .................................................................................................. 21 2. Solenoid Valve (4 stack) ................................................................................. 21

E

3. Remote Control Valve (left/right, travel operations) ........................................ 22

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4. Remote Control Valve Characteristic Diagram ............................................... 24 5. Center Joint .................................................................................................... 26

Backhoe Attachment................................................................................................. 27 1. Cylinder .......................................................................................................... 27 2. Attachments ................................................................................................... 28

Fuel Tank .................................................................................................................. 29 Sump Tank................................................................................................................ 31

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Table of Contents Hydraulic Section Hydraulic Pump Operational Description ............................................................ 1 Configuration and Principle of Operation.................................................................... 1 Flow Control................................................................................................................ 3 1. Constant controlling of simultaneous output..................................................... 3 2. Power-down control by discharge pressure of blade pump (blade shift) .......... 4

Control Valve Operation ...................................................................................... 5 Operation with All Spools in Neutral ........................................................................... 5 1. Main passage ................................................................................................... 5 2. Signal passage................................................................................................. 5 Independent Operation ............................................................................................... 7 1. Travel spool switch-over (Figure 1) ................................................................... 7 2. Backup spool switch-over (Figure 2) ................................................................ 7

AL

3. Swing spool switch-over (Figure 3)................................................................... 8 4. Bucket spool switch-over (Figure 3) ................................................................. 8

RN

5. Boom spool switch-over.................................................................................... 9 6. Arm spool switch-over .................................................................................... 11

TE

7. Blade spool switch-over (Add-on) (Figure 9) .................................................. 13 8. Boom Swing spool switch-over (Add-on) (Figure 9A)..................................... 13

IN

9. Relief valve ..................................................................................................... 14 10. Anti-drift valve (Boom section)........................................................................ 15

E

Combined Operations............................................................................................... 17

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1. Additional operation with travel (Figure 14) .................................................... 17 Relief Valve............................................................................................................... 18 1. Main relief valve.............................................................................................. 18 2. Overload relief valve ....................................................................................... 19

Swing Unit Swing Motor .................................................................................... 20 Functional and Operational Description ................................................................... 20 1. Swash Plate Motor ......................................................................................... 20 2. Parking Brake (for models equipped with parking brakes) ............................. 22 3. Principle of Relief Valve Operation ................................................................. 23 4. Makeup Valve ................................................................................................. 26 5. Reduction Gear (2-stage planetary gear)....................................................... 27

Overview................................................................................................................... 28 1. Features ......................................................................................................... 28 2. Operational Description.................................................................................. 28

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AST-15-00-002EN 3

Table of Contents Travel Unit Travel Motor ..................................................................................... 32 External Dimensional Drawing.................................................................................. 32 Basic Structure and Drawings .................................................................................. 33 1. Basic structure of GM motor........................................................................... 33 2. Parts list.......................................................................................................... 35 Operational Description ............................................................................................ 36 1. Reduction gear ............................................................................................... 36

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E

IN

TE

RN

AL

2. Hydraulic drive section ................................................................................... 37

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Table of Contents Hydraulic Circuit Section Port Locations ..................................................................................................... 1 Hydraulic Pump .......................................................................................................... 1 Control Valve .............................................................................................................. 2 Control Valve .............................................................................................................. 3

Pilot Hose Connection Diagrams ........................................................................ 4 Pilot P & T Lines ......................................................................................................... 4 Pilot Control Lines ...................................................................................................... 6

Functional Description......................................................................................... 8 List of Functions ......................................................................................................... 8 Control Valve Configuration Table............................................................................. 10 Overview .............................................................................................................. 10

Explanation of Hydraulic Circuit and Operations (standard model)................... 11

AL

Travel Circuits ........................................................................................................... 11 High-speed Travel Circuit ..................................................................................... 11

RN

Low-speed Travel Circuit ...................................................................................... 13 Straight-travel Circuit (Boom-Up and Travel-Forward) ......................................... 15

TE

Swing Circuit............................................................................................................. 17 Swing Parking Circuit ........................................................................................... 17

IN

Swing Override Throttle Circuit ............................................................................ 19 Bucket Circuit............................................................................................................ 21 Bucket-Opening Circuit ........................................................................................ 21

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E

Arm CIrcuits.............................................................................................................. 23 Arm-in / Arm-out 2-speed Circuit ......................................................................... 23

Boom Circuits ........................................................................................................... 25 Boom Circuit 1: Boom-up 2-speed Circuit............................................................ 25 Boom Circuit 2: Boom-down Load Holding Valve Circuit ..................................... 27

Boom Swing CIrcuit .................................................................................................. 29 Boom Swing CIrcuit ............................................................................................. 29

Blade Circuits ........................................................................................................... 31 Blade Circuits....................................................................................................... 31

Explanation of Hydraulic Circuit and Operations (option).................................. 33 Backup Circuits......................................................................................................... 33 Breaker and Crusher Circuit (2-speed confluence crusher circuit) ...................... 33 Breaker and Crusher Circuit (breaker circuit) Ultra Small Tail Swing Hydraulic Excavator............................. 36 Backup Reciprocating Circuit (ultra small swing hydraulic excavator).................. 38

Secondary Backup Reciprocating Circuit (ultra small tail swing hydraulic excavator) ............................... 40

5

AST-15-00-002EN 5

Table of Contents Electric Circuits Section Operational Description....................................................................................... 1 Monitor Display ........................................................................................................... 1 1. Monitor switch panel......................................................................................... 1 2. List of Functions ............................................................................................... 2 Engine Control ............................................................................................................ 3 1. Engine start-up control ..................................................................................... 3 2. Engine Start-up Circuit ..................................................................................... 4 3. Monitor Output Control ................................................................................... 10 4. Monitor Display Control .................................................................................. 17

Electric Circuit Diagrams ................................................................................... 23 Electric Circuit Diagram 1 ......................................................................................... 23 Electric Circuit Diagram 2 ......................................................................................... 24

AL

Electric Circuit Diagram: Air Conditioner 1 ............................................................... 25 Electric Circuit Diagram: Air Conditioner 2 ............................................................... 26

RN

Harness Diagrams ............................................................................................ 27 Upper Frame............................................................................................................. 27

TE

Frame Wiring Main Harness ................................................................................ 27 Inside Cab ................................................................................................................ 28

IN

Cab Wiring Main Harness .................................................................................... 28

Wiring Diagrams................................................................................................ 29

E

Electrical Components and Wiring for Upper Frame (frame).................................... 29

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Electrical Components and Wiring for Cab............................................................... 30 Electrical Components and Wiring for Upper Frame (engine) .................................. 31 Electrical Components and Wiring for Upper Frame (battery).................................. 32 Heater....................................................................................................................... 33 Air Conditioner .......................................................................................................... 34 Inside Frame ........................................................................................................ 34 Inside Caiob ......................................................................................................... 35

6

AST-15-00-002EN 6

Table of Contents Maintenanse section Measuring / Adjusting Pressure .......................................................................... 1 Measuring Pressure ................................................................................................... 1 1. Basic conditions ............................................................................................... 1 2. Pressure settings.............................................................................................. 1 3. Ports for measuring pressure ........................................................................... 2 4. Preparation for Measuring Pressure................................................................. 3 5. Measuring Pressure ......................................................................................... 4 Pressure adjustment................................................................................................... 7 1. Pressure adjusting points ................................................................................. 7 Bleeding Air ................................................................................................................ 9

Attachments Dimensions .................................................................................. 10 Attachment Installation Methods .............................................................................. 10

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Appendix ........................................................................................................... 11 Unit Conversion Table............................................................................................... 11

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New Hydraulic Oil ..................................................................................................... 12 Long-life hydraulic oil (IDEMITSU Daphne Super Hydro 46SX) .......................... 12

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Compatibility...................................................................................................... 13

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IN

List of Common Features and Compatibility of Major Parts ..................................... 13

7

AST-15-00-002EN 7

Specifications Specifications

SH80

Specifications Overall 1. Main Data Model name

SH80-3B

Operating weight

8430 kg

Engine output

40 kW/2000 min-1

Bucket capacity

Heaped 0.28 m3 Leveled 0.20 m3

2. Performance Model name 9.5 min-1

Travel speed

Low speed 3.3 km/h High speed 5.1 km/h

Maximum pulling force

59.2 kN

Grade ability

70 % (35°)

Ground pressure

38 kPa (450 mm grouser shoe)

RN

Swing speed

3. Main Body Dimensions Model name

Main body width

2320 mm

Upper swing body width

2225 mm

Cab width

1065 mm

Main body height

2700 mm

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

3510 mm

TE

SH80-3B

Main body length

Swing radius (rear end)

AL

SH80-3B

1655 mm

Swing body rear end distance 1235 mm Swing body rear section bottom height

745 mm

Distance between tumblers

2210 mm

Overall track length

2845 mm

Overall track width

2320 mm

Distance between tracks

1870 mm

Track shoe width

450 mm (options 600 mm)

Minimum ground clearance (to bottom of lower frame)

360 mm

1

AST-15-01-002EN 1

Specifications 4. Engine Model name

SH80-3B

Name

Isuzu AU-4LE2X diesel engine

Model

4-cycle, water cooled, overhead valve, vertical in-line, direct injection type, turbocharger with air cooled intercooler

Number of cylinders - bore x stroke

4 - φ85 mm x 96 mm

Total stroke volume

2179 cc

Maximum torque

210 N•m/1500 min-1

Fuel consumption ratio

240 g/kW•h max.

Starter

24 V

3.2 kW

Charging generator

24 V

50 A

AC type

Battery

24 V

64 Ah/5 Hr

x2

AL

5. Cooling System Model name φ475 mm

x7

Intake

RN

Fan type

SH80-3B

Capacity

27690 kcal/h

Fin type

Wavy

Fin pitch

1.75 mm

IN

Oil cooler

TE

Radiator

15390 kcal/h

Fin type

Wavy

Fin pitch

1.75 mm

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

Capacity

Inter cooler

Capacity

3611 kcal/h

Fin type

Wavy

Fin pitch

2.0 mm

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2 2

Specifications 6. Upper Side Work System Model name Model

SH80-3B Backhoe attachment

Components, dimensions, working dimensions Bucket weight with side cutter

204 kg

178 kg

Standard (1.71 m)

Long (2.12 m)

1710 mm

2120 mm

Heaped 0.28 m3 (leveled 0.20 m3)

Heaped 0.22 m3 (leveled 0.16 m3)

Bucket width

730 mm

600 mm

Bucket width with side cutter

804 mm

673 mm

Bucket radius

1050 mm

1050 mm

3500 mm

Arm type Arm length Bucket capacity

177° 7030 mm

Maximum digging radius at ground line

6890 mm

Maximum digging depth

4180 mm

4590 mm

Maximum vertical straight wall digging depth

3080 mm

3550 mm

6390 mm

6600 mm

4390 mm

4600 mm

2750 mm

2910 mm

5060 mm

5080 mm

Maximum dump height

TE

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

Minimum swing radius at front

E

Maximum digging height

Height for minimum swing radius at front

RN

Maximum digging radius

IN

Bucket wrist angle

AL

Boom length

3

7400 mm 7270 mm

AST-15-01-002EN 3

Specifications 7. Operating Device Model name

SH80-3B

Operator’s seat Position

Left side

Structure

Adjustable forward and back, reclining mechanism, with seat suspension

Cab

Steel enclosure, reinforced glass all sides

Levers and pedals For travel use

Lever and pedal type (hydraulic pilot type)

x2

For operating machine use Lever type (hydraulic pilot type)

x2

For blade use

x1

Lever type (hydraulic pilot type)

Instruments and switches Travel mode select switch

Low-speed/high-speed switch type

One-touch idle

Knob switch type

Engine emergency stop

Switch type

AL

Monitor device

RN

Machine status display (full dot liquid crystal)

Analog

Engine coolant temperature gauge

Analog

Hour meter

Digital type

E

IN

Fuel gauge

TE

Instrument (full dot liquid crystal except for hour meter)

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

Machine status and warning alarms * has warning alarm Overheat Refill fuel

* *

Battery charge Engine oil pressure

* *

Check engine Engine preheat

*

Illumination equipment

Working light

Cab:

24 V

55 W

x1

House:

24 V

55 W

x1

Boom:

24 V

70 W

x1

24 V

6W

x1

Interior light

Horn

Electric horn

Others

Wiper with intermittent function, window washer, air conditioner, clock, rear view mirrors (right and rear side) 1 each

AST-15-01-002EN

x1

4 4

Specifications 8. Swing Units Model name

SH80-3B

Swing circle

Swing bearing type (with internal gear)

Swing hydraulic motor

Fixed displacement piston motor

Reduction gear

Planetary gear 2-stage reduction gear

Swing parking brake

Mechanical lock (operational lever linkage type)

x1

9. Travel Lower Body Model name

SH80-3B

Travel hydraulic motor

Variable displacement piston motor

Reduction gear

Planetary gear 2-stage reduction gear

Travel brake

Hydraulic lock

Parking brake

Mechanical lock (travel lever linkage type)

x2

Track shoe Assembly-type triple grouser shoe

Number of shoes (per side)

x 39

Shoe width

450 mm (options 600 mm)

Grouser height

20 mm

Link pitch

154 mm

Number of lower rollers (per side)

x5

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H Track belt tension adjuster

TE

x1

E

Number of upper rollers (per side)

IN

Roller

RN

AL

Model

Grease cylinder type (with cushion spring)

10.Dozer Blade Model name

Width of blade

2320 mm

Height of blade

450 mm

SH80-3B

Maximum lift above ground 415 mm

Maximum drop below ground 205 mm

5

AST-15-01-002EN 5

Specifications Hydraulic Equipment 1. Hydraulic Device Model name Hydraulic pump drive type

SH80-3B Direct engine link (no transmission)

Hydraulic pump Double variable displacement piston pump

x1

Gear pump

x2

Gear pump (for blade use)

24.2 L/min

Gear pump (for pilotr use)

21.4 L/min

Discharge volume

Piston pump

2 x 68 L/min

Pump control method

Simultaneous output full-horsepower control

Model

29.4 MPa (Boom / Arm / Bucket / Boom swing / Travel) Set pressure of main relief valve

22.6 MPa (Swing)

33.3 MPa (Boom swing right) Set pressure of overload relief valve

AL

22.6 MPa (Blade)

31.9 MPa (Boom / Arm / Bucket / Boom swing left)

RN

25.5 MPa (Blade)

TE

2. Control Valve, Cylinder Model name

IN

Control valve Model

Double spool Quintuple spool

Operating type

Hydraulic pilot type: travel, swing, blade and operating machine

E

One-piece type

Number of cylinders x tube bore

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

Cylinder

x1 x2

SH80-3B

x1

-

rod diameter

-

stroke

Boom cylinder

1

x φ110 mm

-

φ70 mm

-

911 mm

Arm cylinder

1

x φ95 mm

-

φ60 mm

-

797 mm

Bucket cylinder

1

x φ85 mm

-

φ55 mm

-

665 mm

Blade cylinder

1

x φ100 mm

-

φ60 mm

-

180 mm

Boom swing cylinder

1

x φ95 mm

-

φ55 mm

-

640 mm

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6 6

Specifications Capacities, Filters 1. Coolant and Oil Capacities Model name

SH80-3B

Coolant

10.2 L

Fuel

100 L

Engine lubricating oil

9L

Travel reduction gear lubri1.1 L cating oil (one side) Hydraulic oil

97.3 L

Hydraulic oil tank regulation amount

50 L

2. Hydraulic Oil Filters Model name

SH80-3B 150 mesh

Return filter (inside tank)

6 µm

AL

Suction filter (inside tank)

RN

Pilot line filter (inside hous8 µm ing)

3. Fuel Filter

Pre-filter

10 µm

IN

4 µm

SH80-3B

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

Main filter

TE

Model name

7

AST-15-01-002EN 7

Overall View Main body Section

SH80

Overall View Overall View (SH80-3B) 1. Standard Arm (1.71 m)

RN

AL

Note: 1. Numbers are subject to change without notice due to design change or other reason.

Note: 2. The figures give values that include the shoe lug height (20 mm).

TE

2. Long Arm (2.12 m)

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E

IN

Note: 1. Numbers are subject to change without notice due to design change or other reason.

Note: 2. The figures give values that include the shoe lug height (20 mm).

8

AST-15-03-002EN 1

Work Range Diagram Main body Section

SH80

Work Range Diagram Work Range Diagram (SH80-3B) 1. Standard Arm (1.71 m)

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

Note: 1. Numbers are subject to change without notice due to design change or other reason.

Note: 2. The figures give values that exclude the shoe lug height (20 mm).

9

AST-15-04-002EN 1

Work Range Diagram 2. Long Arm (2.12 m)

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

Note: 1. Numbers are subject to change without notice due to design change or other reason.

Note: 2. The figures give values that exclude the shoe lug height (20 mm).

AST-15-04-002EN

10 2

Optional Components Optional Components

SH80

Optional Components List of Optional Components ◎ Standard Model

SH80-3B ◎

450G shoe (Link chain rubber crawler)

●

600G shoe

●

Blade

◎

Lower under cover

◎

High-performance return filter

◎

Travel alarm

◎

Breaker circuit (for standard arm)

●

Shuttle circuit

●

Multi purpose (2 pumps flow + breaker circuit)

●

2nd option circuit

●

Attachment reinforcement

●

Air conditioner

◎

Heater

●

Seat with arm and headrest

◎

Travel pedal

◎

RN ◎

KAB seat

◎

TE

Seat belt

◎

Air cleaner double element

◎

Radiator anti-dust net

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

AM/FM radio

● ◎ ◎

E

Rear view mirror

IN

ISO operation type Quick change (2-way)

Remarks

AL

450G shoe

z Optional

◎ ●

12 V power supply

11

AST-15-05-002EN 1

Major Equipment Main body Section

SH80

Major Equipment Equipment Configuration

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

Overall

12

AST-15-06-003M 1

E

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H RN

TE

IN AL

Major Equipment Operator’s Cab

AST-15-06-003M

13

2

E

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H RN

TE

IN AL

NOTES 1) AMOUNT OF WEIGHT OPTIONALLY. 2) ※ IS OPTIONAL. DON'T

CONTAIN

2 2 1 1 1 2 2 1 2

2 3 4 5 6 7 8 9 10

RECOIL SPRING ＆ ROLLER ASSY TRACTION EQUIPMENT ASSY TRACTION MOTOR LINE ASSY CENTER JOINT ASSY ※ LOWER UNDER COVER ASSY GROUSER SHOE 450 ※ GROUSER SHOE 600 BLADE ASSY ※ LINK CHAIN SHOE 450

QTY 1

SYM 1

DESCRIPTION LOWER FRAME ASSY (BLADE)

Main Equipment Table Main body Section SH80

Main Equipment Table

Lower Mechanism Assembly Diagrams (with blade)

14

AST-15-07-005E

1

Main Equipment Table Lower Component 1. Travel Unit Part No.

KAA10310

Manufacturer

Nabtesco Corporation

Motor type

Variable displacement piston motor Automatic 2nd-speed switchover with parking brake

Intake amount

48.0/30.5 cm3/rev

Operating pressure

29.4 MPa {4260 psi}

Operating flow

68.0 L/min {18 gpm}

Brake torque

5.54 kN•m min. {4086 lbf•ft} (including reduction gear)

Relief valve set pressure

38.25 ± 1.45 MPa at 15 L/min {5550 ± 210 psi}

Automatic 2nd-speed switchover pressure

23.8 MPa at 3.9 MPa {3450 psi at 570 psi}

Reduction gear Planetary gear 2-stage reduction gear

Reduction ratio

45.97 83 kg {183 lb}

RN

Dry weight

2. Take-up Roller KAA1255

Weight

45.1 kg {99.4 lb}

IN 4.3 kg {9.5 lb}

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

Weight

KAA1182

E

Part No.

TE

Part No.

3. Upper-roller

AL

Reduction gear type

4. Lower-roller Part No.

KAA1160

Weight

13.5 kg {29.8 lb}

AST-15-07-005E

15 2

Main Equipment Table 5. Recoil Spring Item

Part No.

Weight (kg) {lb}

QTY

Yoke

KAA1194

7.7 {17}

1

High strength bolt

M12 x 40

102R012Y040R

0.1 {0.2}

2

High strength washer

12

KHN0296

-

2

KAA1170

6.3 {13.9}

1

Threaded rod Nut with deep grooves

M30

165R030HSN

0.3 {0.7}

1

Spring pin

6 x 56

338W060Z056B

-

1

Recoil spring

KAA1169

14.1 {31.1}

1

Grease cylinder assembly

KAA1219

8.8 {19.4}

1

Assembly

Total

37.3 {82.3}

Mounting length of spring

402 mm

6. Shoes Part No.

450 grouser

KAA10200

Link

KAA10230

Shoes

KAA1175

39

Bolt

KAA1176

156

RN

TE

Nut

425.4 kg {937.6 lb} 1 set

156

KAA10210

479.8 kg {1057.5 lb}

KAA10230

1 set

KAA1230

39

KAA1176

156

Nut

KAA1177

156

450 geo grip

KAA10220

424.4 kg {935.4 lb}

Link

KAA10230

Shoes

KAA1179

39

Bolt

KAA1176

156

Nut

KAA1177

156

450 Rubber Truck (with special core metal)

KAA1181

421.0 kg {927.9 lb}

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

Bolt

E

Shoes

Weight or Quanity

KAA1177

IN

600 grouser Link

AL

Item

16

1 set

AST-15-07-005E 3

Main Equipment Table Upper Component 1. Swing Unit Swing motor assembly Part No.

KAC0177

Swing motor Part No.

-

Manufacturer

KYB Corporation

Motor type

Fixed displacement piston motor With parking brake 44.1 cm3/rev

Operating pressure

22.6 MPa {3280 psi}

Operating flow

68.0 L/min {18 gpm}

Mechanical brake torque

174.1 N•m min. {1540.7 lbf•tf}

Brake off pressure

4.9 MPa {710 psi} max.

Relief valve set pressure

22.6 ± 0.3 MPa at 57.5 L/min {3280 ± 44 psi at 15 gpm}

AL

Intake amount

Swing reduction gear -

Manufacturer

KYB Corporation

Reduction gear type

Planetary gear 2-stage reduction gear

Reduction ratio

20.615

Part No.

TE

KAB10010

76

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

Number of teeth

IN

Turntable bearing

80.0 kg {176.3 lb}

E

Dry weight

Weight

RN

Part No.

91.6 kg {202 lb}

Counterweight

Part No.

KAB10540

Weight

1235 kg {2723 lb}

AST-15-07-005E

17 4

Main Equipment Table Engine-related 1. Engine KAH11170

Engine model name

Isuzu AU-4LE2X diesel engine

Engine type

4-cycle, water cooled, overhead valve, vertical in-line, direct injection type

Number of cylinders - bore - stroke

4 - φ85.0 mm - 96 mm {4 - φ3.35 in - 3.78 in}

Total exhaust amount

2179 cc

Compression ratio

18.3

Rated output

40 kW/2000 min-1 {53.6 HP/2000 min-1}

Maximum torque

200 N•m/approx. 1500 min-1 {1770 lbf•in/approx. 1500 min-1}

Fuel consumption ratio

240 g/kW•h max.

Engine dry weight

About 191 kg {427.6 lb}

Engine dimensions

L 757.1 - W 650.7 - H 753.7 mm {L 29.8 - W 25.6 - H 29.7 in}

Oil pan

All direction 350, inclinable

Cooling fan

φ475 mm - suction type - 7 vanes, plastic

AL

Part No.

RN

With bell mouth-type fan guide 1.03 (reduction)

Charging generator

24 V, 50A AC type

Starter motor

24 V, 3.2 kW reduction type

Coolant capacity

2.8 L {0.7 gal}

Direction of rotation

IN

Max.: 10.4 L {2.7 gal} Min.: 7.6 L {2.0 gal} (not including oil filter) Right (as seen from fan)

E

Oil pan capacity

TE

Pulley ratio

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

Compliant with JISD 0006-2000.

2. Muffler

Part No.

KAH11200

Manufacturer

SANKEI GIKEN KOGYO CO., LTD.

Model

φ190 x 490 mm (φ7.48 x19.29 in)

Weight

13.0 kg {28.7 lb}

18

AST-15-07-005E 5

Main Equipment Table 3. Air Cleaner (double element) Part No.

KAH11210

Manufacturer

Nippon Donaldson Ltd

Element (outer)

KAH1219

Element (inner)

KAH1386

Weight

1.7 kg {3.7 lb}

Part No.

KRH11190

Manufacturer

T. RAD Co., Ltd.

Oil cooler

Radiator

Air cooler

12.0 kg {26.4 lb}

Oil capacity

4.4 L {1.2 gal}

Weight

5.4 kg {12 lb}

Coolant capacity

5.1 L {1.3 gal}

Weight

4.5 kg {10 lb}

Water Capacity

4.1 L {1.1 gal} 50 kg {110 lb}

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

Total weight

Weight

AL

4. Radiator

AST-15-07-005E

19 6

Main Equipment Table Hydraulic Device 1. Hydraulic pump Part No.

KAJ4590

Manufacturer

Bosch Rexroth Co., Ltd

Main pump Pump type

Double variable displacement piston pump

Displacement volume

34.0 x 2 cm3/rev

Operating pressure Input revolution speed

Rated

29.4 MPa {4260 psi}

Rated

2000 min-1

Max.

2250 min-1

Maximum discharge flow

68 x 2 L/min at 2000 min-1 {18 x 2 gpm at 2000 min-1 }

Pilot pump Fix displacement gear pump

Displacement volume

10.7 cm3/rev

Operating pressure

4.2 MPa {610 psi}

Maximum discharge flow

21.4 L/min at 2000 min-1 {5.6 gpm at 2000 min-1 }

RN

AL

Pump type

TE

Blade pump

Fixed displacement gear pump

Displacent volume

12.1 cm3/rev

24.2 L/min at 2000 min-1 {6.4 gpm at 2000 min-1 }

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

Maximum output

22.6 MPa {3280 psi}

E

Operating pressure

IN

Pump type

Control method

Full hosepower angle control in concurrence Hosepower control by blade pump operation pressure

Dry weight

51.4 kg {113 lb}

20

AST-15-07-005E 7

Main Equipment Table Control-related 1. Control Valve Part No.

KAJ5076

Manufacturer

KYB Corporation

Maximum flow

75.8 L/min at 2230 min-1 {20 gpm at 2230 min-1}

Overload set pressure other

31.9 ± 0.3 MPa at 20 L/min {4630 ± 44 psi at 5.3 gpm}

boom swing right

33.3 ± 0.3 MPa at 20 L/min {4830 ± 44 psi at 5.3 gpm}

boom swing left

31.9 ± 0.3 MPa at 20 L/min {4630 ± 44 psi at 5.3 gpm}

Main relief set pressure

29.4 ± 0.3MPa at 44L/min {4260 ± 44psi at 11.6 gpm}

Function

Straight travel circuit Boom up; 2-speed, internal conflver for arm

AL

Boom load holding circuit Arm-in forced regenerativ circuit

Swing override variable throttle valve 85 kg {187 lb}

RN

Weight

TE

2. Solenoid Valve (4 stack) KHJ15440

Manufacturer

YUKEN KOGYO CO., LTD.

Maximum flow

4.5 MPa {650 psi}

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

Rated pressure

P → B 20 L/min other 5 L/min

E

Valve specifications

IN

Part No.

Port size

P,T,B port

G3/8

C1, C2, C3 ports

G1/4

Solenoid specifications

Operating voltage

20 - 32 V DC

Power consumption

17 W max.

Weight

AST-15-07-005E

4.7 kg {10.4 lb}

21 8

Main Equipment Table 3. Remote Control Valve (left/right, travel operations) (1) Valve for left/right operations Part No.

KHJ2911

Manufacturer

Kawasaki Precision Machinery Ltd.

Operating pressure

3.92 MPa {570 psi}

Secondary pressure

0.64 - 2.45 MPa {93 - 355 psi} primary short type

Operating angle

Operating torque

1, 3 ports

19°

2, 4 ports

25°

1 ports

0.58 - 2.03 N•m {5.13 - 18 lbf•in}

3 ports

0.47 - 1.92 N•m {4.16 - 17 lbf•in}

2, 4 ports

0.71 - 2.30 N•m {6.28 - 20.36 lbf•ft}

Weight

1.6 kg (3.5 lb)

(2) Valve for travel operation KHJ13980

Manufacturer

Nishina Industrial Co., Ltd.

Operating pressure

3.92 MPa {570 psi}

Secondary pressure

0.64 - 2.45 MPa {92.8 - 355 psi} primary short type

Operating angle

12.4°

Damper

6.87 N•m at 0.018 m/s {60.8 lbf•ft at 0.018 m/s} 4.7 kg {10.4 lb}

E

Valve for blade operations

KHJ1986

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

Part No.

RN

2.62 - 8.58 N•m {23 - 76 lbf•ft}

Weight

(3)

TE

valve

IN

Operating torque

AL

Part No.

Manufacture

Nishina Indeustrial Co., Ltd.

Operating pressure

3.92 MPa {570 psi}

Secondary pressure

0.64 - 2.45 MPa {92.8 - 355 psi} Primary pressure short type

Operating angle

10°

Operating torque

See the figure below.

Weight

0.7 kg {1.5 lb}

22

AST-15-07-005E 9

Main Equipment Table (4) Valve for boom swing operations Part No.

KHJ2278

Manufacture

Nishina Indeustrial Co., Ltd.

Operating pressure

3.92 MPa {570 psi}

Secondary pressure

0.59 ± 0.1 - 3.14 ± 0.3 MPa {85.6 - 455 psi} Primary pressure short type

Operating angle

10.0 ± 0.3°

Operating torque

2.80 to 5.70 N•m

Hydraulic oil operation temperature ISO VG46 -20 to 100 ℃ range 0.7 kg {1.5 lb}

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

Weight

AST-15-07-005E

23 10

Main Equipment Table 4. Remote Control Valve Characteristic Diagram

RN

AL

(1) Operation remote control valve control diagram

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

(2) Travel remote control valve control diagram

24

AST-15-07-005E 11

Main Equipment Table

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

(3) Blade remote control valve control diagram

AST-15-07-005E

25 12

Main Equipment Table 5. Center Joint Part No.

KAA10120

Operating pressure

High pressure passage

Flow

(ABCDEF)

29.4 MPa {4260 psi}

Drain port (T)

0.5 MPa {73 psi}

Pilot port (P)

3.9 MPa {570 psi}

High pressure passage

(ABCDEF)

68 L/min {18 gpm}

Drain port (T)

15 L/min {4 gpm}

Pilot port (P)

23 L/min {6 gpm}

Number of revolutions

15 min-1 {15 rpm}

Torque

No load

160 N•m {1420 lbf•in}

When pressurizing 2ports

190 N•m {1680 lbf•in}

Backward

Forward right

G1/2

Port B

Backward

Forward left

G1/2

Port C

Forward

Backward right

G1/2

Port D

Forward

Backward left

G1/2

Blade up

Port F

Blade down

Port T

Drain port

Port P

Pilot port

Weight

40 kg {88 lb}

G3/8 G3/8 G3/8 G1/4

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

Port E

AL

Port A

26

AST-15-07-005E 13

Main Equipment Table Backhoe Attachment 1. Cylinder (1) Boom cylinder Part No.

KAV2034

Manufacturer

KYB Corporation

Cylinder bore

φ110 mm

Rod diameter

φ70 mm

Maximum retracted length

1408 mm

Stroke

911 mm

Weight

103 kg {227 lb}

(2) Arm cylinder KAV2436

Manufacturer

KYB Corporation

Cylinder bore

φ95 mm

Rod diameter

φ60 mm

Maximum retracted length

1270 mm

Stroke

797 mm

Weight

78 kg {172 lb}

KYB Corporation φ85 mm φ55 mm

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

Rod diameter

IN

Cylinder bore

KAV2440

E

Manufacturer

RN

TE

(3) Bucket cylinder Part No.

AL

Part No.

Maximum retracted length

1035 mm

Stroke

665 mm

Weight

51 kg {112 lb}

(4) Blade cylinder Part No.

KAV2085

Manufacturer

KYB Corporation

Cylinder bore

φ100 mm

Rod diameter

φ60 mm

Maximum retracted length

530 mm

Stroke

180 mm

Weight

34 kg {75 lb}

AST-15-07-005E

27 14

Main Equipment Table (5) Boom swing cylinder Part No.

KAV2787

Manufacturer

KYB Corporation

Cylinder bore

φ95 mm

Rod diameter

φ55 mm

Maximum retracted length

1085 ± 30 mm

Stroke

640 ± 2.0 mm

Weight

56 kg {90 lb}

2. Attachments (1) Bucket type

General digging

○

Light digging

△

For loading only

×

Do not use

0.17

0.22

0.28

0.34

m3

0.09

0.14

0.16

0.20

0.26

Number

3

3

3

4

4

Without side cutter

mm

370

480

600

730

865

With side cutter

mm

-

-

673

804

945

Standard arm (1.71 m)

◎

◎

◎

●

○

Long arm (2.12 m)

◎

◎

●

△

×

Leveled

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

Number of teeth

Type of arm specified

◎

0.11

Bucket capacity

Bucket width

Standard bucket

AL

RN

m3

Heaped

●

28

AST-15-07-005E 15

E

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H RN

TE

IN AL

Main Equipment Table

Fuel Tank

AST-15-07-005E

29

16

Main Equipment Table Part No.

KAH11710

Individual part weight

18 kg {39.7 lb}

Tank capacity

100 L {26.3 gal}

Fuel

Light Oil (for diesel engine) DESCRIPTION

SYM

QTY

1

1

SEMS BOLT M10X20

2

1

HIGH BOLT STRENGTH M10 x 40

3

4

HIGE WASHER STRENGTH

4

4

BOND 262

5

NEED

PLATE SHIM

6

NEED

PLATE SHIM

7

NEED

SENSOR COVER

8

1

PLUG

9

1

HOSE ADAPTER

10

1

HOSE ADAPTER

11

1

DRAIN COCK

12

1

NIPPLE

13

1

FUEL SENSOR

14

1

NON-ASBESTOS PACKING

15

1

LIQUID PACKING 1194

16

NEED

PAN SCREW HD M5X12

17

5

RN

AL

FUEL TANK

2) TIGHTEN BOLTS TO THE INDICATED TORQUE AFTER APPLYING. LOCTITE ♯ 262 TO THE THREAD.

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

NOTES 1) CAPACITY OF THE FUEL TANK IS 100L.

30

AST-15-07-005E 17

E

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H RN

TE

IN AL

Main Equipment Table

Sump Tank

AST-15-07-005E

31

18

Main Equipment Table Part No.

KAJ11230

Individual part weight

56.7 kg {125 lb}

Tank capacity

78 L {20.5 gal}

Oil

Hydraulic oil DESCRIPTION

SYM

QTY

AIR BREATHER

1

1

HEX BOLT SOC HD M6 x 16

2

4

SPRING WASHER

3

4

SEMS BOLT M10 x 30

4

4

SUMP TANK

5

1

SEMS BOLT M10 x 20

6

6

PLATE SHIM (T=2)

7

NEED

PLATE SHIM (T=0.8)

8

NEED

PLUG G3/4

9

3

CUSHION SEAL

10

1

HIGH STRENGTH BOLT M12 x 45

11

4

HIGH STRENGTH WASHER

12

4

BOND #262

13

NEED

14

1

COMPRESSION SPRING

15

1

AL

STRAINER RELIEF VALVE

16

1

RETURN FILTER

17

1

18

1

OIL GAUGE LEVEL

19

1

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

RETURN FILTER LBX / CASE

32

AST-15-07-005E 19

Hydraulic Pump Operational Description Hydraulic Section

SH80

Hydraulic Pump Operational Description Configuration and Principle of Operation

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

The pump consists of a main pump (1), a blade pump (2) and a pilot pump (3), which are connected in series.

The main pump is a swash-plate type variable displacement piston pump, which delivers two equal volumes using one cylinder block. The cylinder block has ten pistons inside. Those pistons divert and alternately deliver the oil to Delivery Ports (5 and 6).

Each group of 5 pistons works as one pump.

1

AST-15-10-002E 1

Hydraulic Pump Operational Description

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

When the drive shaft (10), which is connected to the engine, rotates, the cylinder block (11) connected to the shaft via spline and the piston section (12) rotates.

Since the piston section (12) is pushed towards the swash plate (14) via retainer (13), it rotates on the inclined plane of the swash plate (14) and reciprocates within the cylinder block (11) according to the incline angle of the swash plate (14).

The piston (12) draws in oil while going down the inclined plane of the swash plate (14) and discharges oil while coming up.

The oil from the tank is taken from the inlet port (9), which is shared by all the pumps, and is divided inside the cover (4) into the main pump (1), the blade pump (2) and the pilot pump (3). The oil to the main pump (1) passes the control plate (15) and is drawn in by the piston (12) in cylinder block (11).

The oil delivered from the piston (12) is alternately divided into the passages (20, 21) in the control plate (15), and will be discharged from the delivery ports (5, 6) of each group of 5 pistons.

The discharge volume of the pump fluctuates according to the changes in piston stroke in conjunction with the changes in the incline angle of the swash plate (14). The operation of the swash plate (14) is regulated by the discharge pressure in the main pump and the discharge pressure in the blade pump.

(See below for details.)

AST-15-10-002E

2 2

Hydraulic Pump Operational Description Flow Control 1. Constant controlling of simultaneous output

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

The pump output will be maintained at a certain level by increasing / decreasing the flow according to the pump discharge pressure.

The force generated by the discharge pressure acts on the swash plate (14) via the piston section (12).

The force of the discharge pressure generates a moment (return moment) to decrease the incline angle by using the difference between the center of piston and the center of incline rotation in swash plate.

The return moment varies according to the discharge pressure and the incline angle.

3

AST-15-10-002E 3

Hydraulic Pump Operational Description Before the incline When the discharge pressure is low, the return moment is also small and the spring (16) is not bent.

Thus the swash plate (14) is at a maximum incline angle to maintain maximum discharge.

After the incline When the discharge pressure increases, the return moment also increases. As a result the spring (16) is bent and the incline angle of the swash plate (14) will move to the position where the return moment and the spring force become balanced, reducing the discharge volume.

As the discharge volume further increases, the incline angle decreases accordingly. The spring (17) will also start to bend to keep the volume decreasing.

2. Power-down control by discharge pressure of blade pump (blade shift)

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

An over-torque condition of the input shaft due to the simultaneous high-pressure operations of the main pump and the blade pump is prevented by changing the output characteristics of the main pump through the discharge pressure of the blade pump.

The discharge pressure on the blade pump acts on the shift piston (18) via passage (19).

When the discharge pressure on the blade pump increases, the force on the shift piston increases and the moment counteracting the springs (16, 17) is generated on the swash plate (14).

The moment acting on the swash plate (14) increases because extra moment generated by the shift piston force is added to the return moment which is generated by the main pump discharge pressure.

Therefore, when the discharge pressure on the blade pump is high, the swash plate (14) starts its incline even if the discharge pressure on the main pump is low.

Thus, an over-torque on the input shaft will not take place because the main pump output becomes low when the pressure on the blade pump is high.

AST-15-10-002E

4 4

Control Valve Operation Hydraulic Section

SH80

Control Valve Operation Operation with All Spools in Neutral 1. Main passage

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE R

NA L

The oil supplied from Port P1 passes the neutral passage (2) via passage (1) and flows through Travel (Right), Backup, Boom 2 and Arm 1 sequentially. The oil passed through Arm 1 flows into the tank passage through passage (3) to be discharged into the tank ports (T1, T2).

Also, the oil supplied from Port P1 through passage (4) is directed into the parallel passage (7) through passage (6) by way of the bridge (5) and travel straight valve. Then, Backup, Swing, Boom 2, and Arm 1 sections will be communicated via each check valve and the flow will be stopped by the spools in each section. However, because the parallel passage (7) is connected with the neutral passage (2) via passage (8) and check valve, the oil will flow into the parallel passage (7) from Port P1 without passing the travel straight valve when Travel (Right) is not taking place.

In the same manner, the oil supplied from Port P2 flows into the neutral passage (10) via passage (9). It then returns to the main body via the inlet section through passage (11), and flows into the tank passage through neutral cut spool via passage (12).

Also, the oil supplied from Port P2 is communicated with Travel (Left), Bucket, Boom 1 and Arm 2 sections via the parallel passage (13) and check valve. The flow is stopped by the spools in each section.

The oil supplied from Port PR5 (the third pump) flows in the neutral passage (27) through the inlet section passage (26). The oil passing the blade section (add-on) flows into tank 1 passage through passage (28) via the outlet section.

Also, the oil supplied from Port PR5 is communicated with the blade section via parallel passage (29) and check valve, and the flow is stopped by the spool.

2. Signal passage

Front control signals The oil from the hydraulic power source for signals, which enters Port PP, is directed into Port PA (Front signal) through throttle (13). It also flows into the 5-way valve side of the front control section through passage (14). It then passes passage (15), inlet section, passage (16) and the 4way valve side of the front section, and will be discharged from passage (17) into Port DR (Drain Port).

Travel control signals The oil from the hydraulic power source for signals, which enters Port PP, is directed into Port PT (Travel signal) through throttle (18). It also will be discharged from passage (17) into Port DR (Drain Port) by way of passage (20) and Travel left spool.

Travel straight valve switch-over signals The oil from the hydraulic power source for signals which enters Port PP, flows from passage (22) into the travel right spool passing throttles (13, 21) to be discharged from the neck part of the spool into the tank passage. At the same time, it flows into the travel left spool through passage (23), and will be discharged from the neck part of the spool into tank passage. At this time, the oil which flows into passage (23), will be directed through the annular passage (24) into the pressure chamber (25) for switching over travel straight valve.

5

AST-15-11-002E 1

E

CO US N E FID O E F N TS TI M AL GL : F O OR BA T L H

TE R

IN

NA L

Control Valve Operation

6

AST-15-11-002E 2

Control Valve Operation Independent Operation 1. Travel spool switch-over (Figure 1)

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE R

NA L

Because switching the travel right spool by adding pressure to Port Pa1 (Pb1) closes the neutral passage (A) and shuts off the downstream flow, the oil supplied from Port P1 will pass the neck of the travel right spool through neutral passage (A) and will flow into cylinder Port A1 (B1).

The returning oil from cylinder Port B1 (A1) passes the neck of the travel right spool and flows into the tank passage.

In the same manner, because switching the travel left spool by adding pressure to Port Pa6 (Pb6) closes neutral passage (B) and shuts off the downstream flow, the oil supplied from Port P2 flows into cylinder Port A6 (B6) by way of neutral passage (B), passage (C) and the neck of the travel left spool.

The returning oil from cylinder Port B6 (A6) passes the neck of the travel left spool and flows into the tank passage.

2. Backup spool switch-over (Figure 2)

If this section is to be used, first remove the stopper plugs on the cylinder port and on the pilot cap.

Additionally, replace the shut off valve with an overload release valve and remove the stopper plug on Port P4 if necessary. Because switching the backup spool by adding pressure to Port Pa2 (Pb2) closes neutral passage (A) and shuts off the downstream flow, the oil supplied from Port P1 pushes up the check valve (1) through parallel passage (B) and flows into cylinder Port A2 (B2) by way of passage (C) and the neck of backup spool. The returning oil from cylinder Port B2 (A2) passes the neck of the backup spool and flows into the tank passage. This section can also be merged with an external source through Port P4.

7

AST-15-11-002E 3

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE R

NA L

Control Valve Operation

3. Swing spool switch-over (Figure 3) Because switching the swing spool by adding pressure to Port Pa3 (Pb3) closes neutral passage (A) and shuts off the downstream flow, the oil supplied from Port P1 pushes up the check valve (1) through parallel passage (B) and flows into cylinder Port A3 (B3) by way of passage (C) and the neck of the swing spool.

The returning oil from cylinder Port B3 (A3) passes the neck of the swing spool and flows into the tank passage.

4. Bucket spool switch-over (Figure 3) Because switching the bucket spool by adding pressure to Port Pa7 (Pb7) closes neutral passage (D) and shuts off the downstream flow, the oil supplied from Port P2 pushes up the check valve (2) through parallel passage (E) and flows into cylinder Port A7 (B7) by way of passage (F) and the neck of the bucket spool. The returning oil from cylinder Port B7 (A7) passes the neck of the bucket spool and flows into the tank passage.

AST-15-11-002E

8 4

Control Valve Operation 5. Boom spool switch-over [1] Neutral Position (Figure 4) The valve has an anti-drift valve installed on the cylinder bottom side of Boom 1.

In the neutral position, the poppet (1) is firmly seated by the pressure on Port A7, which was directed to the spring chamber (C) through passage (A), poppet (2) and passage (B).

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE R

NA L

[2] Boom-up (2-pump confluence) (Figure 5) Because switching the boom 1 spool by adding pressure to Port Pa8 closes neutral passage (A) and shuts off the downstream flow, the oil supplied from Port P2 pushes up the check valve (1) through parallel passage (B), passes passage (C) and the neck of the boom 1 spool, then pushes open the poppet (2) in the anti-drift valve and flows into cylinder Port A7. Because switching the boom 2 spool and adding pressure to Port Pa4 at the same time will close neutral passage (D) and shut off the downstream flow, the oil supplied from Port P1 pushes up the check valve (3) through parallel passage (E) and flows into cylinder port A7, by way of passage (F), neck of the boom 2 spool and passage (G). The returning oil from cylinder Port B7 passes the neck of the boom 1 spool and flows into the tank.

[3] Boom-down (Figure 6) Because switching the boom 1 spool by adding pressure to Port Pb8 closes neutral passage (A) and shuts of the downstream flow, the oil supplied from Port P2 pushes up the check valve (1) through parallel passage (B) and flows into cylinder Port B7 by way of passage (C) and the neck of the boom 1 spool. Switching the boom 1 spool and adding pressure to Port pc2 at the same time in order to switch poppet (3) in the anti-drift valve will reduce the pressure in spring chamber (D) to open poppet (2). The returning oil from cylinder Port A7 will pass the neck of the boom 1 spool and flow into the tank passage.

9

AST-15-11-002E 5

E

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H TE R

IN

NA L Control Valve Operation

AST-15-11-002E 10 6

Control Valve Operation 6. Arm spool switch-over

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

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[1] Dump (2-pump confluence) (Figure 7) Switching the arm 1 spool by adding pressure to Port Pa5 closes the neutral passage (A). The oil supplied from Port P1 pushes up the tandem check valve (1) through neutral passage (A) and flows into cylinder Port A5 by way of passage (C) and the neck of the arm 1 spool. At the same time, part of the oil supplied from Port P1 will flows into cylinder Port A5 by way of parallel passage (B), annular restriction (D), parallel check valve (2) and passage (C). Switching the arm 1 spool and adding pressure to Port Pa9 at the same time in order to switch the arm 2 spool will close the neutral passage (E). The oil supplied from Port P2 pushes up the tandem check valve (3) through neutral passage (E) and flows into cylinder Port A5 by way of passage (G), neck of the arm 2 spool and passage (I). At the same time, part of the oil supplied from Port P2 will flow into cylinder Port A5 by way of parallel passage (F), annular restriction (H), parallel check valve (4), passage (G) and passage (I).

The returning oil from the cylinder Port B5 flows into the tank passage through the neck of the arm 1 spool and also flows into the tank passage by way of passage (J) and the neck of the arm 2 spool.

The annular restriction (D) works as a primary restriction for a simultaneous operation with swing movements. The annular restriction (H) works as a primary restriction for a simultaneous operation with boom.

[2] Crowd (2-pump confluence) (Figure 8) Switching the arm 1 spool by adding pressure to Port Pb5 will close the neutral passage (A), and the oil supplied from Port P1 pushes up the tandem check valve (1) through neutral passage (A) and flows into cylinder Port B5 by way of passage (C) and the neck of arm 1 spool. At the same time, part of the oil supplied from Port P1 flows into cylinder Port B5 by way of parallel passage (B), annular restriction (D), parallel check valve (2) and passage (C).

Switching the arm 1 spool and adding pressure to Port Pb9 at the same time in order to switch the arm 2 spool will close the neutral passage (E). The oil supplied from Port P2 pushes up the tandem check valve (3) through neutral passage (E) flows into cylinder Port A5 by way of passage (G), neck of the arm 2 spool and passage (I). At the same time, part of the oil supplied from Port P2 flows into cylinder Port B5 by way of parallel passage (F), annular restriction (H), parallel check valve (4), passage (G) and passage (I).

The returning oil from cylinder Port B5 flows into the tank by way of the neck of the arm 1 spool, passage (K) and annular restriction (L). At this time, part of the returning oil pushes the check valve (5) with restriction and flows into passage (C) via passage (M), increasing the supply volume fed to cylinder Port B5 (Regenerative circuit).

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Control Valve Operation 7. Blade spool switch-over (Add-on) (Figure 9)

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Because switching the blade spool by adding pressure to Port Pra2 (Prb2) closes the neutral passage (A) and shuts off the downstream flow, the oil supplied from Port PR5 pushes up the check valve (1) through parallel passage (B) and flows into cylinder Port AR2 (BR2) by way of passage (C) and neck of the blade spool.

The returning oil from cylinder Port BR2 (AR2) passes the neck of the blade spool and flows into the tank passage.

8. Boom Swing spool switch-over (Add-on) (Figure 9A)

Because switching the boom swing spool by adding pressure to Port pra1 (prb1) closes the neutral passage (A) and shuts off the downstream flow, the oil supplied from Port PR5 pushes up the check valve (1) through parallel passage (B) and flows into cylinder Port AR1 (BR1) by way of passage (C) and neck of the boom swing spool.

The returning oil from cylinder Port BR1 (AR1) passes the neck of the boom swing spool and flows into the tank passage.

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AST-15-11-002E 9

Control Valve Operation [1] Main relief valve (Figure 10) The oil in Port P1 is directly connected with the inlet passage (A) of the main relief valve via common check valve (1), while the oil in Port P2 is directly connected with the inlet passage (A) of the main relief valve via common check valve (2).

The main relief valve prevents the maximum pressure in pumps P1 and P2 from exceeding their programmed values. (The operational description for main relief valve is provided separately.)

[2] Overload relief valve In each cylinder port of Boom 1, Arm 1, Bucket and Offset, an overload relief valve is installed to prevent abnormal boosts of pressure on the actuator due to external forces.

The maximum pressure will also be regulated if the programmed pressure is lower than the pressure on main relief valve.

The overload relief valve also prevents cavitation by drawing oil in from the tank when the pressure on cylinder port becomes negative.

(The operational description for the overload relief valve is provided separately.)

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9. Relief valve

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Control Valve Operation 10.Anti-drift valve (Boom section)

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The anti-drift valve is installed on the boom bottom side of cylinder port A7 to prevent the natural drop of boom cylinder.

[1] Neutral Status (Figure 11) The pressure on cylinder Port A7 passes the hollow cavity in poppet (1) via passage (A) and will be directed to the spring chamber (C) through passage (B).

The force of the spring and the pressure acting on the area differences in the poppet (2) areas work to firmly seat poppets (1, 2).

[2] Up (Figure 12) The oil supplied from the pump pushes open poppet (1) and flows out from cylinder Port A7.

[3] Down (Figure 13) Switching poppet (1) by adding pressure to Port Pc2 will direct the oil in spring chamber (C) to the drain Port dr2 by way of passage (B), the hollow cavities in poppet (1) and spool (3). This opens poppet (2) and the returning oil from cylinder Port A7 flows into the tank passage through the boom 1 spool.

The function can also be added to the cylinder port on the arm rod side.

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Control Valve Operation Combined Operations 1. Additional operation with travel (Figure 14)

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Operating the frontal control (in any section other than Travel) during traveling straight forward/backward or during a spin turn (simultaneous operation of travel right/left), or traveling straight forward/ backward or spin-turning during the operation of the frontal control will switch over the travel straight valve (1) due to the oil from the hydraulic power source for signals, which entered from Port PP. Therefore, the oil supplied from Port P2 (shown by arrows) is shut off from the neutral passage (C) on the 4-way valve side and will flow into parallel passage (D) on the 4-way valve side. It will also flow into parallel passage (B) on the 5-way valve side by way of the neck of travel straight valve and passage (E). Thus, the actuator for the frontal control is operated by the oil supplied from Port P2.

At this time, the oil supplied from Port P1 (shown by arrows) is shut off from parallel passage (B) on the 5-way valve side and flows into cylinder Ports (A1, B1) in Travel Right Section through neutral passage (A) on the 5-way valve side. It also flows into the neutral passage (C) on the 4-way valve side past passage (F) and the neck of travel straight valve, then flows into cylinder Ports (A6, B6) in the Travel Left Section through the hollow cavity in sleeve. Thus, travel is operated by the oil supplied from Port P1 and straight travel is maintained.

Part of the oil supplied from Port P2 passes annular restriction (G), pushes up poppet (3) to be supplied to the travel controls. This helps eliminate the decelerating shocks at the time of travel straight valve (1) switch-over.

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Control Valve Operation Relief Valve 1. Main relief valve

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(1) Operation of main relief valve [1] The relief valve is incorporated between the neutral passage “HP” and the tank passage “LP”. The oil will flow through the throttle of main poppet (1) to fill in the internal cavity (C). Also, the sleeve (2) and the main poppet (1) act on different areas “A, B” to ensure secure seating.

[2] When the pressure on neutral passage “HP” reaches the programmed pilot spring force, the pilot poppet (3) opens. The oil flows around the peripheral of pilot poppet (3) and is directed into tank passage “LP” by way of drilled hole (D) and annular space (E).

[3] As the pilot poppet (3) opens, the pressure in the internal space (C) decreases. As the main poppet (1) opens, the oil in “HP” flows directly into passage “LP”.

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Control Valve Operation 2. Overload relief valve (1) Relief valve operation

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[1] The relief valve is incorporated between the cylinder Port “HP” and the low-pressure passage “LP”. The oil passes the hole on piston (C) and fills the internal space (G). It then acts on different areas <A> and <B> to make sleeve (K) and main poppet (D) securely seated.

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[2] When the pressure on neutral passage “HP” reaches the programmed pilot poppet spring force, the pilot poppet (E) opens. The oil flows around the peripheral of poppet and is directed into the low pressure side “LP” through the drilled hole (H).

[3] As poppet (E) opens, the flow of oil passing the throttle (I) in piston (C) is generated, and a difference in pressure grows between the passage “HP” and the back side of piston (C). The piston (C) then moves and becomes securely seated with the poppet (E).

[4] The oil flow from passage “HP” to the back side of poppet (D) will be restricted to the area (F) only, which is the annular space between poppet (D) and piston (C) and the throttle. As a result, the difference in pressure grows larger. Consequently, the poppet (D) opens and the oil flows directly into passage “LP”.

(2) Intake An anti-void unit is installed to supply oil when cavitation takes place in cylinder Port “HP”. When the pressure on cylinder port “HP” is lower than the pressure on the low pressure side “LP”, the sleeve (K) opens due to the area difference between <A> and <B>. The oil enters the cylinder Port “HP” from the low pressure side “LP” to prevent cavitation.

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Swing Unit Swing Motor Hydraulic Section

SH80

Swing Unit Swing Motor Functional and Operational Description 1. Swash Plate Motor Refer to Structural Drawing Figure 1.

The cylinder block has 9 pistons installed. Also, the end of the cylinder block contacts the valve plates, which have two crescent-shaped ports A and B.

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Principle of torque generation When high pressure oil (Pressure P) is introduced into Port B, the oil pushes the swash plate by force per one piston (F = P x Ap, where Ap is the sectional area of a piston). The piston receives the reaction corresponding to the force from the swash plate. As a result, a component is generated in the rotational direction of the reaction. Then, rotational force is generated on the cylinder block by the collection of forces in the rotational direction of the piston on the high pressure side.

The torque then is transferred to the shaft via spline for rotation. On the other hand, when the high pressure oil is introduced to Port A, the rotational direction will be reverse to the case described above. The output torque and the number of revolutions are calculated according to the following equations:

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Swing Unit Swing Motor

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Figure 1. Structural Drawing of Motor

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Swing Unit Swing Motor 2. Parking Brake (for models equipped with parking brakes) The parking brake is a hydraulic release type, wet multiple disc structure, having a shaft lock mechanism where brake ON/OFF is switched by external signal pressure.

[1] When parking brake is ON See Figure 2-1: Structural drawing. When the hydraulic oil for brake release is shut off, the disc is connected to the peripheral of the cylinder block via splines. The brake piston (secured to prevent its rotation) is pushed by the force of spring, and the cylinder block and the case are secured by the force of friction. The shaft, therefore, will be locked.

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[2] When parking brake is OFF See Figure 2-2: Structural drawing. When the hydraulic oil for brake release is introduced to the brake cylinder chamber (C) through Port PB (Port PG for models with parking brake), the brake piston starts moving due to release pressure against the force of spring. The shaft then will be free to rotate since there is no friction.

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AST-15-12-002E 3

Swing Unit Swing Motor 3. Principle of Relief Valve Operation The relief valve determines the driving force and the braking force at the time of hydraulic shovel swing. They are installed on lines A and B of the main port. It also has a circuit which forces the returning oil from relief valve to go back to the opposing main low pressure line via makeup valve.

Also, it is designed to reduce shocks at start of acceleration / deceleration. The relief valve structure has two components: [1] Area difference direct acting relief valve [2] Shockless piston as shown in Figure 3-1.

Shockless type relief valves help eliminate shocks and stresses generated on intensified components.

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• Pressure Setting of Relief Valve versus Adjustment Volume of Relief Valve (for reference) Per one time: Approximate 9.7 MPa {1406 psi} Do not attempt to make adjustments as long as there are no problems.

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Swing Unit Swing Motor The relief valve operates in two steps as follows:

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• Initial stage (see Figure 3-2) At the beginning of the operation, the shockless pin moves to maintain low pressure in the spring chamber. Thus, the area for receiving pressure on poppet will be the area of poppet seat (S1).

This is considerably large compared to the area for receiving pressure at the normal relief setting (S1-S2). The relief operating pressure, therefore, will be held low until the shockless spin has completely moved.

The duration for which the pressure is held low will be determined according to the orifice diameter between poppet and piston, the area of free piston for receiving pressure, and the free piston stroke.

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Swing Unit Swing Motor • Second stage (see Figure 3-3) By the time the shockless piston has moved completely, the pressure in the spring chamber has risen, and the front and the back pressures of the poppet have become equal. The relief valve, therefore, operates on the pressure setting for normal operation.

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Figure 4 compares the pressure waveforms between the conventional type and the shockless type.

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Swing Unit Swing Motor 4. Makeup Valve

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The makeup valve functions in two ways as described below: First it keeps the swing body from overrunning by preventing cavitation, which is caused by swing body overrun. If the motor had pumped due to inertia of the swing body and the motor revolutions have exceeded the adequate number of revolutions suitable for the oil inflow to motor, the shortage of oil will be supplemented into the main motor circuit via the makeup valve. Thus, the generation of vacuum in the circuit will be prevented. Secondly, it maintains the normal circuit conditions for braking by preventing the generation of vacuum in the circuit. The situation applies at the time of braking, for example, when a closed circuit was formed between the control valve and the motor. The makeup valve supplements the amount of the motor drainage and the valve leakage to prevent the circuit from being vacuumized.

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Swing Unit Swing Motor 5. Reduction Gear (2-stage planetary gear)

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See the sectional drawing below.

The motor shaft (1) is spline-jointed to the drive gear (2). The driving force from the hydraulic motor is transferred to the planetary gear (3), which engages with the drive gear (2). The planetary gear (3) engages with the ring gear in the reduction gear housing (4). The planetary gear thus revolves along the gear ring while it rotates. The planetary gear (3) is held by the holder (5) via a bearing.

The holder transfers the orbital motion of the planetary gear (3) to the sun gear (6), which is spline jointed to the holder. The sun gear (6) engages with the planetary gear (7) and transfers orbital motion to the planetary gear (7) in the same manner as in the first step. The planetary gear (7) revolves as it rotates because it engages with the ring gear in housing (4). Since the planetary gear (7) is held by holder (8) via a bearing, the holder (8) transfers the orbital motion of the planetary gear (7) to the pinion shaft (9), which is spline jointed to the holder.

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Swing Unit Swing Motor Overview 1. Features [1] The valve enhances operability by reducing the number of reverse rotations when the swing body stops.

[2] As the valve has few components and is structurally simple, maintaining the valve is easy.

2. Operational Description The anti-reverse valve prevents reverse rotational motion caused by entrapped pressure at the time the swing body is stopped. This is achieved by directly connecting the motor’s main line to the makeup line for a certain period of time when the motor stops.

The anti-reverse valve consists of the following parts as shown in Figure 1.

[1] Check valve [2] Flow control valve (integrated in check valve) [3] Sleeve (Combined with check valve to form a high pressure selection valve.)

[4] Orifice A

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[5] Orifice B

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Swing Unit Swing Motor

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Swing Unit Swing Motor When control valve is in neutral (Ports P1, P2 on the motor at the same pressure.) The check valve will be balanced at the center with the spring force.

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When the swing body is activated, the check valve on high pressure side is pushed and the check valve will be seated.

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At the time of applying the brake, the check valve is stroked by the brake pressure and will be seated.

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Swing Unit Swing Motor After the motor has been stopped by the braking action of the valve unit, it will try to move in the reverse direction due to the entrapped pressure in the main line. This reverse pressure will seat the shuttle valve (sleeve) in check valve onto the check valve on low pressure side. An oil passage is thus formed between the port on which reverse pressure is applied (Port Pv2) and the port which is connected to the main makeup line (Port Cv). Through this oil passage, the reverse pressure will be released into Port Cv.

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At the same time, the reverse pressure pushes the check valve in the direction opposite of the direction of braking. The flow control valve integrated into the check valve, which now is the low pressure side, releases oil in the damper chamber 1 at a fixed volume. The check valve, therefore, starts stroking at a fixed speed.

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In the end, the check valve becomes seated and the oil passage formed between Port Pv2 and Port Cv is blocked.

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Travel Unit Travel Motor Hydraulic Section

SH80

Travel Unit Travel Motor

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External Dimensional Drawing

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AST-15-13-002E 1

Travel Unit Travel Motor Basic Structure and Drawings

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1. Basic structure of GM motor

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Travel Unit Travel Motor

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Travel Unit Travel Motor 2. Parts list

AST-15-13-002E

PART NAME

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O-ring O-ring Snap ring Ball bearing Ball bearing Roller Piston Shoe Pivot Parallel pin Spring Valve seat Valve Sleeve Coller Plug Spring O-ring Backup ring O-ring O-ring Shim Piston O-ring Backup ring Rear flange Plug Spool Plug Spring retainer Valve Spring Spring O-ring O-ring Pallalel pin Hex.socket bolt Hex.socket plug Spool Spring Steel ball Hex.socket plug Filter Orifice Plug Plug O-ring Name plate

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QTY 1 1 1 1 3 1 4 1 4 4 3 1 1 2 3 4 3 4 2 1 1 3 2 3 1 2 2 1 1 2 1 4 1 1 1 1 9 9 1 1 1 2 1 1 10 1 2 3 1

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Hub Spindle Carrier Sun gear(1) Planetary gear(1) Sun gear(2) Planetary gear(2) Thrust coller(1) Thrust washer(1) Thrust washer(2) Thrust washer(3) Cover Ring nut Ball bearing Needle roller bearing Needle roller bearing Inner ring Inner ring Floating seal Plug O-ring O-ring Plug Hex.head bolt Steel ball Parallel pin O-ring O-ring Ring Hex.socket set screw Retainning ring Hex.head bolt Washer Shaft Swash plate Cylinder block Piston Shoe Retainning plate Thrust ball Timing plate Washer Washer Piston Spring Spring Friction plate Mating plate Oil seal

SYM 1 2 3 4 5 6 7 9 10 11 12 13 22 24 27 28 29 30 31 33 35 37 39 40 41 42 43 44 45 47 50 51 52 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 132

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SYM 135 139 145 149 150 151 161 162 167 171 190 201 202 203 204 205 206 207 208 211 212 213 214 215 216 301 321 323 324 325 327 328 330 336 338 342 345 352 363 366 368 375 379 380 382 383 392 399

QTY 1 1 1 1 1 3 1 1 2 2 1 2 2 2 2 2 2 2 4 2 2 2 2 2 4 1 1 1 2 2 2 2 2 2 3 1 8 3 1 1 1 4 1 1 3 1 1 1

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Travel Unit Travel Motor Operational Description 1. Reduction gear (1) Functions This reduction gear unit is composed of two stage planetary gear mechanism.

The reduction gear reduces the high seed of hydraulic motor and converts it low-speed, hightorque rotation.

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(2) Operating Description The rotation of hydraulic motor shaft is transmitted to sun gear [4] of the first stage which is linked with shaft [102] in spline.

Sun gear [4] is meshed with three planetary gears [5], and three planetary gears [5] mesh with hub [1] while rotating on their axis.

At that time, the hub is rotated by the rotation of the planetary gears [5].

The hub rotation is transmitted to carrier [3] which connected to planetary gears [5], and that causes sun gear [6] rotation of the second stage.

The rotation of sun gear [6] is transmitted to the hub via four planetary gears [7] of the second stage.

The generated rotation of reduction gear is output rotation.

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Travel Unit Travel Motor 2. Hydraulic drive section This section describes the hydraulic motor, brake valve, parking brake, and high-low 2-speed switching mechanism of the hydraulic motor.

(1) Function [1] Hydraulic motor Hydraulic motor is referred to as a swash plate type axial piston motor which converts the pressure oil power fed by pump into rotary motion.

[2] Brake valve 1) Travel motor controls the force of rotational inertia of the body to brake and stop the rotation smoothly.

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2) Check valve function to prevent hydraulic motor from cavitation.

3) Open the port to release the parking brake force at travel motor operation, and close the port at a standstill.

[3] Relief valve 1) Softens the shock when starting the hydraulic motor, softens the shock when stopping the hydraulic motor, and prevents cavitation through the relief operation (reduction of the stop brake sound).

2) When sudden pressure operates on the hydraulic motor, the relief valve keeps the pressure to a predetermined level or less to prevent damage to the hydraulic motor.

[4] High-low 2-speed switching mechanism Switches the hydraulic motor between high speed rotation with low torque, and low speed rotation with high torque.

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[5] Parking brake The parking brake is used the prevent machine from running away or slipping while parking on a slope using the friction plate type brake mechanism, and it installed on the hydraulic motor.

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Travel Unit Travel Motor (2) Principle and operational description

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[1] Hydraulic motor Hydraulic fluid fed by pump enters rear flange [301] of travel motor, and is led from timing plate [109] to cylinder block [104] through brake valve mechanism. This pressure oil is led to only the one side of (Y1)-(Y2) tied between top dead point and bottom dead point of piston [105] stroke. And the pressure led to one side of cylinder block pushes 4 or 5 pistons [105], generating the power (F1 kgf = P kgf/cm2 x A cm2). This power enters on swash plate [103], but swash plate is fixed having an angle ( α) against axis of drive shaft [102], and divided into component of force (F2, F3). And the radial component of force (F3) generated various torque (T= F3 x ri) against line. The total torque T [= Σ(F3 x ri)] is connected turning effort, and rotates cylinder block [104] through piston [105].

The cylinder block [104] is connected with drive shaft [102] with spline, and rotates drive shaft [102] to transmit torque.

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Travel Unit Travel Motor [2] Brake valve Port (A) and Port (B) are the input and output ports for the working fluid. The following description assumes that the working fluid (hydraulic) is fed through port (A).

If the fluid is fed through port (B), the flow and motion are reversed. The direction of Rotation of the motor is also reversed.

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1) During normal operation Hydraulic fluid is fed from the pump to port (A), causing the hydraulic motor to rotate. The details are as follows.

First, the hydraulic fluid fed from the pump enters at port (A) and opens the valve [327].

The fluid oases through the valve [327], enters the hydraulic motor through port (C) and applies rotary force to the hydraulic motor.

At the same time, hydraulic fluid enters at port (A) and passes through small holes in the spool [323] and through channel (a) to chamber (b).

The hydraulic pressure in chamber (b) causes the spool [323] to move from the central position to the left. At this time a groove in the spool [323] forms a channel for hydraulic fluid to pass between port (D) and port (B).

Hydraulic fluid ejected from the hydraulic motor flows from port (D) to port (B), and the hydraulic motor rotates. The hydraulic fluid returns to the oil tank.

Also, as the spool [323] oscillates to the left, hydraulic fluid enters port (E). The hydraulic fluid at port (E) flows to the parking brake and 2-speed switching valve.

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Travel Unit Travel Motor

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2) Stopping (by applying the brake) If pressurized oil supply through the port (A) is suspended while traveling, the hydraulic force to push up the spool is lost, and the spool [323] which is slid to left side, tries to return to the neutral position through the spring retainer [325] due to the spring [328] force.

At that time, through the oil in the chamber (b) tries to flow out to the port (A) side through the passage (a) in the spool [323], its flow is restricted and some back pressure is generated by the throttle effect in the passage (a) controlling the return speed of the spool [323].

At the same time, the hydraulic motor tries to rotate with its inertia force even though the pressurized oil is suspended, and the return oil from the hydraulic motor tries to return to the port (B) side from the port (D) through the passages on spool groove and rear flange.

When the spool [323] entirely return to neutral position, the passage on the hydraulic motor of the oil return side is completely closed by the spool [323], and the hydraulic motor ceases its rotation. While machine working, the brake valve smoothly stops rotation of the hydraulic motor which tries to rotate with its inertia force, by means of throttling the return side passage of the hydraulic motor, generating back pressure due to shape of the spool groove and controlling the return speed of the spool [323].

On the other hand, when braking is operated, the hydraulic motor tries to rotate with its inertia force and to intake oil with its pumping function.

However, because the intake side is closed its passage with the spool [323], the oil supply is suspended. This causes cavitation in the hydraulic motor. To prevent the cavitation, the valve [327] is operated by very slight negative pressure to open the passages of port (A) side and intake port (C) of the hydraulic motor.

And when pressurized oil is supplied through the port (B), each motion of the mentioned parts above becomes symmetrical right and left to stop the hydraulic motor.

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Travel Unit Travel Motor

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3) Anti-racing function During normal operation, when a hydraulic motor is rotated by an outside force, a condition called racing runaway can occur. For example when used as the drive motor for a excavator, racing can occur when the vehicle moves down a steep slope.

This section describes the mechanism used to prevent this condition.

During normal operation, the hydraulic motor is rotated by an outside force. The pressure of the hydraulic fluid feed (at port (A) or port (B)) falls.

As the pressure approaches the level at which racing begins, the spool [323] begins moving to the center towards the central position. The movement of the spool [323] reduces the size of the flow channel from port (D) to port (B) on the output side of the hydraulic motor. This restricts the amount of hydraulic fluid ejected from port (D) to port (B). At the same time the pressure at port (D) (back pressure) increases.

Thus racing is prevented by controlling the flow rate and pressure at the escape port from the hydraulic motor.

AST-15-13-002E

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Travel Unit Travel Motor

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[3] Operation description of relief valve 1) Starting The pressurized oil supplied from the pump is led to port (C) from port (A). Port (C) is connected with the hydraulic pressure motor. Therefore, the hydraulic motor can give torque with the pressurized oil led to port (C). At this time, the valve [202-a] of the relief valve(R/V) “A”is not opened for the pressurized oil of port (C). The piston [214-a] moves to the stroke end of the direction of an arrow with the pressurized oil. The oil of chamber (x) is led to port (D) through the orifice (c) of the sleeve [203-a], the orifice (b) of the valve [202-a]. The pressurized oil of port (C) opens the valve [202-b] (b) of the relief valve “B”with set pressure, and pressurized oil is led to port (D). The pressurized oil from port (C) is led to the chamber (y) through the orifice (f) of the valve [202-b], the orifice (g) of the sleeve [203-b].

If the piston [214-b] reaches the stroke end, the pressure between the orifice (f) of the valve [202-b] and the orifice (g) of the sleeve [203-b] will rise. The cracking pressure of the valve [202-b] turns into more than the system pressure of the excavator with the pressure during two orifices, and the valve [202-b] is closed.

The pressure of port (C) rises by the operation of the relief valve (R/V)“A”and“B”, and the hydraulic motor can obtain torque.

42

AST-15-13-002E 11

Travel Unit Travel Motor The pressure of the port (C) at starting is as follows.

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However, when the piston [214-b] position has reached the stroke end in the case of the last stop, the valve [202-b] of the relief valve (R/V) “B”is not opened.

The pressure of the port (C) in this case is as follows.

E

The pressure of the port (C) at starting changes with the piston [214-b] positions.

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※ When the pressurized oil supplied from the pump is led to port (D) from port (B), operation explanation becomes what replaced the relief valve (R/V) “A”and relief valve (R/ V) “B”.

AST-15-13-002E

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Travel Unit Travel Motor

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2) Stopping If supply of pressurized oil in Port (A) is lost, the counter balance valve will return to neutrality.

Port (D) will be intercepted if the counter balance valve returns to neutrality.

However, since the hydraulic motor rotates according to inertia, the pressure is generated in port (D).

The pressurized oil of port (D) is led to the chamber (x) through the orifice (b) of the valve [202-a], the orifice (c) of the sleeve [203-a].

The piston [214-a] moves to the stroke end of the direction of an arrow with the pressurized oil led to the chamber (x).

While the piston [214-a] is moving, the pressure in the chamber (x) does not rise.

The pressurized oil of port (D) opens the valve [202-a] of the relief valve (R/V)“A”with set pressure, and pressurized oil flows into port (C). (Pressure under piston movement : Primary relief pressure) The pressure of port (D) is controlled by the operation of the relief valve (R/V) “A”, and the cavitation is prevented by supplying oil to port (C).

If the piston [214-a] reaches the stroke end, the pressure of chamber (x) and the pressure between the orifice (b) of the valve [202-a] and the orifice (c) of the sleeve [203-a] will rise, and the valve [202-a] is closed.

At this time, the relief valve (R/V) “A”is relieved above the system pressure of the excavator, and stops the hydraulic motor. (Pressure at the time of the completion of a piston move : Secondary relief pressure) The piston [214-b] of the relief valve (R/V) “B”moves to the direction of an arrow with the pressurized oil of port (D).

The oil of chamber (y) is led to port (C) through the orifice (g) of the sleeve [203-b], the orifice (f) of the valve [202-b].

44

AST-15-13-002E 13

Travel Unit Travel Motor The pressure of the port (D) at stopping is as follows.

: Primary relief pressure : Secondary relief pressure

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Pressure under piston movement Pressure at the time of the completion of a piston move

AST-15-13-002E

45 14

Travel Unit Travel Motor

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[4] High-low 2-speed switching mechanism 1) Low speed When the pilot pressure is shut off from port (P), the GM motor is low speed level.

At this time the spool [363] is pressed the left side by the force of the spring [366], the pressurized oil supply at port (F) is shut off.

The oil in chamber (S) is released into the motor case through the spool [363].

The force of the piston [161] is small. The swash plate [103] is parallel to side (Y).

At this time the swash plate [103] is tilted at a maximum ( θ1). thus leading to lowspeed operation.

46

AST-15-13-002E 15

Travel Unit Travel Motor

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2) High speed When the pilot pressure supplied to port (P), the GM motor is high speed level. At this time the pressure overcomes the force of the spring [366] and the spool [363] is pressed the right side. The pressurized oil supply from port (F) is then introduced into chamber (S) through the spool [363] . The force of the piston [161] is increased by the pressurized oil of chamber (S). The piston [161] pushes the swashl plate [103] up until it touches side (X) and keeps it. At this time the swash plate [103] is tilted at a minimum (θ2), thus leading io high-speed operation.

AST-15-13-002E

47 16

Travel Unit Travel Motor

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3) Automatic switching from high speed to low speed As the load on the hydraulic motor increases, the pressure at port (A) or (B) Increases.

While operating at the high speed level, when the pressure at port (A) or (B) reaches setting pressure, the spool [363] is pressed leftwards. From this point, the operation is as described for ' Low Speed Level '. The force of piston [161] is reduced, and the hydraulic fluid of chamber (S) is opened to drain (motor case) through the spool [363]. The swash plate [103] is positioned along side (Y).

At this time the swash plate [103] has its maximum angle ( θ1). Thus in this state the hydraulic motor has maximum displacement with low rotary speed.

48

AST-15-13-002E 17

Travel Unit Travel Motor

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[5] Parking brake 1) Travering Hydraulic fluid is fed from the pump to port (A) or port (B), causing the brake valve spool [323] to move to the left or right. The movement of the spool [323] opens port (E). The hydraulic oil is fed from port (E) to cylinder chamber (c). When the hydraulic pressure reaches 0.63 MPa (6.42 kgf/cm2), the force of the piston [112] exceeds the force of the spring [113]. The piston [112] moves in the direction of the rear flange [301]. The pressure from the piston [112] on the mating plates [116] and the friction plates [115] disappears, and the friction plates [115] is able to rotate freely.

The friction plate [115] is locked to the cylinder block [104] of the hydraulic motor. Thus the braking force of the cylinder block [104] is released, and the hydraulic motor is able to rotate freely.

AST-15-13-002E

49 18

Travel Unit Travel Motor

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2) Stopping The supply of hydraulic fluid to port (A) or (B) is Stopped. The brake valve spool [323] moves to the center position, shutting off port (E). The pressure in cylinder chamber (c) falls. When this pressure falls below 0.63 MPa (6.42 kgf/cm2), the hydraulic force of the piston [112] becomes less than the force of the spring [113]. The spring [113] causes the piston [112] to press against the mating plates [116] and friction plates [115].

This pressure creates the friction that serves as the braking force. The friction plate [115] is locked to the cylinder block [104] of the hydraulic motor.

The cylinder block [104] is Iocked with the shaft [102] of the hydraulic motor.

Thus brake torque is applied to the hydraulic motor while stopped.

50

AST-15-13-002E 19

Port Locations Hydraulic Circuit Section

SH80

Port Locations Hydraulic Pump Port name

Port size

Inlet port

SAE 2

A1, A2

Delivery port

G3/4

A3

Delivery port

G1/2

PP

Pilot port

G3/8

PPG

Gauge port (pilot)

G1/4 (plug)

P3G

Gauge port (3rd pump)

G1/4 (plug)

R1

Drain port

G1/2 (plug)

R2

Air bleeding port

M10 x 1.0 (plug)

G1, G2

Gauge port

G1/4 (plug)

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AST-15-14-002E 1

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Port Locations

Control Valve

AST-15-14-002E

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2

Port Locations Control Valve Line name

Main port

Line name

Main port

A1

Travel (forward-left) pilot line

pb1

Backup(1) line

A2

Backup pilot line

pb2

Swing-right line

A3

Swing-left pilot line

pb3

Arm-out line

A5

Boom (2)-down pilot line

pb4

Travel line (backward-right)

A6

Arm-in pilot line

pb5

Bucket-close line

A7

Travel (forward-right) pilot line

pb6

Boom-up line

A8

Bucket-open pilot line

pb7

Travel line (forward-left)

B1

Boom-down pilot line

pb8

Backup(1) line

B2

2-speed arm-in pilot line

pb9

Swing-left line

B3

Load holding at boom

pc2

Arm-in line

B5

Return line

Travel line (forward-right)

B6

Bypass filter

T5

Bucket-open line

B7

Pilot drain

dr2

Boom-down line

B8

Backup confluence pilot line

pcc

Blade-up line

AR2

Blade-down line

BR2

Blade-up pilot line

pra2

DR1

Pressure line

RN

Drain

AL

Travel line (backward-left)

P1, P2, PP P3, P4

Attachment signal pressure measurement

PA

Travel signal pressure measurement

PT

TE

Backup confluence line

T1, T2, T3, T4

prb2

Swing-right pilot line

pra1

pa1

Swing-left pilot line

prb1

pa2

Swing-right line

AR1

pa3

Swing-left line

BR1

2-speed boom-up pilot line

pa4

Backup (2) pilot line

pra3, prb3

Arm-out pilot line

pa5

Backup (2) line

AR3, BR3

Travel (backward-right) pilot line

pa6

Blade pressure line

Bucket-close pilot line

pa7

Plug

Boom-up pilot line

pa8

2-speed arm-out pilot line

pa9

Backup pilot line

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

Swing-right pilot line

E

Travel (backward-left) pilot line

IN

Blade-down pilot line

3

PR5 B4

AST-15-14-002E 3

Pilot Hose Connection Diagrams Hydraulic Circuit Section

SH80

Pilot Hose Connection Diagrams

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Pilot P & T Lines

AST-15-15-002E

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Pilot Hose Connection Diagrams

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Pilot P & T Lines

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AST-15-15-002E 2

Pilot Hose Connection Diagrams

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Pilot Control Lines

AST-15-15-002E

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Pilot Hose Connection Diagrams

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Pilot Control Lines

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AST-15-15-002E 4

Functional Description Hydraulic Circuit Section

SH80

Functional Description List of Functions Description of Functions

Operational Description

High-speed

High speeds can be achieved by setting the two-stage incline angle of the travel motor to the smaller angle.

The load pressure for travel motor will automatically swith speeds to low when necessary.

page 11

Low-speed

Low speeds can be achieved by setting the two-stage incline angle of the travel motor to the larger angle.

page 13

Straight travel

Straight travel is maintained in spite of attachment/swing operations during travel.

page 15

Item Travel circuits:

Swing circuits:

AST-15-17-002E

AST-15-17-002E

page 17

Override throttle

Swing pushing is obtained by the swing override throttle integrated in the control valve.

page 19

AST-15-17-002E

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Bucket circuits:

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Parking

1. While the swing lever is positioned at neutral, the swing parking will be activated to fully hold the swing.

2. Shifting through the swing lever will release the mechanical brake to start the normal swing operation. The swing parking will also stay released if attachments such as boom, arm and bucket were operated following the swing operation.

3. The swing parking will be activated 5 seconds after the swing lever is put in neutral or the attachment movement is stopped.

Opens the bucket by switching the bucket spool.

Bucket-closing

Closes the bucket by switching the bucket spool.

1. Switch-over of arm (2) spools enables the internal confluence, thus achieving higher speeds.

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

Arm-in/arm-out 2-speeds

page 21 page 22

AST-15-17-002E

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Arm circuits:

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Bucket-opening

8

page 23

AST-15-16-002E 1

Functional Description Description of Functions

Operational Description

Boom-up 2-speeds

Switch-over of boom (2) spools enables the internal confluence, thus achieving higher speeds.

page 25

Boom-down

1. The boom-down movement will be enabled by releasing the load holding valve integrated in the control valve.

2. The bleed-off circuit works to control high pressures. It also reduces windage.

page 27

Item Boom circuits:

AST-15-17-002E

Boom Swing Circuits: Boom Swing Blade Circuits: Blade Operation Backup circuits:

AST-15-17-002E

Swing the boom by switching the boom swing spool.

AST-15-17-002E Operating the blade by switching the blade spool.

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page 33 A secondary backup section can be added as an option to accommodate special attachments such as a rotating fork.

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Other

Cushion valves work to moderate shocks.

They are installed on the boom pilot line.

page 40

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Cushion valve

page 31

AST-15-21-002E

Breaker and Crusher Circuit Secondary circuit

page 29

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Note: See the tables in the following pages for the relationship between each specification and the optional equipment.

AST-15-16-002E

9 2

Functional Description Control Valve Configuration Table Overview Control valves are configured as follows according to model and specification.

Standard

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Optional

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AST-15-16-002E 3

Explanation of Hydraulic Circuit and Operations (standard model) Hydraulic Circuit Section

SH80

Explanation of Hydraulic Circuit and Operations (standard model) Travel Circuits High-speed Travel Circuit

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With High-Speed Travel, high speeds can be achieved by setting the two-stage incline angle of the travel motor to the smaller angle.

The circuit has a travel motor, which 5 switches over to lower speeds by utilizing load pressure on the travel motor while traveling at high speeds.

The oil discharged from A1 enters port P1 of the control valve entry, while the oil from A2 enters port P2 of the control valve entry. Each flow goes into the travel motor through the switch-over of the left and right travel spool. By these flows, the machine travels forward and backward. To obtain high speeds, electronic signals are sent to the switch panel through the travel change-over switch. Then electronic signals are sent from the switch panel to the solenoid valve for 2-speed travel in the assembly valves to switch the assembly valves. This enables the original pilot pressure (4.2 MPa) {609 psi} from port C1 of the assembly valves to be connected with port P of the left and right travel motors through the rotating joint. The original pressure (4.2 MPa) {609 psi} that entered port P of the left and right travel motors positions the incline angle of the travel motor to the smaller angle, enabling faster speeds.

AST-15-17-002E

11 1

Explanation of Hydraulic Circuit and Operations (standard model)

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High-speed Travel Circuit

12

AST-15-17-002E 2

Explanation of Hydraulic Circuit and Operations (standard model) Low-speed Travel Circuit

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The travel patterns are normal. Turning the key OFF once and switching it back ON during highspeed travel will always set the speed back to low.

The oil discharged from A1 enters port P1 of the control valve entry, while the oil from A2 enters into port P2 of the control valve entry. Each flow goes into the travel motor through the switch-over of the left and right travel spool. By these flows, the machine travels forward and backward. The 2-speed travel solenoid valve will be turned OFF and the hydraulic oil in port P of the travel motor will be connected to the pilot tank line.

AST-15-17-002E

13 3

Explanation of Hydraulic Circuit and Operations (standard model)

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Low-speed Travel Circuitt

14

AST-15-17-002E 4

Explanation of Hydraulic Circuit and Operations (standard model) Straight-travel Circuit (Boom-Up and Travel-Forward)

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The following applies when travel and boom-up operations are conducted at the same time.

The hydraulic oil that entered the pilot pump from PP, which was connected to the tank via travel spool, becomes blocked off by the switch-over of travel spool. Also, the switch-over of the spool to the boom blocks off the branch channels from PP via all spools for attachments (boom, arm, bucket, swing, including offset if equipped with this), which were connected to the tank. Therefore, the hydraulic oil from the pilot pump entering through PP cannot flow any further, and the circuit pressure rises up to the original pressure of (4.2 MPa) {609 psi} . This original pressure acts on the pilot chamber of the straight travel valve and switches over the straight travel valve. The switch-over of the straight travel valve enables P1 to achieve travel and P2 to drive attachments. The left and the right pressures are equal for travel because one pump drives those motors, thus enabling straight travel. In addition, extra hydraulic oil from P2 is supplied to the travel side through a check with travel confluence throttle to keep the speed loss to a minimum.

This also applies when travel and the upper actuators other than boom are operated at the same time.

AST-15-17-002E

15 5

Explanation of Hydraulic Circuit and Operations (standard model)

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Straight-travel Circuit (Boom-Up and Travel-Forward)

16

AST-15-17-002E 6

Explanation of Hydraulic Circuit and Operations (standard model) Swing Circuit Swing Parking Circuit Once the engine is turned on and the swing lever is positioned in neutral, the swing brake solenoid valve will be turned ON (SH75: 12 V, SH135: 24 V) and the swing parking brake will be activated.

When the swing pressure switch is turned ON by the shifting of the lever, the output to the swing brake solenoid valve from the switch panel will be turned OFF. This releases the swing parking brake and enables the swing operation. In another case, if an attachment such as an arm is moved within 5 s after the swing lever was returned to neutral, a lateral force will be generated for the swing movement. In order to prevent the dragging caused by braking, the parking bake will also be released.

Once the signals from attachment pressure switch (2.0 MPa {290 psi} : ON, 1.5 MPa {218 psi} : OFF) are sent to the switch panel and the output to swing brake solenoid valve from switch panel is turned OFF, the swing parking brake will be released.

5 s after the swing pressure switch and the attachment pressure switch are turned OFF, the solenoid valve will be turned ON, enabling the swing parking brake to operate.

Key switch

Swing pressure switch

Attachment pressure switch

Swing brake solenoid valve

Swing motor mechanical brake

OFF

OFF

OFF

OFF

ON*

Key Switch OFF

ON

OFF

OFF

ON

ON

Key Switch ON

ON

OFF

ON

ON

ON

Attachment operations

ON

ON

ON

OFF

OFF

Independent operation of swing

ON

ON

ON

OFF

OFF

Attachment + swing operation

ON

OFF

OFF

ON

Attachment in neutral

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Notes:

ON (in 5 s)

Remarks

E

• The attachment pressure switch will be ON when the spool is switched over for either boom, arm, bucket or swing (including offset if equipped with this) and activates the original pilot pressure.

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

• When an asterisk (*) accompanies the “swing motor mechanical brake ON” statement, it indicates that the swing parking release pressure automatically returns to the tank pressure because all else is OFF, which in turn activates the mechanical brake.

AST-15-17-002E

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Explanation of Hydraulic Circuit and Operations (standard model) Swing Parking Circuit

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Independent operation of swing

18

AST-15-17-002E 8

Explanation of Hydraulic Circuit and Operations (standard model) Swing Override Throttle Circuit

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Providing an override throttle on the parallel circuit enables the pressure to rise at combined operation of arm and swing, thus securing the swing force for press digging operation.

AST-15-17-002E

19 9

Explanation of Hydraulic Circuit and Operations (standard model)

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Swing Override Throttle Circuit

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AST-15-17-002E 10

Explanation of Hydraulic Circuit and Operations (standard model) Bucket Circuit Bucket-Opening Circuit

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When the bucket control lever is moved to the opening side, the pilot pressured oil is supplied to Port pb7 of the control valve.

The bucket spool will be in a preparation state.

The hydraulic pressured oil delivered from the hydraulic pump A1 is supplied to a bucket spool through a center bypass oil circuit also it is supplied to the rod side of a bucket cylinder.

Accordingly, the bucket opens by contraction of the rod of the bucket cylinder.

The returned oil from the bucket cylinder bottom runs into the tank oil circuit through a bucket spool.

21

AST-15-17-002E 11

Explanation of Hydraulic Circuit and Operations (standard model)

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Bucket-Closing Circuit

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AST-15-17-002E 12

Explanation of Hydraulic Circuit and Operations (standard model) Arm CIrcuits Arm-in / Arm-out 2-speed Circuit

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The oil discharged from A1 is supplied to the arm (1) spool via parallel oil passage through central bypass oil passage or straight travel spool.

TheArm-in / Arm-out 2-speed circuit has a configuration where the discharged oil from A2 is supplied to the arm (2) spool through the central bypass oil passage or parallel oil passage to merge at the upstream of the arm (1) spool.

The returning oil from the cylinder will be allowed to merge with the oil on the supply side through self regeneration only when the arm is in (when the pressure of oil on the supply side becomes lower than the pressure of oil returning).

AST-15-17-002E

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Explanation of Hydraulic Circuit and Operations (standard model)

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Arm-in / Arm-out 2-speed Circuit

24

AST-15-17-002E 14

Explanation of Hydraulic Circuit and Operations (standard model) Boom Circuits Boom Circuit 1: Boom-up 2-speed Circuit

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The oil discharged from A1 is supplied to the boom (2) spool through the parallel oil passage via the right travel spool or the straight travel valve, and merges at the downstream of the boom (1) spool.

The oil discharged from A2 merges with the oil discharged from boom (2) by way of parallel oil passage and the boom (1) spool, and flows into the bottom side of the boom cylinder via holding valve.

AST-15-17-002E

25 15

Explanation of Hydraulic Circuit and Operations (standard model)

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Boom-up 2-speed Circuit

26

AST-15-17-002E 16

Explanation of Hydraulic Circuit and Operations (standard model) Boom Circuit 2: Boom-down Load Holding Valve Circuit

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The boom-down pilot pressure goes into port Pb8 of the control valve and the main control valve spool moves to the left.

Also, the pilot pressure enters Port Pc2 and moves the load holding valve spool to the left. Through this movement, the oil in the spring chamber of the load holding valve check passes the load holding valve spool, creating a connection to the tank. As a result, the pressure on the spring chamber decreases and the load holding valve check will be released.

The pressurized oil on the boom cylinder bottom side returns to the tank line as the load holding valve opens. As a result, the boom cylinder rod retracts and the boom is lowered.

Also, the bleed-off circuit controls high pressures, which in turn reduces windage.

AST-15-17-002E

27 17

Explanation of Hydraulic Circuit and Operations (standard model)

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Boom-down Load Holding Valve Circuit

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AST-15-17-002E 18

Explanation of Hydraulic Circuit and Operations (standard model) Boom Swing CIrcuit Boom Swing CIrcuit

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

As the boom swing remote control valve is switched over, the pilot oil enters Port prb1 or pra1.

The oil at P2 from the hydraulic pump then flows into the boom swing cylinder via Port BR1 or AR1 through the boom swing valve. The returning oil flows into the tank through Port AR1 or BR1.

AST-15-17-002E

29 19

Explanation of Hydraulic Circuit and Operations (standard model)

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

Boom Swing CIrcuit

30

AST-15-17-002E 20

Explanation of Hydraulic Circuit and Operations (standard model) Blade Circuits Blade Circuits

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

As the blade remote control valve is switched over, the pilot oil enters Port prb2 or pra2.

The oil at PR5 from the gear pump then flows into the blade cylinder through the Parallel passage.

The returning oil flows into the tank through Port AR2 or BR2.

31

AST-15-17-002E 21

Explanation of Hydraulic Circuit and Operations (standard model)

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

Blade Circuits

32

AST-15-17-002E 22

Explanation of Hydraulic Circuit and Operations (option) Hydraulic Circuit Section

SH80

Explanation of Hydraulic Circuit and Operations (option) Backup Circuits Breaker and Crusher Circuit (2-speed confluence crusher circuit)

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

The solenoid valve will be turned ON by turning the switch inside the cab toward the crusher side.

By stepping on the backup pedal, the pilot pressure from the remote control valve passes through the solenoid valve via shuttle valve and enters Port P of the holding valve and Port Pb2 of the backup (2) spool.

The backup (2) spool moves to the right and shuts off the central bypass.

The pilot pressure from the solenoid valve acts on Port pcc of the confluence spool and moves the spool to the left to shut off the central bypass.

The oil in Port P2 thus flows into the holding valve through Port P3 of the control valve.

The holding valve acts on the holding valve release spool by communicating the pilot pressure from the solenoid valve to Port P. The valve thus returns the oil in the spring chamber to the tank and releases the check in the holding valve.

The oil at Port P3 of the control valve enters Port P4, which is upstream of the control valve backup spool, through the holding valve check. It then merges with the oil from P1.

AST-15-21-002E

33 1

Explanation of Hydraulic Circuit and Operations (option)

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

Breaker and Crusher Circuit (2-speed confluence crusher circuit)

34

AST-15-21-002E 2

Explanation of Hydraulic Circuit and Operations (option)

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

Breaker and Crusher Circuit (backup line holding valve)

AST-15-21-002E

35 3

Explanation of Hydraulic Circuit and Operations (option) Breaker and Crusher Circuit (breaker circuit) Ultra Small Tail Swing Hydraulic Excavator

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

By turning the switch in the cab to the breaker side and stepping on the pedal, the pilot pressure, which entered Pb2 in the control valve, switches over to the backup spool. As a result, the pressurized oil from A1 will be supplied to the breaker through the direction valve.

AST-15-21-002E

36 4

Explanation of Hydraulic Circuit and Operations (option)

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

Breaker and Crusher Circuit (breaker circuit) Ultra Small Tail Swing Hydraulic Excavator

37

AST-15-21-002E 5

Explanation of Hydraulic Circuit and Operations (option) Backup Reciprocating Circuit (ultra small swing hydraulic excavator)

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

As the back up remote control valve is switched over, the pilot oil enters Port pra1 or Port prb1. The oil at P2 then flows into the backup valve AR1 or Port BR1 through the parallel passage.

The returning oil flows into the tank through Port BR1 or Port AR1.

AST-15-21-002E

38 6

Explanation of Hydraulic Circuit and Operations (option)

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

Backup Reciprocating Circuit (ultra small swing hydraulic excavator)

39

AST-15-21-002E 7

Explanation of Hydraulic Circuit and Operations (option) Secondary Backup Reciprocating Circuit (ultra small tail swing hydraulic excavator)

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

As the backup remote control valve is switched over, the pilot oil enters Port prb3 or Port pra3. The oil at PR5 from the gear pump then flows into the backup valve BR3 or Port AR3 through the parallel passage. The returning oil flows into the tank through Port AR3 or Port BR3.

Drain lines are pre-installed in the secondary backup section to accommodate special attachments such as a rotating fork.

AST-15-21-002E

40 8

Explanation of Hydraulic Circuit and Operations (option)

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

Secondary Backup Reciprocating Circuit (ultra small tail swing hydraulic excavator)

41

AST-15-21-002E 9

Operational Description Operational Description

SH80

Operational Description Monitor Display 1. Monitor switch panel

4.Overheat

10.Wiper switch

2.Coolant temperature gauge

5.Abnormal engine oil pressure

11.Washer switch

3.Hour meter

6.Low fuel

12.Working light switch

7.Battery charge error

13.High-speed travel switch

8.-

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

9.Glow (Preheat) Indicator

AL

1.Fuel gauge

1

AST-15-28-002EN 1

Operational Description 2. List of Functions ( ○ : Standard, OPT: Optional, -: Not provided) Functions

SH80-3B

1

Engine Start-up Control

2

Engine Start-up Circuit

4

Throttle control

○

See page 5/22

2.2

One-touch idling

○

See page 7/22

2.3

EGR cut control

○

See page 8/22

3.1

2-speed travel

○

See page 10/22

3.2

Swing brake

○

See page 11/22

3.3

Travel alarm

○

See page 12/22

3.4

Working light

○

See page 13/22

3.5

Windshield wiper/washer

○

See page 14/22

3.6

Power cut delay

○

See page 16/22

4.1

Overheat warning

○

See page 17/22

4.2

Engine oil pressure warning

○

See page 19/22

4.3

Low fuel warning

○

See page 20/22

4.4

Battery charging warning

○

See page 21/22

4.5

Glow timer (auto)

○

See page 22/22

4.6

Hour meter

Gate lock

Radio

AM/FM

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

Heater

E

Interior light 5

○

IN

Horn

AL

Monitor Display Control

See page 3/22

RN

Monitor Output Control

○

2.1

TE

3

Remarks

○ ○ ○ ○ ○

6

Air Conditioner

OPT

See Air Conditioner

7

Combined Line for Breaker and Crusher

OPT

See Hydraulic Circuit

8

Interference Prevention System

AST-15-28-002EN

-

See Interference Prevention System

2 2

Operational Description Engine Control 1. Engine start-up control [1] Power supply (key switch at ON position) 1) Battery relay is energized.

2) Power is supplied to the initial excitation port (IG) in the alternator. (The alternator does not generate electricity until the input signal is recognized.)

3) Power is supplied to the monitor to initiate operation.

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

[2] Cranking (key switch at Start) 1) Energizing the safety relay will initiate the power to be supplied to the starter relay integrated in the starter motor, thus activating the starter motor.

2) When the engine is started through the starter motor, signals will be output from the alternator to the safety relay.

3) When the engine reaches to the required rotational speed, the signals from the alternator to the safety relay will be activated then the power supply to the starter motor stops.

As a result the starter motor stops its operation (if the cranking continues).

4) When the engine starts, the power generation begins at the alternator B terminal and the supply of power is supplied to each load while batteries are also recharged. The terminal L on the alternator starts its output at the same time, activating the battery charging warning and the hour meter.

(See Monitor Display for details.)

[3] Low-temperature start-up feature / preheat (key switch at HEAT or at ST) 1) The heat relay is also energized during cranking (key switch at ST) to supply power to the air heater.

This is to maintain the temperature achieved through manual preheating.

3

AST-15-28-002EN 3

Operational Description

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

2. Engine Start-up Circuit

AST-15-28-002EN

4 4

Operational Description (1) Throttle control

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

[1] Configuration

Note: The idling and the high-idling positions for the engine governor are pre-adjusted by the engine supplier before delivery.

5

AST-15-28-002EN 5

Operational Description [2] Operational Description 1) When the power is supplied to the throttle motor, the control device compares the throttle volume signal and the potentiometer signal. It then outputs a signal to the DC motor to move the rack to the target position set by the throttle volume.

2) The DC motor then makes a normal or reverse rotation according to the signal received from the control device.

3) The output from the DC motor will be transferred to the reduction gears via the rack. The rack rotates the governor lever by allowing the PULL cable to stroke to increase/decrease the engine revolutions.

TE

RN

AL

4) The potentiometer signals interlock with the rack. When the signal coincides with the throttle volume signal, the control device will stop the output of the command signal for motor rotation.

5) The rack strokes are controlled by the Pull side L/S and the Return side L/S.

E

IN

6) When the working tension on the throttle motor reaches 20.3 N or above, the overload protection circuit will be initiated to prevent the DC motor seizure.

Note: When the limit switch becomes damaged by an open circuit or a short circuit, the conditions will be as follows:

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

• Damage by open circuit: The DC motor alters the engine rpm in response to the throttle volume. The current continues to flow to the DC motor at the time of maximum engine rpm and during idling. The overload is thus detected and the output to the DC motor will be stopped.

• Damage by short circuit: The rack does not move to the side where a short circuit has taken place in the limit switch. If the limit switch has a short circuit on the Pull side, the rack can only move toward the Return side from the location it was in when the short circuit took place (to the limit switch on the Return side).

If the limit switch had a short circuit on the Return side, the rack can move to the Pull side only (to the limit switch on the Pull side).

AST-15-28-002EN

6 6

Operational Description

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

(2) One-touch idling

Note: When the motor output is ON, the control device moves the rack to the idling position regardless of the throttle volume location.

7

AST-15-28-002EN 7

Operational Description (3) EGR cut control The purpose of EGR cut control is to reduce nitrogen oxide (NOx), which occurs easily at high combustion temperatures, by opening EGR and partially mixing the exhaust gas with the suction air to reduce the combustion temperature.

1) Operation explanation

IN

TE

RN

AL

[1] When the coolant temperature reaches 60 ℃ or higher, the EGR cut relay is turned ON. (When the coolant temperature is less than 60 ℃, EGR is closed. However, note that there is a hysteresis setting for the opening side at 60 ℃ and the closing side at 55 ℃, and EGR will not close immediately even if the coolant temperature drops below 60 ℃.)

[2] When the EGR cut relay is ON, the sensor reads the boost pressure and engine speed and the following graph operations are performed.

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

When the boost pressure is less than 4 kPa, EGR opens when the engine speed is 1850 min-1 or higher, and EGR closes when the engine speed is less than 1820 min-1.

AST-15-28-002EN

8 8

Operational Description

RN

AL

When the boost pressure is 15 kPa, EGR opens when the engine speed is 1400 min-1 or higher, and EGR closes when the engine speed is less than 1250 min-1. *: Once EGR is open, it does not close until the engine speed reaches a level where it is set to close.Conversely, once EGR is closed, it does not open until the engine speed reaches a level where it is set to open.

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

When the boost pressure is 4 kPa or higher but less than 15 kPa, EGR opens when the engine speed is 1850 min-1 or higher, and EGR closes when the engine speed is less than 1250 min-1. *: Once EGR is open, it does not close until the engine speed reaches a level where it is set to close.Conversely, once EGR is closed, it does not open until the engine speed reaches a level where it is set to open.

9

AST-15-28-002EN 9

Operational Description 3. Monitor Output Control (1) 2-Speed travel [1] Configuration

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

[2] Operation

• If the key switch is turned ON again after it was turned OFF, the low travel speed is always selected.

AST-15-28-002EN

10 10

Operational Description (2) Swing brake

AL

[1] Configuration

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

[2] Operation

• The brake will go ON 5 s after the attachment switch is turned OFF. • The brake will go ON 3 s after the power cut delay.

11

AST-15-28-002EN 11

Operational Description (3) Travel alarm [1] Configuration

RN

AL

[2] Operation

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

• The travel pressure switch will also be turned ON through steering/pivot turn operations, thus activating the alarm.

AST-15-28-002EN

12 12

Operational Description Working light

AL

[1] Configuration

E

IN

TE

RN

[2] Operation

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

(4)

• If the key switch is turned ON again after it was turned OFF, the working lights and the rear lights will be reset.

13

AST-15-28-002EN 13

Operational Description (5) Windshield wiper / washer

RN

AL

[1] Configuration

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

[2] Operation 1) Wiper

AST-15-28-002EN

14 14

Operational Description 2) Windshield wiper / washer

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

• The LED for intermittent/continuous movements will not be turned ON when the windshield washer switch is turned ON.

15

AST-15-28-002EN 15

Operational Description (6) Power cut delay [1] Configuration

TE

RN

AL

[2] Operation

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

• Due to the overcurrent protection circuit provided in the monitor output, the monitor will not be damaged in the event that a short circuit occurs in the harness or in the battery relay coil.

AST-15-28-002EN

16 16

Operational Description 4. Monitor Display Control (1) Overheat warning

RN

AL

[1] Configuration

Resistance(Ω)

(50) {122}

80 {176}

(153.9)

32.3

100 {212}

120 {248}

IN

Temperature ( ℃ {° F})

TE

Thermo-sensor specifications for analog meter

18.4

16.1

E

Thermostat switch (coolant) specifications 105 {221}

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H Switch ON ( ℃ {° F})

Thermostat switch (oil) specifications Switch ON ( ℃ {° F})

98 {208.4}

Switch OFF ( ℃ {° F})

91 {195.8}

17

AST-15-28-002EN 17

Operational Description [2] Operation

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

• When the overheat signal falls 1V or below, the monitor recognizes this as the switch being ON and turns the LED on. Therefore, even when the signal line is removed, the LED will still be turned ON.

AST-15-28-002EN

18 18

Operational Description (2) Engine oil pressure warning [1] Configuration Pressure switch Model 3B type 80

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

[2] Operation

29 kPa {4.2 psi} or less

• Even if a warning is requested, the buzzer will not be activated until the key switch signal (cranking signal) is received.

19

AST-15-28-002EN 19

Operational Description (3) Low fuel warning [1] Configuration Fuel sensor specifications Fuel remaining Sensor resistance (Ω)

1/2

Full

90

38

10

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

[2] Operation

Empty

• When the thermistor resistance falls to 37 ohm or below, the monitor recognizes this as the signal being ON and turns on the LED.

AST-15-28-002EN

20 20

Operational Description Battery charge warning [1] Configuration

E

IN

TE

RN

AL

[2] Operation

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

(4)

• Even if a warning is requested, the buzzer will not be activated until the key switch signal (cranking signal) is received.

• When the alternator signal falls below 6V, the monitor turns the warning ON.

21

AST-15-28-002EN 21

Operational Description (5) Glow timer (auto) [1] Configuration

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

[2] Operation

AST-15-28-002EN

22 22

Electric Circuit Diagrams Electric Circuits Section

SH80

Electric Circuit Diagrams

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

Electric Circuit Diagram 1

23

AST-15-31-002E 1

Electric Circuit Diagrams

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

Electric Circuit Diagram 2

AST-15-31-002E

24 2

Electric Circuit Diagrams

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

Electric Circuit Diagram: Air Conditioner 1

25

AST-15-31-002E 3

Electric Circuit Diagrams

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

Electric Circuit Diagram: Air Conditioner 2

AST-15-31-002E

26 4

Harness Diagrams Electric Circuits Section

SH80

Harness Diagrams Upper Frame

CO US N E FID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE R

NA L

Frame Wiring Main Harness

27

AST-15-23-002E 1

Harness Diagrams Inside Cab

CO US N E FID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE R

NA L

Cab Wiring Main Harness

28

AST-15-23-002E 2

Wiring Diagrams Electric Circuits Section

SH80

Wiring Diagrams Electrical Components and Wiring for Upper Frame (frame) SYM

QTY

1

2

WIRE HARNESS

2

1

PRESS. SWITCH

3

2

HORN

4

1

THERMO SWITCH

5

1

WIRING HARNESS

6

1

TRAVEL ALARM

7

1

CO US N E FID O E F N TS TI M AL GL : F O OR BA T L H

D

E

A

IN

TE R

NA L

DESCRIPTION PRESS. SWITCH

F

C

B

L

G

H

K

J

I

L

29

AST-15-33-002M 1

Wiring Diagrams Electrical Components and Wiring for Cab DESCRIPTION LOUD SPEAKER

B

TE R

NA L

A

QTY

1

2

NOTHING

2

-

ANTENNA CODE

3

1

DC-DC CONVERTER

4

1

WIRE HARNESS

5

1

BUZZER (24V)

6

1

SOCKET (DC12V)

7

1

CONTROLLER

8

1

CHANGE OVER RELAY

9

10

ROCKER SWITCH

10

1

WORKING LIGHT

11

1

MONITOR 24V

12

1

STARTER SWITCH ASSY

13

1

ROCKER SWITCH

14

1

ROCKER SWITCH

15

1

CO US N E FID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

B

SYM

A

30

AST-15-33-002M 2

Wiring Diagrams Electrical Components and Wiring for Upper Frame (engine) DESCRIPTION

SYM

QTY

1

1

E

CO US N E FID O E F N TS TI M AL GL : F O OR BA T L H

B

IN

TE R

NA L

THERMO SENSOR

C

E

31

AST-15-33-002M 3

Wiring Diagrams Electrical Components and Wiring for Upper Frame (battery) DESCRIPTION

SYM

QTY

1

1

BATTERY HOLDER

2

1

BATTERY 95D31R

3

2

BATTERY CABLE

4

1

BATTERY CABLE

5

1

BATTERY CABLE

6

1

BATTERY RELAY

7

1

FUSE

8

1

FUSE 50A

9

1

CO US N E FID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE R

NA L

BATTERY CABLE

A

32

AST-15-33-002M 4

E

CO US N E FID O E F N TS TI M AL GL : F O OR BA T L H

TE R

IN

NA L

Wiring Diagrams

Heater

33

AST-15-33-002M 5

Wiring Diagrams Air Conditioner

CO US N E FID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE R

NA L

Inside Frame

34

AST-15-33-002M 6

Wiring Diagrams Inside Caiob DESCRIPTION

QTY

1

4

CONTROL PANEL

2

1

CO US N E FID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE R

NA L

SYM

CHANGE OVER RELAY

35

AST-15-33-002M 7

Measuring / Adjusting Pressure Maintenanse section

SH80

Measuring / Adjusting Pressure Measuring Pressure 1. Basic conditions 45 - 55 ℃ {113 - 131 ° F}

Oil temperature

2200 min-1

Engine revolutions at no load

2. Pressure settings Relief valve Individual pressure settings

Actual readings measured on machines (reference)

29.4 MPa at 44 L/min {4264 psi at 11.6 gpm}

29.7 MPa {4307 psi}

Arm relief

Up

31.9 MPa at 20 L/min {4626 psi at 5.3 gpm}

33.5 MPa {4858 psi}

Fasten main relief 180° + Boom-up relief

Down

31.9 MPa at 20 L/min {4626 psi at 5.3 gpm}

33.2 MPa {4815 psi}

Fasten main relief 180° + Boom-down relief

Out

31.9 MPa at 20 L/min {4626 psi at 5.3 gpm}

32.7 MPa {4742 psi}

Fasten main relief 180° + Arm-out relief

In

31.9 MPa at 20 L/min {4626 psi at 5.3 gpm}

33.0 MPa {4786 psi}

Fasten main relief 180° + Arm-in relief

Open

31.9 MPa at 20 L/min {4626 psi at 5.3 gpm}

33.1 MPa {4800 psi}

Fasten main relief 180° + Bucket-open relief

Closed

31.9 MPa at 20 L/min {4626 psi at 5.3 gpm}

33.1 MPa {4800 psi}

Fasten main relief 180° + Bucket-closed relief

22.6 MPa at 57.5 L/min {3277 psi at 15.2 gpm}

25.0 MPa {3625 psi}

Swing relief

Left

22.6 MPa at 57.5 L/min {3277 psi at 15.2 gpm}

25.0 MPa {3625 psi}

Swing relief

33.3 MPa at 20 L/min {4830 psi at 5.3 gpm}

33.7 MPa {4888 psi}

Fasten main relief 180° + Boom swing-right relief

Left

31.9 MPa at 20 L/min {4626 psi at 5.3 gpm}

32.9 MPa {4772 psi}

Fasten main relief 180° + Boom swing-left relief

22.6 MPa at 24 L/min {3277 psi at 6.3 gpm}

23.3 MPa {3379 psi}

Blade-up relief

Up

25.5 MPa at 20 L/min {3698 psi at 5.3 gpm}

26.5 MPa {3843 psi}

Fasten blade main relief 180° + Blade-up relief

Down

25.5 MPa at 20 L/min {3698 psi at 5.3 gpm}

26.5 MPa {3843 psi}

Fasten blade main relief 180° + Blade-down relief

4.2 MPa {609 psi}

3.8 MPa {551 psi}

Lever neutral

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

Right

Main

Blade

Overload relief

Pilot relief

AL

Right Swing relief

Boom swing port relief

RN

Bucket overload relief

TE

Arm overload relief

IN

Boom overload relief

E

Main relief pressure

Method of measurement

1

AST-15-25-002E 1

Measuring / Adjusting Pressure 3. Ports for measuring pressure

RN

AL

[1] Main pump

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

[2] Pilot line

AST-15-25-002E

2 2

Measuring / Adjusting Pressure 4. Preparation for Measuring Pressure

TE

RN

[2] Positioning the machine • Position the machine on solid level ground.

Lower the boom so the arm end touches the ground with the bucket cylinder out at stroke end and the arm cylinder out at stroke end.

The blade should also be lowered to touch the ground.

AL

[1] Items needed • Pressure gauges for 50 MPa {7250 psi} for 10 MPa {1450 psi} • Tools: Spanners (closed wrench), 17 mm and 27 mm Hexagonal bar wrenches, 5 mm and 6 mm • Other: Cloth, cleaning solution, temperature gauge

[3] Relieving pressure in circuit

IN

• Turn the starter switch off and confirm that the engine has stopped. Turn the key on again.

Note: Do not start the engine.

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

• Operate each lever 10 times or more and check that the attachments no longer move.

Then turn off the starter switch.

[4] Relieving pressure in hydraulic oil tank • Press the air breather button located on the hydraulic oil tank to release the pressure in the tank.

3

AST-15-25-002E 3

Measuring / Adjusting Pressure [5] Attaching the pressure gauge See section 3 on the previous page for the port positions for measuring.

Measuring actuator

Port

Pressure gauge

Port size

Tool

Main, Left travel, Offset Swing, Arm

G1

49.1 MPa {7121 psi} G1/4

Hexagonal bar wrench 6 mm

Main, Right travel,Bucket Boom

G2

49.1 MPa {7121 psi} G1/4

Hexagonal bar wrench 6 mm

Pilot

P2

9.8 MPa {1421 psi}

Spanner 17 mm

Blade

P3G

49.1 MPa {7121 psi} G1/4

G1/4

Hexagonal bar wrench 6 mm

[6] Checking oil temperature Check hydraulic oil temperatures using a temperature gauge.

Oil temperature

45 - 55 ℃ {113 - 131° F}

AL

If the oil temperature is low, follow the instructions for warm-up in the Operator’s Manual to increase the temperature.

The preparation is now complete.

5. Measuring Pressure

RN

[1] Main relief pressure Lever operation

Arm-in relief

[2] Swing relief pressure

E

Lever operation

29.4 ± 1.0 MPa {4264 ± 145 psi}

IN

Pressure setting

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

Pressure gauge to be used Pressure setting

50 MPa {7250 psi}

TE

Pressure gauge to be used

Swing relief

50 MPa {7250 psi} 24.6 ± 1.0 MPa {3567 ± 145 psi}

Attach the pressure gauge to the G1 side of the pressure detection port on the main pump.

When measuring the pressure for swing, first activate the mechanical brake by disconnecting the connector on the swing pressure switch located on the lower left of the cab.

The swing pressure switch will be revealed after removing the side cover located on the lower left of the cab. See the figure on next page.

AST-15-25-002E

4 4

Measuring / Adjusting Pressure CAUTION:

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

RN

AL

• Before positioning the swing lever in place for the first time, the engine revolutions should be reduced to approximately 1,100 min-1.

When the swing is confirmed to be no longer moving, increase the engine revolutions to the maximum.

• Disconnecting the hose to the swing motor’s parking release port PB or inserting the connector of the solenoid valve for switching for high speed into swing brake solenoid to change the speed to high mode would also work for measuring pressure along with disconnecting the connector.

(At this point, leave the connector for the swing brake solenoid disconnected.)

[3] Pilot relief pressure

Lever operation

Pressure gauge to be used Pressure setting

Neutral 10 MPa {1450 psi} 3.9 ± 0.2 MPa {570 ± 29 psi}

[4] Blade relief pressure Main relief pressure for blade Lever operation

Pressure gauge to be used Pressure setting

Blade up 50 MPa {7250 psi} 23.0 ± 1.0 MPa {3335 ± 145 psi}

5

AST-15-25-002E 5

Measuring / Adjusting Pressure Overload relief pressure for blade Lever operation

Blade up / down

Pressure gauge to be used

50 MPa {7250 psi}

Pressure setting

26.4 ± 1.0 MPa {3829 ± 145 psi}

Overload relief pressure for boom swing Lever operation

Boom swing-right / left

Pressure gauge to be used

49.1 MPa {7121 psi}

Actual pressure setting (Right)

33.7 ± 1.0 MPa {4888 ± 145 psi}

Actual pressure setting (Left)

32.9 ± 1.0 MPa {4772 ± 145 psi}

When measuring the overload relief pressure, fasten the main relief valve of the blade 180° to temporarily adjust it.

[5] Other overload relief pressures Boom up

Boom down

Arm out

Bucket open

Arm in

33.5 ± 1.0 MPa {4860 ± 145 psi}

33.4 ± 1.0 MPa {4844 ± 145 psi}

Port for detection

G2

G1

32.8 ± 1.0 MPa {4760 ± 145 psi}

RN

Actual pressure reading

Bucket closed

AL

Lever operation

G2

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

Temporary adjustments are required because the overload relief pressures of the attachments are set higher than those for the main relief.

AST-15-25-002E

6 6

Measuring / Adjusting Pressure Pressure adjustment 1. Pressure adjusting points

Tool needed Lock nut

Actual pressure setting

Adjustment screw

TE

Location

RN

AL

(1) Control valve

(1)

Main

(2)

Boom-up

(3)

Boom-down

(4)

Arm-out

(5)

Arm-in

(6)

Bucket-open

33.1 MPa {4801 psi}

(7)

Bucket-closed

33.1 MPa {4801 psi}

(8)

Backup (1)-in

IN

29.7 MPa {4308 psi}

Backup (1)-out

17.8 MPa {2582 psi}

33.5 MPa {4859 psi} 33.2 MPa {4815 psi}

32.7 MPa {4743 psi}

E

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H (9)

17 mm

Pressure per one turn of adjustment screw

33.0 MPa {4786 psi}

-

Hexagonal wrench 6 mm

-

(10) Boom swing-right

33.7 MPa {4888 psi}

(11) Boom swing-left

32.9 MPa {4772 psi}

(12) Blade main

23.3 MPa {3379 psi}

(13) Blade-up

26.5 MPa {3844 psi}

(14) Blade-down

26.5 MPa {3844 psi}

(15) Backup (2)-in

-

(16) Backup (2)-out

-

7

21.2 MPa {3075 psi}

AST-15-25-002E 7

Measuring / Adjusting Pressure

RN

AL

(2) Hydraulic pump

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

(3) Swing motor

Tool needed

Name

Lock nut

Pressure setting

Adjustment screw

Pressure per one turn of adjustment screw

(13)

Pilot

24 mm

14 mm

3.9 MPa {570 pai}

0.6 MPa {87 psi}

(14)

Swing Motor

17 mm

Hexagonal wrench 6 mm

24.6 MPa {3570 psi}

9.7 MPa {1410 psi}

AST-15-25-002E

8 8

Measuring / Adjusting Pressure

RN

AL

Bleeding Air

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE

Start the engine and keep it at idle. Remove the rubber cap on the air bleeder. Loosen the air bleeding valve gradually to bleed air.

9

AST-15-25-002E 9

Attachments Dimensions Maintenanse section

SH75

Attachments Dimensions

Standard arm

Item Dimension (mm) {in}

CO US N E FID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

TE R

NA L

Attachment Installation Methods

A

B

C

D

1700 {66.9}

407 {16.0}

310 {12.2}

42 {1.6}

F

G

H

I

J1

J2

K1

K2

L1

L2

M1

M2

N

O

P

Q

R

S

T

U1

U2

185 {7.2}

259 {10.1}

390 {15.3}

110 {4.3}

90 {3.5}

50 {1.9}

50 {1.9}

190 {7.4}

190 {7.4}

311 {12.2}

320 {12.5}

191 {7.5}

210 {8.2}

50 {1.9}

300 {11.8}

390 {15.3}

380 {14.9}

190 {7.4}

71 {2.7}

190 {7.4}

50 {1.9}

55 {2.1}

Bucket and arm mounting section

Item

V

W

Dimension (mm) {in}

50 {1.9}

328 {12.9}

Bucket Link

E

Bucket Pin

Item

Arm Link

Bucket

Bucket cylinder

Bucket and bucket link mounting section

X

Y

V

W

X

Y

Max. retracted length

18 {0.7}

13 {0.5}

50 {1.9}

303 {11.9}

18 {0.7}

13 {0.5}

1035 {40.7}

stroke

width at top section

665 {26.1}

70 {2.7}

10

AST-15-27-002E 1

Appendix Maintenanse section

SH80

Appendix Unit Conversion Table —(x)→ ←(÷)—

SI units

Kgf

9.807

N

Ibf

4.448

N

Kgf•cm

0.0981

N•m

Ibf•ft

1.356

N•m

0.113

N•m

0.0981

MPa

0.1013

MPa

Ibf•in

0.0069

MPa

mmHg

133.3

Pa

inHg

3386

Pa

Kgf•m/s

0.00981

KW

Ibf•ft/s

0.00136

KW

PS

0.7355

HP

0.746

Kgf•m

9.807

J

Kcal

4186

J

Kgf•s/cm2

98067

Pa•s

0.001

Pa•s

0.1

Pa•s

Ibf•in kgf/cm

2

atm

TE

RN

2

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

St

KW

KW

-6

m2/s

0.0001

m2/s

1 x 10

E

cSt

IN

cP P

AL

Gravitational unit

11

AST-15-34-001E 1

Appendix New Hydraulic Oil Long-life hydraulic oil (IDEMITSU Daphne Super Hydro 46SX) Features Currently used oil Zinc (referred as Zn-DTP afterwards) is used in the abrasive resistant hydraulic oil (Zn type hydraulic oil), which is currently used, as a wear prevention agent (extreme pressure additive agent) and anti-oxidation agent. However, it is prone to thermally decompose rapidly and generate sludge since in recent years hydraulic devices have become smaller and use higher pressure. As a result, it becomes impossible to use these devices for a long period because there is a risk of failure occurrence such as filter blockage, sludge substance accumulation at the bottom of the tank, misoperation of control valves, quicker wear in devices, etc.

AL

About new hydraulic oil Two types of additives are used: one is an anti-wear agent that generates less thermal-decomposed sludge, the other is an anti-oxidation agent that controls partial oxidation deterioration at high temperatures. Because of the usage of these additives, heat resistance and oxidation stability have improved two or more times as much as the ones for the currently used oil. In addition, other performance such as lubricating and defoaming characteristics have maintained the same or higher level as the ones for the currently used oil. By achieving this, the life has been extended.

1. Reduced sludge generation 2. Low copper corrosion As a result, the extended exchange period has been realized.

TE

RN

Adopted non-zinc type additives which have excellent heat resistance

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

E

IN

Table 1. The Results of High Pressure Circulation Deterioration Test (Source: IDEMITSU Test Results)

The life of hydraulic oil is usually determined by the changes in three factors below: [1] Changes in kinematic viscosity over time (No significant difference is found between new hydraulic oil and currently used oil.)

[2] Changes in total oxidation over time (Considerable improvement has been made. See Table 1) [3] Changes in sludge generation over time (Considerable improvement has been made. See Table 1) To evaluate the heat resistance and oxidation stability of hydraulic oil, high pressure circulation tests are generally used. Judging from the results above, it can be concluded that the new hydraulic oil has a life period twice as long as the one for the currently used oil.

Note: If new oil is mixed with 10% or more of the currently used oil (MOBILE DTE25B), its properties will turn back to the ones of the currently used oil.

AST-15-34-001E

12 2

Compatibility Compatibility

SH80

Compatibility List of Common Features and Compatibility of Major Parts Common features

{: Common parts

U: Partially different

Compatibility

←{→: Compatible in both directions

⎯{→, ⎯ × →, ←{⎯, ← × ⎯: ← × →: Not compatible in either Compatible in one direction direction

Common Features

SH80-3

Compatibility

×: Different

SH80-3B

Compatibility

CX75SR

Common Features

KAA1132

←×→

KAA10310

←○→

KAA10310

○

○

KAA10200

←○→

KAA10200

←○→

KAA10200

○

Shoe alone

○

KAA1175

←○→

KAA1175

←○→

KAA1175

○

Link ASSY

○

KAA10230

←○→

KAA10230

←○→

KAA10230

○

ASSY

○

KAA10220

←○→

KAA10220

←○→

KAA10220

○

Shoe alone

○

KAA1179

←○→

KAA1179

←○→

KAA1179

○

Link ASSY

○

KAA10230

←○→

KAA10230

←○→

KAA10230

○

Outer

○

KAA1160

←○→

KAA1160

←○→

KAA1160

○

Upper roller

○

KAA1182

←○→

KAA1182

←○→

KAA1182

○

Take-up roller

○

KAA1255

←○→

KAA1255

←○→

KAA1255

○

Drive sprocket

○

KAA1133

←○→

KAA1133

←○→

KAA1133

○

Center joint

KAA10120

←○→

KAA10120

←○→

KAA10120

Counterweight

○ ×

KAB0785

←×→

KAB10540

←×→

KAB10430

○ ×

Turntable bearing

○

KAB10010

←○→

KAB10010

←○→

KAB10010

○

Swing motor

KAC0177

←○→

KAC0177

←○→

KAC0177

○

Engine

○ ×

KAH1395

←×→

KAH11170

←○→

KAH11170

○

Radiator / oil cooler / inter cooler

×

KAH1348

←×→

KAH11190

←○→

KAH11190

○

×

KAH1353

←×→

KAH11210

←○→

KAH11210

○

Muffler

×

KAH1355

←×→

KAH11200

←○→

KAH11200

○

Fuel tank

×

KAH1430

←×→

KAH11720

←×→

KAH1425

×

Hydraulic pump

○

KAJ4590

←○→

KAJ4590

←○→

KAJ4590

Control valve

○

KAJ5076

←○→

KAJ5076

←×→

KAJ4761

○ ×

Remote control valve (operation)

○

KHJ2911

←○→

KHJ2911

←○→

KHJ2911

○

Remote control valve (travel)

○

KHJ13980

←○→

KHJ13980

←○→

KHJ13980

○

Remote control valve (Blade)

○ ×

ASSY

CO US N F E ID O E F N TS TI M AL GL : F O OR BA T L H

Hydraulic oil tank

RN

Air cleaner

TE

Lower roller

IN

Shoe / link (link chain)

KHJ1986

←○→

KHJ1986

←○→

KHJ1986

○

KAJ4956

←×→

KAJ10610

←○→

KAJ10610

○

E

Shoe / link (iron)

AL

× ASSY

Travel motor

Operator's cab

×

KHN18480

←×→

KHN19150

←○→

KHN19150

○

Operator's seat

○

KHN3244

←○→

KHN3244

←×→

KHN19580

×

Monitor

×

KHR4105

←×→

KHR4104

←○→

KHR4104

○

Thlottle monitor

×

KHR13900

←×→

KHR20260

←○→

KHR20260

○

Unit G

×

KHR3744

←×→

KHR20020

←○→

KHR20020

○

Compressor G

×

KHR3741

←×→

KHR18970

←○→

KHR18970

○

Condenser G

○ ×

KHR3742

←○→

KHR3742

←○→

KHR3742

○

KHR3743

←×→

KHR18990

←○→

KHR18990

○

Boom

○

KAV2831

←○→

KAV2831

←×→

KAV11630

×

Arm

○

KAV2610

←○→

KAV2610

←×→

KAV2576

×

Air conditioner

Receiver dryer G

Bucket

○

KAV2274

←○→

KAV2274

←○→

KAV2274

○

Blade

○

KAV10610

←○→

KAV10610

←○→

KAV10610

Boom cylinder

○

KAV2034

←○→

KAV2034

←×→

KAV2434

○ ×

Boom swing cylinder

○

KAV2787

←○→

KAV2787

-

-

-

Arm cylinder

○

KAV2436

←○→

KAV2436

←○→

KAV2436

○

Bucket cylinder

○

KAV2440

←○→

KAV2440

←○→

KAV2440

○

Blade cylinder

○

KAV2085

←○→

KAV2085

←○→

KAV2085

○

13

AST-15-26-002EN 1