Hitachi EX5600-7B Hydraulic Excavator Tier 4 Final Cummins engine Operational Technical Manual PNOTO by www.heydownloads.com

PART NO.

TOKGB91-EN-00

EX5600-7B HYDRAULIC EXCAVATOR

Technical Manual Operational Principle

TECHNICAL MANUAL OPERATIONAL PRINCIPLE

EX5600-7B

Hydraulic Excavator Tier 4 Final Cummins engine

LOADER SPECIFICATIONS TOKGB91-EN-00

PRINTED IN JAPAN (K) 2017, 04

Service Manual consists of the following separate Part No. Technical Manual (Operational Principle) : Vol. No.TOKGB91-EN Technical Manual (Troubleshooting) : Vol. No.TTKGB91-EN Workshop Manual : Vol. No.WKGB91-EN

INTRODUCTION To The Reader This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine. The machine specification and description according to destination may be explained on this manual.

 If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual. (Note: Do not tear off the form. Copy it for usage.):  Technical Information Center Hitachi Construction Machinery Co., Ltd.  TEL: 81-29-832-7084  FAX: 81-29-831-1162  E-mail: HCM-TIC-GES@hitachi-kenki.com

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

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

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

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

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

 Information included in the Engine Manual: Technical information needed for redelivery and delivery and maintenance and repair of the machine, operation and activation of all devices and systems, troubleshooting and assemble / disassemble procedures.

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

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

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

Trademark AdBlue® is a registered trademark of the Verband der Automobilindustrie e.V. (VDA).

TOKGB91-EN-00(20181003)

IN-1

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

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

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

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

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

symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.

fNOTE: Indicates supplementary technical information or knowhow.

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

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

Quantity

To Convert From

Into

Multiply By

Length

0.03937

0.003281

US gal

0.2642

US qt

1.057

yd3

1.308

Weight

2.205

Force

kgf

0.10197

lbf

0.2248

Torque

N·m

kgf·m

Pressure

MPa

kgf/cm

MPa

psi

145.0

Power

1.360

1.341

Temperature

°C

°F

°C×1.8+32

Velocity

km/h

mph

0.6214

min

rpm

1.0

L/min

US gpm

0.2642

mL/rev

cc/rev

1.0

Volume

Flow rate

TOKGB91-EN-00(20181003)

-1

IN-2

0.10197 2

10.197

SYMBOL AND ABBREVIATION Symbol / Abbreviation TO TT T/M W, W/M T4F

IDU DLU ELUF

ELUT

MCU

HMU

CSU ECM EHU

HTC LTC PFU

PMU ODR

Name

Explanation

Technical manual (Operational principle) Technical manual (Troubleshooting) Technical manual Workshop manual Workshop manual (Removal and Installation, Disassembly and Assembly). EPA Tier 4 Final EPA(The United States Environmental Protection Agency) Tier 4 Final emissions regulations for Non-road mobile machines take effect on Jan,2015. The engine which powers the machine in this manual complies with this regulations. Information Display Unit Information display controller. IDU displays the information from each controller on the monitor. Data Logging Unit Data logging unit. DLU records the information from each controller. Electric Lever Control Unit for Front Electric control lever controller for controlling the front attachment operation. ELUF controls the pilot pressure which supplies to the control valve according to the control lever stroke. Electric Lever Control Unit for Travel Electric control lever controller for controlling the travel operation. ELUT controls the pilot pressure which supplies to the control valve according to the control lever stroke. Monitor Control Unit Controller for the alarm monitor and sub control. MCU judges the alarms, controls the oil cooler fan, and controls autolubrication control. Hydraulic System Monitoring Unit Hydraulic system monitoring unit. HMU monitors the condition of the hydraulic components such as swing motor and others and the oil cooler. Contamination Sensing Unit Contamination sensing unit. CSU senses contaminants in the drain circuits of the main pump, swing motor, and travel motor. Engine Control Module Engine controller. ECM controls fuel injection amount according to the machine operating condition. Engine Heat Balance Monitoring Unit Engine cooling system monitoring unit. EHU monitors the engine cooling system condition such as HTC radiator, LTC radiator, and others. High Temperature Cooling Circuit HTC indicates the engine cooling circuit. Low Temperature Cooling Circuit LTC indicates the supercharger cooling circuit. Pump Flow Control Unit Pump flow rate control controller. PFU calculates the target pump displacement of each main pump and controls each pump flow rate. Pump Monitoring Unit Pump monitoring unit. PMU monitors the drain pressure of main pump. Operation Data Recorder Operation data recorder. ODR automatically records the data related to the detected information which has been set.

TOKGB91-EN-00(20181003)

SY-1

SYMBOL AND ABBREVIATION Symbol / Abbreviation ACU

Name

Explanation

Aerial Angle Control Unit

BPU

Basic Performance Monitoring Unit

FMU

Fatigue Monitoring Unit

GSM

Global System for Mobile Communications Controller

WIU GPS CAN

Wireless Interface Unit Global Positioning System Controller Area Network

Aerial angle control unit. ACU controls the circumference check of the machine by using the monitor. Basic performance monitoring unit. BPU semiautomatically measures the basic performance. Mechanical fatigue monitoring unit. FMU monitors mechanical fatigue of the structures. Communication controller. GSM is a type of wireless communication system, is used in more than on 100 countries around Europe and Asia, and becomes the factual global standards of the mobile telephone. WIU outputs the machine operation data to PC via wireless LAN.

EDQR Valve

Electric Dual Quick Response Valve

SCR

Selective Catalytic Reduction

ECU

Electronic Control Unit

NOx DEF

Nitrogen Oxide Diesel Exhaust Fluid

LCD C/U ENG. REG. (L) (R)

Liquid Crystal Display Control Unit Engine Regulator (Left) (Right)

TOKGB91-EN-00(20181003)

CAN communication. CAN is a serial communications protocol internationally-standardized by ISO (International Organization for Standardization). EDQR valve receives command current according to the electric control lever stroke, flows pilot pressure oil according to this command current to the control valve, and moves the spool of the control valve. The urea SCR system injects diesel exhaust fluid to nitrogen oxide (NOx) exhausted from the engine and purifies NOx. Urea SCR system controller. ECU sends the signals from the sensors of urea SCR system to ECM. Diesel exhaust fluid. The diesel exhaust fluid concentration is 32.5 %, which is specified in ISO22241.

SY-2

SECTION AND GROUP SECTION 1 GENERAL Group 1 Specifications CONTENTS

Group 2 Component Layout Group 3 Component Specifications

SECTION 2 SYSTEM TECHNICAL MANUAL (Operational Principle)

Group 1 Controller Group 2 Control System Group 3 ELU System Group 4 Hydraulic System Group 5 Electrical System Group 6 Air Conditioning System

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

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

TOKGB91-EN-00(20181003)

TECHNICAL MANUAL (Troubleshooting) SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction Group 2 Standard Group 3 Engine Test Group 4 Machine Performance Test Group 5 Component Test

SECTION 5 TROUBLESHOOTING Group 1 Diagnosing Procedure Group 2 Monitor Group 3 Cross Reference Table Group 4 Component Layout Group 5 Troubleshooting A Group 6 Troubleshooting B Group 7 Air Conditioner Group 8 e-Service Group 9 After treatment Device

WORKSHOP MANUAL SECTION 1 GENERAL INFORMATION Group 1 Precautions for Disassembling and Assembling Group 2 Tightening Group 3 Painting Group 4 Bleeding Air Group 5 Releasing Pressure Group 6 Preparation SECTION 2 MAINTENANCE STANDARD Group 1 Upperstructure Group 2 Undercarriage Group 3 Loder Front Attachment SECTION 3 UPPERSTRUCTURE Group 1 Cab Group 2 Cab Bed Group 3 Counterweight Group 4 Upperstructure Group 5 Engine Unit Group 6 Pump Device Group 7 Control Valve Group 8 Other Valves Group 9 Swing Device Group 10 Aftertreatment Device Group 11 Hydraulic Oil Tank Group 12 Fuel Tank Group 13 Lift Cylinder (Fast-Filling System) Group 14 Lift Cylinder (Folding Stairway)

TOKGB91-EN-00(20181003)

SECTION 4 UNDERCARRIAGE Group 1 Swing Bearing Group 2 Travel Device Group 3 Travel Brake Valve Group 4 Drive Tumbler Group 5 Center Joint Group 6 Adjuster Cylinder Group 7 Front Idler Group 8 Upper and Lower Roller Group 9 Track Group 10 Accumulator Group 11 Welding Repair Procedure SECTION 5 LOADER FRONT ATTACHMENT Group 1 Front Attachment Group 2 Cylinder Group 3 Bushing Group 4 Angle Sensor Group 5 Other Valve

SECTION 1

GENERAL CONTENTS Group 1 Specifications

Specifications........................................................................ T1-1-1 Working Range..................................................................... T1-1-2

Group 2 Component Layout

Main Component (Overview).......................................... T1-2-1 Main Component (Loading Shovel).............................. T1-2-2 Electrical System (Left Frame)......................................... T1-2-3 Electrical System (Around Cab Bed).............................. T1-2-4 Electrical System (In Cab).................................................. T1-2-5 Electrical System (Isolation Switch Box) ..................... T1-2-8 Electrical System (Relay Box)........................................... T1-2-9 Electrical System (Electrical Equipment Box)...........T1-2-10 Electrical System (Relay Layout of Electrical Equipment Box).........................................T1-2-11 Electrical System (LED Layout of Contamination Sensor Amplifier)...........................T1-2-12 Electrical System (Monitoring Controller Box)........T1-2-13 Electrical System (Left Pump Compartment Controller Box)...............................................................T1-2-14 Electrical System (Right Frame)....................................T1-2-15 Electrical System (Right Pump Compartment Controller Box)...............................................................T1-2-16 Electrical System (Center Frame)..................................T1-2-17 Electrical System (Angle Sensor)..................................T1-2-18 Left Engine...........................................................................T1-2-19 Left Air Cleaner ..................................................................T1-2-20 Around Left Radiator........................................................T1-2-21 Around Left Pump.............................................................T1-2-23 Left 4-Unit Pump................................................................T1-2-26 Left Pilot Panel....................................................................T1-2-27 EDQR Valve...........................................................................T1-2-28 Left Urea SCR System........................................................T1-2-29 Folding Stairway.................................................................T1-2-31 Right Engine .......................................................................T1-2-34 Right Air Cleaner ...............................................................T1-2-35 Around Right Radiator.....................................................T1-2-36 Around Right Pump..........................................................T1-2-38 Right 4-Unit Pump.............................................................T1-2-41 Around Oil Cooler..............................................................T1-2-42 Auto-Lubrication Device.................................................T1-2-43 Right Urea SCR System....................................................T1-2-44 Control Valve.......................................................................T1-2-46 Center Pilot Panel...............................................................T1-2-50 Hydraulic Oil Tank..............................................................T1-2-51 Fuel Tank...............................................................................T1-2-52

TOKGB91-EN-00(20181003)

Fast-Filling System.............................................................T1-2-53 Fast-Filling Panel................................................................T1-2-54 Swing Device . ....................................................................T1-2-55 Center Joint..........................................................................T1-2-56 Travel Device.......................................................................T1-2-57 Undercarriage.....................................................................T1-2-58

Group 3 Component Specifications

Engine...................................................................................... T1-3-1 Engine Accessories.............................................................. T1-3-5 Hydraulic Component........................................................ T1-3-6 Electrical Component.......................................................T1-3-10 Others....................................................................................T1-3-12

KGB91T-1-1

(Blank)

TOKGB91-EN-00(20181003)

KGB91T-1-2

SECTION 1 GENERAL Group 1 Specifications Specifications

C(C')

E D I

H F

TKGB-01-01-001

Model Type of Front-End Attachment Bucket Capacity (Heaped) Operating Weight Engine Engine Power A: Overall Width B: Cab Height C: Rear End Swing Radius C': Rear End Length D: Minimum Ground Clearance E: Counterweight Clearance F: Undercarriage Length G: Undercarriage Width H: Sprocket Center to Idler Center I: Track Shoe Width Ground Pressure Swing Speed Travel Speed (Fast/Slow) Gradeability

EX5600-7B Hydraulic Excavator Loader Front Backhoe Front 3 3 PCSA 29.0 m (37.9 yd ) PCSA 34.0 m3 (44.5 yd3) 554000 kg (1221000 lb) 525000 kg (1157000 lb) Cummins QSKTA50-CE 1119 kW/1800 min-1 (1520 PS/1800 rpm) ×2 10300 mm (33 ft 10 in) *8600 mm (28 ft 3 in) 7970 mm (26 ft 2 in) 7860 mm (25 ft 9 in) *1100 mm (3 ft 7 in) *2910 mm (9 ft 7 in) 9350 mm (30 ft 8 in) 7400 mm (24 ft 3 in) 7000 mm (22 ft 12 in) 1400 mm (4 ft 7 in) (Grouser shoe) 248 kPa (36.0 psi) 235 kPa (34.1 psi) 3.3 min-1 (rpm) 2.3/1.6 km/h (1.4/1.0 mph) 30° (tanθ = 0.58)

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

TOKGB91-EN-00(20181003)

T1-1-1

SECTION 1 GENERAL Group 1 Specifications Working Range Loading Shovel

H E

A G

B D TKGB-01-01-002

Category Item A: Minimum Digging Distance B: Minimum Level Crowding Distance C: Level Crowding Distance D: Maximum Digging Reach E: Maximum Cutting Height F: Maximum Dumping Height G: Maximum Digging Depth H: Working Radius at Maximum Dumping Height I: Maximum Bucket Opening Width

TOKGB91-EN-00(20181003)

T1-1-2

Loading Shovel 6400 mm (20 ft 12 in) 10050 mm (32 ft 12 in) 5350 mm (17 ft 7 in) 17000 mm (55 ft 9 in) 19200 mm (62 ft 12 in) 13100 mm (42 ft 12 in) 4800 mm (15 ft 9 in) 8900 mm (29 ft 2 in) 2700 mm (8 ft 10 in)

SECTION 1 GENERAL Group 1 Specifications Backhoe

E B

8' G A' A TKGB-01-01-003

Category Item A: Maximum Digging Reach A': Maximum Digging Reach (on ground) B: Maximum Digging Depth B': Maximum Digging Depth (8' level) C: Maximum Cutting Height D: Maximum Dumping Height E: Maximum Veritcal Wall F: Minimum Swing Radius G: Minimum Level Crowding Distance H: Minumum Dumping Height

TOKGB91-EN-00(20181003)

T1-1-3

Backhoe 20200 mm (66 ft 3 in) 19400 mm (63 ft 8 in) 8800 mm (28 ft 11 in) 8700 mm (28 ft 7 in) 19700 mm (64 ft 8 in) 12200 mm (40 ft) 4300 mm (14 ft 1 in) 9900 mm (32 ft 6 in) 7200 mm (23 ft 8 in) 5200 mm (17 ft 1 in)

SECTION 1 GENERAL Group 1 Specifications (Blank)

TOKGB91-EN-00(20181003)

T1-1-4

SECTION 1 GENERAL Group 2 Component Layout Main Component (Overview) R8

R1 R2

R3 R C L U U2

U1 C7

C8 C1 L9

C2 C3 L2

L8 L7

L10

L11 L12 L5 L4

L-

Left Frame

L1- Left Engine (Refer to T1-2-19.) L2- Left Air Cleaner (Refer to T1-220.) L3- Around Left Radiator (Refer to T1-2-21.) L4- Around Left Pump (Refer to T1-2-23.) L5- Left Urea SCR Muffler Unit (Refer to T1-2-30.) L6- Left DEF Tank (Refer to T1-229.) L7- Blower Motor (For Cab Bed Pressurization) (2 Used) L8- Washer Tank L9- Air Cleaner (For Cab Bed Pressurization) L10- Left Pilot Panel (Refer to T1-227.) L11- EDQR Valve (Refer to T1-2-28.) L12- Folding Stairway (Refer to T12-31.)

TOKGB91-EN-00(20181003)

R-

Right Frame

C-

R1- Right Engine (Refer to T1-234.) R2- Right Air Cleaner (Refer to T12-35.) R3- Around Right Radiator (Refer to T1-2-36.) R4- Around Right Pump (Refer to T1-2-38.) R5- Right Urea SCR Muffler Unit (Refer to T1-2-45.) R6- Right DEF Tank (Refer to T1-244.) R7- Around Oil Cooler (Refer to T1-2-42.) R8- Auto-Lubrication Device (Refer to T1-2-43.)

Center Frame

C1- Control Valve (Refer to T1-246.) C2- Hydraulic Oil Tank (Refer to T1-2-51.) C3- Fuel Tank (Refer to T1-2-52.) C4- Fast-Filling System (Refer to T1-2-53.) C5- Swing Device (Refer to T1-255.) C6- Center Joint (Refer to T1-2-56.) C7- Swing Bearing C8- Fuel Cooler C9- Center Pilot Panel (Refer to T1-2-50.)

T1-2-1

TKGB-01-02-100

U-

Undercarriage

U1- Travel Device (Refer to T1-257.) U2- Adjuster Cylinder (2 Used)

SECTION 1 GENERAL Group 2 Component Layout Main Component (Loading Shovel) 7

8 A

6 5

3 TKGB-01-02-011

View A

123-

Arm Cylinder Level Cylinder Bucket Cylinder (2 Used)

TOKGB91-EN-00(20181003)

456-

Dump Cylinder (2 Used) Bucket Arm

789-

T1-2-2

Boom Boom Cylinder (2 Used) Make-Up Valve (2 Used)

TKGB-01-02-012

10- Solenoid Valve

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

4 5

12 13 15

26 25 24

20 19

12345678-

Work Light (Upper Front of Cab) (2 Used) Wiper Motor Maintenance Light (Front Side of Cab Bed) Entrance Light (Rear of Cab) Air Conditioner Unit (3 Used) Monitoring Controller Box (Refer to T1-2-13.) Maintenance Light (Rear Side of Cab Bed) Electrical Equipment Box (Refer to T1-2-10.)

TOKGB91-EN-00(20181003)

91011121315-

Work Light (Left Side of Left Pump Compartment) Maintenance Light (Left Pump Compartment) Maintenance Light (Left Engine Compartment (L1)) Maintenance Light (Left Engine Compartment (L2)) Emergency Engine Stop Switch 3 Emergency Engine Stop Switch 4

16- Work Light (Rear Side of Left Radiator) 17- Left Pump Compartment Controller Box (Refer to T1-214.) 18- Emergency Engine Stop Switch 2 19- Air Conditioner Compressor Unit 20- Isolation Switch Box (Refer to T1-2-8.) 21- Battery (6 Used)

T1-2-3

TKGB-01-02-002

22- Entrance Light (Rear of Left Fender) 23- Relay Box (Refer to T1-2-9.) 24- Motion Alarm (Left) 25- Work Light (Lower Front of Cab Bed) (2 Used) 26- Condenser (With ReceiverDryer) (3 Used) 27- Work Light (Upper Front of Cab Bed) (2 Used)

SECTION 1 GENERAL Group 2 Component Layout Electrical System (Around Cab Bed) Detail A

2 1

A 4 TKGB-01-02-003

Ambient Air Temperature Sensor 1

TKGB-01-02-004

Ambient Air Temperature Sensor 2 (For Cummins) (R)

34-

TOKGB91-EN-00(20181003)

T1-2-4

Ambient Air Temperature Sensor 3 (For Cummins) (L) Horn

56-

Limit Switch 2 (Cab Bed Door) Limit Switch 1 (Cab Bed Door)

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

4 5 6

13 14

27 26

25 A

24 23

B 20

TKEB-01-02-068

Detail B

31 40

33 34

35 36

TKGB-01-02-006

123456789-

Main Monitor Aerial Angle Monitor (Option) Rear View Monitor (Option) Front View Monitor (Option) Electric Control Lever (Left)/ Horn Switch Electric Control Pedal (Bucket Close) (only LD) Electric Control Lever (Travel) Electric Control Pedal (Bucket Open) (only LD) Electric Control Lever (Right)/ Horn Switch

10111213141516-

Pilot Control Shut-Off Lever Warning Light (Red) Caution Light (Yellow) Wiper/Washer Switch Wiper Interval Switch Key Pad Air Conditioner Controller (Right) 17- Air Conditioner Controller (Left) 18- Air Conditioner Controller (Rear) 19- Radio

2021222324252627282930-

Unused Unused Unused Unused Buzzer Stop Switch Maintenance Mode Switch Fast Filling Switch Maintenance Light Switch Day/Night Mode Switch Work Light Switch Emergency Engine Stop Switch 1 31- Engine Control Dial (R)

fNOTE: LD: Loading Shovel

TOKGB91-EN-00(20181003)

T1-2-5

TKGB-01-02-005

32333435363738394041-

Engine Start Switch (R) Engine Stop Switch (R) Dome Light Switch Entrance Light Switch Key Switch Auto-Idle Switch Travel Mode Switch Engine Stop Switch (L) Engine Start Switch (L) Engine Control Dial (L)

SECTION 1 GENERAL Group 2 Component Layout 3

2 1

TKEB-01-02-070 Detail A

1234-

Hour Meter Dome Light (Front) Dome Light (Rear) ELUF

TOKGB91-EN-00(20181003)

56-

ELUT ACU

T1-2-6

Satellite Communication Terminal (Option)/Mobile Communication Terminal (Option)

TKEB-01-02-071

SECTION 1 GENERAL Group 2 Component Layout A Detail B

T146-01-03-023 TKEB-01-02-072

Detail A

5 6

1234-

Power Source Terminal Fuse Box (Cab 1) Fuse Box (Cab 2) Cigar Lighter

TOKGB91-EN-00(20181003)

5678-

12V Socket Download Connector (for DLU) Data Link Connector (for ECM) DC-DC Converter 2

9101112-

T1-2-7

DC-DC Converter 1 IDU Buzzer WIU (Option)

13- DLU

TKEB-01-02-073

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

A 1

TKEB-01-02-015

TKGB-01-02-007

Indicator

TOKGB91-EN-00(20181003)

Isolation Switch (Battery Circuit)

T1-2-8

Isolation Switch (Starter Circuit)

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

41 38 42 43

39 44 40

45 46 47 48

37 36 35

5 6

7 8 9 10 3 4

32 31 A

17 11

18 12 19

30 TKGB-01-02-098

14 20 15 21 16 22

27 26 25

23 TKGB-01-02-099

1234567891011121314-

Battery Relay 1 Battery Relay 2 Battery Relay 3 Battery Relay 4 Starter Relay (L1) Starter Relay (L2) Starter Relay (R1) Starter Relay (R2) Fuse (250 A) (For Folding Stairway Pump 1) Fuse (250 A) (For Folding Stairway Pump 2) Slow Blow Fuse 1 (75 A) (For Fuse Box 1, 3) Slow Blow Fuse 2 (75 A) (For Fuse Box 2, 3, 4) Slow Blow Fuse 3 (75 A) (For Fuse Box 2, 3, 4) Slow Blow Fuse 4 (75 A) (For Fuse Box 2, 3, 4)

TOKGB91-EN-00(20181003)

15- Slow Blow Fuse 5 (75 A) (For Fuse Box 4) 16- Slow Blow Fuse 6 (75 A) (For Fuse Box 3, 4) 17- Slow Blow Fuse 7 (45 A) (For ECM (L) Main Power) 18- Slow Blow Fuse 8 (45 A) (For ECM (R) Main Power) 19- Slow Blow Fuse 9 (75 A) (For Folding Stairway Relay) 20- Slow Blow Fuse 10 (75 A) (For Starter Relay (L)) 21- Slow Blow Fuse 11 (75 A) (For Starter Relay (R)) 22- Slow Blow Fuse 12 (45 A) (For Option) 23- Fuse (200 A) (For Alternator (R)) 24- Fuse (400 A) (For Prelube Relay (R)) 25- Prelube Relay (R)

26- Fuse (200 A) (For Alternator (L)) 27- Fuse (400 A) (For Prelube Relay (L)) 28- Prelube Relay (L) 29- Fuse 2 (5 A) (Prelube (R)) 30- Fuse 1 (5 A) (Prelube (L)) 31- Prelube Control Relay (R) 32- Engine Start Cancellation Relay (R2) 34- Fuse Box (DEF) 35- Engine Start Cancellation Relay (L2) 36- Prelube Control Relay (L) 37- DEF Line Heater Relay (L1) 38- DEF Line Heater Relay (L2) 39- Dosing Module Relay (L1) 40- Dosing Module Relay (L2) 41- DEF Line Heater Relay (R1) 42- DEF Line Heater Relay (R2) 43- Dosing Module Relay (R1) 44- Dosing Module Relay (R2)

T1-2-9

45464748-

Engine Protection Relay (L) Alternator Signal Relay (L) Engine Protection Relay (R) Alternator Signal Relay (R)

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

TKGB-01-02-090

Detail A

5 6 7 8 9 10 11 12

14 15 16

TKGB-01-02-091 B-

Refer to Relay Layout on T1-211.

12-

Electrical Equipment Box Light Limit Switch (Electrical Equipment Box Door) CSU HMU MCU

345-

TOKGB91-EN-00(20181003)

678-

Engine Fault Code Indicator Light Engine Diagnostic Switch (L) Engine Fault Code Select Switch (L)

Engine Fault Code Select Switch (R) 10- Engine Diagnostic Switch (R) 11- Lamp Check Switch 12- Auto-Lubrication Interval Switch

T1-2-10

13141516-

Fuse Box 4 Fuse Box 3 Fuse Box 2 Fuse Box 1

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

C D

E F G

TKGB-01-02-092 14- Work Light Relay (4) (Front Side of Right Frame) 15- Work Light Relay (5) (Rear of Left Frame, Rear of Right Frame) 16- Work Light Relay (6) (Left Side of Left Frame, Right Side of Right Frame) 17- Entrance Light Relay (1) (Cab Bed, Left Fender)

[4]

27- Delayed Power OFF Relay

[17]

40- ELU Pilot Control Shut[31] Off Solenoid Valve Relay

[5]

28- Travel Mode Relay

[18]

[32]

[6]

29- Fast Filling Relay

[19]

[7]

30- Horn Air Compressor Relay (L2)

[21]

18- Entrance Light Relay (2) (Cab) [L6] 19- Maintenance Light Relay (1) (Left Engine Compartment) [L7] 20- Maintenance Light Relay (2) (Left Pump Compartment, Right Pump Compartment) [L8] 21- Maintenance Light Relay (3) (Unused) [L9] 22- Maintenance Light Relay (4) (Cab Bed) [L10] 23- Maintenance Light Relay (5) (Oil Cooler Compartment) [1] 24- Maintenance Light Relay (6) (Control Valve)

[8]

31- Horn Air Compressor Relay (R2) 32- Horn Relay

[22]

41- ELU PWM Power Relay (1) (For Key ON Signal Monitoring) 42- ELU PWM Power Relay (2) (For Pilot Control Shut-Off Switch ON Signal Monitoring) 43- ELU PWM Power Relay (3) (For Emergency Engine Stop Switch ON Signal Monitoring) 44- Folding Stairway Relay 1

[23]

45- Engine Start Cancellation Relay (L)

[36]

[10]

33- Wiper Relay (2) (For Wiper Stop Position Control)

[24]

46- Engine Start Cancellation Relay (R)

[37]

[11]

34- Washer Motor Relay

[25]

[12]

35- Prelube Signal Relay (L)

[26]

[13]

36- Prelube Signal Relay (R)

[27]

47- Alternator Signal Relay [38] (L) 48- Alternator Signal Relay [39] (R) 49- Grease Tank Level Signal [40] Relay (1)

[14]

[28]

50- Grease Tank Level Signal [41] Relay (2)

[2]

[15]

37- Air Conditioner Condenser Fan Motor Relay (Right) 38- Air Conditioner Condenser Fan Motor Relay (Left) 39- Air Conditioner Condenser Fan Motor Relay (Rear)

[29]

51- Cab Bed Pressurization Relay

Horn Air Compressor Relay (L1)

[L1]

Horn Air Compressor Relay (R1)

[L2]

Wiper Relay (1) (For Slow [L3] Speed Control)

Wiper Relay (3) (For Fast Speed Control)

[L4]

Air Conditioner Main Relay (Right) Air Conditioner Main Relay (Left)

[L5]

67-

Air Conditioner Main Relay (Rear)

Cab Bed Pressurization Blower Motor Relay (1) 9- Cab Bed Pressurization Blower Motor Relay (2) 10- Fuel Cooler Fan Motor Relay 11- Work Light Relay (1) (Front Left Side of Cab Bed) 12- Work Light Relay (2) (Front Right Side of Cab Bed) 13- Work Light Relay (3) (Upper Front of Cab)

[3]

25- Maintenance Light Relay (7) (Right Engine Compartment) 26- Fast Filling Panel Position Relay

[9]

[16]

fNOTE: Alphanumeric characters in parentheses are the relay No. in the circuit diagram.

TOKGB91-EN-00(20181003)

T1-2-11

[30]

[33]

[34]

[35]

[42]

SECTION 1 GENERAL Group 2 Component Layout Electrical System (LED Layout of Contamination Sensor Amplifier) A

Detail A

3 4 5 6

7 8 9 10 11 12

13 14 15 16 17 18 1920 21

TKEB-01-02-064

TKGB-01-02-091

123456-

Main Pump L1 Main Pump L2 Main Pump L3 Main Pump L4 Main Pump L5 Main Pump L6

789101112-

Unused Unused Main Pump R1 Main Pump R2 Main Pump R3 Main Pump R4

131415161718-

fNOTE: Refer to the following items for the layout of the contamination sensor.  Main Pumps L1 to L6 : T1-2-25  Main Pumps R1 to R6 : T1-2-40  Swing Motor : T1-2-55  Travel Motor : T1-2-56

TOKGB91-EN-00(20181003)

T1-2-12

Main Pump R5 Main Pump R6 Unused Unused Swing Motor (Left Front) Swing Motor (Left Rear)

19- Swing Motor (Right Front) 20- Swing Motor (Right Rear) 21- Travel Motor

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

TKGB-01-02-008

Detail A

123-

ODR FMU (Option) BPU (Option)

TOKGB91-EN-00(20181003)

TKEB-01-02-062

Swing Angular Rate Sensor (Upperstructure)

56-

T1-2-13

Inclination Angle Sensor (Pitch) Inclination Angle Sensor (Roll)

Fuse Box (Monitoring)

SECTION 1 GENERAL Group 2 Component Layout Electrical System (Left Pump Compartment Controller Box) Detail A

TKGB-01-02-009 TKGB-01-02-010

9 8 7

123-

DEF Fill Line Heater Signal Relay (L) DEF Fill Hose Heater Relay (L) DEF Fill Line Heater Relay (L)

TOKGB91-EN-00(20181003)

456-

PMU (L) PFU (L) EHU (L)

78-

T1-2-14

DEF Piping In-Line Filter Heater Relay (L) DEF Receiver Heater Relay (L)

DEF Shut-Off Valve Heater Relay (L)

SECTION 1 GENERAL Group 2 Component Layout Electrical System (Right Frame)

12 11 10 TKGB-01-02-018

12345-

Maintenance Light (Oil Cooler Compartment) Motion Alarm (Right) Maintenance Light (Right Engine Compartment (R2)) Maintenance Light (Right Pump Compartment) Work Light (Right Side of Right Pump Compartment)

TOKGB91-EN-00(20181003)

67-

89-

Maintenance Light (Right Engine Compartment (R1)) Right Pump Compartment Controller Box (Refer to T12-16.) Emergency Engine Stop Switch 6 Work Light (Rear of Right Radiator)

10- Emergency Engine Stop Switch 5 11- Emergency Engine Stop Switch 7 12- Valve Limit Switch (Return) 13- Work Light (Front Side of Right Frame) (2 Used)

T1-2-15

SECTION 1 GENERAL Group 2 Component Layout Electrical System (Right Pump Compartment Controller Box) Detail A

1 2 A 3

TKGB-01-02-031

6 TKGB-01-02-032

123-

PFU (R) DEF Receiver Heater Relay (R) DEF Shut-Off Valve Heater Relay (R)

TOKGB91-EN-00(20181003)

456-

DEF Piping In-Line Filter Heater Relay (R) PMU (R) DEF Fill Line Heater Signal Relay (R)

789-

T1-2-16

DEF Fill Hose Heater Relay (R) DEF Fill Line Heater Relay (R) EHU (R)

SECTION 1 GENERAL Group 2 Component Layout Electrical System (Center Frame) A

Detail A

TKGB-01-02-033

View B

4 TKGB-01-02-041

TKGB-01-02-040

123-

Maintenance Light (Control Valve) Electric Pump Motion Alarm (Rear)

TOKGB91-EN-00(20181003)

45-

Pressure Sensor (Bucket Cylinder Bottom Side) Pressure Sensor (Arm Cylinder Rod Side)

67-

T1-2-17

Pressure Sensor (Arm Cylinder Bottom Side) Pressure Sensor (Bucket Cylinder Rod Side)

89-

Pressure Sensor (Boom Cylinder Bottom Side) Pressure Sensor (Boom Cylinder Rod Side)

SECTION 1 GENERAL Group 2 Component Layout Electrical System (Angle Sensor) B

TKGB-01-02-034

View A

Detail B

TKGB-01-02-036 TKGB-01-02-035

123-

Detail C

Boom Angle Sensor Arm Angle Sensor Bucket Angle Sensor

TKGB-01-02-037

TOKGB91-EN-00(20181003)

T1-2-18

SECTION 1 GENERAL Group 2 Component Layout Left Engine

View A

TKGB-01-02-056

View B

12345-

Engine Speed Sensor (L) Prelube Pressure Switch (L) Fuel Filter (Stage 1) ECM (L) Fuel Filter (Stage 2)

TOKGB91-EN-00(20181003)

67-

Prelube Motor (L) Starter Upper: Starter (L1) Lower: Starter (L2) Oil Filter

12 TKEB-01-02-053

TKEB-01-02-052

Engine Oil Temperature Sensor (L) 10- Engine Oil Level Sensor (L) 11- Coolant Filter 12- Alternator (L)

T1-2-19

SECTION 1 GENERAL Group 2 Component Layout Left Air Cleaner 1

TKGB-01-02-046

Detail A

2 3

TKGB-01-02-047

Air Cleaner (L)

TOKGB91-EN-00(20181003)

Air Cleaner Restriction Switch (L1)

T1-2-20

Air Cleaner Restriction Switch (L2)

SECTION 1 GENERAL Group 2 Component Layout Around Left Radiator View A

D A

2 3 C

TKGB-01-02-051 View B

TKGB-01-02-048

5 Detail C

TKGB-01-02-052 Detail D

1234-

HTC Radiator (L) LTC Radiator (L) LTC Radiator Front Air Temperature Sensor (L) HTC Radiator Outlet Coolant Temperature Sensor (L)

TOKGB91-EN-00(20181003)

567-

TKGB-01-02-050

LTC Radiator Outlet Coolant Temperature Sensor (L) HTC Radiator Inlet Coolant Temperature Sensor (L1) HTC Radiator Inlet Coolant Temperature Sensor (L2)

LTC Radiator Inlet Coolant Temperature Sensor (L) 9- HTC Radiator Rear Air Temperature Sensor (L1) 10- HTC Radiator Rear Air Temperature Sensor (L2)

T1-2-21

TKGB-01-02-049

SECTION 1 GENERAL Group 2 Component Layout

TKGB-01-02-053

View A

View B

TKGB-01-02-054

TKGB-01-02-055

Water Tank (L)

TOKGB91-EN-00(20181003)

Coolant Level Check Switch (L1)

T1-2-22

Coolant Level Sensor (L)

Coolant Level Check Switch (L2)

SECTION 1 GENERAL Group 2 Component Layout Around Left Pump 1

13 12

11 10 9 D

TKGB-01-02-013

Views A, B, C

Detail D

14 17

16 15 TKEB-01-02-080 1-

345-

Main Pump L1 (Pump Transmission Side)/Main pump L2 (Pump End Side) Main Pump L3 (Pump Transmission Side)/Main pump L4 (Pump End Side) High-Pressure Strainer (for Main Pump L5) High-Pressure Strainer (for Main Pump L6) Pump Transmission Oil Filter

TOKGB91-EN-00(20181003)

Main Pump L5 (Pump Transmission Side)/Main pump L6 (Pump End Side) 7- Left 4-Unit Pump (Refer to T1-2-26.) 8- Pilot Filter 9- Pilot Relief Valve 10- High-Pressure Strainer (for Main Pump L2) 11- High-Pressure Strainer (for Main Pump L1)

12- High-Pressure Strainer (for Main Pump L4) 13- High-Pressure Strainer (for Main Pump L3) 14- Swash Plate Angle Sensor (Main Pumps L1, L3, L5) 15- Swash Plate Angle Sensor (Main Pumps L2, L4, L6) 16- Control Solenoid Valve (Main Pumps L1, L3, L5)

T1-2-23

TKGB-01-02-072

17- Control Solenoid Valve (Main Pumps L2, L4, L6) 18- Pump Transmission Oil Temperature Sensor (L) 19- Bypass Check Valve (for Pump Transmission Oil Pump)

SECTION 1 GENERAL Group 2 Component Layout 1

7 8

9 10

13 12 11

6 5

TKGB-01-02-014

View A

View B

22 16 17

15 19 123456-

Drain Pressure Sensor (Main Pump L1) Delivery Pressure Sensor (Main Pump L1) Regulator Pressure Sensor (Main Pump L1) Drain Pressure Sensor (Main Pump L2) Delivery Pressure Sensor (Main Pump L2) Regulator Pressure Sensor (Main Pump L2)

TOKGB91-EN-00(20181003)

20 7-

TKEB-01-02-081

TKEB-01-02-031

Pump Transmission Oil Level Switch (L) 8- Drain Pressure Sensor (Main Pump L3) 9- Delivery Pressure Sensor (Main Pump L3) 10- Regulator Pressure Sensor (Main Pump L3) 11- Drain Pressure Sensor (Main Pump L4) 12- Delivery Pressure Sensor (Main Pump L4)

13- Regulator Pressure Sensor (Main Pump L4) 14- Delivery Pressure Sensor (Oil Cooler Fan Motor Pump) 15- Regulator Pressure Sensor (Oil Cooler Fan Motor Pump) 16- Drain Pressure Sensor (Main Pump L5) 17- Delivery Pressure Sensor (Main Pump L5) 18- Regulator Pressure Sensor (Main Pump L5)

T1-2-24

19- Drain Pressure Sensor (Main Pump L6) 20- Delivery Pressure Sensor (Main Pump L6) 21- Regulator Pressure Sensor (Main Pump L6) 22- Control Solenoid Valve (Oil Cooler Fan Motor Pump)

SECTION 1 GENERAL Group 2 Component Layout

TKGB-01-02-015

12-

Contamination Sensor (Main Pump L1) Contamination Sensor (Main Pump L2)

TOKGB91-EN-00(20181003)

34-

Contamination Sensor (Main Pump L3) Contamination Sensor (Main Pump L4)

56-

T1-2-25

Contamination Sensor (Main Pump L5) Contamination Sensor (Main Pump L6)

SECTION 1 GENERAL Group 2 Component Layout Left 4-Unit Pump

TKGB-01-02-016

TKBD-01-02-003

12-

4-Unit Pump Oil Cooler Fan Motor Pump (Plunger Pump)

TOKGB91-EN-00(20181003)

34-

Pilot Pump (Gear Pump) Air Conditioner Compressor Motor Pump (Gear Pump)

T1-2-26

Pump Transmission Oil Pump (Gear Pump)

SECTION 1 GENERAL Group 2 Component Layout Left Pilot Panel

TKGB-01-02-093

Detail A

10 9 5

6 TKGB-01-02-094 1-

23-

Relief Valve (For Air Conditioner Compressor Motor Pump Circuit) Accumulator (For Pilot) EDQR Valve (Upper)*

4567-

EDQR Valve (Lower)* Pilot Filter Pilot Relief Valve Fast Filling Solenoid Valve

89-

*: Refer to T1-2-28. TOKGB91-EN-00(20181003)

T1-2-27

Reducing Valve (For Travel Mode Control) Travel Mode Selector Solenoid Valve

10- Pressure Sensor (Pilot Shut-Off Solenoid Valve) 11- Pilot Shut-Off Solenoid Valve

SECTION 1 GENERAL Group 2 Component Layout EDQR Valve

1 10

17 9

18 27 28 29 30 31 32 33

19 20 21 22 23 24 25

34 26

12345678-

Pilot Pressure Sensor (Valve Warmer Solenoid Valve 1) Pilot Pressure Sensor (Swing Left) Pilot Pressure Sensor (Left Travel Forward) Pilot Pressure Sensor (Bucket Tilt-In) Pilot Pressure Sensor (Boom Lower) Pilot Pressure Sensor (Boom Raise) Pilot Pressure Sensor (LD: Bucket Open/BH: Unused) Pilot Pressure Sensor (Right Travel Forward)

910111213141516171819-

Valve Warmer Solenoid Valve Temperature Sensor 1 Valve Warmer Solenoid Valve 1 Swing Left Solenoid Valve Left Travel Forward Solenoid Valve Bucket Tilt-In Solenoid Valve Boom Lower Solenoid Valve Boom Raise Solenoid Valve LD: Bucket Open Solenoid Valve/BH: Unused Right Travel Forward Solenoid Valve Pilot Pressure Sensor (Valve Warmer Solenoid Valve 2) Pilot Pressure Sensor (Right Travel Reverse)

TKGB-01-02-095

20- Pilot Pressure Sensor (Left Travel Reverse) 21- Pilot Pressure Sensor (LD: Arm Extend/BH: Arm Roll-In) 22- Pilot Pressure Sensor (LD: Arm Retract/BH: Arm Roll-Out) 23- Pilot Pressure Sensor (Bucket Tilt-Out) 24- Pilot Pressure Sensor (LD: Bucket Close/BH: Unused) 25- Pilot Pressure Sensor (Swing Right) 26- Valve Warmer Solenoid Valve Temperature Sensor 2 27- Valve Warmer Solenoid Valve 2 28- Right Travel Reverse Solenoid Valve

fNOTE: LD: Loading Shovel BH: Backhoe TOKGB91-EN-00(20181003)

T1-2-28

29- Left Travel Reverse Solenoid Valve 30- LD: Arm Extend Solenoid Valve/BH: Arm Roll-In Solenoid Valve 31- LD: Arm Retract Solenoid Valve/BH: Arm Roll-Out Solenoid Valve 32- Bucket Tilt-Out Solenoid Valve 33- LD: Bucket Close Solenoid Valve/BH: Unused 34- Swing Right Solenoid Valve

SECTION 1 GENERAL Group 2 Component Layout Left Urea SCR System Left DEF Tank A

Detail A

3 TKGB-01-02-019

View B

TKGB-01-02-020

TKGB-01-02-021

123-

DEF Tank (L) DEF Piping In-Line Filter 1 (L-Right Bank) DEF Piping In-Line Filter 2 (L-Left Bank)

TOKGB91-EN-00(20181003)

456-

DEF Sensor Unit (L) DEF Supply Module 1 (L-Right Bank) DEF Supply Module 2 (L-Left Bank)

78-

T1-2-29

DEF Tank Coolant Valve (L) DEF Supply Module Coolant Valve (L)

SECTION 1 GENERAL Group 2 Component Layout Left Urea SCR Muffler Unit B

View A

TKGB-01-02-022

Detail B

12-

ECU (NOx Sensor 1 (L-Left Bank)) ECU (Temperature Sensor 1 (L-Left Bank))

TOKGB91-EN-00(20181003)

TKGB-01-02-023

34-

ECU (NOx Sensor 2 (L-Right Bank)) ECU (Temperature Sensor 2 (L-Right Bank))

567-

T1-2-30

Dosing Module 2 (L-Right Bank) Dosing Module 1 (L-Left Bank) SCR Muffler

TKGB-01-02-024

SECTION 1 GENERAL Group 2 Component Layout Folding Stairway Folding Stairway Section B

Detail D

Section A

Section C

Detail E

15 11

TKGB-01-02-038 1234-

Folding Stairway Relay 2 Folding Stairway Relay 3 Folding Stairway Relay 4 Limit Switch (For Extending Detection)

TOKGB91-EN-00(20181003)

567-

Limit Switch (For Extending Stroke End Control) Limit Switch (For Retracting Stroke End Control) Limit Switch (For Retracting Detection)

8- Folding Stairway Pump 9- Valve Unit (Refer to T1-2-33.) 10- Work Light (For Folding Stairway) 11- Folding Stairway Alarm/Flash Light

T1-2-31

12- Limit Switch (Pilot Lock Lever) 13- Folding Stairway Cylinder 14- Folding Stairway Relay Lock Lever 15- Switch Box (Refer to T1-2-32.)

SECTION 1 GENERAL Group 2 Component Layout Switch Box

TKEB-01-02-058

TKEB-01-02-057

In Switch Box 4

T18N-01-03-005

TKGB-01-02-039

12-

Retract Switch Extend Switch

34-

TOKGB91-EN-00(20181003)

Emergency Folding Stairway Stop Switch Switch Box

T1-2-32

Isolation Switch (Folding Stairway Pump 2)

67-

Isolation Switch (Folding Stairway Pump 1) Switch Cover Plate

SECTION 1 GENERAL Group 2 Component Layout Valve Unit 1

7 8 14

T18L-01-02-034

15 3

B A1 A2

10 5

4 7

M T

12345-

Overload Relief Valve (Folding Stairway Cylinder Bottom Side) Orifice Check Valve Check Valve Check Valve

TOKGB91-EN-00(20181003)

Folding Stairway Solenoid Valve 3 7- Main Relief Valve 8- Check Valve 9- Check Valve 10- Throttle Valve

T18L-01-02-035

11- Folding Stairway Solenoid Valve 1 12- Check Valve 13- Folding Stairway Solenoid Valve 2 14- Slow Return Valve

15- Overload Relief Valve (Folding Stairway Cylinder Rod Side)

T1-2-33

SECTION 1 GENERAL Group 2 Component Layout Right Engine

View A

TKGB-01-02-056

View B

12345-

Engine Speed Sensor (R) Prelube Pressure Switch (R) Fuel Filter (Stage 1) ECM (R) Fuel Filter (Stage 2)

TOKGB91-EN-00(20181003)

67-

Prelube Motor (R) Starter Upper: Starter (R1) Lower: Starter (R2) Oil Filter

12 TKEB-01-02-053

TKEB-01-02-052

Engine Oil Temperature Sensor (R) 10- Engine Oil Level Sensor (R) 11- Coolant Filter 12- Alternator (R)

T1-2-34

SECTION 1 GENERAL Group 2 Component Layout Right Air Cleaner 1

TKGB-01-02-057

Detail A

2 3

TKGB-01-02-058

Air Cleaner (R)

TOKGB91-EN-00(20181003)

Air Cleaner Restriction Switch (R1)

T1-2-35

Air Cleaner Restriction Switch (R2)

SECTION 1 GENERAL Group 2 Component Layout Around Right Radiator 1

View A

2 A

TKGB-01-02-060 View B

4 TKGB-01-02-059

Detail C

TKGB-01-02-063 Detail D

1234-

HTC Radiator (R) LTC Radiator (R) LTC Radiator Front Air Temperature Sensor (R) HTC Radiator Outlet Coolant Temperature Sensor (R)

TOKGB91-EN-00(20181003)

67-

LTC Radiator Outlet Coolant Temperature Sensor (R) HTC Radiator Inlet Coolant Temperature Sensor (R1) HTC Radiator Inlet Coolant Temperature Sensor (R2)

TKGB-01-02-061

TKGB-01-02-062

LTC Radiator Inlet Coolant Temperature Sensor (R) 9- HTC Radiator Rear Air Temperature Sensor (R1) 10- HTC Radiator Rear Air Temperature Sensor (R2)

T1-2-36

SECTION 1 GENERAL Group 2 Component Layout

TKGB-01-02-064

View A

TKGB-01-02-054

TKGB-01-02-055

Water Tank (R)

TOKGB91-EN-00(20181003)

Coolant Level Check Switch (R1)

T1-2-37

Coolant Level Sensor (R)

Coolant Level Check Switch (R2)

SECTION 1 GENERAL Group 2 Component Layout Around Right Pump 1

8 9

TKGB-01-02-017

Views A, B, C

Detail D

14 17

16 15 TKEB-01-02-080

34-

Main Pump R1 (Pump Transmission Side)/Main pump R2 (Pump End Side) Main Pump R3 (Pump Transmission Side)/Main pump R4 (Pump End Side) High-Pressure Strainer (for Main Pump R1) High-Pressure Strainer (for Main Pump R2)

TOKGB91-EN-00(20181003)

High-Pressure Strainer (for Main Pump R3) 6- High-Pressure Strainer (for Main Pump R4) 7- High-Pressure Strainer (for Main Pump R5) 8- High-Pressure Strainer (for Main Pump R6) 9- Pilot Filter 10- Pilot Relief Valve

11- Main Pump R5 (Pump Transmission Side)/Main pump R6 (Pump End Side) 12- Right 4-Unit Pump (Refer to T1-2-41.) 13- Pump Transmission Oil Filter 14- Swash Plate Angle Sensor (Main Pumps R1, R3, R5) 15- Swash Plate Angle Sensor (Main Pumps R2, R4, R6)

T1-2-38

TKGB-01-02-073

16- Control Solenoid Valve (Main Pumps R1, R3, R5) 17- Control Solenoid Valve (Main Pumps R2, R4, R6) 18- Pump Transmission Oil Temperature Sensor (R) 19- Bypass Check Valve (for Pump Transmission Oil Pump)

SECTION 1 GENERAL Group 2 Component Layout 1

7 8

9 10

13 12 11

6 5 4

TKGB-01-02-014

View A

View B

22 16 17

15 19 123456-

Drain Pressure Sensor (Main Pump R1) Delivery Pressure Sensor (Main Pump R1) Regulator Pressure Sensor (Main Pump R1) Drain Pressure Sensor (Main Pump R2) Delivery Pressure Sensor (Main Pump R2) Regulator Pressure Sensor (Main Pump R2)

TOKGB91-EN-00(20181003)

20 7-

TKEB-01-02-081

TKEB-01-02-031

Pump Transmission Oil Level Switch (R) 8- Drain Pressure Sensor (Main Pump R3) 9- Delivery Pressure Sensor (Main Pump R3) 10- Regulator Pressure Sensor (Main Pump R3) 11- Drain Pressure Sensor (Main Pump R4) 12- Delivery Pressure Sensor (Main Pump R4)

13- Regulator Pressure Sensor (Main Pump R4) 14- Delivery Pressure Sensor (Oil Cooler Fan Motor Pump) 15- Regulator Pressure Sensor (Oil Cooler Fan Motor Pump) 16- Drain Pressure Sensor (Main Pump R5) 17- Delivery Pressure Sensor (Main Pump R5) 18- Regulator Pressure Sensor (Main Pump R5)

T1-2-39

19- Drain Pressure Sensor (Main Pump R6) 20- Delivery Pressure Sensor (Main Pump R6) 21- Regulator Pressure Sensor (Main Pump R6) 22- Control Solenoid Valve (Oil Cooler Fan Motor Pump)

SECTION 1 GENERAL Group 2 Component Layout

TKGB-01-02-015

12-

Contamination Sensor (Main Pump R1) Contamination Sensor (Main Pump R2)

TOKGB91-EN-00(20181003)

34-

Contamination Sensor (Main Pump R3) Contamination Sensor (Main Pump R4)

56-

T1-2-40

Contamination Sensor (Main Pump R5) Contamination Sensor (Main Pump R6)

SECTION 1 GENERAL Group 2 Component Layout Right 4-Unit Pump

TKGB-01-02-016

TKBD-01-02-003

12-

4-Unit Pump Oil Cooler Fan Motor Pump (Plunger Pump)

TOKGB91-EN-00(20181003)

34-

Pilot Pump (Gear Pump) Auxiliary (Gear Pump)

T1-2-41

Pump Transmission Oil Pump (Gear Pump)

SECTION 1 GENERAL Group 2 Component Layout Around Oil Cooler 2

View A

TKGB-01-02-065

View B

11 12

TKGB-01-02-067

TKGB-01-02-066 12346-

Oil Cooler 1 Oil Cooler 2 Oil Cooler 1 Front Air Temperature Sensor Pump Transmission Oil Cooler 1 Pump Transmission Oil Cooler 2

TOKGB91-EN-00(20181003)

Oil Cooler 2 Front Air Temperature Sensor 9- Oil Cooler 1 Outlet Hydraulic Oil Temperature Sensor 1 10- Oil Cooler 1 Outlet Hydraulic Oil Temperature Sensor 2 11- Oil Cooler 2 Outlet Hydraulic Oil Temperature Sensor 1

12- Oil Cooler 2 Outlet Hydraulic Oil Temperature Sensor 2 13- Oil Cooler 2 Rear Air Temperature Sensor 2 14- Oil Cooler Fan Motor 2 15- Oil Cooler 2 Rear Air Temperature Sensor 1

T1-2-42

16- Oil Cooler 1 Rear Air Temperature Sensor 2 17- Oil Cooler Fan Motor 1 18- Oil Cooler 1 Rear Air Temperature Sensor 1 19- Oil Cooler Inlet Hydraulic Oil Temperature Sensor

SECTION 1 GENERAL Group 2 Component Layout Auto-Lubrication Device Detail A

TKGB-01-02-071

TKGB-01-02-068

Detail B

View C

7 1

9 10

TKGB-01-02-069

123456-

Grease Pump Vent Valve Air Breather Grease Pressure Gauge Pressure Switch Auto-Lubrication Mode Switch

TOKGB91-EN-00(20181003)

789-

Grease Tank Level Sensor (Lower) Grease Tank Level Sensor (Upper) Hydraulic Oil Pressure Gauge

10- Auto-Lubrication Solenoid Valve 11- Grease Filter 12- Auto-Lubrication Interval Switch

T1-2-43

TKGB-01-02-070

SECTION 1 GENERAL Group 2 Component Layout Right Urea SCR System Right DEF Tank

TKGB-01-02-025

Detail A

View B

TKGB-01-02-026

12-

DEF Tank (R) DEF Piping In-Line Filter 1 (R-Left Bank)

TOKGB91-EN-00(20181003)

34-

DEF Piping In-Line Filter 2 (R-Right Bank) DEF Sensor Unit (R)

TKGB-01-02-027

56-

T1-2-44

DEF Supply Module 1 (R-Left Bank) DEF Supply Module 2 (R-Right Bank)

78-

DEF Tank Coolant Valve (R) DEF Supply Module Coolant Valve (R)

SECTION 1 GENERAL Group 2 Component Layout Right Urea SCR Muffler Unit B A

View A

Detail B

12-

ECU (NOx Sensor 1 (R-Left Bank)) ECU (Temperature Sensor 1 (R-Left Bank))

TOKGB91-EN-00(20181003)

TKGB-01-02-029

34-

ECU (NOx Sensor 2 (R-Right Bank)) ECU (Temperature Sensor 2 (R-Right Bank))

TKGB-01-02-028

567-

T1-2-45

Dosing Module 2 (R-Right Bank) Dosing Module 1 (R-Left Bank) SCR Muffler

TKGB-01-02-030

SECTION 1 GENERAL Group 2 Component Layout Control Valve

fNOTE: The illustration shows the layout viewed from the machine front.

TKGB-01-02-042

12-

Control Valve 1 (Upper Left) Control Valve 2 (Middle Left)

TOKGB91-EN-00(20181003)

34-

Control Valve 3 (Lower Left) Control Valve 4 (Upper Right)

56-

T1-2-46

Control Valve 5 (Middle Right) Control Valve 6 (Lower Right)

SECTION 1 GENERAL Group 2 Component Layout Control Valves 1, 4

Control Valve 4 (Upper Right)

Control Valve 1 (Upper Left)

1 2

8 9

10 11

20 21 22

16 23

17 5 6

12 13

24 25 26

18 7

19 TKGB-01-02-043

Control Valve 4 (Upper Right) 12345678910111213-

Make-Up Valve (Arm Extend) Overload Relief Valve (Arm Extend) Make-Up Valve (Bucket Open) Overload Relief Valve (Bucket Open) Main Relief Valve (Boom Raise) Overload Relief Valve (Boom Raise) Main Relief Valve Overload Relief Valve (Arm Retract) Make-Up Valve (Arm Retract) Overload Relief Valve (Bucket Close) Overload Relief Valve (Bucket Close) Overload Relief Valve (Bucket Tilt-In) Make-Up Valve (Bucket Tilt-In)

TOKGB91-EN-00(20181003)

Control Valve 5 (Upper Left) 14151617181920212223242526-

T1-2-47

Make-Up Valve (Bucket Tilt-Out) Overload Relief Valve (Bucket Tilt-Out) Make-Up Valve (Boom Lower) Overload Relief Valve (Boom Lower) Overload Relief Valve (Swing Right) Main Relief Valve Overload Relief Valve (Bucket Tilt-In) Make-Up Valve (Bucket Tilt-In) Overload Relief Valve (Arm Extend) Make-Up Valve (Arm Extend) Overload Relief Valve (Boom Raise) Make-Up Valve (Boom Raise) Overload Relief Valve (Swing Left)

SECTION 1 GENERAL Group 2 Component Layout Control Valves 2, 5

Control Valve 5 (Middle Right)

Control Valve 2 (Middle Left)

8 9

10 11

21 22

5 6

12 13

17 18

24 25

TKGB-01-02-044

Control Valve 5 (Middle Right) 12345678910111213-

Make-Up Valve (Bucket Tilt-In) Overload Relief Valve (Bucket Tilt-In) Make-Up Valve (Boom Lower) Overload Relief Valve (Boom Lower) Main Relief Valve (Arm Extend) Overload Relief Valve (Arm Extend) Main Relief Valve Overload Relief Valve (Bucket Tilt-Out) Make-Up Valve (Bucket Tilt-Out) Overload Relief Valve (Boom Raise) Make-Up Valve (Boom Raise) Overload Relief Valve (Arm Retract) Make-Up Valve (Arm Retract)

TOKGB91-EN-00(20181003)

Control Valve 2 (Middle Left) 14151617181920212223242526-

T1-2-48

Make-Up Valve (Bucket Tilt-In) Overload Relief Valve (Bucket Tilt-In) Overload Relief Valve (Bucket Close) Overload Relief Valve (Bucket Close) Make-Up Valve (Arm Retract) Overload Relief Valve (Arm Retract) Main Relief Valve Overload Relief Valve (Boom Raise) Make-Up Valve (Boom Raise) Overload Relief Valve (Bucket Open) Make-Up Valve (Bucket Open) Overload Relief Valve (Arm Extend) Make-Up Valve (Arm Extend)

SECTION 1 GENERAL Group 2 Component Layout Control Valves 3, 6

Control Valve 6 (Lower Right)

Control Valve 3 (Lower Left)

7 8

9 10

14 15

21 22

11 12

17 18

24 25

TKGB-01-02-045

Control Valve 6 (Lower Right) 12345678910111213-

Make-Up Valve (Bucket Tilt-In) Overload Relief Valve (Bucket Tilt-In) Make-Up Valve (Boom Lower) Overload Relief Valve (Boom Lower) Overload Relief Valve (Swing Right) Main Relief Valve Overload Relief Valve (Bucket Tilt-Out) Make-Up Valve (Bucket Tilt-Out) Overload Relief Valve (Arm Extend) Make-Up Valve (Arm Extend) Overload Relief Valve (Boom Raise) Make-Up Valve (Boom Raise) Overload Relief Valve (Swing Left)

TOKGB91-EN-00(20181003)

Control Valve 3 (Lower Left) 14151617181920212223242526-

T1-2-49

Make-Up Valve (Arm Retract) Overload Relief Valve (Arm Retract) Make-Up Valve (Boom Raise) Overload Relief Valve (Boom Raise) Make-Up Valve (Bucket Tilt-Out) Overload Relief Valve (Bucket Tilt-Out) Main Relief Valve Overload Relief Valve (Arm Extend) Make-Up Valve (Arm Extend) Overload Relief Valve (Boom Lower) Make-Up Valve (Boom Lower) Overload Relief Valve (Bucket Tilt-In) Make-Up Valve (Bucket Tilt-In)

SECTION 1 GENERAL Group 2 Component Layout Center Pilot Panel A

TKGB-01-02-096 Detail A

TKGB-01-02-097

12-

Boom Lower Priority Selector Valve Boom Raise Priority Selector Valve

TOKGB91-EN-00(20181003)

3456-

Control Valve 4 (Upper Right) Control Valve 5 (Middle Right) Control Valve 6 (Lower Right) Control Valve 3 (Lower Left)

78-

T1-2-50

Control Valve 2 (Middle Left) Control Valve 1 (Upper Left)

SECTION 1 GENERAL Group 2 Component Layout Hydraulic Oil Tank

3 4

A TKGB-01-02-074

View A

8 12-

Pressure Sensor (For Hydraulic Oil Tank) Bypass Filter

TOKGB91-EN-00(20181003)

34-

TKGB-01-02-075

Hydraulic Oil Level Check Switch Hydraulic Oil Level Warning Switch

567-

T1-2-51

Air Bleeding Solenoid Valve Hydraulic Oil Temperature Sensor Valve Limit Switch (L-Suction)

Valve Limit Switch (R-Suction)

SECTION 1 GENERAL Group 2 Component Layout Fuel Tank Detail A

4 5 6

TKGB-01-02-077

TKGB-01-02-076

12-

Fuel Level Switch (High) Fuel Level Switch (Low)

TOKGB91-EN-00(20181003)

34-

Fuel Level Float Sensor Fuel Cooler Fan Motor (Upper)

56-

T1-2-52

Fuel Cooler Fan Motor (Right) Fuel Cooler Fan Motor (Left)

SECTION 1 GENERAL Group 2 Component Layout Fast-Filling System

TKGB-01-02-078

Detail A

3 1

12-

Slow Return Valve Check Valve

TOKGB91-EN-00(20181003)

Lift Cylinder

TKGB-01-02-079

T1-2-53

Fast Filling Panel (Refer to T1-2-54.)

Fast Filling Panel Position Switch

SECTION 1 GENERAL Group 2 Component Layout Fast-Filling Panel

13 TKGB-01-02-080

12345-

Coolant (Left Radiator) Unused Pump Transmission Oil (Left Pump) Gear Oil (Swing Device Right Rear) Gear Oil (Swing Device Right Front)

TOKGB91-EN-00(20181003)

6789-

Fuel Full Warning Light Hydraulic Oil Grease Tank Fill Warning Light Pump Transmission Oil (Right Pump) 10- Unused 11- Coolant (Right Radiator) 12- Fuel

13141516-

DEF Fill (Right DEF Tank) Engine Oil (Right Engine) Grease Gear Oil (Swing Device Left Front) 17- Gear Oil (Swing Device Left Rear) 18- Engine Oil (Left Engine)

T1-2-54

19- DEF Fill (Left DEF Tank)

SECTION 1 GENERAL Group 2 Component Layout Swing Device 1

TKGB-01-02-081 Detail A

Detail B

15 16

13 12

TKGB-01-02-082 12345-

Swing Motor (4 Used) Swing Motor Inlet Pressure Sensor Contamination Sensor (Swing Motor Right Rear) Drain Pressure Sensor (Swing Motor Right Rear) Contamination Sensor (Swing Motor Left Rear)

TOKGB91-EN-00(20181003)

Drain Pressure Sensor (Swing Motor Left Rear) 7- Make-Up Valve (Swing Motor Left Rear) 8- Relief Valve (Swing Motor Left Rear) 9- Relief Valve (Swing Motor Right Rear) 10- Make-Up Valve (Swing Motor Right Rear)

17 TKGB-01-02-083

11- Make-Up Valve (Swing Motor Right Front) 12- Contamination Sensor (Swing Motor Right Front) 13- Drain Pressure Sensor (Swing Motor Right Front) 14- Make-Up Valve (Swing Motor Left Front) 15- Drain Pressure Sensor (Swing Motor Left Front)

T1-2-55

16- Contamination Sensor (Swing Motor Left Front) 17- Relief Valve (Swing Motor Left Front) 18- Relief Valve (Swing Motor Right Front)

SECTION 1 GENERAL Group 2 Component Layout Center Joint A

TKGB-01-02-084

Detail A

View B

3 5 B TKGB-01-02-085

12-

Pressure Sensor (For Adjuster Cylinder End) Slip Ring

TOKGB91-EN-00(20181003)

Contamination Sensor (Travel Motor)

TKGB-01-02-086

T1-2-56

Swing Angular Position Switch (5 Used)

Swing Angular Rate Sensor (Undercarriage)

SECTION 1 GENERAL Group 2 Component Layout Travel Device

5 9

3 8 7 6

TKGB-01-02-087

123-

Travel Reduction Gear (Left) Travel Motor (Left Rear) Travel Motor (Left Front)

TOKGB91-EN-00(20181003)

456-

Travel Brake Valve (Left Rear) Travel Brake Valve (Left Front) Travel Reduction Gear (Right)

789-

T1-2-57

Travel Motor (Right Rear) Travel Motor (Right Front) Travel Brake Valve (Right Rear)

10- Travel Brake Valve (Right Front)

SECTION 1 GENERAL Group 2 Component Layout Undercarriage F 1 2

F-

Machine Front Side

TKGB-01-02-088 View A

4 7

3 5

6 TKGB-01-02-089 12-

Adjuster Cylinder Grease Fitting

Accumulator (For Adjuster Cylinder)

45-

TOKGB91-EN-00(20181003)

T1-2-58

Pilot Pressure Control Valve (For Travel Stop) Relief Valve

67-

Reducing Valve Check Valve

SECTION 1 GENERAL Group 3 Component Specifications Engine Manufacturer Model Type Cyl. No.- Bore × Stroke Piston Displacement Rated Output (Gross) Compression Ratio Dry Weight Firing Order Rotation Direction Dimension Overall length × width × height

TOKGB91-EN-00(20181003)

CUMMINS, Inc QSKTA50-CE Diesel, 4 cycle, 60° V, water-cooled, direct injection type, Exhaust turbo charged type (with LTC radiator) 16-159×159 mm (16-6.3×6.3 in) 50 L (13 US gal) 1119 kW/1800 min-1 (1520 PS/1800 rpm) 14.7:1 6100 kg (13500 lb) 1R-1L-3R-3L-2R-2L-5R-4L-8R-8L-6R-6L-7R-7L-4R-5L Counterclockwise (Viewed from flywheel side) 2844×1541×1842 mm (9 ft 4in ×5 ft ×6 ft)

T1-3-1

SECTION 1 GENERAL Group 3 Component Specifications COOLING SYSTEM Cooling Fan Fan Pulley Ratio Thermostat

Water Pump

LUBRICATION SYSTEM

Lubrication Pump Type Oil Filter Engine Oil Capacity STARTING SYSTEM Model Voltage / Output ENGINE STOP Stop Method SYSTEM ALTERNATOR Type Voltage / Output SUPERCHARGING Type SYSTEM FUEL SYSTEM Type AFTERTREATMENT Urea SCR System DEVICE Model Dimension Overall length × width × height

TOKGB91-EN-00(20181003)

Dia. 1651 mm (5ft 5 in), 8 Blades 0.5 Engine Line LTC Line Cracking 82 °C (180 °F) 46 °C (115 °F) Temperature Full Open 94 °C (201 °F) 57 °C (135 °F) Centrifugal Coolant Capacity 170 L (45 US gal) Type Engine Unit 140 L (37 US gal) LTC Line 30 L (8 US gal) Gear Type Paper Element Type (for Full-Flow and Bypass Filters) 290 L (77 US gal) (HIGH), 255 L (67 US gal) (LOW) 50MT-400 24 V/9 kW ×2 (24 V/12 PS ×2) Electronic Control AC Generator with Diode Rectifier 24 V/140 A Exhaust-Turbocharger Type Cummins MCRS SCR4000 1331×575×805 mm (4 ft 4 in ×1 ft 11 in ×2 ft 7 in)

T1-3-2

SECTION 1 GENERAL Group 3 Component Specifications IMPORTANT: This list shows design specifications, which are not servicing standards. Performance Fuel Consumption (When rated, Gross) Maximum Output Torque (Gross) No Load Speed Fast: Slow:

TOKGB91-EN-00(20181003)

210 g/kW·h (154 g/PS·h) 6750 N·m/1400 min-1 (4980 lbf·ft/1400 rpm) 1950 ± 30 min-1 (rpm) 780 ± 30 min-1 (rpm)

T1-3-3

SECTION 1 GENERAL Group 3 Component Specifications Engine Performance Curve (QSKTA50-CE) Test Condition: The engine operating with fuel system, water pump, and 4.5 kPa (0.7 psi) inlet air restriction with 148.1 mm (5.8 in) inner diameter pipe, and with 6.8 kPa (1 psi) exhaust restriction with 197.9 mm (7.8 in) inner diameter pipe; not included are alternator, fan, optional equipment and driven components. Curves shown above represent gross engine performance capabilities obtained and corrected in accordance with SAE J1995 conditions of 100 kPa (14.5 psi) barometric pressure [91 m (300 ft) altitude] 25 °C (77 °F) inlet air temperature, and 1 kPa (0.1 psi) water vapor pressure with SAE No.2 diesel fuel. N·m

min-1

N P:

Output

TOKGB91-EN-00(20181003)

Torque

T1-3-4

Engine Speed

TKEB-01-03-001

SECTION 1 GENERAL Group 3 Component Specifications Engine Accessories RADIATOR ASSEMBLY

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

Core Dimension (height × width × depth) Core Rows Fin Pitch Fin Type Capacity Radiation Area FUEL COOLER Core Dimension (height × width × depth) Fin Pitch Fin Type Capacity Radiation Area Test Pressure BATTERY Type Nominal Voltage Capacity Discharge Characteristics (-15 °C)

TOKGB91-EN-00(20181003)

LTC Radiator HTC Radiator (999×2)×(841×2)×91 mm (999×2)×(841×2)×126 mm ((3 ft 3 in ×2)×(3 ft ×2)×4 in) ((3 ft 3 in ×2)×(3 ft ×2)×5 in) 5 7 3.6 mm (0.1 in) 2.8 mm (0.1 in) Plate Fin Plate Fin 75 L (20 US gal) 117 L (31 US gal) 226.6 m2 (271 yd2) 196.7 m2 (235.3 yd2) Oil Cooler Pump Transmission Oil Cooler 1500×942×160 mm 284.4×312×40 mm (4 ft 11 in ×3 ft ×6 in) (11 in ×1 ft ×1.6 in) 1 1 (Outer) 6.0/2 mm (Inner) 4.5/2 mm 3.5 mm Corrugated Corrugated 48.5 L (12.8 US gal) 2 L (2 US qt) 2 2 3.34 m2 (4 yd2) 135.24 m (162 yd ) 859×720.5×50 mm (2 ft 9.8 in ×2 ft 4.4 in ×2.0 in) 4.5/2 mm Corrugated 11.9 L (3.1 US gal) 24.01 m2 (28.7 yd2) 1 MPa (145 psi) 245H52 12 V 176 Ah (5-Hour Rate) NOTE: 185 Ah (20-Hour Rate) CCA Discharge Current Duration 30-Second Voltage at Discharge Dimension (height × width × length)

T1-3-5

1170 A 500 A 7.8 min 9.9 V 266×276×518 mm (10.5 in ×10.9 in ×1 ft 8 in)

SECTION 1 GENERAL Group 3 Component Specifications Hydraulic Component PUMP DEVICE

Drive Gear Ratio ENG : Main Pump ENG : 4-Unit Pump 1:1.019 1:1.081 MAIN PUMPS Type Swash Plate Type Variable Displacement Tandem Plunger Pump (L1 TO L4, R1 Theoretical 208 cm3/rev (12.7 in3/rev) TO R4) Displacement MAIN PUMPS Type Swash Plate Type Variable Displacement Tandem Plunger Pump (L5, L6, R5, Theoretical 236 cm3/rev (14.4 in3/rev) R6) Displacement REGULATOR Type Hydraulic Pressure Operated Type 4-UNIT PUMP Fan Motor Pump Pilot Pump (Pump Air Conditioner (Common Transmission Side) Compressor Motor with right Pump (Center Side) and left Type Swash Plate engines) Type Variable Gear Pump Displacement Plunger Pump 56 cm3/rev 45 cm3/rev Theoretical 93 cm3/rev 3 3 (5.7 in /rev) (3.4 in /rev) (2.7 in3/rev) Displacement CONTROL Type Pilot Operated Type, Multi Block 4-Spools VALVE Main Relief Set29.4 MPa (200 L/min) (4260 psi (53 US gpm)) Pressure Overload Relief 31.4 MPa (300 L/min) (4550 psi (79 US gpm)) Set-Pressure Overload Relief Set-Pressure 15.7 MPa (370 L/min) (2880 psi (98 US gpm)) (Bucket Open/ Close)

TOKGB91-EN-00(20181003)

T1-3-6

Pump Transmission Oil Pump (Pump End Side)

13 cm3/rev (0.8 in3/rev)

SECTION 1 GENERAL Group 3 Component Specifications SWING DEVICE SWING MOTOR

TRAVEL DEVICE TRAVEL MOTOR

TRAVEL BRAKE VALVE OIL COOLER FAN MOTOR AIR CONDITIONER COMPRESSOR MOTOR

Type Reduction Gear Ratio Type Theoretical Displacement Relief Set-Pressure Parking Brake Release Pressure Type Reduction Gear Ratio Type Theoretical Displacement (Fast/ Slow) Parking Brake Release Pressure Relief Set-Pressure Flow Rate Theoretical Displacement

Two Stage Reduction Planetary Gear 22.67 Swash Plate Type, Fixed Displacement Axial Plunger Motor 737 cm3/rev (45 in3/rev) 24.5 MPa (3550 psi) 1.8 to 2.6 MPa (260 to 375 psi) Spur Gear and Two Stage Reduction Planetary Gear 151.692 Swash Plate Type Variable Displacement Axial Plunger Motor 1027 cm3/rev (Slow) 718 cm3/rev (Fast) 3 (44 in /rev) (63 in3/rev) 1.90 MPa (275 psi) 29.4 MPa (4260 psi) 660 L/min (174 US gpm) 180 cm3/rev (11 in3/rev)

Theoretical Displacement

48 cm3/rev (3 in3/rev)

TOKGB91-EN-00(20181003)

T1-3-7

SECTION 1 GENERAL Group 3 Component Specifications CYLINDER

Boom Cylinder Rod Diameter 300 mm (11.8 in) Cylinder Bore 420 mm (16.5 in) Stroke 3200 mm (10 ft 6 in) Fully 5070 mm Retracted (16 ft 7.6 in) Length

CYLINDER

Rod Diameter Cylinder Bore Stroke Fully Retracted Length

TOKGB91-EN-00(20181003)

Arm Cylinder 260 mm (10.2 in) 360 mm (14.2 in) 2500 mm (8 ft 2.4 in) 4020 mm (13 ft 2.3 in)

Bucket Cylinder 250 mm (9.8 in) 340 mm (13.4 in) 2350 mm (7 ft 8.5 in) 4390 mm (14 ft 4.8 in)

Level Cylinder

Dump Cylinder

Lift Cylinder (Fast-Filling System)

300 mm (11.8 in) 420 mm (16.5 in) 970 mm (3 ft 2.2 in) 2710 mm (8 ft 10.7 in)

160 mm (6.3 in) 280 mm (11.0 in) 625 mm (2 ft 0.6 in) 1700 mm (5 ft 6.9 in)

40 mm (1.6 in) 70 mm (2.8 in) 240 mm (9.4 in) 512 mm (1 ft 8.2 in)

T1-3-8

Lift Cylinder (Folding Stairway Cylinder) 40 mm (1.6 in) 65 mm (2.6 in) 870 mm (2 ft 10 in) 1160 mm (3 ft 10 in)

SECTION 1 GENERAL Group 3 Component Specifications 3-SPOOL SOLENOID VALVE UNIT

PILOT SHUT-OFF SOLENOID VALVE

OIL COOLER BYPASS CHECK VALVE EDQR VALIVE FOR ELECTRIC CONTROL LEVER TRAVEL MODE SELECTOR SOLENOID VALVE FAST-FILLING PANEL RAISE/LOWER SOLENOID VALVE REDUCING VALVE FOR TRAVEL MODE CONTROL PILOT PRESSURE CONTROL VALVE FOR TRAVEL STOP FILTER (FILTRATION GRAIN SIZE)

Model Rated Voltage Coil Resistance Type Rated Voltage Maximum Input Flow Cracking Pressure Model Rated Voltage Coil Resistance Type Rated Voltage Maximum Input Flow Type Rated Voltage Maximum Input Flow Secondary Set-Pressure

3-Spool Proportional Solenoid Valve DC24V 22 Ω ON/OFF Solenoid Valve DC24 V 60 L/min (16 US gpm) 245 kPa at 40 L/min (36 psi at 11 US gpm) 8-Spool Proportional Solenoid Valve DC24 V 22 Ω ON/OFF Solenoid Valve DC24 V 60 L/min (16 US gpm) ON/OFF Solenoid Valve DC24 V 60 L/min (16 US gpm) 2.4±0.1 MPa (350±15 psi)

Cracking Pressure

11.8±1.0 MPa (1710±145 psi)

Full-Flow Filter Suction Filter Pilot Filter Fuel Filter

β10>2.0 177μ m (80 mesh) 10μ m Stage1: 5μ m Stage2: Outer Layer 3μ m Inner Layer 2μ m 120μ m 105μ m 5μ m β10>2.0 Piping In-Line Filter 40μ m Supply Module (Main) 30μ m

High-Pressure Strainer Pump Transmission Oil Filter Bypass Filter Drain Filter DEF Filter

TOKGB91-EN-00(20181003)

T1-3-9

SECTION 1 GENERAL Group 3 Component Specifications Electrical Component BATTERY RELAY

Rated Voltage Minimum Operating Voltage Open Circuit Voltage Excited Current

STARTER RELAY

Rated Voltage Minimum Operating Voltage Restoration Voltage Rated Voltage Minimum Operating Voltage Restoration Voltage Model Voltage Work Light (Upper Left Side of Cab) Work Light (Upper Right Side of Cab) DC24 V/50 W Work Light (Left Bed (Upper Left/Lower Left)) Work Light (Left Bed (Upper Right/Lower Right)) Work Light (Folding Stairway) DC24 V/70 W Halogen Work Light (Front Left Side of Right Fender) Work Light (Front Right Side of Right Fender) DC24 V/50 W Work Light (Center Frame (Right Side/Left Side)) Work Light (Rear of Frame (Right Side/Left Side)) Entrance Light (Rear of Cab) Entrance Light (Left Fender) Maintenance Light (Pump Compartment) (Right/Left) Maintenance Light 1 (Engine Compartment) (Right/Left) DC24 V/70 W Halogen Maintenance Light 2 (Engine Compartment) (Right/Left) Maintenance Light (Oil Cooler Compartment) Control Valve Maintenance Light Refrigerant 134 a Cooling Ability over 4.5 kW (6.1 PS) Cool Air Volume over 550 m3 (720 yd3) Heating Ability over 5.8 kW (7.9 PS) Warm Air Volume over 390 m3 (510 yd3) Temperature Adjusting System Electronic Type Refrigerant Quantity Refrigeration Cycle 1 = 1000±50 g (3±0.1 lb) Refrigeration Cycle 2 = 850±50 g (1.9±0.1 lb) Refrigeration Cycle = 800±50 g (1.8±0.1 lb) Compressor Oil Quantity 180 cm3 (11 in3) Application for Level Indicator Type Capacitance Switch Application for Warning (CUMMIMS) Type Capacitance Switch Operating Pressure 6.2±0.6 kPa (900±87 psi)

ALTERNATOR RELAY HORN (LEFT) ILLUMINATION

AIR CONDITIONER

COOLANT LEVEL CHECK SWITCH COOLANT LEVEL SENSOR AIR CLEANER RESTRICTION SWITCH FUEL LEVEL SENSOR (for Warning) HYDRAULIC OIL LEVEL CHECK SWITCH

TOKGB91-EN-00(20181003)

DC24 V less than DC20 V at 20 °C (68 °F) less than DC9 V at 20 °C (68 °F) less than 0.5 A at DC24 V and 20 °C (68 °F) DC24 V less than DC16 V at 25 °C (77 °F) 1 to 8 V at 25 °C (77 °F) DC24 V less than DC16 V at 20 °C (68 °F) 1 to 10 V at 20 °C (68 °F) HS21A DC24 V

Type

Float Type

Application

Pump Transmission Oil Level Switch for Level Indicator, for Warning

T1-3-10

SECTION 1 GENERAL Group 3 Component Specifications AMBIENT TEMPERATURE SENSOR

COOLANT TEMPERATURE SENSOR

Application

Operating Temperature Application

Operating Temperature OIL TEMPERATURE SENSOR Application

FUEL TEMPERATURE SENSOR PRESSURE SENSOR

Operating Temperature Application Operating Temperature Application

Operating Pressure DRAIN PRESSURE SENSOR Application PRESSURE SENSOR in HYDRAULIC OIL TANK PILOT PRESSURE SENSOR

Operating Pressure Operating Pressure

Atmospherical Temperature Sensor LTC Radiator Front Air Temperature Sensor HTC Radiator Rear Air Temperature Sensor 1 Oil Cooler Front Air Temperature Sensor Oil Cooler Rear Air Temperature Sensor -30 to 120 °C (-22 to 248 °F) LTC Radiator Inlet Coolant Temperature Sensor HTC Radiator Inlet Coolant Temperature Sensor LTC Radiator Outlet Coolant Temperature Sensor HTC Radiator Outlet Coolant Temperature Sensor -30 to 120 °C (-22 to 248 °F) Hydraulic Oil Temperature Sensor Pump Transmission Oil Temperature Sensor Pump Transmission Oil Cooler Outlet Oil Temperature Sensor Oil Cooler Inlet Oil Temperature Sensor Oil Cooler Outlet Oil Temperature Sensor -30 to 120 °C (-22 to 248 °F) Fuel Cooler Inlet Fuel Temperature Sensor Fuel Cooler Outlet Fuel Temperature Sensor -30 to 120 °C (-22 to 248 °F) Delivery Pressure Sensors (Main Pumps L1 to L6, R1 to R6) Delivery Pressure Sensor (Oil Cooler Fan Motor Pump) Boom Cylinder Bottom Side Pressure Sensor Boom Cylinder Rod Side Pressure Sensor Swing Motor Inlet Pressure Sensor 0 to 34.3 Mpa (0 to 4970 psi) Swing Motor Drain Pressure Sensor for Main Pumps L1 to L6, R1 to R6 0 to 1.0 Mpa (0 to 145 psi) 0 to 1.0 Mpa (0 to 145 psi)

for EDQR Valve for detecting abnormal track tension Operating Pressure 0 to 4.9 Mpa (0 to 710 psi) PRESSURE SWITCH Auto-Lubrication Device 23.5 Mpa (3410 psi) ELECTRIC CONTROL LEVER Front Attachment/Swing Travel Bucket Open/Close Mechanical Control Angle XY Axis±15 ° to 20 ° ±12.4 ° ±12.4 ° Operating Force XY Axis Approx. 2 to 21 to 29 N (4.7 to 40 to 63 N (9 to Approx. 8 N (0.5 to 1.8 lbf ) 6.5 lbf ) 14.2 lbf ) Total Resistance 2 kΩ±15 % Neutral Detection Angle ±3 ° ±3 ° Output Voltage 1.0 to 4.0 V 1.0 to 4.0 V ACCELERATOR SENSOR Total Resistance 5 kΩ±20 % Output 0.4 ±0.1 V at Slow idle position 4.4 ±0.1 V at Fast idle position FOLDING STAIRWAY PUMP Maximum Motor Output 2.4 kW (3.3 PS) Pump Displacement 2.43 cm3/rev (0.15 in3/rev) GREASE TANK LEVEL Application For Grease Level Indicator SENSOR Type Electrostatic Capacity Type INCLINATION ANGLE Application For Measurement of Body Angle Tilting (Pitch, Roll) SENSOR Effective Tilting Angle -60 °~+60 ° SWING ANGULAR RATE Application For Measurement of Swing Angle (Upperstructure, SENSOR Undercarriage) Usable Voltage DC 7 to 24 V DEF LEVEL SENSOR Application For DEF Level Indicator Measuring Range 35 mm to 546 mm (1.4 in to 21.5 in) with Float

TOKGB91-EN-00(20181003)

Application

T1-3-11

SECTION 1 GENERAL Group 3 Component Specifications Others GREASE CAPACITY GREASE MAXIMUM DELIVERY PRESSURE GREASE DELIVERY AMOUNT

TOKGB91-EN-00(20181003)

673 L (178 US gal) (Grease Tank) 24.5±0.5 Mpa (3550±73 psi) 9.6 L/min (2.5 US gpm)

T1-3-12

MEMO

TOKGB91-EN-00(20181003)

MEMO

TOKGB91-EN-00(20181003)

SECTION 2

SYSTEM CONTENTS Group 1 Controller

Outline..................................................................................... T2-1-1 MCU: Monitor Control Unit (Alarm Monitor and Sub-Control System Control Unit)............................ T2-1-6 ELUF: Electric Lever Control Unit for Front (Electric Control Lever Controller for Controlling Front Attachment Operation)..........T2-1-12 ELUT: Electric Lever Control Unit for Travel (Electric Control Lever Controller for Controlling Travel Operation)..................................T2-1-16 PFU: Pump Flow Control Unit (Pump Flow Rate Control Controller)....................T2-1-20 IDU: Information Display Unit (Information Display Controller).............................T2-1-25 ECM: Engine Control Module (Engine Controller).......................................................T2-1-32 DLU: Data Logging Unit . ................................................T2-1-34 CSU: Contamination Sensing Unit...............................T2-1-36 HMU: Hydraulic System Monitoring Unit..................T2-1-38 PMU: Pump Monitoring Unit.........................................T2-1-40 EHU: Engine Heat Balance Monitoring Unit (Engine Cooling System Monitoring Unit)..........T2-1-42 ODR: Operation Data Recorder.....................................T2-1-44 BPU: Basic Performance Monitoring Unit.................T2-1-46

Other Actuator Circuits . .................................................T2-4-22 Travel Shock Absorbing/Travel Stop Circuit.............T2-4-23

Group 5 Electrical System

Outline..................................................................................... T2-5-1 Main Circuit............................................................................ T2-5-2 Electric Power Circuit (Key Switch: OFF)...................... T2-5-4 Electric Power Circuit (Key Switch: ACC)...................... T2-5-6 Electric Power Circuit (Key Switch: ON)........................ T2-5-8 Engine Starting Circuit (Engine Start Switch: ON)..........................................T2-5-20 Charging Circuit (Key Switch: ON-Engine: Running).........................T2-5-24 Engine Stop Circuit............................................................T2-5-26 Surge Voltage Prevention Circuit.................................T2-5-32

Group 6 Air Conditioning System

Outline..................................................................................... T2-6-1 Functions of Main Components..................................... T2-6-2 Functions of Main Electrical Parts.................................. T2-6-3

Group 2 Control System

Outline..................................................................................... T2-2-1 Engine Control...................................................................... T2-2-3 Pump Control......................................................................T2-2-12 Sub-Control System Control..........................................T2-2-26 Fast-Filling Panel Lower Control...................................T2-2-28 Folding Stairway Control.................................................T2-2-40 Travel Mode Control.........................................................T2-2-44 Cab Bed Pressurization Control....................................T2-2-48

Group 3 ELU System

Outline..................................................................................... T2-3-1 Pilot Shut-Off Control......................................................... T2-3-2 Boom Lower Flow Rate Regeneration Control.......... T2-3-4 Cylinder Stroke End Shock Prevention Control......... T2-3-6 Adjuster Cylinder End Travel Limitation Control...... T2-3-8 Swing Stop Control...........................................................T2-3-10

Group 4 Hydraulic System

Outline..................................................................................... T2-4-1 Pilot Circuit............................................................................. T2-4-2 Main Circuit............................................................................ T2-4-6

TOKGB91-EN-00(20181003)

KGB91T-2-1

(Blank)

TOKGB91-EN-00(20181003)

KGB91T-2-2

SECTION 2 SYSTEM Group 1 Controller Outline The controllers are provided in this machine for the control, monitoring, display, and log data communication. Each controller communicates by using the CAN circuit and sends or receives the required signal.

TOKGB91-EN-00(20181003)

T2-1-1

SECTION 2 SYSTEM Group 1 Controller Controller The following controllers are provided in this machine.  MCU: Monitor Control Unit Alarm Monitor and Sub-Control System Control Unit  ELUF: Electric Lever Control Unit for Front Electric Control Lever Controller for Controlling Front Attachment Operation  ELUT: Electric Lever Control Unit for Travel Electric Control Lever Controller for Controlling Travel Operation  PFU (L), PFU (R): Pump Flow Control Unit (L), Pump Flow Control Unit (R) Pump Flow Rate Control Controller  IDU: Information Display Unit Information Display Controller  ECM(L), ECM (R): Engine Control Module (L), Engine Control Module (R) Engine Controller

fNOTE: ECM(L) and ECM (R) consist of ECM(P), ECM(C1),

ECM(C2), and ECM(C3) respectively.  DLU: Data Logging Unit Data Logging Unit  CSU: Contamination Sensing Unit Contamination Sensing Unit  HMU: Hydraulic System Monitoring Unit Hydraulic System Monitoring Unit  PMU (L), PMU (R): Pump Monitoring Unit (L), Pump Monitoring Unit (R) Pump Monitoring Unit  EHU (L), EHU (R): Engine Heat Balance Monitoring Unit (L), Engine Heat Balance Monitoring Unit (R) Engine Cooling System Monitoring Unit  ODR: Operation Data Recorder Operation Data Recorder  BPU: Basic Performance Monitoring Unit Basic Performance Monitoring Unit  WIU: Wireless Interface Unit (Option) Wireless Interface Unit

TOKGB91-EN-00(20181003)

T2-1-2

SECTION 2 SYSTEM Group 1 Controller ECM(L) ECM(P)

ECM(C1)

ECM(R)

ECM(C2)

ECM(C3)

ECM(P)

ECM(C1)

ECM(C2)

ECM(C3)

SAE J1939-CAN

3 EHU(L)

DLU

EHU(R)

WIU

DLU-CAN MCU

Ke-CAN HiKe-CAN

IDU

ELUF

ELUT

PFU(L)

PMU(L)

HMU

ODR

CSU

PFU(R)

PMU(R)

BPU

HiSe-CAN

6 TKGB-02-01-001

123-

GPS Antenna MPDr. Satellite Communication Terminal

TOKGB91-EN-00(20181003)

45-

Mobile Communication Terminal Swing Angular Rate Sensor (Upperstructure)

T2-1-3

Swing Angular Rate Sensor (Undercarriage)

SECTION 2 SYSTEM Group 1 Controller CAN Circuit CAN (Controller Area Network) is ISO Standards of the serial communication protocol. Five networks (CAN bus (C)) in the following are equipped for this machine.  J1939-CAN (1) is mainly used for the engine control.  Ke-CAN (2) is mainly used for display and log data communication.  HiKe-CAN (3) is used for the control data communication.  HiSe-CAN (4) is used for communication of the swing angular rate data.  DLU-CAN (5) is used for communication between WIU (option) and DLU. CAN bus (C) consists of two wire harnesses, CAN-H (High) (A) and CAN-L (Low) (B). Each controller reads signal and data on the CAN bus (C) due to the potential difference between CAN-H (High) (A) and CAN-L (Low) (B). Each controller arranges potential difference of the CAN bus (C) and sends the signal and data to other controllers. Termination resistors (120 Ω) (6) are installed to both ends of CAN bus (c).

TOKGB91-EN-00(20181003)

B TKEB-02-05-017

AB-

T2-1-4

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

C-

CAN Bus

SECTION 2 SYSTEM Group 1 Controller

ECM(R)

ECM(L) ECM(P)

ECM(C1)

ECM(C2)

ECM(C3)

ECM(P)

ECM(C1)

ECM(C2)

ECM(C3)

WIU

IDU

6 MCU

DLU

EHU(R)

EHU(L)

6 2 6

6 3

ELUF

ELUT

PFU(L)

PMU(L)

HMU

CSU

ODR

BPU

PFU(R)

PMU(R)

6 4 TKGB-02-01-020

123-

J1939-CAN Ke-CAN HiKe-CAN

TOKGB91-EN-00(20181003)

456-

HiSe-CAN DLU-CAN Termination Resistor (120 Ω)

T2-1-5

Swing Angular Rate Sensor (Upperstructure)

Swing Angular Rate Sensor (Undercarriage)

SECTION 2 SYSTEM Group 1 Controller MCU: Monitor Control Unit (Alarm Monitor and Sub-Control System Control Unit) Outline  Auto-Idle Control When all following conditions exist, MCU sends the signal equivalent to the auto-idle speed to ECM (L) and ECM (R).  Auto-idle switch (1): ON  Control lever: All control levers are in the neutral position. ECM (L) and ECM (R) change the engine speed into the auto-idle speed.  Fast-Filling Panel Lower Control When all following conditions exist, MCU activates the fast filling solenoid valve (10).  Pilot shut-off lever: LOCK position  Fast filling switch (8): ON Pressure oil from the pilot pump is supplied to the lift cylinder and the fast-filling panel is lowered. When the pilot shut-off lever is in the UNLOCK position, MCU prevents the fast-filling panel from lowering.  Auto-Lubrication Control MCU activates the auto-lubrication solenoid valve (11) according to the interval set by the auto-lubrication interval switch (7). Therefore, MCU controls lubrication of the front joint pins and swing bearing.  Oil Cooler Fan Control MCU controls the pump control solenoid valves (L, R) (12, 13) of the oil cooler fan motor pump according to the signal from the hydraulic oil temperature sensor (14). Therefore, MCU controls the speed of the oil cooler fan motor.

fNOTE: Refer to T2-2 for details of MCU control.

TOKGB91-EN-00(20181003)

T2-1-6

SECTION 2 SYSTEM Group 1 Controller 1

2 3

MCU

ECM(L)

ECM(R) J1939-CAN

Ke-CAN

ELUF

5 6 7

a b c d

13 TKGB-02-01-002

3 minutes

12345-

Auto-Idle Switch Auto-Lubrication Mode Switch Pressure Switch Pilot Shut-Off Switch Fast Filling Panel Position Switch Fast Filling Panel Position Relay

TOKGB91-EN-00(20181003)

5 minutes

Auto-Lubrication Interval Switch 8- Fast Filling Switch 9- Fast Filling Relay 10- Fast Filling Solenoid Valve 11- Auto-Lubrication Solenoid Valve

10 minutes

12- Pump Control Solenoid Valve (L) 13- Pump Control Solenoid Valve (R) 14- Hydraulic Oil Temperature Sensor

T2-1-7

15 minutes

15- Regulator Pressure Sensor (Oil Cooler Fan Motor Pump) (L) 16- Regulator Pressure Sensor (Oil Cooler Fan Motor Pump) (R)

SECTION 2 SYSTEM Group 1 Controller  Wiper Control MCU operates wiper motor (9) at the slow, fast, or intermittent operation according to the signal from wiper switch (15). MCU operates wiper motor (9) at the intermittent operation according to the interval set by wiper interval switch (19).  Power Shut-Off Delay Control MCU shuts off excited current at the delayed power off relay (7) when the specified time (which can be set from 15 seconds to 10 minutes) has passed after turning OFF key switch (13). Therefore, battery relay (8) is turned OFF and current is stopped supplying from the battery. Time setting can be performed on monitor display (1).  Fuel Level Measurement MCU detects the signal from fuel level float sensor (14) and fuel level switches (High, Low) (5, 6), and sends it to IDU. IDU displays the fuel level on monitor display (1). (Refer to T2-1-25 for IDU Meter Display Item.)  Grease Level Measurement MCU detects the signal from grease tank level switches (2, 3, 4), and sends it to IDU. IDU displays the grease level on monitor display (1). (Refer to T2-1-25 for IDU Meter Display Item.)

TOKGB91-EN-00(20181003)

T2-1-8

SECTION 2 SYSTEM Group 1 Controller

MCU

IDU

Ke-CAN

2 14

3 15 4 16

5 6 18 19

8 7

TKGB-02-01-003

1234-

Monitor Display Grease Tank Level Switch (Middle) Grease Tank Level Switch (High) Grease Tank Level Switch (Low)

TOKGB91-EN-00(20181003)

5678910-

Fuel Level Switch (High) Fuel Level Switch (Low) Delayed Power OFF Relay Battery Relay Wiper Motor Wiper Relay 1

111213141516-

T2-1-9

Wiper Relay 2 Wiper Relay 3 Key Switch Fuel Level Float Sensor Wiper Switch Washer Switch

17- Washer Motor 18- Washer Motor Relay 19- Wiper Interval Switch

SECTION 2 SYSTEM Group 1 Controller  Alarm Judgment MCU performs the following judgments. 1. Auto-lubrication control (Buzzer: ON) 2. Alternator operation 3. Pump transmission oil level low 4. Hydraulic oil level low (Buzzer: ON) 5. Air cleaner restriction (L, R) 6. Emergency Engine Stop Switches 1 to 7 (8 to 14) ON/OFF Status (ON/OFF) 7. Valves opening/closing (Buzzer: ON) 8. Electrical equipment box door opening 9. Folding stairway lowering 10. Hydraulic oil overheating (Buzzer: ON) 11. Fast-filling panel lowering 12. Fuel level 13. Grease level (Buzzer: ON)

fNOTE: MCU turns on warning light LED (red) (h) or LED (yellow) (g) according to judgment. At the same time, IDU turns on each indicator on monitor display (1) in response to the CAN information.

fNOTE: As for folding stairway lowering alarm and fast-

filling panel lowering alarm, when the pilot shut-off lever is set to the UNLOCK position, the buzzer also sounds.

 Troubleshooting MCU performs the following failure diagnosis.  Sensors connected to MCU  J1939-CAN communication  Ke-CAN communication MCU turns on LED (yellow) (g) and sends trouble information to IDU and DLU. IDU displays trouble information on the monitor display (1). DLU records trouble information.

TOKGB91-EN-00(20181003)

T2-1-10

SECTION 2 SYSTEM Group 1 Controller

MCU

IDU

5 DLU

6 Ke-CAN

2 3 7

b 18

19 11 14

10 13

9 12

21 22

24 17

25 26

c d e f

g h

TKGB-02-01-004 ab-

Alternator Line Key Switch ON Signal Line

cd-

To ECM(L) To ECM(R)

ef-

12-

Monitor Display Air Cleaner Restriction Switch (L) Air Cleaner Restriction Switch (R) Hydraulic Oil Level Warning Switch Hydraulic Oil Level Check Switch Pressure Switch (For Lubrication) Air Bleeding Solenoid Valve Emergency Engine Stop Switch 1

Emergency Engine Stop Switch 2 Emergency Engine Stop Switch 3 Emergency Engine Stop Switch 4 Emergency Engine Stop Switch 5 Emergency Engine Stop Switch 6 Emergency Engine Stop Switch 7 Valve Limit Switch (Return) Valve Limit Switch (L-Suction)

17- Valve Limit Switch (R-Suction) 18- Grease Tank Level Switch (Middle) 19- Grease Tank Level Switch (Upper) 20- Grease Tank Level Switch (Lower) 21- Pilot Shut-Off Switch 22- Fast Filling Panel Position Switch 23- Limit Switch 4 (For Retracting Detection) 24- Limit Switch (Electrical Equipment Box Door)

345678-

TOKGB91-EN-00(20181003)

10111213141516-

T2-1-11

Alternator Signal (L) Line Alternator Signal (R) Line

gh-

Warning Light LED (Yellow) Warning Light LED (Red)

25- Pump Transmission Oil Level Switch (L) 26- Pump Transmission Oil Level Switch (R) 27- Hydraulic Oil Temperature Sensor 28- Fuel Level Float Sensor 29- Auto-Lubrication Solenoid Valve

SECTION 2 SYSTEM Group 1 Controller ELUF: Electric Lever Control Unit for Front (Electric Control Lever Controller for Controlling Front Attachment Operation) Outline  Pilot Shut-Off Control ELUF shifts the pilot shut-off solenoid valve relay (5) according to the signal of the pilot shut-off lever switch (4), and activates or stops the pilot shut-off solenoid valve (6). Therefore, pressure oil is supplied or is stopped supplying to EDQR (Electric Dual Quick Response) valve (7).  Pilot Pressure Control for Control Valve ELUF activates solenoid valves (8 to 15) of EDQR valve (7) according to the signal from the electric control lever (front attachment, swing) (16). EDQR valve (7) supplies pilot pressure oil according to the signal to the control valve.  Swing Stop Control ELUF disables the swing control lever signal according to the signal from the fast filling position switch (3) or limit switch 4 (for retracting detection) (1). Consequently, the machine is stopped swinging.  Cylinder Stroke End Shock Prevention Control When ELUF judges that the cylinder rod is near the stroke end position due to the signals from angle sensors (17, 18, 19), ELUF controls the solenoid valve of EDQR valve (7) corresponding to the operation. Therefore, ELUF reduces pilot pressure acting on the control valve. At the same time, ELUF sends the electric control lever (16) signal equivalent to the reduced pilot pressure to PFU (L) and PFU (R). PFU (L) and PFU (R) perform the positive control and reduce the pump delivery flow rate.

fNOTE: Refer to T2-3 for details of ELUF control.

TOKGB91-EN-00(20181003)

T2-1-12

SECTION 2 SYSTEM Group 1 Controller

2 ELUF

HiKe-CAN

Ke-CAN b

7 8 9 10 17 11 12

13 14

15 TKGB-02-01-021

To ELUT, PFU (L), PFU (R)

Limit Switch 4 (For Retracting Detection) Limit Switch 5 (For Lock Lever Lock Position Detection) Fast Filling Panel Position Switch Pilot Shut-Off Switch

234-

TOKGB91-EN-00(20181003)

To MCU, IDU, DLU, ELUT

Pilot Shut-Off Solenoid Valve Relay 6- Pilot Shut-Off Solenoid Valve 7- EDQR Valve 8- Boom Raise Solenoid Valve 9- Boom Lower Solenoid Valve 10- Bucket Tilt-Out Solenoid Valve 11- Bucket Tilt-In Solenoid Valve

1213141516-

Swing Left Solenoid Valve Swing Right Solenoid Valve Arm Extend Solenoid Valve Arm Retract Solenoid Valve Electric Control Lever (Front Attachment, Swing) 17- Bucket Angle Sensor 18- Arm Angle Sensor

T2-1-13

19- Boom Angle Sensor

SECTION 2 SYSTEM Group 1 Controller  Troubleshooting ELUF performs the following failure diagnosis.  Sensors connected to ELUF  HiKe-CAN communication  Ke-CAN communication  Detection of the stick of the solenoid valve of EDQR valve (4) ELUF sends trouble information to IDU and DLU. ELUF turns on warning light LED (red) (d) or LED (yellow) (c). IDU displays trouble information on the monitor display. DLU records trouble information.

fNOTE: When ELUF detects the stick of the solenoid

valve of EDQR valve (4), ELUF turns OFF the pilot shut-off solenoid valve (3) and automatically stops supplying pilot pressure to EDQR valve (4).

TOKGB91-EN-00(20181003)

T2-1-14

SECTION 2 SYSTEM Group 1 Controller

HiKe-CAN

ELUF

Ke-CAN b

13 2

c 15 d 4

9 21 10 22 11 12 TKGB-02-01-022

To ELUT, PFU (L), PFU (R)

To MCU, IDU, DLU, ELUT

Warning Light LED (Yellow)

Warning Light LED (Red)

12-

Pilot Shut-Off Switch Pilot Shut-Off Solenoid Valve Relay Pilot Shut-Off Solenoid Valve EDQR Valve Boom Raise Solenoid Valve Boom Lower Solenoid Valve

789101112-

Bucket Tilt-Out Solenoid Valve Bucket Tilt-In Solenoid Valve Swing Left Solenoid Valve Swing Right Solenoid Valve Arm Extend Solenoid Valve Arm Retract Solenoid Valve

13- Electric Control Lever (Front Attachment, Swing) 14- Pilot Pressure Sensor 15- Boom Raise 16- Boom Lower 17- Bucket Tilt-Out 18- Bucket Tilt-In

19202122-

Swing Left Swing Right Arm Extend Arm Retract

3456-

TOKGB91-EN-00(20181003)

T2-1-15

SECTION 2 SYSTEM Group 1 Controller ELUT: Electric Lever Control Unit for Travel (Electric Control Lever Controller for Controlling Travel Operation) Outline  Pilot Pressure Control for Control Valve ELUT activates solenoid valves (5 to 10) of EDQR valve (4) according to the signal from the electric control lever (travel) (2). EDQR valve (4) supplies pilot pressure oil according to the signal to the control valve.  Adjuster Cylinder End Travel Regulation Control When the cushion piston of the adjuster cylinder reaches the stroke end during travel operation, ELUT receives the signal from pressure sensor (3). ELUT stops travel operation of the same direction. When perform reverse travel operation and the cushion piston gets away from the stroke end, the machine can travel for both direction.  Boom Lower Flow Rate Regeneration Control ELUT calculates the control signal according to the boom lower signal from ELUF. Therefore, ELUT controls the boom lower make-up solenoid valve (12). Pilot pressure of the boom lower make-up solenoid valve (12) shifts the make-up valve. Pressure oil from the boom cylinder bottom side flows to the boom cylinder rod side. Pressure oil which is used for the boom lower operation is reduced and more pressure oil is delivered to the other actuators. Then, the combined operation can be smoothly performed.

fNOTE: Refer to T2-3 for details of ELUT control.

TOKGB91-EN-00(20181003)

T2-1-16

SECTION 2 SYSTEM Group 1 Controller

ELUT

HiKe-CAN

a Ke-CAN

b 2

5 6 7 8 9 10 11

TKGB-02-01-005

To ELUF, PFU (L), PFU (R)

To MCU, IDU, DLU, ELUF

123456-

Pilot Shut-Off Switch Electric Control Lever (Travel) Pressure Sensor EDQR Valve Bucket Open Solenoid Valve Bucket Close Solenoid Valve

Left Travel Forward Solenoid Valve Left Travel Reverse Solenoid Valve Right Travel Forward Solenoid Valve

TOKGB91-EN-00(20181003)

89-

10- Right Travel Reverse Solenoid Valve 11- 3-Spool Solenoid Valve 12- Boom Lower Make-Up Solenoid Valve

T2-1-17

SECTION 2 SYSTEM Group 1 Controller  Troubleshooting ELUT performs the following failure diagnosis.  Sensors connected to ELUT  HiKe-CAN communication  Ke-CAN communication  Detection of the stick of the solenoid valve of EDQR valve (11) ELUT sends trouble information to IDU and DLU, and turns on warning light LED (red) (d) or LED (yellow) (c). IDU displays trouble information on the monitor display. DLU records trouble information.

fNOTE: When ELUT detects the stick of the solenoid

valve of EDQR valve (11), ELUT sends the signal to ELUF. ELUF turns OFF the pilot shut-off solenoid valve and automatically stops supplying pilot pressure to EDQR valve (11).

TOKGB91-EN-00(20181003)

T2-1-18

SECTION 2 SYSTEM Group 1 Controller

ELUT

HiKe-CAN

Ke-CAN

b 1

c d 11

4 5

6 13

16 10

17 18 19

TKGB-02-01-006

To ELUF, PFU (L), PFU (R)

To MCU, IDU, DLU, ELUF

12345678-

Pilot Shut-Off Switch Electric Control Lever (Travel) Pilot Pressure Sensor Bucket Open Bucket Close Left Travel Forward Left Travel Reverse Right Travel Reverse

91011121314-

Right Travel Forward Boom Lower Make-Up EDQR Valve Bucket Open Solenoid Valve Bucket Close Solenoid Valve Left Travel Forward Solenoid Valve

15- Left Travel Reverse Solenoid Valve 16- Right Travel Forward Solenoid Valve 17- Right Travel Reverse Solenoid Valve 18- 3-Spool Solenoid Valve

TOKGB91-EN-00(20181003)

T2-1-19

Warning Light LED (Yellow)

Warning Light LED (Red)

19- Boom Lower Make-Up Solenoid Valve

SECTION 2 SYSTEM Group 1 Controller PFU: Pump Flow Control Unit (Pump Flow Rate Control Controller) Outline  Pump Swash Angle Control PFU (L) and PFU (R) compare the main pump target displacement values which have been calculated by positive control and horsepower control. PFU (L) and PFU (R) select the target displacement value which has smaller pump swash angle. PFU (L) and PFU (R) activate the pump control solenoid valve (7). Therefore, the swash angle is changed and the pump delivery flow rate is controlled.

 Positive Control ELUF and ELUT sends the signal according to the operation (stroke) of electric control levers (1 to 4) to PFU (L) and PFU (R). PFU (L) and PFU (R) calculate the target pump displacement of each main pump according to the signal.  Horsepower Control  Speed Sensing Control MCU sends the target engine speed according to engine control dials (L, R) (5, 6) position to PFU (L) and PFU (R). PFU (L) and PFU (R) increase or decrease the main pump target torque according to the difference between the received target engine speed and the actual engine speed detected by engine speed sensors (L, R) (11, 12).

 Pump Learning Control PFU (L) and PFU (R) automatically learn current value, regulator pressure, and pump swash angle when activating the pump control solenoid valve (7). PFU (L) and PFU (R) apply the values for the pump swash angle control.

 Relief Flow Rate Decrease Control PFU (L) and PFU (R) minimize the main pump target torque when the main pump delivery pressure becomes high during arm extend or bucket tilt-in operation.

fNOTE: Refer to T2-2 for details of PFU control.

 Swing High Pressure Decrease Horsepower Control PFU (L) and PFU (R) decrease the target torque of main pumps L5, L6, R5, and R6 (P5, P6, P11, and P12) according to the delivery pressure when the delivery pressure of main pumps L5, L6, R5, and R6 (P5, P6, P11, and P12) becomes high during swing operation.  Constant Horsepower Control PFU (L) and PFU (R) calculate the target displacement of each main pump according to the pump delivery pressure by using the target torque which allocated to the main pumps L1 to L6, R1 to R6 (P1 to P12).

TOKGB91-EN-00(20181003)

T2-1-20

SECTION 2 SYSTEM Group 1 Controller

Ke-CAN

ELUF

ELUT

MCU

HiKe-CAN

PFU(L)

PFU(R)

9 10

P12 9 10 P11

9 10

8 7

P10 9 10

9 10

ENG.(L)

ENG.(R)

TKGB-02-01-007

P1- Main Pump L1 P2- Main Pump L2 P3- Main Pump L3

P4- Main Pump L4 P5- Main Pump L5 P6- Main Pump L6

P7- Main Pump R1 P8- Main Pump R2 P9- Main Pump R3

P10- Main Pump R4 P11- Main Pump R5 P12- Main Pump R6

678910-

11- Engine Speed Sensor (L) 12- Engine Speed Sensor (R)

Electric Control Lever (Arm, Swing) Electric Control Lever (Boom, Bucket)

45-

TOKGB91-EN-00(20181003)

Electric Control Lever (Left Travel) Electric Control Lever (Right Travel) Engine Control Dial (L)

T2-1-21

Engine Control Dial (R) Pump Control Solenoid Valve Swash Plate Angle Sensor Regulator Pressure Sensor Delivery Pressure Sensor

SECTION 2 SYSTEM Group 1 Controller  Troubleshooting PFU (L) and PFU (R) perform the following failure diagnosis.  Sensors connected to PFU (L) and PFU (R)  Ke-CAN communication  HiKe-CAN communication PFU (L) and PFU (R) send trouble information to IDU and DLU and turns on LED (yellow) (a). IDU displays trouble information on the monitor display. DLU records trouble information.

TOKGB91-EN-00(20181003)

T2-1-22

SECTION 2 SYSTEM Group 1 Controller

Ke-CAN

PFU(L)

PFU(R)

P2 9 10 P1

P3 9 10 P4

P6 9 10 P5

P8 9 10 P7

P10 9 10 P9

P12 9 10 P11

ENG.(L)

ENG.(R)

Warning Light LED (Yellow)

P4- Main Pump L4 P5- Main Pump L5 P6- Main Pump L6

P7- Main Pump R1 P8- Main Pump R2 P9- Main Pump R3

78-

9- Regulator Pressure Sensor 10- Delivery Pressure Sensor

11- Engine Speed Sensor (L) 12- Engine Speed Sensor (R)

TOKGB91-EN-00(20181003)

TKGB-02-01-008

To IDU, DLU

P1- Main Pump L1 P2- Main Pump L2 P3- Main Pump L3 Pump Control Solenoid Valve Swash Plate Angle Sensor

T2-1-23

P10- Main Pump R4 P11- Main Pump R5 P12- Main Pump R6

SECTION 2 SYSTEM Group 1 Controller (Blank)

TOKGB91-EN-00(20181003)

T2-1-24

SECTION 2 SYSTEM Group 1 Controller IDU: Information Display Unit (Information Display Controller) Outline

Key Pad

IDU receives the data by using the CAN communication and key pad. IDU displays the data on the monitor display.  Meter Display The display data such as the meter data and machine model information is sent to IDU from other controllers (MCU, ECM (L), ECM (R), PFU (L), PFU (R), ELUF, DLU, HUM, and ODR). IDU displays these data on the monitor display. Meter Display Item 1- Engine Coolant Temperature Gauge (L) 2- Engine Oil Temperature Gauge (L)

TKEB-05-05-003 Monitor Display

3- Engine Oil Pressure Gauge (L)

3 16 4 5 17 6 18 7 8

9 10 19

4- Engine Speed meter (L) 5- DEF Gauge (L)

6- Engine Coolant Temperature Gauge (R) 7- Engine Oil Temperature Gauge (R) 8- Engine Oil Pressure Gauge (R) 9- Engine Speed meter (R) 10- DEF Gauge (R) 11- Machine Inclination/Travel Indicator 12- Grease Gauge 13- Fuel Gauge

11 TKGB-02-01-009

14- Hydraulic Oil Temperature Gauge Other Display Item 15- Machine Model 16- Operating Pattern of Electric Control Levers 17- Ambient Temperature Gauge 18- Clock 19- Hour Meter 20- Status Indication (Refer to T2-1-28.)

TOKGB91-EN-00(20181003)

T2-1-25

SECTION 2 SYSTEM Group 1 Controller Flow of Displayed Data Display Item Input Signal Engine Coolant Coolant Temperature Sensor (L) (1) Temperature Gauge (L) Engine Oil Temperature Engine Oil Temperature Sensor (L) (2) Gauge (L) Engine Oil Pressure Engine Oil Pressure Sensor (L) (3) Gauge (L) Engine Speed mater (L) Engine Speed Sensor (L) (18) DEF Gauge (L) DEF Sensor (L) (4) Engine Coolant Coolant Temperature Sensor (R) (6) Temperature Gauge (R) Engine Oil Temperature Engine Oil Temperature Sensor (R) (7) Gauge (R) Engine Oil Pressure Engine Oil Pressure Sensor (R) (8) Gauge (R) Engine Speed meter (R) Engine Speed Sensor (R) (19) DEF Gauge (R) DEF Sensor (R) (9) Grease Gauge Grease Tank Level Switches (15, 16, 17) Fuel Gauge Fuel Level Float Sensor (12) Fuel Level Switches (13, 14) Hydraulic Oil Hydraulic Oil Temperature Sensor (11) Temperature Gauge Operating Pattern of Operating Pattern Signal (c) of Electric Electric Control Levers Control Levers Ambient Temperature Ambient Air Temperature Sensor (20) Gauge Machine Model IDU Machine Model Information Clock IDU Built-In Clock Display Item Machine Inclination/ Travel Indicator

Input Signal Body Tilt Sensors (Pitch, Roll) (21, 22) Swing Angular Rate Sensors HiSe-CAN (Upperstructure, Undercarriage) (23, 24)

Display Item Hour Meter

Input Signal Engine Speed Sensor (L) (18) Crank Speed Sensor (L) (5) Engine ON Signal (L) (a) Engine Speed Sensor (R) (19) Crank Speed Sensor (R) (10) Engine ON Signal (R) (b)

TOKGB91-EN-00(20181003)

ECM(L)

J1939-CAN

PFU(L) ECM(L) ECM(R)

Ke-CAN J1939-CAN

PFU(R) ECM(R) MCU

Ke-CAN J1939-CAN Ke-CAN

ELUF HMU

ODR

Ke-CAN

PFU(L) ECM(L)

Ke-CAN J1939-CAN

DLU

PFU(R) ECM(R)

Ke-CAN J1939-CAN

T2-1-26

Output IDU

Ke-CAN

Output IDU

SECTION 2 SYSTEM Group 1 Controller

IDU J1939-CAN

ECM(L)

3 4

5 6 7

ECM(R)

8 9

b a b

10 11

DLU

12 13 14

MCU

Ke-CAN

16 17 18

PFU(L)

PFU(R)

HMU

ELUF

c 21

ODR

22 HiSe-CAN

24 TKGB-02-01-010

Engine ON Signal (L)

Engine ON Signal (R)

Coolant Temperature Sensor (L) Engine Oil Temperature Sensor (L) Engine Oil Pressure Sensor (L) DEF Sensor (Level) (L) Crank Speed Sensor (L) Coolant Temperature Sensor (R)

Engine Oil Temperature Sensor (R) Engine Oil Pressure Sensor (R) DEF Sensor (Level) (R) Crank Speed Sensor (R) Hydraulic Oil Temperature Sensor Fuel Level Float Sensor Fuel Level Switch (High)

14- Fuel Level Switch (Low) 15- Grease Tank Level Switch (Upper) 16- Grease Tank Level Switch (Middle) 17- Grease Tank Level Switch (Lower) 18- Engine Speed Sensor (L) 19- Engine Speed Sensor (R)

23456-

TOKGB91-EN-00(20181003)

8910111213-

T2-1-27

Operating Pattern Signal of Electric Control Levers 20212223-

Ambient Temperature Sensor Body Tilt Sensor (Pitch) Body Tilt Sensor (Roll) Swing Angular Rate Sensor (Upperstructure) 24- Swing Angular Rate Sensor (Undercarriage) 25- Monitor Display 26- Key Pad

SECTION 2 SYSTEM Group 1 Controller Status Indication Items a- Prelube Indicator (L) b-

DEF Line Heater Indicator (L)

Front Attachment Indicator

Auto-Idle Indicator

Folding Stairway Indicator

Fast Filling Panel Indicator

Auto-Lubrication Indicator

Travel Mode Indicator

Pilot Shut-Off Lever Indicator

DEF Line Heater Indicator (R)

Prelube Indicator (R)

Flow of Status Indication Data Display Item Prelube Indicator (L) DEF Line Heater Indicator (L) Front Attachment Indicator Auto-Idle Indicator Folding Stairway Indicator

TKGB-02-01-009

Fast Filling Panel Indicator Auto-Lubrication Indicator Travel Mode Indicator Pilot Shut-Off Lever Indicator DEF Line Heater Indicator (R) Prelube Indicator (R)

Input Signal Prelube Signal Relay (L) (35) DEF Line Heater Relay (L) (27) Attachment Detection Signal (a) Auto-Idle Switch (29) Limit Switch 4 (For Retracting Detection) (30) Fast Filling Panel Position Relay (31) Auto-Lubrication Mode Switch (32) Travel Mode Switch (37) Pilot Shut-Off Switch (34) DEF Line Heater Relay (R) (28) Prelube Signal Relay (R) (36)

TOKGB91-EN-00(20181003)

T2-1-28

Output IDU ECM(L) ELUF MCU

J1939-CAN Ke-CAN

ELUF ECM(R)

Ke-CAN J1939-CAN

SECTION 2 SYSTEM Group 1 Controller

IDU

35 ECM(L)

36 37

J1939-CAN

ECM(R)

DLU

29 30

MCU

31 32

Ke-CAN

a ELUF

26 TKGB-02-01-011

Attachment Detection Signal

2526272829-

Monitor Display Key Pad DEF Line Heater Relay (L) DEF Line Heater Relay (R) Auto-Idle Switch

TOKGB91-EN-00(20181003)

30- Limit Switch 4 (For Retracting Detection) 31- Fast Filling Panel Position Relay 32- Auto-Lubrication Mode Switch

34353637-

T2-1-29

Pilot Shut-Off Switch Prelube Signal Relay (L) Prelube Signal Relay (R) Travel Mode Switch

SECTION 2 SYSTEM Group 1 Controller Service Menu Screen  Current Alarms Faults List IDU receives abnormality from each controller. IDU displays the fault codes and trouble details on the monitor display.

 Maintenance History/Maintenance Warning Output IDU displays the replacement alert of the air filter, engine oil, and hydraulic oil on the monitor display according to the set interval. IDU can record the replaced date, hour meter reading at the time, and replacement number of times.

 System Check IDU checks communication between each controller. IDU displays communication status; normal or abnormal on the monitor display.

 Various Setup  Maintenance Setup The replacement interval of each consumable part can be set. The maintenance information can be initialized.

 Automatic Snapshot List When the alarm occurs, IDU automatically records the temperature and pressure data for 90 seconds before warning and 10 seconds after warning. The recorded data can be later checked by using the key pad.

 Time Adjust Time adjustment for built-in clock can be done by inputing time difference when the world standard time can be received by DLU. The local time is set when the world standard time can not be received by DLU.

 Monitor and manual snapshot The temperature and pressure data can be checked by manually operating when necessary. The displayed date can be recorded and later checked. The recorded data can be deleted (only all data deletion).  Life IDU displays cumulative information including cumulative engine running hours and machine operating hours from DLU on the monitor display.  Controller Information IDU displays the software version of each controller on the monitor display.

 Setting Put-out Lights Delay Time IDU can set the time setting until the work light turns off from the key switch OFF. The time settings are 15 sec. /30 sec. /1 min. /3 min. /5 min. /10 min.  Language setup IDU can select the language on the monitor display.

fNOTE: Refer to T5-2 in the separated Technical Manual

 Log Data History IDU displays event information from DLU on the monitor display.

TOKGB91-EN-00(20181003)

T2-1-30

for details.

SECTION 2 SYSTEM Group 1 Controller Other Controls  Starting Processing and Check IDU processes the following items at the start of operation.  Buzzer Check  Level check checks coolant, engine oil, and hydraulic oil levels.  Electric control lever check checks neutral position of control levers, model name setting, front setting and multi lever setting.  Buzzer Output IDU sounds the buzzer according to the specified alarm signal from each controller.

TOKGB91-EN-00(20181003)

T2-1-31

SECTION 2 SYSTEM Group 1 Controller ECM: Engine Control Module (Engine Controller) Outline  Fuel Injector Control ECM (L) and ECM (R) activate injectors (L, R) (13, 35) and control the engine by receiving MCU target engine speed and the signals from control sensors such as crank speed sensors (L, R) (1, 23), boost pressure sensors (L, R) (2, 24), and common rail pressure sensors (L, R) (3, 25).  Troubleshooting Control ECM (L) and ECM (R) control the engine speed, fuel injection amount, and engine stop by receiving the erratic data from control sensors such as crank speed sensors (L, R) (1, 23), boost pressure sensors (L, R) (2, 24), common rail pressure sensors (L, R) (3, 25), engine coolant temperature sensors (L, R) (4, 26), and engine intake air temperature sensors (L, R) (5, 27) against MCU target engine speed. ECM (L) and ECM (R) indicate trouble information by turning on or blinking each lamps (14, 15, 16, 36, 37, 38) of engine fault code indicator light. Then, ECM (L) and ECM (R) turn on warning light LED (red) (a) or LED (yellow) (b).

 Urea SCR System Control ECM (L) and ECM (R) activate dosing modules (L, R) (22, 44) according to the signals from NOx sensors (L, R) (6, 28). Dosing modules (L, R) (22, 44) inject DEF into exhaust gas. Therefore, NOx is converted into nitrogen and water, and NOx is reduced from exhaust gas. ECM (L) and ECM (R) monitor the signals from control sensors such as DEF sensors (L, R) (7, 29) and ambient temperature sensors (ECM) (L, R) (8, 30). ECM (L) and ECM (R) perform the control for defrosting DEF and preventing DEF from freezing when DEF may freeze. The control circulates engine coolant in DEF supply modules (L, R) (19, 41) and DEF tanks (L, R) (21, 43). The control supplies current to the heaters of dosing modules (L, R) (22, 44) and DEF hose heaters (L, R) (10, 32). ECM (L) and ECM (R) open/close wastegate valves (L, R) (17, 39) according to the signals from control sensors such as the SCR exhaust temperature sensors (L, R) (9, 31), and adjust the SCR catalyst temperature.

fNOTE: Refer to T2-2 for details of ECM control.

TOKGB91-EN-00(20181003)

T2-1-32

SECTION 2 SYSTEM Group 1 Controller 13

ECM(L)

1 2

15 a

6 7 8 10

17 19

21 22 12

J1939-CAN MCU

ECM(R)

23 24

37 a

28 29 30 32

39 41

43 44 34

TKGB-02-01-012 a-

Warning Light LED (Red)

123-

Crank Speed Sensor (L) Boost Pressure Sensor (L) Common Rail Pressure Sensor (L) Engine Coolant Temperature Sensor (L) Engine Intake Air Temperature Sensor (L) NOx Sensor (L) DEF Sensor (L) Ambient Temperature Sensor (ECM) (L) SCR Exhaust Temperature Sensor (L)

10- DEF Hose Heater (L) 11- Heater Relay (DEF Hose) (L) 12- Heater Relay (Dosing Module) (L) 13- Injector (L) 14- Engine Maintenance Lamp (L) 15- Engine Stop Lamp (L) 16- Engine Warning Lamp (L) 17- Wastegate Valve (L) 18- Coolant Control Valve (L) 19- DEF Supply Module (L) 20- Coolant Control Valve (L) 21- DEF Tank (L) 22- Dosing Module (L)

456789-

TOKGB91-EN-00(20181003)

Warning Light LED (Yellow) 23- Crank Speed Sensor (R) 24- Boost Pressure Sensor (R) 25- Common Rail Pressure Sensor (R) 26- Engine Coolant Temperature Sensor (R) 27- Engine Intake Air Temperature Sensor (R) 28- NOx Sensor (R) 29- DEF Sensor (R) 30- Ambient Temperature Sensor (ECM) (R) 31- SCR Exhaust Temperature Sensor (R)

T2-1-33

32- DEF Hose Heater (R) 33- Heater Relay (DEF Hose) (R) 34- Heater Relay (Dosing Module) (R) 35- Injector (R) 36- Engine Maintenance Lamp (R) 37- Engine Stop Lamp (R) 38- Engine Warning Lamp (R) 39- Wastegate Valve (R) 40- Coolant Control Valve (R) 41- DEF Supply Module (R) 42- Coolant Control Valve (R) 43- DEF Tank (R) 44- Dosing Module (R)

SECTION 2 SYSTEM Group 1 Controller DLU: Data Logging Unit Outline  Daily Report Data DLU records the input signals from various sensors and switches of the machine as the daily report data.  History Information DLU records the history of downloading, program updating, hour meter setting, time setting, and serial No. setting.

 Parameters Setting DLU internal parameter can be set by using MPDr. (4).  Satellite Communication Terminal (Option)/Mobile Communication Terminal (Option) DLU sends the daily report data recorded in DLU to satellite communication terminal (2) or mobile communication terminal (3).

 Monitor System Monitoring DLU monitors communication status with the connected units by using CAN (J1939-CAN, Ke-CAN, HiKe-CAN), and records abnormality if any.  Built-in Clock Control DLU incorporates built-in clock (a) and GPS receiver (b). Built-in clock (a) is corrected to the Greenwich mean time, using GPS receiver (b).

 WIU (Option) WIU (Wireless Interface Unit) downloads log data from DLU by using RS232C communication, and records them in its built-in memory. The log data recorded in WIU can be downloaded to the PC (6) by using Wi-Fi in a short amount of times.

 Warning Detection DLU records warning information with stamped time.  Operating Condition Detection DLU processes the data every 30 minutes and every a day.  Snapshot The recorded snapshot data in IDU can be downloaded via DLU.  Service Tool Communication DLU can communicate with MPDr. (4).

TOKGB91-EN-00(20181003)

T2-1-34

SECTION 2 SYSTEM Group 1 Controller

1 DLU

J1939-CAN

∙a ∙b

ECM(L)

ECM(R)

c Ke-CAN

IDU

4 MCU

c 7

CSU

5 d

HMU

EHU(L) EHU(R) PMU(L) PMU(R) PFU(L) PFU(R)

ELUF HiKe-CAN ELUT

TKGB-02-01-013

ab-

Built-In Clock GPS Receiver

Connect to one side or the other.

Wi-Fi Communication

12-

GPS Antenna Satellite Communication Terminal (Option)

Mobile Communication Terminal (Option) MPDr.

56-

WIU (Option) PC (Special software installed)

TOKGB91-EN-00(20181003)

T2-1-35

Download Connector (Only one place can be used.)

SECTION 2 SYSTEM Group 1 Controller CSU: Contamination Sensing Unit Outline CSU senses the amount of contaminant (metal particles) with contamination sensors (1) in the drain circuits for main pumps L1 to L6, R1 to R6 (P1 to P12), swing motors (2 to 5), and travel motors (6) (When the amount of contaminant increases, the resistance values is lower.). CSU sends the detection signal of all contamination sensors (1) by using Ke-CAN every one second. When any one of the resistance values is less than the specified value, CSU turns on warning light LED (yellow) (a). IDU receives the signal and displays the alarm on the monitor display. At the same time, DLU records the alarm.

TOKGB91-EN-00(20181003)

T2-1-36

SECTION 2 SYSTEM Group 1 Controller

CSU

CH1

CH2

CH3

CH4

CH5

CH6

CH9

CH10

CH17

CH11

CH18

P10

CH12

CH19

P11

CH13

CH20

P12

CH14

CH21

Ke-CAN

TKGB-02-01-014

Warning Light LED (Yellow)

Battery Line

To IDU, DLU

P1- Main Pump L1 P2- Main Pump L2 P3- Main Pump L3

P4- Main Pump L4 P5- Main Pump L5 P6- Main Pump L6

P7- Main Pump R1 P8- Main Pump R2 P9- Main Pump R3

12-

34-

56-

Contamination Sensor Swing Motor (Left Front)

TOKGB91-EN-00(20181003)

Swing Motor (Left Rear) Swing Motor (Right Front)

T2-1-37

Swing Motor (Right Rear) Travel Motor (C/J)

P10- Main Pump R4 P11- Main Pump R5 P12- Main Pump R6

SECTION 2 SYSTEM Group 1 Controller HMU: Hydraulic System Monitoring Unit Outline HMU monitors the hydraulic system according to the signals from pressure sensors (1) of swing motors and hydraulic oil tank and temperature sensors (11 to 22) of oil coolers and so on. IDU displays the pressure and temperature on the monitor screen in the monitor display according to the detected data of pressure sensors (1) and temperature sensors (11 to 22). At the same time, DLU records the pressure and temperature of pressure sensors (1) and temperature sensors (11 to 22). HMU judges that cab bed doors (L, R) are opened/ closed by using the limit switches (cab bed doors (L, R)) (9, 10). When HMU judges that cab bed doors (L, R) are opened, HMU turns on warning light LED (yellow) (b). IDU displays the cab bed doors (L, R) open/close state on the monitor display. At the same time, DLU records the cab bed doors (L, R) open/close state.

TOKGB91-EN-00(20181003)

T2-1-38

SECTION 2 SYSTEM Group 1 Controller

HMU

Ke-CAN

12 1 13

15 1

16 17

18 19 8 9

20 1 21

22 TKGB-02-01-015

To IDU, DLU

Warning Light LED (Yellow)

12-

Pressure Sensor Swing Motor Pressure (Swing Right) Swing Motor Pressure (Swing Left) Swing Motor Drain Pressure (Left Front) Swing Motor Drain Pressure (Left Rear) Swing Motor Drain Pressure (Right Front)

Swing Motor Drain Pressure (Right Rear) Hydraulic Oil Tank Pressure Limit Switch (Cab Bed Door (L)) Limit Switch (Cab Bed Door (R)) Ambient Temperature Sensor Oil Cooler 1 Front Air Temperature Sensor Oil Cooler 1 Rear Air Temperature Sensor 1

3456-

TOKGB91-EN-00(20181003)

8910111213-

14- Oil Cooler 1 Rear Air Temperature Sensor 2 15- Oil Cooler 2 Front Air Temperature Sensor 16- Oil Cooler 2 Rear Air Temperature Sensor 1 17- Oil Cooler 2 Rear Air Temperature Sensor 2 18- Oil Cooler Inlet Hydraulic Oil Temperature Sensor

T2-1-39

19- Oil Cooler 1 Outlet Hydraulic Oil Temperature Sensor 1 20- Oil Cooler 1 Outlet Hydraulic Oil Temperature Sensor 2 21- Oil Cooler 2 Outlet Hydraulic Oil Temperature Sensor 1 22- Oil Cooler 2 Outlet Hydraulic Oil Temperature Sensor 2

SECTION 2 SYSTEM Group 1 Controller PMU: Pump Monitoring Unit Outline PMU (L) and PMU (R) monitor the pumps by using the signals from drain pressure sensors (1) of the drain circuits in main pumps L1 to L6, R1 to R6 (P1 to P12) and delivery pressure sensors (oil cooler fan motor pump (L, R)) (2, 3). IDU displays the pressure on the monitor screen in the monitor display according to the detected data of drain pressure sensors (1) and delivery pressure sensors (2, 3). At the same time, DLU records the pressure of drain pressure sensors (1) and delivery pressure sensors (2, 3).

TOKGB91-EN-00(20181003)

T2-1-40

SECTION 2 SYSTEM Group 1 Controller

PMU(L)

Ke-CAN

2 PMU(R)

P10

P11

P12

3 TKGB-02-01-016

To IDU, DLU

P1- Main Pump L1 P2- Main Pump L2 P3- Main Pump L3

P4- Main Pump L4 P5- Main Pump L5 P6- Main Pump L6

P7- Main Pump R1 P8- Main Pump R2 P9- Main Pump R3

Drain Pressure Sensor

TOKGB91-EN-00(20181003)

Delivery Pressure Sensor (Oil Cooler Fan Motor Pump (L))

T2-1-41

Delivery Pressure Sensor (Oil Cooler Fan Motor Pump (R))

P10- Main Pump R4 P11- Main Pump R5 P12- Main Pump R6

SECTION 2 SYSTEM Group 1 Controller EHU: Engine Heat Balance Monitoring Unit (Engine Cooling System Monitoring Unit) Outline EHU (L) and EHU (R) monitor the engine cooling system by using the signals from temperature sensors (4 to 11, 17 to 24) in the HTC radiator and LTC radiator. IDU displays the temperature on the monitor screen in the monitor display according to the detected data of temperature sensors (4 to 11, 17 to 24). At the same time, DLU records the temperature of temperature sensors (4 to 11, 17 to 24). EHU (L) and EHU (R) judge the fluid level condition of the engine related components by using the signals from coolant level check switches (1, 2, 14, 15) and engine oil level sensors (3, 16) of the oil pan when the key switch is in the ON position. When amount of coolant and oil is sufficient, IDU displays the level alarm icon of the monitor display in green.

TOKGB91-EN-00(20181003)

T2-1-42

SECTION 2 SYSTEM Group 1 Controller EHU(L)

1 2

3 4 5 6 7 8 9 10

Ke-CAN

EHU(R)

14 15

16 17 18 19 20 21 22 23 24

TKGB-02-01-017 a-

To IDU, DLU

Coolant Level Check Switch 1 (L) Coolant Level Check Switch 2 (L) Engine Oil Level Sensor (L) LTC Radiator Front Air Temperature Sensor (L) HTC Radiator Rear Air Temperature Sensor 1 (L) HTC Radiator Rear Air Temperature Sensor 2 (L)

23456-

TOKGB91-EN-00(20181003)

LTC Radiator Inlet Coolant Temperature Sensor (L) 8- LTC Radiator Outlet Coolant Temperature Sensor (L) 9- HTC Radiator Inlet Coolant Temperature Sensor 1 (L) 10- HTC Radiator Inlet Coolant Temperature Sensor 2 (L) 11- HTC Radiator Outlet Coolant Temperature Sensor (L)

14- Coolant Level Check Switch 1 (R) 15- Coolant Level Check Switch 2 (R) 16- Engine Oil Level Sensor (R) 17- LTC Radiator Front Air Temperature Sensor (R) 18- HTC Radiator Rear Air Temperature Sensor 1 (R) 19- HTC Radiator Rear Air Temperature Sensor 2 (R)

T2-1-43

20- LTC Radiator Inlet Coolant Temperature Sensor (R) 21- LTC Radiator Outlet Coolant Temperature Sensor (R) 22- HTC Radiator Inlet Coolant Temperature Sensor 1 (R) 23- HTC Radiator Inlet Coolant Temperature Sensor 2 (R) 24- HTC Radiator Outlet Coolant Temperature Sensor (R)

SECTION 2 SYSTEM Group 1 Controller ODR: Operation Data Recorder Outline  Machine Inclination Evaluation ODR detects the signals from body tilt sensor (pitch) (3) and body tilt sensor (roll) (4), and sends them to IDU. IDU displays the machine inclination on the monitor display. (Refer to T2-1-25 for IDU Meter Indication.)  Traveling Direction Evaluation ODR detects the signals from swing angular rate sensor (upperstructure) (1) and swing angular rate sensor (undercarriage) (2), and measures the swing angle. As the sensitivity error of swing angular rate sensors (1, 2) is large, ODR corrects the error of the measured values by using swing angular position switches 1 to 5 (5 to 9) as the correcting point. ODR sends the corrected value to IDU. IDU displays the traveling direction on the monitor display. (Refer to T2-1-25 for IDU Meter Indication.)  Troubleshooting ODR performs the following failure diagnosis.  Sensors connected to ODR  HiSe-CAN communication  Ke-CAN communication ODR sends trouble information to IDU and DLU. IDU displays trouble information on the monitor display. DLU records trouble information.

TOKGB91-EN-00(20181003)

T2-1-44

SECTION 2 SYSTEM Group 1 Controller

ODR

1 HiSe-CAN

Ke-CAN

3 4 b 5 6 7 8 9

TKGB-02-01-018

To IDU, DLU

Warning Light LED (Yellow)

Swing Angular Rate Sensor (Upperstructure) Swing Angular Rate Sensor (Undercarriage) Body Tilt Sensor (Pitch)

45-

Body Tilt Sensor (Roll) Swing Angular Position Switch 1 Swing Angular Position Switch 2

23-

TOKGB91-EN-00(20181003)

78-

T2-1-45

Swing Angular Position Switch 3 Swing Angular Position Switch 4

Swing Angular Position Switch 5

SECTION 2 SYSTEM Group 1 Controller BPU: Basic Performance Monitoring Unit Outline  Cylinder Pressure Measurement BPU detects the signals from pressure sensors (1 to 6) in the hydraulic circuits of the boom, arm, and bucket cylinders, and sends them to IDU. IDU displays the detected value on the monitor screen in the monitor display.  Troubleshooting BPU performs the following failure diagnosis.  Sensors connected to BPU  Ke-CAN communication BPU sends trouble information to IDU and DLU. IDU displays trouble information on the monitor display. DLU records trouble information.

TOKGB91-EN-00(20181003)

T2-1-46

SECTION 2 SYSTEM Group 1 Controller

BPU

Ke-CAN

6 TKGB-02-01-019

To IDU, DLU

Pressure Sensor (Boom Cylinder Bottom Side) Pressure Sensor (Boom Cylinder Rod Side)

TOKGB91-EN-00(20181003)

34-

Pressure Sensor (Arm Cylinder Bottom Side) Pressure Sensor (Arm Cylinder Rod Side)

56-

T2-1-47

Pressure Sensor (Bucket Cylinder Bottom Side) Pressure Sensor (Bucket Cylinder Rod Side)

SECTION 2 SYSTEM Group 1 Controller (Blank)

TOKGB91-EN-00(20181003)

T2-1-48

SECTION 2 SYSTEM Group 2 Control System Outline Each movement of machine is controlled by the following control units.  Engine Control: ECM (L), ECM (R)  Pump Control : PFU (L), PFU (R)  Sub-Control System Control : MCU  Other Control Two engine pump units are installed in this machine. They separately perform the controls in case of no description. (L) and (R) are omitted in the following procedures.

fNOTE: Refer to Group 3 ELU System for the electric lever control.

The controls of each controller are as follows. Engine Control (ECM) Input Signal Target Engine Speed Signal from MCU Crank Speed Sensor Intake Manifold Temperature Sensor Crank Speed Sensor Intake Manifold Temperature Sensor Engine Coolant Temperature Sensor Engine Oil Pressure Sensor Coolant Level Sensor Fuel Temperature Sensor Crank Case Pressure Sensor Coolant Pressure Sensor Engine Oil Temperature Sensor Crank Speed Sensor Engine Oil Pressure Sensor Engine Coolant Temperature Sensor Fuel Temperature Sensor Intake Manifold Temperature Sensor DEF Sensor DEF Pressure Sensor SCR Inlet Temperature Sensor SCR Exhaust Temperature Sensor NOx Sensor DEF Supply Module Monitoring Signal Dosing Module Monitoring Signal Boost Pressure Sensor

TOKGB91-EN-00(20181003)

Output Injector

Control Engine Speed Control

Injector Ether Solenoid Valve Injector

Low Temperature Start Control

Injector

Slow Idle Control at Low Temperature

Injector

Engine Output Restriction Control (INDUCEMENT)

T2-2-1

Engine Protection Control

SECTION 2 SYSTEM Group 2 Control System Pump Control (PFU) Input Signal Signals from ELUF and ELUT Target Engine Speed Signal from MCU Engine Speed Sensor Pump Delivery Pressure Sensor Signal from ELUF

Output Pump Control Solenoid Valve Pump Control Solenoid Valve

Positive Control Target Displacement Horsepower Control Target Displacement Regulator Pressure Sensor Pilot Shut-Off Signal from ELUF Pump Learning Command Signal from IDU Swash Plate Angle Sensor Regulator Pressure Sensor

Pump Control Solenoid Valve

Control Positive Control Horsepower Control  Speed Sensing Control  Relief Flow Rate Decrease Control  Swing High Pressure Decrease Horsepower Control  Constant Horsepower Control Pump Swash Angle Control

Pump Control Solenoid Valve

Pump Learning Control

Output ECM

Control Auto-Idle Control

Fast Filling Relay

Fast-Filling Panel Lower Control

Auto-Lubrication Solenoid Valve

Auto-Lubrication Control

Sub-Control System Control (MCU) Input Signal Engine Control Dial Auto-Idle Switch Signal from ELUF (Including Signal from ELUT) Pilot Shut-Off Switch Fast Filling Switch Fast Filling Panel Position Switch Auto-Lubrication Mode Switch Pressure Switch Auto-Lubrication Interval Switch Hydraulic Oil Temperature Sensor Wiper Switch Wiper Interval Switch

Oil Cooler Fan Motor Speed Control Oil Cooler Fan Motor Speed Control Solenoid Valve Wiper Relay 1 Wiper Control Wiper Relay 2 Wiper Relay 3

Other Control Folding Stairway Control Travel Mode Control Cab Bed Pressurization Control

TOKGB91-EN-00(20181003)

T2-2-2

SECTION 2 SYSTEM Group 2 Control System Engine Control Engine Speed Control Purpose: The engine speed control controls the engine speed and output torque in response to operation amount of the engine control dial and engine loads. The procedures for ECM (L) are explained here. Operation: 1. ECM (L) receives the target engine speed signal in response to operation amount of engine control dial (L) (4) from MCU.

4. ECM (L) judges loading condition of engine and controls the optimum fuel injection amount of injector (L) (2).

2. ECM (L) activates injector (L) (2) in response to this signal and controls the engine speed.

5. ECM (L) sends detected data of crank speed sensor (L) (1) to IDU.

3. At the same time, ECM (L) receives the signal from crank speed sensor (L) (1).

3 MCU

ENG.(L)

ECM(L)

J1939-CAN

IDU

ECM(R)

ENG.(R)

TKGB-02-02-001

12-

Crank Speed Sensor (L) Injector (L)

TOKGB91-EN-00(20181003)

34-

Engine Control Dial (L) Engine Control Dial (R)

56-

T2-2-3

Crank Speed Sensor (R) Injector (R)

SECTION 2 SYSTEM Group 2 Control System Low Temperature Start Control (Option) Purpose: The low temperature start control injects ether into the intake manifold when intake air temperature is low (less than -5 °C). Therefore, the engine starting ability is improved. The procedures for ECM (L) are explained here. Operation: 1. When the key switch is set to the ON position, the intake manifold temperature sensor (L) (5) sends the signal to ECM (L). 2. When engine start switch (L) (2) is pushed and intake air temperature is less than -5 °C, ECM (L) excites ether solenoid valve (L) (7) and turns starter (L) (11). 3. When the signal from crank speed sensor (L) (4) reaches 500 min-1, ECM (L) stops exciting ether solenoid valve (L) (7). 4. The engine (L) starting ability is improved by injecting ether into intake air. 5. When engine (L) does not start, push engine stop switch (L) (3). Push engine start switch (L) (2) again.

TOKGB91-EN-00(20181003)

T2-2-4

SECTION 2 SYSTEM Group 2 Control System

6 7

10 1 ECM(L)

ENG.(L)

17 18

21 12 ENG.(R)

ECM(R)

13 14

TKGB-02-02-002

12345-

Key Switch ON Signal Engine Start Switch (L) Engine Stop Switch (L) Crank Speed Sensor (L) Intake Manifold Temperature Sensor (L)

TOKGB91-EN-00(20181003)

67891011-

Ether Bottle (L) Ether Solenoid Valve (L) Ether Line (L) Intake Manifold (L) Injector (L) Starter (L)

1213141516-

T2-2-5

Key Switch ON Signal Engine Start Switch (R) Engine Stop Switch (R) Crank Speed Sensor (R) Intake Manifold Temperature Sensor (R)

171819202122-

Ether Bottle (R) Ether Solenoid Valve (R) Ether Line (R) Intake Manifold (R) Injector (R) Starter (R)

SECTION 2 SYSTEM Group 2 Control System Engine Protection Control Purpose: When ECM detects abnormality, the engine protection control is activated and decreases pump driving torque. Therefore, engine load is reduced and the engine is prevented from damage. The procedures for ECM (L) are explained here. Operation: 1. When ECM (L) receives following abnormal signals from sensors (2, 5), ECM (L) sends information to J1939-CAN.  Intake Manifold Temperature (High)  Coolant Temperature (High)  Engine Oil Pressure (Low)  Coolant Level (Low)  Fuel Temperature (High)  Crank Case Pressure (High)  Coolant Pressure (Low)  Engine Oil Temperature (High) 2. ECM (L) decreases fuel injection amount of injector (L) (4). Any one of three protection controls is activated.  Engine output torque is decreased.  Engine speed is decreased.  Engine is stopped. 3. MCU receives abnormal condition of the engine from ECM (L) and sends information to PFU (L). 4. PFU (L) decreases the main pump swash plate angles of main pumps L1 to L6 (P1 to P6) and decreases delivery flow rate so that torque of each pump becomes minimum value (520 N·m). Therefore, engine (L) load is reduced and engine (L) is protected.

TOKGB91-EN-00(20181003)

T2-2-6

SECTION 2 SYSTEM Group 2 Control System

a b c d e f g

ECM(L)

h i j k e m n

ENG.(L)

ECM(R)

ENG.(R)

J1939-CAN

MCU

Ke-CAN

PFU(L)

PFU(R)

P12

P10

P11

TKGB-02-02-003

12-

Crank Speed Sensor (L) Intake Manifold Temperature Sensor (L)

345-

Intake Manifold (L) Injector (L) Sensors

67-

Crank Speed Sensor (R) Intake Manifold Temperature Sensor (R)

8- Intake Manifold (R) 9- Injector (R) 10- Sensors

Engine Coolant Temperature Sensor (L) Engine Oil Pressure Sensor (L) Coolant Level Sensor (L) Fuel Temperature Sensor (L)

efg-

Crank Case Pressure Sensor (L) Coolant Pressure Sensor (L) Engine Oil Temperature Sensor (L)

Engine Coolant Temperature Sensor (R) Engine Oil Pressure Sensor (R) Coolant Level Sensor (R) Fuel Temperature Sensor (R)

lCrank Case Pressure Sensor (R) m- Coolant Pressure Sensor (R) n- Engine Oil Temperature Sensor (R)

bcd-

P1- Main Pump L1 P2- Main Pump L2 P3 Main Pump L3

TOKGB91-EN-00(20181003)

P4- Main Pump L4 P5- Main Pump L5 P6- Main Pump L6

ijk-

P7- Main Pump R1 P8 Main Pump R2 P9- Main Pump R3

T2-2-7

P10- Main Pump R4 P11- Main Pump R5 P12- Main Pump R6

SECTION 2 SYSTEM Group 2 Control System Slow Idle Control at Low Temperature Purpose: The slow idle control at low temperature keeps engine speed at slow idle speed at the low temperature. Therefore, the engine seizure due to engine fast speed running at the low temperature is prevented. The procedures for ECM (L) are explained here. Operation: 1. When the engine has started and engine oil pressure is over 103.4 kPa, ECM (L) starts measuring following temperature.  Coolant Temperature  Fuel Temperature  Intake Manifold Temperature 2. If any one of three temperature is less than 10 °C, ECM (L) keeps engine speed at slow idle speed for 30 seconds. 3. IDU receives the signal of slow idle control at low temperature from ECM (L) and displays it on the monitor display. 4. When 30 seconds have passed after keeping engine speed at slow idle speed, ECM (L) keeps engine speed at slow idle speed until time shown in the table according to coolant temperature. Coolant Temperature (°C) -18 -4 -1 2 4 10 100

Time (sec) Being Kept at Slow Idle Speed 600 600 120 2 1 1 1

5. When this control is finished, engine speed is kept at slow idle speed regardless of the engine control (L) dial (5) position.

fNOTE: When engine control dial (L) (5) which is set in

the position except slow idle speed is returned to the slow idle speed position, this control is deactivated.

TOKGB91-EN-00(20181003)

T2-2-8

SECTION 2 SYSTEM Group 2 Control System

1 2 3

5 MCU

ECM(L)

J1939-CAN

ENG.(L)

7 8 9

IDU

ECM(R)

ENG.(R)

TKGB-02-02-004

123-

Engine Oil Pressure Sensor (L) Engine Coolant Temperature Sensor (L) Fuel Temperature Sensor (L)

TOKGB91-EN-00(20181003)

456-

Intake Manifold Temperature Sensor (L) Engine Control Dial (L) Engine Control Dial (R)

789-

T2-2-9

Engine Oil Pressure Sensor (R) Engine Coolant Temperature Sensor (R) Fuel Temperature Sensor (R)

10- Intake Manifold Temperature Sensor (R)

SECTION 2 SYSTEM Group 2 Control System Engine Output Restriction Control (INDUCEMENT) Purpose: When ECM (L) and ECM (R) detect that DEF level becomes low or malfunction occurs on the urea SCR system, the engine output restriction control gradually decreases the engine torque and speed. The procedures for ECM (L) are explained here. Operation: 1. When ECM (L) receives following abnormal signals from each sensor, ECM (L) sends information to J1939-CAN.

2. MCU receives abnormal condition from ECM (L) and sends information to PFU (L), ELUF, and ELUT. 3. The engine output restriction control combines controls (A to D) and prevents engine stall. sensor, DEF quality sensor, and DEF temperature sensor.

DEF Level

less than 2.5 % 0% Malfunction 2.5 hours after malfunction 3.75 hours after malfunction 4 hours after malfunction Malfunction 2.5 hours after malfunction 3.75 hours after malfunction 4 hours after malfunction Malfunction 4 hours after malfunction 525 to 535 °C 535 to 550 °C Over 550 °C

DEF Quality

Malfunction 1 of Urea SCR System

Malfunction 2 of Urea SCR System SCR Inlet Temperature

TOKGB91-EN-00(20181003)

B: Engine Speed Restriction Control MCU sets the target engine speed signal in response to operation amount of engine control dial (L) (12) to the restriction speed, and sends it to ECM (L). ECM (L) reduces engine speed to the restriction speed. ELUF and ELUT send the signal that the operation amount of electric control levers (25, 26) is controlled to the specified value to the solenoid valve of EDQR valve (27). PFU (L) receives the signal from ELUF and ELUT, and keeps the pump delivery flow rate at minimum. ELUT receives the signal that is controlled to the specified valve from ELUF and stops the boom lower flow rate regeneration control. D: Engine Derate Control

fNOTE: DEF sensor unit (L) (1) consists of DEF level Condition

(T2-2-6: Refer to Engine Protection Control.)

C: Operation Restriction Control

 DEF Level (Low)  DEF Quality (Low)  Urea SCR System (Abnormal)  SCR Exhaust Temperature (High)

Item

A: Engine Protection Control

Control A

ECM (L) derates the engine output torque or speed.

B kept at Slow Idle -

C -

D Torque -25 % kept at Slow Idle Torque -25 %

Torque -50 %

restricted at max 1200 min-1 kept at Slow Idle

kept at Slow Idle

Torque -25 %

Torque -50 %

restricted at max 1200 min-1 kept at Slow Idle

kept at Slow Idle

Torque -25 %

Torque -0 to -9 % Torque -10 to -79% Torque -80 %

T2-2-10

SECTION 2 SYSTEM Group 2 Control System

1 2 3 4 5 6

20 21

ECM(L)

14 15 16 17 18 19

ENG.(L)

ECM(R)

ENG.(R)

J1939-CAN

12 MCU

Ke-CAN Hike-CAN

26 PFU(L)

ELUF

PFU(R)

ELUT

27 TKGB-02-02-005

1234567-

DEF Sensor Unit (L) DEF Pressure Sensor (L) SCR Inlet Temperature Sensor (L) SCR Exhaust Temperature Sensor (L) NOx Sensor (L) Boost Pressure Sensor (L) DEF Supply Module Monitoring Signal (L)

TOKGB91-EN-00(20181003)

89101112131415-

Dosing Module Monitoring Signal (L) Crank Speed Sensor (L) Intake Manifold Temperature Sensor (L) Injector (L) Engine Control Dial (L) Engine Control Dial (R) DEF Sensor Unit (R) DEF Pressure Sensor (R)

16- SCR Inlet Temperature Sensor (R) 17- SCR Exhaust Temperature Sensor (R) 18- NOx Sensor (R) 19- Boost Pressure Sensor (R) 20- DEF Supply Module Monitoring Signal (R) 21- Dosing Module Monitoring Signal (R)

T2-2-11

22- Crank Speed Sensor (R) 23- Intake Manifold Temperature Sensor (R) 24- Injector (R) 25- Electric Control Lever (Front Attachment, Swing) 26- Electric Control Lever (Travel) 27- EDQR Valve

SECTION 2 SYSTEM Group 2 Control System Pump Control Positive Control Purpose: The positive control delivers required amount of pressure oil from the main pump to the actuator according to the operation stroke of the control equipment. Operation: 1. ELUF and ELUT send the signal according to the operation stroke of control equipments (1 to 6) to PFU (L) and PFU (R).

5. The pump control solenoid valves (7) control the delivery flow rate of main pumps L1 to L6, R1 to R6 (P1 to P12) according to the command current.

2. PFU (L) and PFU (R) calculate the target pump displacement of main pumps L1 to L6, R1 to R6 (P1 to P12) according to the signal.

6. Therefore, delivery flow rate of main pumps L1 to L4 (P1 to P4) and main pumps R1 to R4 (P7 to P10) is set to 100 to 375 L/min. Delivery flow rate of main pumps L5, L6, R5, and R6 (P5, P6, P11, and P12) is set to 100 to 425 L/min.

3. If the target displacement of the positive control calculated by the signal is smaller than the one calculated by the horsepower control, the value of the positive control is set as the target displacement of main pumps L1 to L6, R1 to R6 (P1 to P12). 4. PFU (L) and PFU (R) send command current according to the main pump target displacement to the pump control solenoid valves (7) of main pumps L1 to L6, R1 to R6 (P1 to P12).

Maximum flow rate (only LD) of each main pump when operating the control lever: Operation Maximum Flow Rate (L/min) P1 P2 P3 P4 Right Travel 100 375 Left Travel 100 375 Swing Boom Raise 375 375 375 375 Boom Lower 100 100 Arm Extend 375 100 375 100 Arm Retract 100 375 100 375 Bucket Tilt-In 375 375 375 375 Bucket Tilt-Out 100 375 375 Bucket Open/Close 375

TOKGB91-EN-00(20181003)

P5 425 425 100 425 425 425 -

T2-2-12

P6 425 425 100 425 425 425 -

P7 375 375 375 100 375 375

P8 375 375 100 375 375 375

P9 375 375 100 375 100 375 100 -

P10 375 375 100 100 375 375 375 -

P11 425 425 100 425 425 425 -

P12 425 425 100 425 425 425 -

SECTION 2 SYSTEM Group 2 Control System

ELUF

ELUT Hike-CAN

PFU(L)

PFU(R)

P6 P5

P2 P1

P12

P11

P8 P7

P10

ENG.(L)

7 ENG.(R)

TKGB-02-02-006

P1- Main Pump L1 P2- Main Pump L2 P3 Main Pump L3

P4- Main Pump L4 P5- Main Pump L5 P6- Main Pump L6

P7- Main Pump R1 P8 Main Pump R2 P9- Main Pump R3

P10- Main Pump R4 P11- Main Pump R5 P12- Main Pump R6

34-

89-

Electric Control Lever (Arm/ Swing) Electric Control Lever (Boom/ Bucket)

TOKGB91-EN-00(20181003)

Bucket Close Control Pedal Electric Control Lever (Left Travel)

67-

T2-2-13

Electric Control Lever (Right Travel) Bucket Open Control Pedal Pump Control Solenoid Valve

Regulator Pressure Sensor Delivery Pressure Sensor

SECTION 2 SYSTEM Group 2 Control System Horsepower Control The horsepower control performs the following controls.  Speed Sensing Control  Relief Flow Rate Decrease Control  Swing High Pressure Decrease Horsepower Control  Constant Horsepower Control Speed Sensing Control Purpose: The speed sensing control controls the pump delivery flow rate in response to the engine speed changes according to the variations in the load. Then, the engine torque power can be utilized more efficiently. The engine stall is prevented when the machine is operated under the adverse conditions such as operating at the high altitude. The procedures for PFU (L) are explained here.

Pump P-Q Diagram

Q B

Operation: 1. MCU calculates the target engine speed according to operation amount of engine control dial (L) (1).

A C

2. PFU (L) receives the signal of the target engine speed from MCU. PFU (L) calculates the difference between the target engine speed and the actual engine speed detected by engine speed sensor (L) (3).

3. PFU (L) increases or decreases the torque according to the calculated difference of engine speed from basic torque (A) of the main pump. and sets the main pump target torque

PQ-

4. If load to engine (L) increases and the actual engine speed becomes slower than the target engine speed, the pump swash angle is reduced and the pump delivery flow rate is reduced. As load to engine (L) is reduced, engine stall is prevented. 5. On the other hand, if load to engine (L) decreases and the actual engine speed becomes faster than the target engine speed, the pump swash angle is increased and the engine torque power can be utilized more efficiently PFU (L).

TOKGB91-EN-00(20181003)

T2-2-14

Pressure Flow Rate

ABC-

Basic Torque Increase Decrease

TKBD-02-02-006

SECTION 2 SYSTEM Group 2 Control System

Ke-CAN

MCU

PFU(L)

PFU(R)

P12

P10

P11

ENG.(L)

ENG.(R)

P1- Main Pump L1 P2- Main Pump L2 P3 Main Pump L3

P4- Main Pump L4 P5- Main Pump L5 P6- Main Pump L6

12-

34-

Engine Control Dial (L) Engine Control Dial (R)

TOKGB91-EN-00(20181003)

P7- Main Pump R1 P8 Main Pump R2 P9- Main Pump R3

Engine Speed Sensor (L) Engine Speed Sensor (R)

T2-2-15

TKGB-02-02-007

P10- Main Pump R4 P11- Main Pump R5 P12- Main Pump R6

SECTION 2 SYSTEM Group 2 Control System Relief Flow Rate Decrease Control Purpose: When the main pump delivery pressure is high, the relief flow rate decrease control decreases the main pump delivery flow rate, prevents loss of hydraulic energy, and prevents hydraulic oil temperature from rising.

Pump P-Q Diagram

Operation: 1. PFU (L) and PFU (R) detect the pressure signals from delivery pressure sensors (3) of main pumps L1 to L6, R1 to R6 (P1 to P12).

Q Q max

2. When one of the following conditions is met and the main pump delivery pressure is over Pc (28.4 MPa), PFU (L) and PFU (R) slowly reduce all pump target torque to the torque for the minimum flow rate.

C Q min

 Arm Extend Operation: Large  Bucket Tilt-In Operation: Large

P TKBD-02-02-008

P- Pressure Q- Flow Rate Pc- Cut-off Starting Pressure

TOKGB91-EN-00(20181003)

T2-2-16

Pr- Main Relief Set Pressure C- Relief Cut Off

SECTION 2 SYSTEM Group 2 Control System

ELUF HiKe-CAN

PFU(L)

PFU(R)

P12

P11

ENG.(L)

P10

ENG.(R)

TKGB-02-02-008

P1- Main Pump L1 P2- Main Pump L2 P3 Main Pump L3

P4- Main Pump L4 P5- Main Pump L5 P6- Main Pump L6

Electric Control Lever (Arm/ Swing)

TOKGB91-EN-00(20181003)

P7- Main Pump R1 P8 Main Pump R2 P9- Main Pump R3

Electric Control Lever (Boom/ Bucket) Delivery Pressure Sensor

T2-2-17

P10- Main Pump R4 P11- Main Pump R5 P12- Main Pump R6

SECTION 2 SYSTEM Group 2 Control System Swing High Pressure Decrease Horsepower Control Purpose: When starting swing operation, the swing high pressure decrease horsepower control reduces the delivery flow rate of main pumps L5, L6, R5, and R6 (P5, P6, P11, and P12), and reduces energy consumption. Pump P-Q Diagram

Operation: 1. PFU (L) and PFU (R) detect the pressure signals from delivery pressure sensors (3) of the main pumps L5, L6, R5, and R6 (P5, P6, P11, and P12).

Q Q max

2. When all following conditions exist, PFU (L) and PFU (R) reduce the pump target torque in response to delivery pressure of main pumps L5, L6, R5, and R6 (P5, P6, P11, and P12).  Swing Operation: Large  Main Pumps L5, L6, R5, and R6 (P5, P6, P11, and P12) Delivery Pressure: High

Q min

Psr Per

P TKBD-02-02-010

P- Pressure Q- Flow Rate Psr- Starting Pressure of Swing High Pressure Decrease Horsepower

TOKGB91-EN-00(20181003)

T2-2-18

Per- Swing Motor Relief Set Pressure Pr- Main Relief Set Pressure

SECTION 2 SYSTEM Group 2 Control System

ELUF HiKe-CAN

PFU(L)

PFU(R)

P12

P11

ENG.(L)

P10

ENG.(R)

TKGB-02-02-008

P1- Main Pump L1 P2- Main Pump L2 P3 Main Pump L3

P4- Main Pump L4 P5- Main Pump L5 P6- Main Pump L6

Electric Control Lever (Arm/ Swing)

TOKGB91-EN-00(20181003)

P7- Main Pump R1 P8 Main Pump R2 P9- Main Pump R3

Electric Control Lever (Boom/ Bucket) Delivery Pressure Sensor

T2-2-19

P10- Main Pump R4 P11- Main Pump R5 P12- Main Pump R6

SECTION 2 SYSTEM Group 2 Control System Constant Horsepower Control Purpose: The constant horsepower control controls each main pump delivery flow rate so that the pump driving torque which is allocated to main pumps L1 to L6, R1 to R6 (P1 to P12) is prevented from exceeding the target torque. The procedures for PFU (L) are explained here. Operation: 1. PFU (L) detects the pressure signals from delivery pressure sensors (3) of main pumps L1 to L6 (P1 to P6). 2. PFU (L) calculates the target displacement of main pumps L1 to L6 (P1 to P6) according to the pump target torque of horsepower control by using the pressure signals from delivery pressure sensors (3) of main pumps L1 to L6 (P1 to P6). 3. The pump target torque of horsepower control is calculated by the speed sensing control, relief flow rate decrease control, and swing high pressure decrease horsepower control. 4. If the target displacement of horsepower control is smaller than the one calculated by the positive control, the value of the horsepower control is set as the main pump target displacement. 5. PFU (L) sends command current according to the main pump target displacement to the each pump control solenoid valve (1). 6. The each pump control solenoid valve (1) control the delivery flow rate of main pumps L1 to L6 (P1 to P6) according to the command current.

TOKGB91-EN-00(20181003)

T2-2-20

SECTION 2 SYSTEM Group 2 Control System

Ke-CAN

ELUF

ELUT

MCU

Hike-CAN

PFU(L)

PFU(R)

P6 P5

P2 P1

P4 P3

P12

P11

ENG.(L)

P10 P9

1 ENG.(R)

TKGB-02-02-009

P1- Main Pump L1 P2- Main Pump L2 P3 Main Pump L3

P4- Main Pump L4 P5- Main Pump L5 P6- Main Pump L6

P7- Main Pump R1 P8 Main Pump R2 P9- Main Pump R3

Pump Control Solenoid Valve

TOKGB91-EN-00(20181003)

Regulator Pressure Sensor

T2-2-21

Delivery Pressure Sensor

P10- Main Pump R4 P11- Main Pump R5 P12- Main Pump R6

SECTION 2 SYSTEM Group 2 Control System Pump Swash Angle Control Purpose: The pump swash angle control compares the target displacement values which have been calculated by positive control and horsepower control. This control activates the pump control solenoid valve (11) for the target displacement value which has smaller pump swash angle. Operation: 1. PFU (L) and PFU (R) compare the target displacement values of main pumps L1 to L6, R1 to R6 (P1 to P12) which have been calculated by positive control (5) and horsepower control (6). PFU (L) and PFU (R) select the target displacement value which has smaller pump swash angle. 2. PFU (L) and PFU (R) compare the selected target displacement value with the pump swash angle detected by regulator pressure sensor (12), calculates the pump swash angle, and send command current (10) to the each pump control solenoid valve (11). 3. The each pump control solenoid valve (11) changes the pump swash angle according to command current (10) and controls the delivery flow rate of main pumps L1 to L6, R1 to R6 (P1 to P12).

fNOTE: The relation between the main pump swash

angle obtained by the pump learning control and the regulator pressure, and the relation between the regulator pressure and the pump control solenoid valve driving current are applied to the pump swash angle control.

Pump Swash Angle Control Flow Chart

2 3

4 TKEB-02-02-015 12345-

Operation Stroke Signal Pump Delivery Pressure Target Engine Speed Actual Engine Speed Positive Control

TOKGB91-EN-00(20181003)

678-

Horsepower Control Positive Control Target Displacement Horsepower Control Target Displacement

9- Pump Swash Angle Control 10- Command Current

T2-2-22

SECTION 2 SYSTEM Group 2 Control System

Ke-CAN

ELUF

ELUT

MCU

Hike-CAN

PFU(L)

P6 P5

PFU(R)

P2 P1

P12

P11

ENG.(L)

P10

11 ENG.(R)

TKGB-02-02-009

P1- Main Pump L1 P2- Main Pump L2 P3 Main Pump L3

P4- Main Pump L4 P5- Main Pump L5 P6- Main Pump L6

11- Pump Control Solenoid Valve

12- Regulator Pressure Sensor

TOKGB91-EN-00(20181003)

P7- Main Pump R1 P8 Main Pump R2 P9- Main Pump R3

T2-2-23

P10- Main Pump R4 P11- Main Pump R5 P12- Main Pump R6

SECTION 2 SYSTEM Group 2 Control System Pump Learning Control Purpose: The pump learning control automatically learns current value, regulator pressure, and pump swash angle, which are the basic values to control the pump, when activating the pump control solenoid valve. This control applies the values for the pump swash angle control. The procedures for PFU (L) are explained here. Operation: 1. PFU (L) receives the pump learning command signal from IDU when the left pump learning start is selected from the pump learning menu screen on the monitor display. 2. When all following conditions exist and the pump learning command signal is input, PFU (L) starts the pump learning.  PFU (L), MCU, ECM (L), IDU, ELUF, CAN communication: No malfunction or no abnormality  Engine (L): Engine speed is over 500 min-1.  Engine control dial (L) (2): Maximum position  Auto-idle switch (4): OFF  Hydraulic oil temperature: 50±5 °C  Pilot shut-off switch (1): OFF 3. When the pump learning control starts, PFU (L) sends current to the pump control solenoid valves (8) of each main pump according to the order of preset current value.

IMPORTANT: When the following work has been performed, perform the pump learning. There are individual differences for delivery flow rate on each main pump. If the following work is not performed, the machine performance may not be enough to output.  When the main pumps and the main pump regulators have been replaced  When the pump control solenoid valves of main pumps have been replaced  When the swash plate angle sensors of main pumps have been replaced  When PFU (L) and PFU (R) have been replaced Perform the pump leaning by operating on the monitor screen. Refer to T5-2 in the separated Technical Manual.

4. Therefore, swash angle of each main pump automatically changes from minimum to maximum range. 5. PFU (L) detects each current value, regulator pressure sensor signal, and swash plate angle sensor signal when activating the pump control solenoid valve. PFU learns the relation among current and pressure, and pressure and swash plate angle. 6. PFU (L) applies the learned value to the pump swash angle control and cancels the individual difference of the pump character.

TOKGB91-EN-00(20181003)

T2-2-24

SECTION 2 SYSTEM Group 2 Control System

Ke-CAN

5 IDU

ELUF

ELUT

MCU

ECM(L)

HiKe-CAN

J1939-CAN

PFU(L)

P6 P5

ECM(R)

PFU(R)

P12

P11

ENG.(L)

P10

ENG.(R)

TKGB-02-02-010

P1- Main Pump L1 P2- Main Pump L2 P3 Main Pump L3

P4- Main Pump L4 P5- Main Pump L5 P6- Main Pump L6

P7- Main Pump R1 P8 Main Pump R2 P9- Main Pump R3

1234-

8- Pump Control Solenoid Valve 9- Swash Plate Angle Sensor 10- Regulator Pressure Sensor

Pilot Shut-Off Switch Engine Control Dial (L) Engine Control Dial (R) Auto-Idle Switch

TOKGB91-EN-00(20181003)

67-

Hydraulic Oil Temperature Sensor Monitor Display Key Pad

T2-2-25

P10- Main Pump R4 P11- Main Pump R5 P12- Main Pump R6

SECTION 2 SYSTEM Group 2 Control System Sub-Control System Control Auto-Idle Control Purpose: The auto-idle control reduces the engine speed of both right and left engines when auto-idle switch (5) is in the ON position and all electric control levers (1, 2) are in neutral. Therefore, the fuel consumption and noise level can be reduced. Operation: 1. MCU monitors the signal of auto-idle switch (5) and the signals (front attachment/swing, travel) from ELUF and ELUT. 2. When all following conditions exist, MCU sends the signal to ECM (L) and ECM (R) in 3 seconds. • Auto-idle switch (5): ON • Signal from ELUF: 0 % • Signal from ELUT: 0 % 3. When ECM (L) and ECM (R) receive the signal, ECM (L) and ECM (R) control injectors (7, 9) and reduce engine speed of both right and left engines to the auto-idle speed (1400±50 min-1). 4. ECM (L) and ECM (R) can recognize that the engine speed is reduced to the auto-idle speed by the signals of crank speed sensors (6, 8). 5. MCU sends the auto-idle mode signal to IDU. IDU displays the auto-idle icon on monitor display (10). 6. When electric control levers (1, 2) are operated and the signal is input, MCU stops sending the signal to ECM (L) and ECM (R). Therefore, ECM (L) and ECM (R) increase engine speed to the engine speed set by engine control dials (L, R) (3, 4).

fNOTE: When the signals from engine control dials (L, R) (3, 4) are less than the auto-idle speed (1400±50 min-1), the auto-idle control is not activated.

TOKGB91-EN-00(20181003)

T2-2-26

SECTION 2 SYSTEM Group 2 Control System

6 7

3 4 MCU

5 ELUF

ECM(L)

ENG.(L)

ELUT J1939CAN

Ke-CAN

10 IDU

ECM(R)

ENG.(R)

TKGB-02-02-011

123-

Electric Control Lever (Front Attachment/Swing) Electric Control Lever (Travel) Engine Control Dial (L)

TOKGB91-EN-00(20181003)

4567-

Engine Control Dial (R) Auto-Idle Switch Crank Speed Sensor (L) Injector (L)

8- Crank Speed Sensor (R) 9- Injector (R) 10- Monitor Display

T2-2-27

SECTION 2 SYSTEM Group 2 Control System Fast-Filling Panel Lower Control Purpose: The fast-filling panel lower control prevents the fast-filling panel from lowering when the the pilot shut-off lever is in the UNLOCK position. When the fast-filling panel is lowered, the machine can not swing. Refer to Group 3 ELU System/Swing Stop Control for this control. Operation:  Pilot Shut-Off Lever: LOCK position 1. When the pilot shut-off switch (4) is in the OFF position (when the control lever can not be operated), MCU connects terminal (b) which is connected to fast filling relay (2) to the ground.

 Pilot Shut-Off Lever: UNLOCK Position 1. When the pilot shut-off switch (4) is in the ON position (when the control lever can be operated), MCU disconnects terminal (b) which is connected to fast filling relay (2) from the ground. 2. Even when fast-filling switch (1) is turned ON under this condition, fast filling relay (2) is not excited and the fast-filling panel does not lower.

2. When fast-filling switch (1) is turned ON under this condition, current flows from terminal (a) of MCU and excites fast filling relay (2). 3. Current from battery (i) flows to the fast filling solenoid valve (3) through fuse #78 and fast filling relay (2). Then, the fast filling solenoid valve (3) is turned ON. 4. Pressure oil from pilot pump (7) flows to the bottom side of lift cylinder (10) through the fast filling solenoid valve (3). Then, the fast-filling panel lowers.

IMPORTANT: Even when the pilot shut-off switch (4) is turned ON while the fast-filling panel is lowering or is in the lowest position, MCU continues to activate the fast filling solenoid valve (3). At the same time, MCU sends the signal to IDU. IDU sounds the buzzer.

5. The fast filling panel position relay (5) is stopped exciting when the fast-filling panel lowers and the fast filling panel position switch (6) is out of the detection range. 6. The signal that the fast filling panel position is out of the detection range is sent to MCU and ELUF. 7. MCU turns on warning light LED (red) (n) and sends the signal to IDU. IDU displays the alarm on the monitor display. 8. ELUF disables the swing operation. (Refer to Swing Stop Control.)

TOKGB91-EN-00(20181003)

T2-2-28

SECTION 2 SYSTEM Group 2 Control System

2 #78

MCU

a b

j k 8

d l 5

e f m 10

h TKEB-02-02-006

abcd-

Power Source for 24V D/I D/O KEY_SW D/I (24V)

efgh-

Power Source for 24V D/I D/I (24V) D/O Ke-CAN

ijkl-

From Battery To Hydraulic Oil Tank Key Switch ON Signal To ELUF

m- To ELUF n- Warning Light LED (Red) o- To IDU

123-

Fast Filling Switch Fast Filling Relay Fast Filling Solenoid Valve

45-

Pilot Shut-Off Switch Fast Filling Panel Position Relay

Fast Filling Panel Position Switch Pilot Pump

8- Pilot Check Valve 9- Slow Return Valve 10- Lift Cylinder

TOKGB91-EN-00(20181003)

T2-2-29

SECTION 2 SYSTEM Group 2 Control System Auto-Lubrication Control Purpose: The auto-lubrication control automatically applies grease to the front joint pins and swing bearing according to the set interval. Operation:  Auto Lubrication 1. MCU monitors auto-lubrication mode switch (6), the engine speed signals from PFU (L) and PFU (R), the crank speed signals from ECM (L) and ECM (R), and engine ON signals (f, g). 2. When MCU detects that the engine speed is over 500 min-1 with auto-lubrication mode switch (6) set in the AUTO position, MCU turns ON autolubrication solenoid valve (12) according to the interval set by the auto-lubrication interval switch (3).

fNOTE: MCU judges that the engine is running when any one of the engine speed signal, crank speed signal, and engine ON signals (f, g) are detected. 3. Pressure oil from pilot pumps (L, R) (14, 15) are supplied to vent valve (9) and grease pump motor (8) through reducing valve (11) when autolubrication solenoid valve (12) is turned ON. Then, grease pump (7) is activated.

4. As pilot pressure enters vent valve (9), vent valve (9) is closed and the return circuit from grease pump (7) to grease tank (10) is blocked. Then, grease is applied to each lubrication circuit. 5. Pressure switch (5) (for lubrication) is installed in the lubrication circuit. When the lubrication circuit pressure increases over the set pressure (23.5 MPa), pressure switch (5) (for lubrication) is turned ON. 6. When MCU detects that pressure switch (5) (for lubrication) is ON, MCU stops outputting to autolubrication solenoid valve (12) and stops lubrication until next interval.

TOKGB91-EN-00(20181003)

T2-2-30

7. When either of the following items occurs, MCU recognizes abnormality.  Auto-lubrication solenoid valve (12) is OFF and pressure switch (5) (for lubrication) is kept ON for 150 seconds  Auto-lubrication solenoid valve (12) is ON and pressure switch (5) (for lubrication) is kept OFF for 150 seconds MCU turns on warning light LED (red) (h) and sends the abnormal signal to IDU by using Ke-CAN. IDU displays the alarm on the monitor display. 8. MCU activates auto-lubrication solenoid valve (12) for 150 seconds every the set interval and continues lubrication until abnormality of pressure switch (5) (for lubrication) is solved.

SECTION 2 SYSTEM Group 2 Control System

e MCU

1 ECM(L)

J1939-CAN

2 ECM(R) IDU

PFU(L)

Ke-CAN

a b c d

PFU(R)

6 5 14 15 7

i j

k 10

abcd-

3 minutes 5 minutes 10 minutes 15 minutes

efgh-

Key Switch ON Signal Engine ON Signal (L) Engine ON Signal (R) Warning Light LED (Red)

1234-

Crank Speed Sensor (L) Crank Speed Sensor (R) Engine Speed Sensor (L) Engine Speed Sensor (R)

Pressure Switch (For Lubrication) Auto-Lubrication Mode Switch Grease Pump Grease Pump Motor

9101112-

TOKGB91-EN-00(20181003)

678-

T2-2-31

TKGB-02-02-012

Front Attachment Lubrication Circuit Swing Bearing Lubrication Circuit

Hose Reel Circuit

Vent Valve Grease Tank Reducing Valve Auto-Lubrication Solenoid Valve

13- Auto-Lubrication Interval Switch 14- Pilot Pump (L) 15- Pilot Pump (R)

SECTION 2 SYSTEM Group 2 Control System  Manual Lubrication by Grease Gun 1. When auto-lubrication mode switch (6) is set to the MANUAL position, MCU keeps auto-lubrication solenoid valve (12) ON. Therefore, grease pump (7) delivers grease and manual lubrication can be performed by grease gun (16). 2. Pressure switch (5) (for lubrication) is installed in the lubrication circuit. When the lubrication circuit pressure increases over the set pressure (23.5 MPa), pressure switch (5) (for lubrication) is turned ON. 3. When pressure switch (5) (for lubrication) is turned ON, MCU stops outputting to auto-lubrication solenoid valve (12). Auto-lubrication solenoid valve (12) is turned OFF and grease pump (7) stops.

fNOTE: In case of manual lubrication, warning light

LED (red) (h) is always turned on and the alarm is always displayed on the monitor display.

TOKGB91-EN-00(20181003)

T2-2-32

SECTION 2 SYSTEM Group 2 Control System

e MCU

1 ECM(L)

J1939-CAN

2 ECM(R) IDU

PFU(L)

Ke-CAN

a b c d

PFU(R)

6 5 14 15 7

i j 16

9 k 10

abcd-

3 minutes 5 minutes 10 minutes 15 minutes

efgh-

Key Switch ON Signal Engine ON Signal (L) Engine ON Signal (R) Warning Light LED (Red)

1234-

Crank Speed Sensor (L) Crank Speed Sensor (R) Engine Speed Sensor (L) Engine Speed Sensor (R)

Pressure Switch (For Lubrication) Auto-Lubrication Mode Switch Grease Pump Grease Pump Motor

9101112-

TOKGB91-EN-00(20181003)

678-

T2-2-33

TKGB-02-02-013

Front Attachment Lubrication Circuit Swing Bearing Lubrication Circuit

Hose Reel Circuit

Vent Valve Grease Tank Reducing Valve Auto-Lubrication Solenoid Valve

13- Auto-Lubrication Interval Switch 14- Pilot Pump (L) 15- Pilot Pump (R) 16- Grease Gun

SECTION 2 SYSTEM Group 2 Control System Oil Cooler Fan Motor Speed Control Purpose: The oil cooler fan motor speed control changes rotation speed of the oil cooler fan motors 1, 2 (8, 9) according to hydraulic oil temperature and optimally keeps hydraulic oil temperature. The speed of the oil cooler fan motors 1, 2 (8, 9) is equally controlled. Operation: 1. The hydraulic oil temperature sensor (1) (for oil cooler fan motor speed control) sends the signal in proportion to hydraulic oil temperature to MCU. 2. MCU controls the pump control solenoid valves (L, R) (3, 6) in proportion to hydraulic oil temperature (c), and changes the pump displacement angle of the oil cooler fan motor pumps (L, R) (2, 5). (Refer to COMPONENT OPERATION/Pump Device.) 3. Therefore, delivery flow rate of the oil cooler fan motor pumps (L, R) (2, 5) is controlled and rotation speed of the oil cooler fan motors 1, 2 (8, 9) is changed. 4. MCU sends detected data of the hydraulic oil temperature sensor (1) to IDU.

Hydraulic Oil Temperature and Oil Cooler Fan Motor Speed a (min-1)

b(mA) 700

1400 1060 min-1

1200 1000

500

800

400

600 400

ab-

300

351 mA (Min)

200

140 min-1 B

200 0 40

600

650 mA (Max)

Oil Cooler Fan Motor Speed Solenoid Valve Command Current

100

65 70 C (°C)

cAB-

0 90

TKGB-02-02-016

Hydraulic Oil Temperature Current Rotation Speed

fNOTE: The oil cooler fan motor speed in the diagram shows the oil cooler fan motor speed at the fast idle speed (1950 min-1) of the engine.

When the hydraulic oil temperature sensor (1) is abnormal, command current to the pump control solenoid valves (L, R) (3, 6) is minimized and rotation speed of the oil cooler fan motors 1, 2 (8, 9) is maximized. Then, MCU turns on warning light LED (yellow) (d) and sends the sensor abnormal signal to IDU by using KeCAN.

TOKGB91-EN-00(20181003)

T2-2-34

SECTION 2 SYSTEM Group 2 Control System

MCU

IDU

3 4

ENG.(L)

6 7 ENG.(R)

TKGB-02-02-014

Warning Light LED (Yellow)

Hydraulic Oil Temperature Sensor Oil Cooler Fan Motor Pump (L)

TOKGB91-EN-00(20181003)

345-

Pump Control Solenoid Valve (L) Regulator Pressure Sensor (L) Oil Cooler Fan Motor Pump (R)

678-

T2-2-35

Pump Control Solenoid Valve (R) Regulator Pressure Sensor (R) Oil Cooler Fan Motor 1

Oil Cooler Fan Motor 2

SECTION 2 SYSTEM Group 2 Control System Wiper Control  Intermittent Operation

 Slow Speed Operation

Purpose: The intermittent operation operates the wiper according to the interval set by wiper interval switch (9).

Purpose: The slow speed operation operates the wiper at slow speed.

Operation: 1. Wiper interval switch (9) inputs signal according to the set interval to MCU. 2. Wiper switch (5) inputs signal of the INT. (C) position to MCU.

Operation: 1. Wiper switch (5) inputs signal of the LOW (B) position to MCU.

3. MCU outputs current from terminal #72-53 according to the interval set by wiper interval switch (9). MCU turns ON wiper relay 1 (3) for one second.

3. When wiper relay 1 (3) is turned ON, current from fuse #75 operates wiper motor (1) at slow speed. 4. When wiper switch (5) is set to the OFF (D) position, MCU inputs signal.

4. When wiper relay 1 (3) is turned ON, current from fuse #75 operates wiper motor (1) once at slow speed. 5. When wiper switch (5) is set to the OFF (D) position, MCU inputs signal. 6. MCU stops current flowing from terminal #7253, outputs current from terminal #72-55, turns ON wiper relay 2 (2), and moves the wiper to the storage position.

TOKGB91-EN-00(20181003)

2. MCU outputs current from terminal #72-53 and turns ON wiper relay 1 (3).

T2-2-36

5. MCU stops current flowing from terminal #7253, outputs current from terminal #72-55, turns ON wiper relay 2 (2), and moves the wiper to the storage position.

SECTION 2 SYSTEM Group 2 Control System 1

#75 #76

5 ·A ·B ·C ·D

42-38(KEY-SW)

42-34(5V) 42-20(A/I) 42-42(GND) 72-36(D/I) 72-53(D/O)

#77

72-55(D/O)

a #21

72-54(D/O)

7 MCU

8 9 ·E ·F ·G ·H ·I

42-34(5V) 42-21(A/I) 42-42(GND)

TKEB-02-02-009

abc-

From Battery Key Switch ON Signal From Key Switch

ABC-

HIGT LOW INT.

DEF-

OFF 25 seconds 20 seconds

123-

Wiper Motor Wiper Relay 2 Wiper Relay 1

456-

Wiper Relay 3 Wiper Switch Washer Switch

789-

Washer Motor Relay Washer Motor Wiper Interval Switch

TOKGB91-EN-00(20181003)

T2-2-37

GHI-

15 seconds 10 seconds 5 seconds

SECTION 2 SYSTEM Group 2 Control System  Fast Speed Operation

 Washer Operation

Purpose: The fast speed operation operates the wiper at fast speed.

Purpose: The washer operation operates the washer and operates the wiper at slow speed.

Operation: 1. Wiper switch (5) inputs signal of the HIGH (A) position to MCU.

Operation: 1. When pushing washer switch (6), washer motor relay (7) are turned ON. Terminal #72-36 of MCU is connected to the ground.

2. MCU outputs current from terminal #72-54 and turns ON wiper relay 3 (4). 3. When wiper relay 3 (4) is turned ON, current from fuse #76 operates wiper motor (1) at fast speed. 4. When wiper switch (5) is set to the OFF (D) position, MCU inputs signal. 5. MCU stops current flowing from terminal #7254, outputs current from terminal #72-55, turns ON wiper relay 2 (2), and moves the wiper to the storage position.

2. When the time after pushing washer switch (6) is less than 1.4 seconds, only washer motor relay (7) is turned ON. Current from fuse #77 operates washer motor (8) and washer liquid is jetted. 3. When the time after pushing washer switch (6) is over 1.4 seconds, washer motor relay (7) is turned ON. Washer liquid is jetted. At the same time, MCU turns ON wiper relay 1 (3) and operates wiper motor (1) at slow speed. 4. When releasing washer switch (6), MCU stops current flowing from terminal #72-53. MCU outputs current from terminal #72-55, turns ON wiper relay 2 (2), and moves the wiper to the storage position.

TOKGB91-EN-00(20181003)

T2-2-38

SECTION 2 SYSTEM Group 2 Control System 1

#75 #76

5 ·A ·B ·C ·D

42-38(KEY-SW)

42-34(5V) 42-20(A/I) 42-42(GND) 72-36(D/I) 72-53(D/O)

#77

72-55(D/O)

a #21

72-54(D/O)

MCU

8 9 ·E ·F ·G ·H ·I

42-34(5V) 42-21(A/I) 42-42(GND)

TKEB-02-02-009

abc-

From Battery Key Switch ON Signal From Key Switch

ABC-

HIGT LOW INT.

DEF-

OFF 25 seconds 20 seconds

123-

Wiper Motor Wiper Relay 2 Wiper Relay 1

456-

Wiper Relay 3 Wiper Switch Washer Switch

789-

Washer Motor Relay Washer Motor Wiper Interval Switch

TOKGB91-EN-00(20181003)

T2-2-39

GHI-

15 seconds 10 seconds 5 seconds

SECTION 2 SYSTEM Group 2 Control System Folding Stairway Control Purpose: The folding stairway control prevents the folding stairway from being operated when the the pilot shut-off lever is in the UNLOCK position. Before the folding stairway cylinder reaches the stroke end, this control decreases operating speed in order to protect the folding stairway. Operation:  Folding Stairway Extend 1. When the folding stairway relay lock lever is released, limit switch 5 (11) (for lock lever lock position detection) is turned OFF. 2. Retract signal (D) is not sent to terminal #91-29 and ELUF locks the swing operation. 3. When the pilot shut-off switch (22) is in the OFF position (when the control lever can not be operated), folding stairway relay 1 (1) is not excited. 4. Current from the battery is supplied to the exciting circuit of folding stairway relay 2 (2), the exciting circuit of folding stairway relay 3 (3), the folding stairway solenoid valve A (14), and the folding stairway solenoid valve C (18).

9. When the folding stairway is extended halfway, limit switch 2 (8) (for extending stroke end control) turns ON and the folding stairway solenoid valve C (18) is connected to the ground. 10. As the folding stairway solenoid valve C (18) is excited, shifts the spool, and disconnects the hydraulic circuit. 11. Pressure oil from the folding stairway pump units 1 (12) and 2 (13) flows to folding stairway cylinders (20) through only orifice A (19). Operating speed of folding stairway cylinders (20) becomes slow.

5. When pushing extend switch (6), the exciting circuits of folding stairway relays 2 (2), 3 (3), and 4 (4) are connected to the ground. 6. As folding stairway relays 2 (2) and 3 (3) are excited, folding stairway pump units 1 (12) and 2 (13) are excited. 7. At the same time, solenoid b (15) of the folding stairway solenoid valve A (14) is excited and shifts the spool.

fNOTE: Even if current is supplied to Solenoid a (16),

Solenoid a (16) is not connected to the ground (electric potential difference: 0). Then, Solenoid a (16) is not excited. 8. Battery power activates folding stairway pump units 1 (12) and 2 (13). Pressure oil from the folding stairway solenoid valve A (14) flows to the rod side of folding stairway cylinder (20) through orifice A (19) or the folding stairway solenoid valve C (18). Then, the folding stairway is extended.

TOKGB91-EN-00(20181003)

T2-2-40

SECTION 2 SYSTEM Group 2 Control System A

13 14

15 8

19 17

16 11

MCU

C D

72-30

23 A

91-63

ELUF

91-29 TKEB-02-02-010

ABC12345678-

From Battery Pilot Shut-Off Switch Signal 24V Power Supply Folding Stairway Relay 1 Folding Stairway Relay 2 Folding Stairway Relay 3 Folding Stairway Relay 4 Retract Switch Extend Switch Limit Switch 1 Limit Switch 2

TOKGB91-EN-00(20181003)

D-

91011121314-

Retract Signal

Limit Switch 3 Limit Switch 4 Limit Switch 5 Folding Stairway Pump Unit 1 Folding Stairway Pump Unit 2 Folding Stairway Solenoid Valve A 15- Solenoid b

16- Solenoid a 17- Folding Stairway Solenoid Valve B 18- Folding Stairway Solenoid Valve C 19- Orifice A 20- Folding Stairway Cylinder (2 Used)

T2-2-41

21222324-

Holding Valve (2 Used) Pilot Shut-Off Switch Pilot Pump Stop Valve

SECTION 2 SYSTEM Group 2 Control System  Folding Stairway Retract 1. When the pilot shut-off switch (22) is in the OFF position (when the control lever can not be operated), folding stairway relay 1 (1) is not excited. 2. Current from the battery is supplied to the exciting circuit of folding stairway relay 2 (2), the exciting circuit of folding stairway relay 3 (3), the folding stairway solenoid valve A (14), and the folding stairway solenoid valve C (18). 3. When pushing retract switch (5), the exciting circuits of folding stairway relays 2 (2) and 3 (3) are connected to the ground. 4. As folding stairway relays 2 (2) and 3 (3) are excited, folding stairway pump units 1 (12) and 2 (13) are excited. 5. At the same time, solenoid a (16) of the folding stairway solenoid valve A (14) is excited and shifts the spool.

11. When stopping pushing retract switch (5), folding stairway relay 4 (4) is stopped exciting. The folding stairway solenoid valve B (17) is excited and shifts the spool. 12. Pressure oil from pilot pump (23) flows to the bottom side of folding stairway cylinders (20). The pushing force of folding stairway cylinders (20) increases and the folding stairway is safely retracted. 13. When the folding stairway relay lock lever is locked, limit switch 5 (11) (for lock lever lock position detection) is turned ON. Therefore, retract signal (D) is sent to terminal #91-29 and ELUF releases the swing operation.

fNOTE: When limit switch 4 (10) (for retracting

detection) is ON and the engine is started, the folding stairway solenoid valve B (17) is automatically excited. At the same time, pressure oil from pilot pump (23) flows to the bottom side of folding stairway cylinders (20). Even when the machine is operated, the folding stairway is secured and does not move.

fNOTE: Even if current is supplied to solenoid b (15),

solenoid b (15) is not connected to the ground (electric potential difference: 0). Then, solenoid b (15) is not excited. 6. Battery power activates folding stairway pump units 1 (12) and 2 (13). Pressure oil flows to the bottom side of folding stairway cylinders (20). Then, the folding stairway is retracted.

fNOTE: When limit switch 4 (10) (for retracting

7. When the folding stairway is retracted halfway, limit switch 3 (9) (for retracting stroke end control) is turned ON and solenoid a (16) of the folding stairway solenoid valve A (14) is stopped exciting. 8. The folding stairway solenoid valve A (14) is neutral and disconnects the hydraulic circuit. 9. Only pressure oil from the folding stairway pump unit 2 (13) flows to folding stairway cylinders (20). Then, operating speed of folding stairway cylinder (20) becomes slow. 10. When the folding stairway is fully retracted, limit switch 4 (10) (for retracting detection) is turned ON.

TOKGB91-EN-00(20181003)

T2-2-42

detection) is ON and extend switch (6) is pushed, folding stairway relay 4 (4) is excited and the folding stairway solenoid valve B (17) is stopped exciting. Therefore, pressure oil from pilot pump (23) does not flow to the bottom side of folding stairway cylinders (20).

SECTION 2 SYSTEM Group 2 Control System A 1

13 14

15 8

19 17

16 11

MCU

C D 72-30

23 A

91-63

ELUF

91-29

TKEB-02-02-010 ABC12345678-

TOKGB91-EN-00(20181003)

D-

91011121314-

Retract Signal

Limit Switch 3 Limit Switch 4 Limit Switch 5 Folding Stairway Pump Unit 1 Folding Stairway Pump Unit 2 Folding Stairway Solenoid Valve A 15- Solenoid b

16- Solenoid a 17- Folding Stairway Solenoid Valve B 18- Folding Stairway Solenoid Valve C 19- Orifice A 20- Folding Stairway Cylinder (2 Used)

T2-2-43

21222324-

Holding Valve (2 Used) Pilot Shut-Off Switch Pilot Pump Stop Valve

SECTION 2 SYSTEM Group 2 Control System Travel Mode Control Purpose: The travel mode control changes the displacement angle of travel motors (9, 10) by using travel mode switch (1) and shifts the travel mode. Operation:  Slow Speed 1. When travel mode switch (1) is OFF (slow speed), current from fuse #22 does not excite travel mode relay (2). 2. The contact of travel mode relay (2) is at the #4 side. The travel mode selector solenoid valve (3) is turned OFF. 3. The pilot pressure is reduced by reducing valve (4) to the set pressure and acts on the spool of the travel mode selector valve (6). 4. However, as the set pressure of the travel mode selector valve (6) is higher than the reduced pilot pressure, the spool of the travel mode selector valve (6) is not shifted. 5. As the main pressure from the control valve (e) acts on tilt piston (7) (slow speed side) and maximizes the travel motor displacement angles of travel motors (9, 10), travel speed becomes slow. 6. The pilot pressure also acts on parking brake (8) and releases parking brake (8). (Refer to COMPONENT OPERATION/Travel Device.) 7. The signal of travel mode switch (1) is not sent to IDU. IDU displays the slow speed mode icon on the monitor display.

TOKGB91-EN-00(20181003)

T2-2-44

SECTION 2 SYSTEM Group 2 Control System 1

IDU

2 #22

b #44

d 3

4 e

7 8

9 ab-

From LED Power Key Switch ON Signal

cd-

From Battery Line Travel Mode Display

From Control Valve

12-

Travel Mode Switch Travel Mode Relay

Travel Mode Selector Solenoid Valve Reducing Valve

567-

Pilot Pump Travel Mode Selector Valve Tilt Piston

TOKGB91-EN-00(20181003)

T2-2-45

TKEB-02-02-012

8- Parking Brake 9- Travel Motor (Left) 10- Travel Motor (Right)

SECTION 2 SYSTEM Group 2 Control System  Fast Speed 1. When travel mode switch (1) is ON (fast speed), current from fuse #22 excites travel mode relay (2). 2. The contact of travel mode relay (2) is connected to the #5 side. The travel mode selector solenoid valve (3) is turned ON. 3. Therefore, the pilot pressure acts on the spring side of reducing valve (4). Then, the pilot pressure without being reduced acts on the spool of the travel mode selector valve (6). 4. The pilot pressure without being reduced shifts the spool of the travel mode selector valve (6). 5. As the main pressure from the control valve (e) acts on tilt piston (7) (fast speed side) and minimizes the travel motor displacement angles of travel motors (9, 10), travel speed becomes fast. 6. The pilot pressure also acts on parking brake (8) and releases parking brake (8). 7. The signal of travel mode switch (1) is sent to IDU. IDU displays the fast speed mode icon on the monitor display.

TOKGB91-EN-00(20181003)

T2-2-46

SECTION 2 SYSTEM Group 2 Control System 1

IDU

#22

b #44

d 3

6 7 8

9 ab-

From LED Power Key Switch ON Signal

cd-

From Battery Line Travel Mode Display

From Control Valve

12-

Travel Mode Switch Travel Mode Relay

Travel Mode Selector Solenoid Valve Reducing Valve

567-

Pilot Pump Travel Mode Selector Valve Tilt Piston

TOKGB91-EN-00(20181003)

T2-2-47

TKEB-02-02-013

8- Parking Brake 9- Travel Motor (Left) 10- Travel Motor (Right)

SECTION 2 SYSTEM Group 2 Control System Cab Bed Pressurization Control Purpose: The cab bed pressurization control pressurizes the cab bed inside and keeps the higher pressure than atmospheric pressure. Then, dust is prevented from entering. Operation: 1. When cab bed doors (L, R) are closed, limit switches 1, 2 (1, 2) (cab bed door) are turned ON. 2. HMU receives the signal that the cab bed door is closed from limit switches 1, 2 (1, 2). 3. The cab bed pressurization relay (3) is excited by engine ON signals (d, e) from ECM (L) and ECM (R). 4. Current from alternator (a) flows through limit switches 1, 2 (1, 2) and the cab bed pressurization relay (3), and excites the cab bed pressurization blower motor relays 1 (4) and 2 (6). 5. Therefore, blower motor 1 (5) and 2 (7) (for cab bed pressurization) are activated and pressurize the cab bed. 6. When cab bed door (L) or door (R) are opened, signal from limit switches 1, 2 (1, 2) (cab bed door) to HMU are turned OFF. 7. The cab bed pressurization blower motor relays 1 (4) and 2 (6) are stopped exciting. 8. HMU sends the cab bed door open alarm to IDU and DLU. IDU displays the alarm on the monitor display. DLU records the cab bed door open alarm.

TOKGB91-EN-00(20181003)

T2-2-48

SECTION 2 SYSTEM Group 2 Control System

#29

a #30 HMU

d e

TKGB-02-02-015 ab-

From Alternator Key Switch ON Signal

cd-

To IDU, DLU Engine ON Signal (L)

Engine ON Signal (R)

123-

Limit Switch 1 (Cab Bed Door) Limit Switch 2 (Cab Bed Door) Cab Bed Pressurization Relay

Cab Bed Pressurization Blower Motor Relay 1 Blower Motor 1 (For Cab Bed Pressurization)

Cab Bed Pressurization Blower Motor Relay 2 Blower Motor 2 (For Cab Bed Pressurization)

TOKGB91-EN-00(20181003)

T2-2-49

SECTION 2 SYSTEM Group 2 Control System (Blank)

TOKGB91-EN-00(20181003)

T2-2-50

SECTION 2 SYSTEM Group 3 ELU System Outline ELUF and ELUT control the following operation system circuits.  Pilot Shut-Off Control  Boom Lower Flow Rate Regeneration Control  Cylinder Stroke End Shock Prevention Control  Adjuster Cylinder End Travel Limitation Control  Swing Stop Control ELUF and ELUT send the main pump swash plate angle control signal to PFU(L) and PFU(R) by using HiKe-CAN.

Input Signal Pilot Shut-Off Switch Electric Control Lever Signal (Boom)

Output Pilot Shut-Off Solenoid Valve Boom Lower Make-Up Solenoid Valve Arm Retract Solenoid Valve Arm Extend Solenoid Valve Bucket Tilt-In Solenoid Valve Bucket Tilt-Out Solenoid Valve Boom Raise Solenoid Valve

Control Pilot Shut-Off Control Boom Lower Flow Rate Regeneration Control Cylinder Stroke End Shock Prevention Control

Electric Control Lever Signal (Arm) Electric Control Lever Signal (Bucket) Electric Control Lever Signal (Boom) Arm Angle Sensor Bucket Angle Sensor Boom Angle Sensor Electric Control Lever Signal (Left Travel) Left Travel Forward Solenoid Valve Adjuster Cylinder End Travel Limitation Control Electric Control Lever Signal (Right Travel) Right Travel Forward Solenoid Pressure Sensor (Adjuster Cylinder End) Valve Left Travel Reverse Solenoid Valve Right Travel Reverse Solenoid Valve Main Pump Swash Plate Angle Control Signal (HiKe-CAN) Electric Control Lever Signal (Swing) Swing Left Solenoid Valve Swing Stop Control Limit Switch 4 (For Retracting Detection) Swing Right Solenoid Valve Fast Filling Panel Position Switch

TOKGB91-EN-00(20181003)

T-2-3-1

SECTION 2 SYSTEM Group 3 ELU System Pilot Shut-Off Control Purpose: ELUF shifts the pilot shut-off solenoid valve relay (2) according to the signal of the pilot shut-off switch (1), and activates the pilot shut-off solenoid valve (3). Therefore, ELUF supplies pressure oil from pilot pump (4) to the pilot circuit. Operation: 1. When all following conditions exist, current from terminal M in key switch (5) flows to ELUF, ELUT, and MCU through fuse #20 of fuse box (cab 1) (6) and pilot shut-off switch (1). At the same time, current excites the pilot shut-off solenoid valve relay (2). Condition  Key Switch (5): ON position  Pilot Shut-Off Switch (1): ON position 2. ELUF, ELUT, and MCU respectively recognizes the pilot shut-off unlock signal. The pilot shut-off unlock signal is sent to IDU by using Ke-CAN (7). IDU displays the unlocked state of the pilot shut-off lever on monitor (8). 3. ELUF outputs the signal after recognizing the pilot shut-off unlock signal. 4. The signal from ELUF is sent to the pilot shutoff solenoid valve (3) through the pilot shut-off solenoid valve relay (2). 5. The spool of the pilot shut-off solenoid valve (3) is shifted and pressure oil from pilot pump (4) is supplied to the pilot circuit.

TOKGB91-EN-00(20181003)

T-2-3-2

SECTION 2 SYSTEM Group 3 ELU System

A 2

TKEB-02-03-001

A-

To Pilot Circuit

12-

Pilot Shut-Off Switch Pilot Shut-Off Solenoid Valve Relay

TOKGB91-EN-00(20181003)

345-

Pilot Shut-Off Solenoid Valve Pilot Pump Key Switch

678-

T-2-3-3

Fuse Box (Cab 1) Ke-CAN Monitor

Pilot Pressure Sensor

SECTION 2 SYSTEM Group 3 ELU System Boom Lower Flow Rate Regeneration Control Purpose: The boom lower flow rate regeneration control flows pressure oil at the boom cylinders (13) bottom sides to the rod sides when performing boom lower operation. Therefore, pressure oil from the pumps which is used for the boom lower operation can be reduced and more pressure oil is delivered to the other actuators. Then, the combined operation can be smoothly performed. Operation: 1. ELUF calculates the target operation pressure signal according to the boom lower operation signal (stroke) from electric control lever (1). ELUF sends command current equivalent to the signal to the boom lower solenoid valve (4) of EDQR valve (upper) (3). 2. The boom lower solenoid valve (4) shifts boom lower spool (5) by pilot pressure oil according to command current. 3. Boom lower spool (5) directly supplies pilot pressure oil to control valves (9 to 12) and shifts boom spools (6). 4. ELUF detects the operation signal according to the boom lower operation (stroke) of electric control lever (1) and sends the operation signal to ELUT by using HiKe-CAN (2). 5. When ELUT receives the operation signal from HiKe-CAN (2), ELUT calculates the command current of the boom lower make-up solenoid valve (8) according to the operation signal. ELUT sends command current to the boom lower make-up solenoid valve (8). 6. The boom lower make-up solenoid valve (8) supplies pilot pressure oil according to command current to the boom lower make-up valves (7) and shifts the valve. 7. A part of pressure oil from the boom cylinders (13) bottom sides is combined with pressure oil from main pumps L1, L2, L5, L6, R3, R4, R5, R6 (P1, P2, P5, P6, P9, P10, P11, P12) according to the open area of the boom lower make-up valves (7), the open area of boom spools (6), and pressure difference between bottom sides and rod sides of boom cylinders (13) due to boom own weight. Then, the combined pressure oil flows to the boom cylinders (13) rod sides.

TOKGB91-EN-00(20181003)

T-2-3-4

SECTION 2 SYSTEM Group 3 ELU System 2 1

13 ELUF 3

ELUT

16 8

14 15 4 5 A4 7

PFU(L)

11 6

PFU(R)

6 6

P12

P10

P11

12 TKGB-02-03-001

P1- Main Pump L1 P2- Main Pump L2

P5- Main Pump L5 P6- Main Pump L6

P9- Main Pump R3 P10- Main Pump R4

123456-

78-

1213141516-

Electric Control Lever HiKe-CAN EDQR Valve (Upper) Boom Lower Solenoid Valve Boom Lower Spool Boom Spools

TOKGB91-EN-00(20181003)

Boom Lower Make-Up Valve Boom Lower Make-Up Solenoid Valve 9- Control Valve (Upper Left) 10- Control Valve (Lower Left) 11- Control Valve (Middle Right)

T-2-3-5

Control Valve (Lower Right) Boom Cylinders Pilot Pumps Pressure Sensor (Boom Lower) Pressure Sensor (Boom Lower Make-Up)

P11- Main Pump R5 P12- Main Pump R6

SECTION 2 SYSTEM Group 3 ELU System Cylinder Stroke End Shock Prevention Control Purpose: The cylinder stroke end shock prevention control reduces the cylinder speed when cylinders (14, 15, 16) reach the stroke end position. Therefore, the shock is reduced when the cylinder reaches the stroke end position. This control improves the ride quality and the machine structure is protected from being damaged by the shock. Target Operation: Boom Raise (B), Arm Retract (C), Arm Extend (D), Bucket Tilt-In (A), Bucket Tilt-Out (E) Operation: 1. ELUF receives the signals of angle sensors (2, 3, 4). When ELUF judges that the cylinder rod is near the stroke end position, ELUF controls command current to the solenoid valves of EDQR valve (upper) (5) and EDQR valve (lower) (6) corresponding to the operation to the specified value. 2. As command current is controlled, pilot pressure supplied from the solenoid valve to the spools of EDQR valve (upper) (5) and EDQR valve (lower) (6) is reduced. Then, the open parts of the spools of EDQR valve (upper) (5) and EDQR valve (lower) (6) are reduced. 3. As pilot pressure supplied from the spools of EDQR valve (upper) (5) and EDQR valve (lower) (6) to the control valve is reduced, the open part of the control valve is reduced. 4. At the same time, ELUF controls the signal according to the operation (stroke) of electric control lever (1) to the specified value, and sends the signal to PFU (L) and PFU (R) by using HiKe-CAN (9). 5. PFU (L) and PFU (R) perform the main pump swash plate angle control according to the signal from ELUF. As pilot pressure supplied to the regulators of the main pumps is reduced, the delivery flow rate of pumps L1 to L6, R1 to R6 (P1 to P12) is decreased.

TOKGB91-EN-00(20181003)

T-2-3-6

SECTION 2 SYSTEM Group 3 ELU System 13 2 3 4

14 5

ELUF 18

AB CDE A

8 6 9 12 C D E

PFU(L)

PFU(R)

P12

P10

P11

TKGB-02-03-002 AB-

Bucket Tilt-In Boom Raise

CD-

Arm Retract Arm Extend

E-

Bucket Tilt-Out

P1- Main Pump L1 P2- Main Pump L2 P3- Main Pump L3

P4- Main Pump L4 P5- Main Pump L5 P6- Main Pump L6

P7- Main Pump R1 P8- Main Pump R2 P9- Main Pump R3

P10- Main Pump R4 P11- Main Pump R5 P12- Main Pump R6

12345-

678910-

1112131415-

16- Boom Cylinders 17- Pilot Shut-Off Solenoid Valve 18- Pilot Pumps

Electric Control Lever Bucket Angle Sensor Arm Angle Sensor Boom Angle Sensor EDQR Valve (Upper)

TOKGB91-EN-00(20181003)

EDQR Valve (Lower) Control Valve (Upper Left) Control Valve (Middle Left) Control Valve (Lower Left) Control Valve (Upper Right)

T-2-3-7

Control Valve (Middle Right) Control Valve (Lower Right) HiKe-CAN Arm Cylinder Bucket Cylinders

SECTION 2 SYSTEM Group 3 ELU System Adjuster Cylinder End Travel Limitation Control Purpose: The adjuster cylinder end travel limitation control stops travel operation when excessive shock is applied to the front idler and adjuster cylinder (12) reaches the stroke end while traveling. Therefore, the machine is protected from shock. Operation: Operation 1 in the Travel limitation Control table in the right is explained here. 1. When adjuster cylinder (12) reaches the stroke end during forward travel operation, travel stop valve (20) is shifted. Pressure oil shifts pilot pressure control valve (21). 2. Pilot pressure oil acts on pressure sensor (1) through pilot pressure control valve (21). ELUT detects abnormal tension according to the signal of pressure sensor (1). 3. ELUT stops sending signals (A, B) to the left travel forward solenoid valve and right travel forward solenoid valve of EDQR valve (upper) (5). ELUT stops the PFU main pump swash plate angle control of PFU (L) and PFU (R) by using HiKe-CAN (2). ELUT sends the adjuster cylinder abnormal tension alarm signal to IDU by using Ke-CAN (3). Then, IDU turns on the tension indicator on monitor (4). 4. The left travel forward solenoid valve and right travel forward solenoid valve of EDQR valve (upper) (5) stop. The travel spools (11) of control valves (7 to 10) are returned to the neutral position. Then, travel operation is stopped. 5. When perform the reverse travel operation, ELUT sends signals (C, D) to the left travel reverse solenoid valve and right travel reverse solenoid valve of EDQR valve (lower) (6). ELUT activates the left travel reverse solenoid valve and right travel reverse solenoid valve. Then, the solenoid valves supply pilot pressure oil. 6. Pilot pressure oil of EDQR valve (lower) (6) shifts the travel spools (11) of control valves (7 to 10) to the reverse side. 7. When adjuster cylinder (12) gets away from the stroke end during reverse travel operation, ELUT detects abnormal tension release according to the signal of pressure sensor (1) for the adjuster cylinder end. The forward travel control and main pump swash plate angle control of PFU (L) and PFU (R) can be performed by using HiKe-CAN (2). 8. The adjuster cylinder abnormal tension alarm signal is stopped sending to IDU by using Ke-CAN (3). Then, IDU turns off the tension indicator on monitor (4). TOKGB91-EN-00(20181003)

Travel Limitation Control Operation that adjuster Travel Opration cylinder (12) reaches the stroke Limitation end 1 Left Right Forward () Forward × Forward × Left Right Reverse Reverse Right 2 Left Spin Right () Forward × Forward Left Right Reverse Reverse × 3 Left Right Spin Left () Forward Forward × Left Right Reverse × Reverse Right 4 Left Reverse () Forward Forward Right Left Reverse × Reverse × Right 5 Left Turn Left ( N) Forward Forward Right Left Reverse × Reverse Right 6 Left Turn Right ( N) Forward × Forward Right Left Reverse Reverse 7 Left Right Turn Right (N ) Forward Forward Left Right Reverse Reverse × 8 Left Right Turn Left (N ) Forward Forward × Left Right Reverse Reverse : Forward : Reverse N: Lever Neutral

T-2-3-8

: Control enabled ×: Control disabled

SECTION 2 SYSTEM Group 3 ELU System 2 5 4 IDU

13 A

15 3

11 B ELUT

21 C

A B C D

19 12

PFU(L)

PFU(R)

P10

TKGB-02-03-003

A-

Left Travel Forward

B-

Right Travel Forward

C-

Right Travel Reverse

D-

Left Travel Reverse

P1- Main Pump L1 P2- Main Pump L2

P3- Main Pump L3 P4- Main Pump L4

P7- Main Pump R1 P8- Main Pump R2

P9- Main Pump R3 P10- Main Pump R4

123456-

789101112-

131415161718-

19- Travel Motor (Right Rear) 20- Travel Stop Valves 21- Pilot Pressure Control Valve

Pressure Sensor HiKe-CAN Ke-CAN Monitor EDQR Valve (Upper) EDQR Valve (Lower)

TOKGB91-EN-00(20181003)

Control Valve (Middle Left) Control Valve (Lower Left) Control Valve (Upper Right) Control Valve (Middle Right) Travel Spools Adjuster Cylinders

T-2-3-9

Pilot Pumps Pilot Shut-Off Solenoid Valve Electric Control Lever (Travel) Travel Motor (Left Front) Travel Motor (Left Rear) Travel Motor (Right Front)

SECTION 2 SYSTEM Group 3 ELU System Swing Stop Control Purpose: The swing stop control stops swing operation when the fast-filling panel or folding stairway is lowered. Therefore, the fast-filling panel and folding stairway are prevented from damage. Operation: 1. When the fast-filling panel or folding stairway is lowered, the signal which is sent from the fast filling panel position switch (3) or limit switch 4 (for retracting detection) (4) to ELUF is 0 V. 2. When performing swing operation under this condition, ELUF disables the signal from electric control lever (1) and the machine can not swing. 3. When the fast-filling panel and folding stairway is retracted, the signals (24 V) are sent from the fast filling panel position switch (3) and limit switch 4 (for retracting detection) (4) to ELUF, and the machine can swing.

TOKGB91-EN-00(20181003)

T-2-3-10

SECTION 2 SYSTEM Group 3 ELU System

5 4

1 3

MCU

ELUF

B 6

PFU(L)

PFU(R)

P12

P11

TKGB-02-03-004

AB-

Swing Left Swing Right

P5- Main Pump L5 P6- Main Pump L6

P11- Main Pump R5 P12- Main Pump R6

123-

Electric Control Lever Fast Filling Panel Position Relay Fast Filling Panel Position Switch

89101112-

TOKGB91-EN-00(20181003)

567-

Limit Switch 4 (For Retracting Detection) HiKe-CAN EDQR Valve (Upper) EDQR Valve (Lower)

T-2-3-11

Control Valve (Upper Left) Control Valve (Lower Right) Pilot Pumps Pilot Shut-Off Solenoid Valve Swing Motor (Left Front)

13- Swing Motor (Left Rear) 14- Swing Motor (Right Front) 15- Swing Motor (Right Rear)

SECTION 2 SYSTEM Group 3 ELU System (Blank)

TOKGB91-EN-00(20181003)

T-2-3-12

SECTION 2 SYSTEM Group 4 Hydraulic System Outline The hydraulic system mainly consists of the pilot circuit, main circuit, other actuator circuits, and travel shock absorbing/travel stop circuit. Pilot Circuit: Power Source Pilot Pump

Related Device Pilot Relief Valve

Main Circuit: Power Source Main Pump

Related Device Control Valve

Supplied to Auto-Lubrication Control Circuit Fast Filling Panel Operation Control Circuit EDQR Valve Operation Control Circuit Accumulator Folding Stairway Control Circuit Pilot Shut-Off Solenoid Valve Swing Parking Brake Release Circuit Travel Parking Brake Release Circuit Travel Mode Selector Valve Travel Mode Control Circuit Pump Regulator Main Pump Control Circuit Oil Cooler Fan Motor Pump Control Circuit 3-Spool Solenoid Valve Boom Lower Make-Up Circuit

Supplied to Motor Cylinder

Other Actuator Circuits: Power Source Pump Transmission Oil Pump

Related Device Pump Transmission Oil Cooler Oil Cooler Fan Motor Pump Oil Cooler Fan Motor Air Conditioner Compressor Motor Air Conditioner Compressor Pump Motor

Travel Shock Absorbing/Travel Stop Circuit: Power Source Related Device Adjuster Cylinder Cushion Piston Travel Stop Valve Pilot Pressure Control Valve

TOKGB91-EN-00(20181003)

T2-4-1

Supplied to Pump Transmission Oil Cooling Circuit Oil Cooler Fan Motor Circuit Air Conditioner Compressor Motor Circuit

Supplied to Accumulator Pressure Sensor

SECTION 2 SYSTEM Group 4 Hydraulic System Pilot Circuit Outline Pressure oil from the pilot pumps of the right and left engines are used in order to operate the following circuits.  Auto-Lubrication Control Circuit (Refer to SYSTEM/ Control System.)  Fast Filling Panel Operation Control Circuit (Refer to SYSTEM/Control System.)  Operation Control Circuit  Folding Stairway Control Circuit (Refer to SYSTEM/ Control System.)  Swing Parking Brake Release Circuit (Refer to COMPONENT OPERATION/Swing Device.)  Travel Parking Brake Release Circuit (Refer to COMPONENT OPERATION/Travel Device.)  Travel Mode Control Circuit (Refer to SYSTEM/ Control System and COMPONENT OPERATION/Travel Device.)  Main Pump Control Circuit, Oil Cooler Fan Motor Pump Control Circuit (Refer to COMPONENT OPERATION/Pump Device.)  Boom Lower Make-Up Circuit Six accumulators are equipped for the pilot circuit. The accumulators supply hydraulic oil to the pilot circuit for a period of time after the engine has been stopped. The pilot pressure in the circuit is kept constant by the pilot relief valve (set pressure: 3.9 MPa (566 psi)).

TOKGB91-EN-00(20181003)

T2-4-2

SECTION 2 SYSTEM Group 4 Hydraulic System 3 21

4 1

8 7 6 8

2 13

11 28

123456-

Auto-Lubrication Control Circuit Fast Filling Panel Operation Control Circuit Operation Control Circuit Folding Stairway Control Circuit Swing Parking Brake Release Circuit Travel Parking Brake Release Circuit

TOKGB91-EN-00(20181003)

78-

9101112131415-

Travel Mode Control Circuit Main Pump Control Circuit, Oil Cooler Fan Motor Pump Control Circuit Boom Lower Make-Up Circuit 4-Unit Pump (2 Used) Pilot Pump (2 Used) Pilot Filter (2 Used) Pilot Relief Valve (2 Used) Accumulator (6 Used) Pilot Shut-Off Solenoid Valve

16- EDQR Valve (Upper) 17- EDQR Valve (Lower) 18- Boom Raise Priority Selector Valve 19- Boom Lower Priority Selector Valve 20- 3-Spool Solenoid Valve Unit 21- Make-Up Valve (2 Used) 22- Main Pumps L1, L2 23- Main Pumps L3, L4 24- Main Pumps L5, L6

T2-4-3

10 25262728-

TKGB-02-04-012

Main Pumps R1, R2 Main Pumps R3, R4 Main Pumps R5, R6 Oil Cooler Fan Motor Pump P13 29- Oil Cooler Fan Motor Pump P14

SECTION 2 SYSTEM Group 4 Hydraulic System Operation Control Circuit 1. Pressure oil from pilot pumps (B4) (2 used) are supplied to EDQR valves (B1, B2) through pilot check valve (B5) and pilot shut-off solenoid valve (A10). 2. When operating electric control levers (A1 to A8), the electrical signal is sent to ELUF, ELUT (A9). ELUF, ELUT (A9) sends signals (1 to 14) to the solenoid valves of EDQR valves (B1, B2). 3. The solenoid valves of EDQR valves (B1, B2) are activated. Pressure oil from pilot pumps (B4) (2 used) are routed to the spools in EDQR valves (B1, B2) as a signal pressure. (Refer to SYSTEM/Control System.) 4. Pressure oil from pilot pumps (B4) (2 used) flow to the control valve through the spools in EDQR valves (B1, B2), and moves the spools in the control valve. (Refer to COMPONENT OPERATION/EDQR Valve.) 5. When the spools in the control valve are moved, pressure oil from the main pump is supplied to each motor and cylinder through the control valve. Then, each motor and cylinder are operated.

TOKGB91-EN-00(20181003)

T2-4-4

SECTION 2 SYSTEM Group 4 Hydraulic System A1

A9 2

10 11

4 9

5 a

A10

14 3 B7

B5 a

B6 B4

TKGB-02-04-013

To Control Valve

A1- Arm A2- Swing A3- Bucket

A4- Boom A5- Left Travel A6- Right Travel

A7- Bucket Open A8- Bucket Close A9- ELUF, ELUT

A10- Pilot Shut-Off Solenoid Valve

B1- EDQR Valve (Upper) B2- EDQR Valve (Lower) B3- Accumulator (6 Used)

B4- Pilot Pump (2 Used) B5- Pilot Check Valve

B6- Boom Raise Priority Selector Valve

B7- Boom Lower Priority Selector Valve

1234-

5678-

9101112-

13- Bucket Open 14- Bucket Close

Arm Extend Arm Retract Swing Right Swing Left

TOKGB91-EN-00(20181003)

Bucket Tilt-In Bucket Tilt-Out Boom Raise Boom Lower

T2-4-5

Left Travel Forward Left Travel Reverse Right Travel Forward Right Travel Reverse

SECTION 2 SYSTEM Group 4 Hydraulic System Main Circuit The main circuit is broadly divided into three circuits.  Suction Circuit  Delivery Circuit  Return Circuit Suction Circuit The suction circuit draws hydraulic oil and is located between hydraulic oil tank (20) and pump (1 to 18, 24). Hydraulic oil tank (20) is connected to suction manifolds (left, right) (22, 23) via each suction piping. Main pumps L1 to L6, R1 to R6 (1 to 12), the oil cooler fan motor pumps P13, P14 (13, 14), pilot pumps (16) (2 used), the air conditioner compressor motor pump (17), and spare pump (18) draw hydraulic oil from suction manifolds (left, right) (22, 23). The folding stairway pump units (24) (2 used) draw hydraulic oil from suction manifold (left) (22). Six suction filters (21) are installed in hydraulic oil tank (20).

TOKGB91-EN-00(20181003)

T2-4-6

SECTION 2 SYSTEM Group 4 Hydraulic System

1 2

3 4

7 8

9 10

5 6

11 12

12345-

19 15

Main Pump L1 (Pump Transmission Side) Main Pump L2 (Pump End Side) Main Pump L3 (Pump Transmission Side) Main Pump L4 (Pump End Side) Main Pump L5 (Pump Transmission Side)

TOKGB91-EN-00(20181003)

Main Pump L6 (Pump End Side) 7- Main Pump R1 (Pump Transmission Side) 8- Main Pump R2 (Pump End Side) 9- Main Pump R3 (Pump Transmission Side) 10- Main Pump R4 (Pump End Side)

11- Main Pump R5 (Pump Transmission Side) 12- Main Pump R6 (Pump End Side) 13- Oil Cooler Fan Motor Pump P13 14- Oil Cooler Fan Motor Pump P14 15- 4-Unit Pump (2 Used) 16- Pilot Pump (2 Used)

T2-4-7

TKGB-02-04-003

17- Air Conditioner Compressor Motor Pump 18- Spare Pump 19- Pump Transmission Oil Pump (2 Used) 20- Hydraulic Oil Tank 21- Suction Filter (6 Used) 22- Suction Manifold (Left) 23- Suction Manifold (Right) 24- Folding Stairway Pump Unit (2 Used)

SECTION 2 SYSTEM Group 4 Hydraulic System Delivery Circuit The delivery circuit delivers hydraulic oil and is located between pumps (1 to 12) and control valves (14 to 19). 1. Hydraulic oil which is delivered by main pumps L1 to L6 (1 to 6) is supplied to control valves 1, 2, 3 (14, 15, 16) through high-pressure strainers (13) (6 used). 2. Hydraulic oil which is delivered by main pumps R1 to R6 (7 to 12) is supplied to control valves 4, 5, 6 (17, 18, 19) through high-pressure strainers (13) (6 used). 3. Supplied hydraulic oil is controlled as follows.  Pressure oil from main pump L1 (1) and main pump L2 (2) is controlled by control valve 3 (16), and is used for right travel (30), arm (29), boom (23), and bucket (20).  Pressure oil from main pump L3 (3) and main pump L4 (4) is controlled by control valve 2 (15), and is used for left travel (25), boom raise (26)/bucket tilt-in (27), bucket open/close (28), and arm (29).  Pressure oil from main pump L5 (5) and main pump L6 (6) is controlled by control valve 1 (14), and is used for swing (24), boom (23), arm extend (21)/ boom lower (22), and bucket (20).  Pressure oil from main pump R1 (7) and main pump R2 (8) is controlled by control valve 4 (17), and is used for left travel (25), boom raise (26)/bucket tilt-in (27), bucket open/close (28), and arm (29).  Pressure oil from main pump R3 (9) and main pump R4 (10) is controlled by control valve 5 (18), and is used for right travel (30), arm (29), boom (23), and bucket (20).  Pressure oil from main pump R5 (11) and main pump R6 (12) is controlled by control valve 6 (19), and is used for swing (24), boom (23), arm extend (21)/ boom lower (22), and bucket (20).

TOKGB91-EN-00(20181003)

T2-4-8

SECTION 2 SYSTEM Group 4 Hydraulic System

21, 22

26, 27

21, 22

1 2

3 4

7 8

5 6

9 10 11 12 TKGB-02-04-004

12345678-

Main Pump L1 Main Pump L2 Main Pump L3 Main Pump L4 Main Pump L5 Main Pump L6 Main Pump R1 Main Pump R2

TOKGB91-EN-00(20181003)

910111213-

Main Pump R3 Main Pump R4 Main Pump R5 Main Pump R6 High-Pressure Strainer (12 Used) 14- Control Valve 1 (Upper Left) 15- Control Valve 2 (Middle Left)

1617181920212223-

T2-4-9

Control Valve 3 (Lower Left) Control Valve 4 (Upper Right) Control Valve 5 (Middle Right) Control Valve 6 (Lower Right) Bucket Arm Extend Boom Lower Boom

24252627282930-

Swing Left Travel Boom Raise Bucket Tilt-In Bucket Open/Close Arm Right Travel

SECTION 2 SYSTEM Group 4 Hydraulic System Return Circuit The return circuit is used for returning hydraulic oil and is located between control valves (1 to 6) and hydraulic oil tank (11). Returning oil from control valves 2, 3, 4, 5 (2, 3, 4, 5) returns to hydraulic oil tank (11) through oil coolers (7) (4 used) and full-flow filters (9) (4 used). When the oil temperature is low (high viscosity), the oil flow resistance increases in oil coolers (7) (4 used). Then, low-pressure relief valves (8) (4 used) are opened and returning oil returns to hydraulic oil tank (11) through low-pressure relief valves (8) (4 used) and full-flow filters (9) (4 used). Returning oil from control valves 1, 6 (1, 6) returns to hydraulic oil tank (11) through low-pressure relief valves (8) (2 used) and full-flow filters (9) (2 used). A part of returning oil directly returns to hydraulic oil tank (11) through bypass filter (10).

TOKGB91-EN-00(20181003)

T2-4-10

SECTION 2 SYSTEM Group 4 Hydraulic System

8 8

10 9

9 11

TKGB-02-04-005

123-

Control Valve 1 (Upper Left) Control Valve 2 (Middle Left) Control Valve 3 (Lower Left)

TOKGB91-EN-00(20181003)

456-

Control Valve 4 (Upper Right) Control Valve 5 (Middle Right) Control Valve 6 (Lower Right)

78-

T2-4-11

Oil Cooler (4 Used) Low-Pressure Relief Valve (6 Used)

9- Full-Flow Filter (6 Used) 10- Bypass Filter 11- Hydraulic Oil Tank

SECTION 2 SYSTEM Group 4 Hydraulic System When Performing Single Operation

 When performing travel operation Pressure oil from control valves 2, 4 (10, 12) is supplied to travel motors (7) (2 used) at the left side when performing left travel operation. Pressure oil from control valves 3, 5 (11, 13) is supplied to travel motors (8) (2 used) at the right side when performing right travel operation.

 When performing boom operation Pressure oil from control valves 1 to 6 (9 to 14) is supplied to boom cylinders (1) (2 used) when performing boom raise operation. Pressure oil from control valves 1, 3, 5, 6 (9, 11, 13, 14) is supplied to boom cylinders (1) (2 used) when performing boom lower operation.  When performing arm operation Pressure oil from control valves 1 to 6 (9 to 14) is supplied to arm cylinder (4) when performing arm extend operation. Pressure oil from control valves 2 to 5 (10 to 13) is supplied to arm cylinder (4) when performing arm retract operation.  When performing bucket operation Pressure oil from control valves 1 to 6 (9 to 14) is supplied to bucket cylinders (2) (2 used) when performing bucket tilt-in operation. Pressure oil from control valves 1, 3, 5, 6 (9, 11, 13, 14) is supplied to bucket cylinders (2) (2 used) when performing bucket tilt-out operation.  When performing open/close operation Pressure oil from control valves 2, 4 (10, 12) is supplied to dump cylinders (3) (2 used) when performing bucket open/close operation.  When performing swing operation Pressure oil from control valves 1, 6 (9, 14) is supplied to swing motors (6) (4 used) when performing swing operation.

TOKGB91-EN-00(20181003)

T2-4-12

SECTION 2 SYSTEM Group 4 Hydraulic System 1

9 12

19 10

13 15

20 21

22 23 11

17 18

TKGB-02-04-006

1234567-

Boom Cylinder (2 Used) Bucket Cylinder (2 Used) Dump Cylinder (2 Used) Arm Cylinder Level Cylinder Swing Motor (4 Used) Travel Motor (Left) (2 Used)

TOKGB91-EN-00(20181003)

891011121314-

Travel Motor (Right) (2 Used) Control Valve 1 (Upper Left) Control Valve 2 (Middle Left) Control Valve 3 (Lower Left) Control Valve 4 (Upper Right) Control Valve 5 (Middle Right) Control Valve 6 (Lower Right)

15- Bucket Spool 16- Arm Extend/Boom Lower Spool 17- Boom Spool 18- Swing Spool 19- Left Travel Spool

T2-4-13

20- Boom Raise/Bucket Tilt-In Spool 21- Bucket Open/Close Spool 22- Arm Spool 23- Right Travel Spool

SECTION 2 SYSTEM Group 4 Hydraulic System When Performing Combined Operation Combined operation of travel and swing, travel and front attachment, or swing and front attachment When performing travel operation, pressure oil from control valves 2, 4 (2, 4) is supplied to travel motors (left) (17) (2 used) and pressure oil from control valves 3, 5 (3, 5) is supplied to travel motors (right) (18) (2 used). When performing swing operation, pressure oil from control valves 1, 6 (1, 6) is supplied to swing motors (16) (4 used). Left travel spools (11), right travel spools (15), and swing spools (10) are located in upstream of other spools of control valves 1 to 6 (1 to 6). The parallel circuit which divides pressure oil and supplies pressure oil to the downstream is not installed in left travel spools (11) and right travel spools (15). Therefore, only control valves 1, 6 (1, 6) are used when performing swing or front attachment operation while traveling. Parallel circuits (g) are installed in only swing spools (10) and boom spools (9) of control valves 1, 6 (1, 6).

fNOTE: Arm spools (14) for arm retract operation are

installed in the downstream of left travel spools (11) and right travel spools (15) in control valves 2 to 5 (2 to 5). As the parallel circuit is not installed in left travel spool (11) and right travel spool (15), combined operation of travel and arm retract is impossible.

fNOTE: Bucket open/close spools (13) are installed in the

 Combined operation of travel and swing Control valves 2 to 5 (2 to 5) are used when performing travel operation. Control valves 1, 6 (1, 6) are used when performing swing operation. As the control valves which are used when performing travel and swing operation are independent, combined operation of travel and swing is possible. Boom raise operation is possible while performing travel and swing operation. However, other front attachment operations are impossible.  Combined operation of travel and front attachment Only control valves 1, 6 (1, 6) are used when performing front attachment operation while traveling. Therefore, the following combined operation is possible while performing travel operation. Travel and boom raise/lower Travel and arm extend Travel and bucket tilt-in/tilt-out

TOKGB91-EN-00(20181003)

T2-4-14

downstream of right travel spools (15) in control valves 2, 4 (2, 4). As the parallel circuit is not installed in right travel spools (15), combined operation of travel and bucket open/close is impossible.

 Combined operation of swing and front attachment Swing spools (10) are located in the upstream of other spools of control valves 1, 6 (1, 6). Therefore, control valves 2 to 5 (2 to 5) are used when performing front attachment operation while swinging. Parallel circuit is installed in boom raise/ bucket tilt-in spools (12) of control valves 2, 4 (2, 4). Parallel circuits are installed in arm spools (14) of control valves 3, 5 (3, 5). Therefore, as pressure oil is supplied the spools in the downstream, combined operation of swing and all front attachments is possible.

SECTION 2 SYSTEM Group 4 Hydraulic System 16 1 7 4

c b

2 11 12

13 i

14 15 3

i g f 18

TKGB-02-04-007

abc-

From Main Pumps L1, L2 From Main Pumps L3, L4 From Main Pumps L5, L6

def-

From Main Pumps R1, R2 From Main Pumps R3, R4 From Main Pumps R5, R6

ghi-

12345-

Control Valve 1 (Upper Left) Control Valve 2 (Middle Left) Control Valve 3 (Lower Left) Control Valve 4 (Upper Right) Control Valve 5 (Middle Right)

678-

Control Valve 6 (Lower Right) Bucket Spool Arm Extend/Boom Lower Spool Boom Spool

10- Swing Spool 11- Left Travel Spool 12- Boom Raise/Bucket Tilt-In Spool 13- Bucket Open/Close Spool

TOKGB91-EN-00(20181003)

T2-4-15

Parallel Circuit Parallel Circuit Parallel Circuit 1415161718-

Arm Spool Right Travel Spool Swing Motor (4 Used) Travel Motor (Left) (2 Used) Travel Motor (Right) (2 Used)

SECTION 2 SYSTEM Group 4 Hydraulic System  Combined operation of boom raise and bucket tilt-in 1. When performing combined operation of boom raise and bucket tilt-in, ELUF (4) activates the boom raise solenoid valve (2) and bucket tilt-in solenoid valve (3) of EDQR valve (upper) (1). 2. Pressure oil from the pilot shut-off solenoid valve flows through the boom raise solenoid valve (2) and bucket tilt-in solenoid valve (3) and shifts boom raise spool (6) and bucket tilt-in spool (5).

Therefore, pressure oil from the main pump flows to the boom cylinders through boom spools (13) of control valves 1, 3, 5, 6 (7, 9, 11, 12) and boom raise/bucket tilt-in spools (15) of control valves 2, 4 (8, 10). Pressure oil from the main pump flows to the bucket cylinders through bucket spools (14) of control valves 3, 5 (9, 11).

3. Pressure oil from the pilot pump flows through boom raise spool (6) of EDQR valve (upper) (1) and shifts boom spools (13) of control valves 1, 3, 5, 6 (7, 9, 11, 12) to the boom raise side. At the same time, the boom raise priority selector valve (16) is also shifted. 4. When the boom raise priority selector valve (16) is also shifted, pilot pressure (K, L) is blocked. Therefore, boom raise/bucket tilt-in spools (15) of control valves 2, 4 (2, 4) are shifted to the boom raise side by pilot pressure (B, D) from boom raise spool (6) of EDQR valve (upper) (1). 5. On the other hand, pressure oil from the pilot pump flows through bucket tilt-in spool (5) of EDQR valve (upper) (1) and shifts bucket spools (14) of control valves 1, 3, 5, 6 (7, 9, 11, 12) to the bucket tilt-in side. 6. As boom spool (13) is located in the upstream of bucket spool (14) of control valves 1, 6 (7, 12), pressure oil from main pumps L5, L6, R5, and R6 does not flow to bucket spools (14). 7. As the parallel circuits are installed in control valves 3, 5 (9, 11), pressure oil from main pumps L1, L2, R3, and R4 flows to bucket spools (14) after being divided in control valves 3, 5 (9, 11).

TOKGB91-EN-00(20181003)

T2-4-16

SECTION 2 SYSTEM Group 4 Hydraulic System

7 14 G

13 4 1

D L

G H

14 K B

13 E

A B C D

F K

14 j TKGB-02-04-014

abc-

Bucket Tilt-In Signal Boom Raise Signal From Pilot Pump

12345-

EDQR Valve (Upper) Boom Raise Solenoid Valve Bucket Tilt-In Solenoid Valve ELUF Bucket Tilt-In Spool

TOKGB91-EN-00(20181003)

fgh-

From Main Pumps L3, L4 From Main Pumps L5, L6 From Main Pumps R1, R2

ij-

From Pilot Shut-Off Solenoid Valve From Main Pumps L1, L2

678910-

Boom Raise Spool Control Valve 1 (Upper Left) Control Valve 2 (Middle Left) Control Valve 3 (Lower Left) Control Valve 4 (Upper Right)

11121314-

Control Valve 5 (Middle Right) Control Valve 6 (Lower Right) Boom Spool Bucket Spool

15- Boom Raise/Bucket Tilt-In Spool 16- Boom Raise Priority Selector Valve

T2-4-17

From Main Pumps R3, R4 From Main Pumps R5, R6

SECTION 2 SYSTEM Group 4 Hydraulic System  Combined operation of boom lower and arm extend 1. When performing combined operation of boom lower and arm extend, ELUF (1) activates the boom lower solenoid valve (3) of EDQR valve (upper) (2) and the arm extend solenoid valve (6) of EDQR valve (lower) (5). 2. Pressure oil from the pilot shut-off solenoid valve flows through the boom lower solenoid valve (3) of EDQR valve (upper) (2) and shifts boom lower spool (4). Pressure oil from the pilot shut-off solenoid valve flows through the arm extend solenoid valve (6) of EDQR valve (lower) (5) and shifts arm extend spool (7).

Therefore, pressure oil from the main pump flows to the boom cylinders through boom spools (14) of control valves 3, 5 (10, 12) and arm extend/boom lower spools (16) of control valves 1, 6 (8, 13). Pressure oil from the main pump flows to the arm cylinder through arm spools (15) of control valves 2, 3, 4, 5 (9, 10, 11, 12).

3. Pressure oil from the pilot pump flows through boom lower spool (4) of EDQR valve (upper) (2) and shifts boom spools (14) of control valves 3, 5 (10, 12) to the boom lower side. At the same time, the boom lower priority selector valve (17) is also shifted. 4. When the boom lower priority selector valve (17) is also shifted, pilot pressure (I, J) is blocked. Therefore, arm extend/boom lower spools (16) of control valves 1, 6 (8, 13) are shifted to the boom lower side by pilot pressure (A, D) from boom lower spool (4) of EDQR valve (upper) (1). 5. On the other hand, pressure oil from the pilot pump flows through arm extend spool (7) of EDQR valve (lower) (5) and shifts arm spools (15) of control valves 2, 3, 4, 5 (9, 10, 11, 12) to the arm extend side. 6. As the parallel circuit is installed in control valves 3, 5 (9, 11), pressure oil from main pumps L1, L2, R3, and R4 flows to boom spools (14) after being divided in control valves 3, 5 (9, 11).

TOKGB91-EN-00(20181003)

T2-4-18

SECTION 2 SYSTEM Group 4 Hydraulic System

a 1

c 2

15 G

16 I

A A

C D

g 9

h 12

d c

5 15

E F

G H

16 15

14 I

j TKGB-02-04-015

abc-

Arm Extend Signal Boom Lower Signal From Pilot Pump

12345-

ELUF EDQR Valve (Upper) Boom Lower Solenoid Valve Boom Lower Spool EDQR Valve (Lower)

TOKGB91-EN-00(20181003)

fgh-

From Main Pumps L3, L4 From Main Pumps L5, L6 From Main Pumps R1, R2

ij-

From Pilot Shut-Off Solenoid Valve From Main Pumps L1, L2

678910-

Arm Extend Solenoid Valve Arm Extend Spool Control Valve 1 (Upper Left) Control Valve 2 (Middle Left) Control Valve 3 (Lower Left)

1112131415-

Control Valve 4 (Upper Right) Control Valve 5 (Middle Right) Control Valve 6 (Lower Right) Boom Spool Arm Spool

16- Arm Extend/Boom Lower Spool 17- Boom Lower Priority Selector Valve

T2-4-19

From Main Pumps R3, R4 From Main Pumps R5, R6

SECTION 2 SYSTEM Group 4 Hydraulic System Boom Lower Flow Rate Regenerative Circuit Purpose: The boom lower flow rate regenerative circuit regenerates pressure oil at the boom cylinder bottom side to the rod side when performing boom lower operation. Therefore, pump flow rate which is used for the boom lower operation can be reduced and other pumps can be allocated to the other actuators. Then, the combined operation can be smoothly performed. Operation: 1. ELUF (2) detects the boom lower operation of electric control lever (1) and sends the signal to ELUT (3). 2. ELUF (2) calculates the target operation pressure signal according to the detected boom lower operation and sends command current to the boom lower solenoid valve (8) of EDQR valve (7). 3. The boom lower solenoid valve (8) shifts boom lower spool (9) by using pilot pressure oil according to command current. 4. Boom lower spool (9) directly supplies pilot pressure oil to the control valve and shifts boom spool (10). 5. ELUT (3) calculates the control signal of the boom lower make-up valve (5) according to the received signal and sends command current to the boom lower make-up solenoid valve (4). 6. The boom lower make-up solenoid valve (4) supplies pilot pressure oil according to command current to the boom lower make-up valves (5) and shifts the valves. 7. A part of pressure oil from the boom cylinder (6) bottom side is combined with pressure oil from the main pump according to the open area of the boom lower make-up valve (5), the meter out open area of boom spool (10), and pressure difference between bottom side and rod side of boom cylinder (6) due to boom own weight. Then, the combined pressure oil regenerates to the boom cylinder (6) rod side. 8. Pressure oil which flows to boom spool (10) of the control valve from the boom cylinder (6) bottom side returns to the hydraulic oil tank.

TOKGB91-EN-00(20181003)

T2-4-20

SECTION 2 SYSTEM Group 4 Hydraulic System

11 10 b

From Main Pump

From Pilot Pump

123-

Electric Control Lever ELUF ELUT

Boom Lower Make-Up Solenoid Valve Boom Lower Make-Up Valve Boom Cylinder

TOKGB91-EN-00(20181003)

56-

78910-

T2-4-21

EDQR Valve Boom Lower Solenoid Valve Boom Lower Spool Boom Spool of Control Valve

TKGB-02-04-010

11- Pilot Shut-Off Solenoid Valve 12- 3-Spool Solenoid Valve Unit

SECTION 2 SYSTEM Group 4 Hydraulic System Other Actuator Circuits Pump Transmission Oil Cooling Circuit The pump transmission oil pumps (5) (2 used) draw pump transmission oil and supply it to oil coolers (4) (2 used). The oil is cooled in oil coolers (4) (2 used) and is returned to pump transmissions (3) (2 used). Oil Cooler Fan Motor Circuit Pressure oil from the oil cooler fan motor pumps (7) (2 used) activate the oil cooler fan motors (2) (2 used). Air Conditioner Compressor Motor Circuit Pressure oil from the air conditioner compressor motor pump (6) activates the air conditioner compressor motor (1).

2 1

123-

Air Conditioner Compressor Motor Oil Cooler Fan Motor (2 used) Pump Transmission (2 used)

TOKGB91-EN-00(20181003)

45-

Oil Cooler (2 used) Pump Transmission Oil Pump (2 used)

67-

T2-4-22

Air Conditioner Compressor Motor Pump Oil Cooler Fan Motor Pump (2 used)

TKGB-02-04-011

SECTION 2 SYSTEM Group 4 Hydraulic System Travel Shock Absorbing/Travel Stop Circuit Purpose: The travel shock absorbing/travel stop circuit protects the machine from shock which is applied to the front idlers while traveling. Depending on shock applied to the front idlers, the travel shock absorbing/travel stop circuit operates as follows.

 When excessive shock is applied to the front idlers: 1. When excessive shock which accumulators (5) cannot absorb is applied to the front idlers, relief valve (4) is relieved.

 When ordinary shock is applied to the front idlers: Accumulators (5) absorb shock.

3. Pressure oil from travel stop valve (3) shifts pilot pressure control valve (6).

2. When cushion piston (2) is moved to the stroke end, travel stop valve (3) is shifted.

4. Pressure oil from pilot pump (8) acts on pressure sensor (7) through pilot pressure control valve (6). ELUT receives the electrical signal from pressure sensor (7).

 When excessive shock is applied to the front idlers: Travel operation is stopped by the signal from ELUT. (Refer to SYSTEM/ELU System/Adjuster Cylinder End Travel Regulation Control.)

5. ELUT stops travel operation.

Operation: When the travel control lever is operated, travel spool (9) of the control valve is shifted. Pressure oil from the main pump is supplied to both right and left travel motors, and the machine starts traveling. At the same time, pressure oil from travel spool (9) is reduced and is supplied to adjuster cylinder (1).

(Refer to SYSTEM/ELU System/Adjuster Cylinder End Travel Regulation Control.)

 When ordinary shock is applied to the front idlers: 1. When shock is applied to the front idlers, cushion piston (2) is pushed. 2. Hydraulic oil at the back of cushion piston (2) flows to accumulators (5). 3. The bladders in accumulators (5) are contracted and absorb shock.

1 3

8 9 6 123-

Adjuster Cylinder Cushion Piston Travel Stop Valve

TOKGB91-EN-00(20181003)

456-

Relief Valve Accumulator Pilot Pressure Control Valve

789-

T2-4-23

Pressure Sensor Pilot Pump Travel Spool

T18N-02-04-015

SECTION 2 SYSTEM Group 4 Hydraulic System (Blank)

TOKGB91-EN-00(20181003)

T2-4-24

SECTION 2 SYSTEM Group 5 Electrical System Outline The electrical circuit is broadly divided into the main circuit, control circuit, and monitor circuit.  The main circuit consists of the engine and the accessory related circuits.  The control circuit consists of the machine operation control related circuits. (Refer to Control System.)  The monitor circuit consists of the machine operation status indication circuits. (Refer to Controller.)

TOKGB91-EN-00(20181003)

T2-5-1

SECTION 2 SYSTEM Group 5 Electrical System Main Circuit The major functions and circuits in the main circuit are as follows.

 The electric power circuit supplies all electric power to all electrical systems on the machine. When key switch (1) is in the OFF, ACC, or ON position, current from the battery makes each electrical equipment operation possible.  The CAN circuit performs communication between each controller.  The starting circuit starts the engine. When engine start switches (2, 3) are operated, the prelube circuit and starting circuit operate engines (L, R).

START

2 3

6 5

 The charging circuit supplies electric power to the batteries and charges them. The generating current from the alternator is the electric power circuit for each electrical equipment.

STOP

 The engine stop circuit stops the engine by using various switches.  Emergency Engine Stop Switch (6)  Valve Limit Switch  Engine Stop Switches (4, 5) OFF

 The surge voltage prevention circuit prevents the occurrence of serge voltage developed when stopping the engine.

ACC ON

TKGB-02-05-016

OFF- ACC- ON- 12345-

TOKGB91-EN-00(20181003)

T2-5-2

Refer to T2-5-4. Refer to T2-5-6. Refer to T2-5-8.

Key Switch Engine Start Switch (L) Engine Start Switch (R) Engine Stop Switch (L) Engine Stop Switch (R)

STARTSTOP67-

Refer to T2-5-20. Refer to T2-5-26.

Emergency Engine Stop Switch Right Console

SECTION 2 SYSTEM Group 5 Electrical System (Blank)

TOKGB91-EN-00(20181003)

T2-5-3

SECTION 2 SYSTEM Group 5 Electrical System Electric Power Circuit (Key Switch: OFF) The battery (2) negative terminal is grounded to the body. The circuit from the battery (2) positive terminal is connected as shown below when key switch (1) is in the OFF position. Battery (2)

Battery Relay 1 (3), Battery Relay 2 (4), Battery Relay 3 (5), Battery Relay 4 (6) Slow Blow Fuse 7 (7) ECM (L) (13) (Main Power) Slow Blow Fuse 8 (8) ECM (R) (14) (Main Power) Slow Blow Fuse 9 (9) Folding Stairway Relay 2 (15), Folding Stairway Relay 3 (16) Fuse (250 A) (10) Folding Stairway Pump 2 (18) (Power) Fuse (250 A) (11) Folding Stairway Pump 1 (17) (Power) Slow Blow Fuse 1 (12) Fuse Box 1 (19)* Fuse Box 3 (20)*

* Fuse Box 1 (19)

Fuse #1 Fuse #2 Fuse #3 Fuse #4 Fuse #5 Fuse #6 Fuse #7 Fuse #8

MCU (21), HMU (22) (Main Power) Delayed Power OFF Relay (23) Third Party Interface (24) (Battery Power) PFU(L) (25), PMU(L) (26), EHU(L) (27) (Main Power) PFU(R) (28), PMU(R) (29), EHU(R) (30) (Main Power) Horn Air Compressor Relay (L1) (31) (Power) Horn Air Compressor Relay (R1) (32) (Power) Power for Folding Stairway Relay 1 (33), Folding Stairway Alarm/Flash Light (34) (Power) Limit Switch (Electrical Equipment Electrical Equipment Box Light (36) Box Door) (35) (Power) Fuse Box (Cab 1) (37)** Fuse Box (Cab 2) (38)** C/U (J1939-CAN) (39) (Main Power) (Option) Monitoring Units (40) (Main Power) (Option) ECM Data Link (L) (41) (Power) ECM Data Link (R) (42) (Power)

Fuse #9 Fuse #10

Fuse Box 3 (20)

** Fuse Box (Cab 1) (37)

Fuse Box (Cab 2) (38)

TOKGB91-EN-00(20181003)

Fuse #11 Fuse #12 Fuse #54 Fuse #55

Fuse #1 Fuse #2 Fuse #3 Fuse #4 Fuse #5 Fuse #6 Fuse #21

Key Switch (1) (Main Power) ELUF (43), ELUT (44) (Main Power) IDU (45) (Battery Power) DLU (46) (Main Power) Communication Terminal (47) (Battery Power) (Option) Radio (48) (Backup Power) WIU (49) (Main Power) (Option)

T2-5-4

SECTION 2 SYSTEM Group 5 Electrical System 21 22 23 24

25 26 27

28 29 30 31 32 33 34

37 38

43 44 45 46 47 48

12 15 7

9 16

14 3

11 5 41 42

2 1234567891011121314-

Key Switch Battery Battery Relay 1 Battery Relay 2 Battery Relay 3 Battery Relay 4 Slow Blow Fuse 7 Slow Blow Fuse 8 Slow Blow Fuse 9 Fuse (250 A) Fuse (250 A) Slow Blow Fuse 1 ECM(L) ECM(R)

TOKGB91-EN-00(20181003)

1516171819202122232425262728-

Folding Stairway Relay 2 Folding Stairway Relay 3 Folding Stairway Pump 1 Folding Stairway Pump 2 Fuse Box 1 Fuse Box 3 MCU HMU Delayed Power OFF Relay Third Party Interface PFU(L) PMU(L) EHU(L) PFU(R)

18 TKGB-02-05-001

29- PMU(R) 30- EHU(R) 31- Horn Air Compressor Relay (L1) 32- Horn Air Compressor Relay (R1) 33- Folding Stairway Relay 1 34- Folding Stairway Alarm/Flash Light 35- Limit Switch (Electrical Equipment Box Door) 36- Electrical Equipment Box Light 37- Fuse Box (Cab 1) 38- Fuse Box (Cab 2)

T2-5-5

3940414243444546474849-

C/U (J1939-CAN) (Option) Monitoring Unit (Option) ECM Data Link (L) ECM Data Link (R) ELUF ELUT IDU DLU Communication Terminal Radio (Backup) WIU (Option)

SECTION 2 SYSTEM Group 5 Electrical System Electric Power Circuit (Key Switch: ACC) 1. When key switch (1) is set to the ACC position, terminal B is connected to terminal ACC in key switch (1). 2. The circuit from terminal ACC in key switch (1) is connected as shown below and makes each accessory operation possible. Key Switch (1) Terminal ACC

Fuse Box (Cab 1) (2)

Fuse #14

Horn Air Compressor Relay (R2) (6) Horn Air Compressor Relay (L2) (10) Horn Relay (14)

Fuse #15 Fuse #16 Fuse #18

TOKGB91-EN-00(20181003)

Horn Air Compressor Horn Air Compressor (R) Relay (R1) (7) (8) (Option) Horn Pressure Switch (R) (9) (Option) Horn Air Compressor Horn Air Compressor (L) Relay (L1) (11) (12) Horn Pressure Switch (L) (13) Horn Switch (15) Horn (R) (16) (Option) Horn (L) (19)

Cigar Lighter (3) Power Source Terminal (4) Radio (5)

T2-5-6

SECTION 2 SYSTEM Group 5 Electrical System

11 10

17 3

14 4

12 8

123456-

Key Switch Fuse Box (Cab 1) Cigar Lighter Power Source Terminal Radio Horn Air Compressor Relay (R2)

TOKGB91-EN-00(20181003)

789-

Horn Air Compressor Relay (R1) Horn Air Compressor (R) (Option) Horn Pressure Switch (R) (Option)

TKGB-02-05-002

10- Horn Air Compressor Relay (L2) 11- Horn Air Compressor Relay (L1) 12- Horn Air Compressor (L) 13- Horn Pressure Switch (L) 14- Horn Relay

T2-5-7

1516171819-

Horn Switch Horn (R) (Option) Battery Fuse Box 1 Horn (L)

SECTION 2 SYSTEM Group 5 Electrical System Electric Power Circuit (Key Switch: ON) 1. When key switch (1) is in the ON position (or the engine is running), terminal B is connected to terminals ACC and M in key switch (1).

6. Current from terminal (sub) (8) and terminal (main) (9) flows to each circuit.

fNOTE: Alternators (6, 7) supply power when the engine is

2. Current from terminal M in key switch (1) flows to fuse #11 and fuse #13 in fuse box (cab 1) (26).

running.

3. Current from fuse #11 flows to battery relays 1 to 4 (2 to 5) through fuse #26 in fuse box 2 (27). Battery relay 1 to 4 (2 to 5) are kept ON. 4. At the same time, current from fuse #13 flows to ECM (L) and ECM (R). ECM (L) and ECM (R) control the condition of engines (L, R) to be able to start. (Refer to T2-5-10.) 5. Current from battery (10) flows to terminal (main) (9), battery relays 1 to 4 (2 to 5), and terminal (sub) (8). Key Switch Fuse Box (Cab 1) (1) Terminal (26) M Terminal Terminal (Main) (9)

Terminal (Sub) (8)

Fuse #11

Fuse Box 2 (27)

Fuse #13

Refer to T2-5-10.

Connected to Slow Blow Fuse 1 (11) Slow Blow Fuse 7 (17) Slow Blow Fuse 8 (18) Slow Blow Fuse 9 (19) Folding Stairway Pump 1 (24) Folding Stairway Pump 2 (25) Slow Blow Fuse 2 (12) Slow Blow Fuse 3 (13) Slow Blow Fuse 4 (14) Slow Blow Fuse 5 (15) Slow Blow Fuse 6 (16) Slow Blow Fuse 10 (20) Slow Blow Fuse 11 (21) Rely Box Fuse #4 (38) Rely Box Fuse #7 (39) Rely Box Fuse #14 (40) Rely Box Fuse #17 (41) Prelube Relays (L, R) (32, 33) Starters (L1, L2, R1, R2) (34 to 37)

TOKGB91-EN-00(20181003)

T2-5-8

Fuse #26

Battery Relays 1 to 4 (2 to 5)

Remark Refer to T2-5-12. ECM (L) (Main Power) ECM (R) (Main Power) Power for Folding Stairway Relay 2 (22) and Folding Stairway Relay 3 (23) Power Power Refer to T2-5-14. Refer to T2-5-14. Refer to T2-5-14. Refer to T2-5-16. Refer to T2-5-16. Starter Relays (L1, L2) (28, 29) Starter Relays (R1, R2) (30, 31) Refer to T2-5-16. Refer to T2-5-16. Refer to T2-5-16. Refer to T2-5-16. Power Power

SECTION 2 SYSTEM Group 5 Electrical System 16

A C

ECM(L) 14

ECM(R)

30 31 38

C 40 41

26 3

35 33 36

4 1

37 5

9 10

TKGB-02-05-003

1234567891011-

Key Switch Battery Relay 1 Battery Relay 2 Battery Relay 3 Battery Relay 4 Alternator (L) Alternator (R) Terminal (Sub) Terminal (Main) Battery Slow Blow Fuse 1

1213141516171819202122-

Slow Blow Fuse 2 Slow Blow Fuse 3 Slow Blow Fuse 4 Slow Blow Fuse 5 Slow Blow Fuse 6 Slow Blow Fuse 7 Slow Blow Fuse 8 Slow Blow Fuse 9 Slow Blow Fuse 10 Slow Blow Fuse 11 Folding Stairway Relay 2

2324252627282930313233-

Folding Stairway Relay 3 Folding Stairway Pump 1 Folding Stairway Pump 2 Fuse Box (Cab 1) Fuse Box 2 Starter Relay (L1) Starter Relay (L2) Starter Relay (R1) Starter Relay (R2) Prelube Relay (L) Prelube Relay (R)

3435363738394041-

Starter (L1) Starter (L2) Starter (R1) Starter (R2) Rely Box Fuse #4 Rely Box Fuse #7 Rely Box Fuse #14 Rely Box Fuse #17

A-

Refer to T2-5-13.

B-

Refer to T2-5-15.

C-

Refer to T2-5-17.

D-

Refer to T2-5-11.

TOKGB91-EN-00(20181003)

T2-5-9

SECTION 2 SYSTEM Group 5 Electrical System Fuse Fuse Box (Cab 1) (2) #13

TOKGB91-EN-00(20181003)

Connected to Emergency Valve Limit Engine Stop Switch Switches 1 to 7 (Return) (16) (9 to 15)

Valve Limit Switch (L-Suction) (17)

Engine Start Switch (R) (21) Engine Stop Switch (L) ECM(L) (20) Valve Limit Engine Start Switch (L) (22) Switch Engine Stop Switch (R) ECM(R) (R-Suction) (18) (19)

T2-5-10

SECTION 2 SYSTEM Group 5 Electrical System 15 ECM(L)

ECM(R)

MCU

3 4 5 6

8 TKGB-02-05-007

12345678-

Key Switch Fuse Box (Cab 1) Fuse Box 2 Battery Relay 1 Battery Relay 2 Battery Relay 3 Battery Relay 4 Battery

A-

Refer to T2-5-13.

TOKGB91-EN-00(20181003)

Emergency Engine Stop Switch 1 10- Emergency Engine Stop Switch 2 11- Emergency Engine Stop Switch 3 12- Emergency Engine Stop Switch 4

13- Emergency Engine Stop Switch 5 14- Emergency Engine Stop Switch 6 15- Emergency Engine Stop Switch 7 16- Valve Limit Switch (Return) 17- Valve Limit Switch (L-Suction)

T2-5-11

181920212223-

Valve Limit Switch (R-Suction) Engine Stop Switch (R) Engine Stop Switch (L) Engine Start Switch (R) Engine Start Switch (L) Air Bleeding Solenoid Valve

SECTION 2 SYSTEM Group 5 Electrical System Slow Blow Fuse #1(1)

Fuse box Fuse Box 1 (8)

Connected to

Remark Main Power Ground Circuit Battery Power Main Power Main Power Power Power Power

#11 #12 #54 #55

MCU, HMU Delayed Power OFF Relay Third Party Interface PFU (L), PMU (L), EHU (L) PFU (R), PMU (R), EHU (R) Horn Air Compressor Relay (L1) Horn Air Compressor Relay (R1) Folding Stairway Relay 1, Folding Stairway Alarm/Flash Light Limit Switch (Electrical Equipment Box Door) Fuse Box (Cab 1) (10)* Fuse Box (Cab 2) (11)* C/U (J1939-CAN) (Option) Monitoring Unit (Option) ECM Data Link (L) ECM Data Link (R)

#1 #2 #3 #4 #5 #6 #21

Connected to Key Switch (7) ELUF, ELUT IDU DLU Communication Terminal (Option) Radio (Back up) WIU (Option)

Remark Main Power Main Power Battery Power Main Power Battery Power Backup Main Power

#1 #2 #3 #4 #5 #6 #7 #8 #9 #10

Fuse Box 3 (9)

* Fuse Fuse Box (Cab 1) (10)

Fuse Box (Cab 2) (11)

TOKGB91-EN-00(20181003)

T2-5-12

Power Main Power Main Power Power Power

SECTION 2 SYSTEM Group 5 Electrical System 7

D 10

11 1 2 3 A

4 5 6

C TKGB-02-05-004

123-

Slow Blow Fuse 1 Slow Blow Fuse 2 Slow Blow Fuse 3

456-

Slow Blow Fuse 4 Slow Blow Fuse 5 Slow Blow Fuse 6

789-

Key Switch Fuse Box 1 Fuse Box 3

10- Fuse Box (Cab 1) 11- Fuse Box (Cab 2)

A-

Refer to T2-5-9.

B-

Refer to T2-5-15.

C-

Refer to T2-5-17.

D-

TOKGB91-EN-00(20181003)

T2-5-13

Refer to T2-5-11.

SECTION 2 SYSTEM Group 5 Electrical System Slow Blow Fuse

Fuse box

#2(2)

Fuse Box 2 (7)

Fuse Box 3 (8) Fuse Box 4 (9) #3(3)

Fuse Box 2 (7)

Fuse Box 3 (8)

Fuse Box 4 (9) #4(4)

Fuse Box 2 (7)

Fuse Box 3 (8)

Fuse Box 4 (9)

TOKGB91-EN-00(20181003)

#31 #32 #33 #56 #57 #69 #70 #34 #35 #36 #41 #48 #49 #50 #73 #74 #27 #29 #30 #37 #38 #44 #45 #46 #53 #58 #60 #67 #68 #77 #78 #79

Connected to

Remark

Air Conditioner Main Relay (Right) Air Conditioner Main Relay (Left) Air Conditioner Main Relay (Rear) PFU (L), EHU (L) PFU (R), EHU (R) Maintenance Light Relay 3 Maintenance Light Relay 4 Air Conditioner Condenser Fan Motor Relay (Right) Air Conditioner Condenser Fan Motor Relay (Left) Air Conditioner Condenser Fan Motor Relay (Rear) Motion Alarms (L, R) Third Party Interface DC-DC Converter 1 Front Monitoring Camera, Rear Monitoring Camera (Option) Entrance Light Relay 1 Entrance Light Relay 2 DC-DC Converter 2 Limit Switch (Cab Bed Door (L)) Cab Bed Pressurization Blower Motor Relay 1 Cab Bed Pressurization Blower Motor Relay 2 DLU Service Tool Communication Terminal (Option) Travel Mode Relay Folding Stairway Relay 4 Emergency Engine Stop Switch 1 ELUF, ELUT Fuel Cooler Fan Motor Relay Electric Pump Maintenance Light Relay 1 Maintenance Light Relay 2 Washer Motor Relay Fast Filling Device Relay CSU

Power Power Power Solenoid Power Solenoid Power Power Power Power Power Power Power Alternator Power Power Power

T2-5-14

Power Power Power Power Power Power Power Power Power Power Power Solenoid Power Power Power Power Power Power Power Main Power

SECTION 2 SYSTEM Group 5 Electrical System

1 B

2 3 A 4 5 6

TKGB-02-05-005

123-

Slow Blow Fuse 1 Slow Blow Fuse 2 Slow Blow Fuse 3

456-

Slow Blow Fuse 4 Slow Blow Fuse 5 Slow Blow Fuse 6

789-

Fuse Box 2 Fuse Box 3 Fuse Box 4

A-

Refer to T2-5-9.

B-

Refer to T2-5-13.

C-

Refer to T2-5-17.

TOKGB91-EN-00(20181003)

T2-5-15

SECTION 2 SYSTEM Group 5 Electrical System Slow Blow Fuse #5(5)

#6(6)

Fuse box Fuse Box 4 (8)

Fuse Box 3 (7)

#61 #62 #63 #64 #65 #66 #47 #51 #52

Fuse Box 4 (8)

Relay Box Fuse #4(9)

#71 #72 #75 #76 #80

Fuse box Fuse Box (DEF) (13)

#7(10)

Fuse Box (DEF) (13)

#14(11)

Fuse Box (DEF) (13)

#17(12)

Fuse Box (DEF) (13)

TOKGB91-EN-00(20181003)

#1 #2 #3 #4 #5 #6 #7 #8 #9 #10 #11 #12 #13 #14 #15 #16 #17 #18 #19 #20

Connected to

Remark

Work Light Relay 1 Work Light Relay 2 Work Light Relay 3 Work Light Relay 4 Work Light Relay 5 Work Light Relay 6 Dome Lights (Front, Rear) Seat Suspension Air Compressor MCU IDU LCD Unit Maintenance Light Relay 5 Maintenance Light Relay 6 Wiper Relay 1 Wiper Relay 3 Maintenance Light Relay 7

Power Power Power Power Power Power Power Power Solenoid Power Main Power Main Power Power Power Power Power Power

Connected to

Remark

Dosing Module Relay (L1) Dosing Module Relay (L2) NOx Sensor (L) DEF Line Heater Relay (L1) DEF Line Heater Relay (L2) DEF Piping In-Line Filter Heater Relay (L) DEF Fill Hose Heater Relay (L) DEF Fill Line Heater Relay (L) DEF Receiver Heater Relay (L) DEF Shut-Off Valve Heater Relay (L) Dosing Module Relay (R1) Dosing Module Relay (R2) NOx Sensor (R) DEF Line Heater Relay (R1) DEF Line Heater Relay (R2) DEF Piping In-Line Filter Heater Relay (R) DEF Fill Hose Heater Relay (R) DEF Fill Line Heater Relay (R) DEF Receiver Heater Relay (R) DEF Shut-Off Valve Heater Relay (R)

Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power Power

T2-5-16

SECTION 2 SYSTEM Group 5 Electrical System 7

1 2 3 A

B C

A 11

TKGB-02-05-006

1234-

Slow Blow Fuse 1 Slow Blow Fuse 2 Slow Blow Fuse 3 Slow Blow Fuse 4

5678-

Slow Blow Fuse 5 Slow Blow Fuse 6 Fuse Box 3 Fuse Box 4

9101112-

Relay Box Fuse #4 Relay Box Fuse #7 Relay Box Fuse #14 Relay Box Fuse #17

A-

Refer to T2-5-9.

B-

Refer to T2-5-13.

C-

Refer to T2-5-15.

TOKGB91-EN-00(20181003)

T2-5-17

13- Fuse Box (DEF)

SECTION 2 SYSTEM Group 5 Electrical System CAN Circuit CAN (Controller Area Network) is ISO Standards of the serial communication protocol. Five networks (CAN bus (C)) in the following are equipped for this machine.  J1939-CAN (1) is mainly used for the engine control.  Ke-CAN (2) is mainly used for display and log data communication.  HiKe-CAN (3) is used for the control data communication.  HiSe-CAN (4) is used for communication of the swing angular rate data.  DLU-CAN (5) is used for communication between WIU (option) and DLU. CAN bus (C) consists of two wire harnesses, CAN-H (High) (A) and CAN-L (Low) (B). Each controller judges the CAN bus (C) level due to the potential difference between CAN-H (High) (A) and CAN-L (Low) (B). Each controller arranges the CAN bus (C) level and sends the signal and data to other controllers. Termination resistors (120 Ω) (6) are installed to both ends of CAN bus (c).

TOKGB91-EN-00(20181003)

B TKEB-02-05-017

AB-

T2-5-18

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

C-

CAN Bus

SECTION 2 SYSTEM Group 5 Electrical System

ECM(R)

ECM(L) ECM(P)

ECM(C1)

ECM(C2)

ECM(C3)

ECM(P)

ECM(C1)

ECM(C2)

ECM(C3)

WIU

IDU

6 MCU

DLU

EHU(R)

EHU(L)

6 2 6

6 3

ELUF

ELUT

PFU(L)

PMU(L)

HMU

CSU

ODR

BPU

PFU(R)

PMU(R)

6 4 TKGB-02-01-020

123-

J1939-CAN Ke-CAN HiKe-CAN

TOKGB91-EN-00(20181003)

456-

HiSe-CAN DLU-CAN Termination Resistor (120 Ω)

T2-5-19

Swing Angular Rate Sensor (Upperstructure)

Swing Angular Rate Sensor (Undercarriage)

SECTION 2 SYSTEM Group 5 Electrical System Engine Starting Circuit (Engine Start Switch: ON) The engine starting circuit when the engine start switch is turned ON position consists of prelube circuit and starting circuit.  The prelube circuit lubricates the engine inside with engine oil before the engine starts running.  When the engine oil pressure increases, the starting circuit starts the engine. The engine starting circuits are installed in the right and left engines. The engine starting circuits for the right and left engines are same. The procedures for the engine starting circuit of the left engine are explained here. Prelube Circuit 1. When engine start switch (L) (2) is turned ON, current from terminal M in key switch (1) excites prelube relay (L) (9) through engine start switch (L) (2), engine start cancellation relay (L, L2) (3, 11), and prelube control relay (L) (4). 2. Current from battery (13) flows to prelube motor (10) through battery relays 1 to 4 (5 to 8) and prelube relay (L) (9). 3. Prelube signal relay (L) is turned ON and prelube indicator (L) on the display in the cab is turned ON. 4. Prelube motor (L) (10) rotates and the engine oil pressure increases. 5. When the engine oil pressure increases, prelube pressure switch (L) (12) is turned ON. Prelube control relay (L) (4) is excited and the circuit is disconnected from prelube relay (L) (9). 7. Prelube motor (L) (10) stops. 8. At the same time, prelube signal relay (L) is turned OFF and prelube indicator (L) on the display is turned OFF.

fNOTE: The illustration on T2-5-21 shows when engine start switch (L) (2) is ON.

TOKGB91-EN-00(20181003)

T2-5-20

SECTION 2 SYSTEM Group 5 Electrical System

ECM(L)

ECM(R)

10 4 a 18

11 2 3

17 12

16 19 15

MCU

5 6 7 8

13 TKGB-02-05-008 ab-

To Prelube Signal Relay (L) To Prelube Signal Relay (R)

123-

Key Switch Engine Start Switch (L) Engine Start Cancellation Relay (L) Prelube Control Relay (L) Battery Relay 1 Battery Relay 2

456-

TOKGB91-EN-00(20181003)

7891011-

Battery Relay 3 Battery Relay 4 Prelube Relay (L) Prelube Motor (L) Engine Start Cancellation Relay (L2) 12- Prelube Pressure Switch (L)

13- Battery 14- Engine Start Switch (R) 15- Engine Start Cancellation Relay (R) 16- Prelube Control Relay (R) 17- Prelube Relay (R) 18- Prelube Motor (R)

T2-5-21

19- Engine Start Cancellation Relay (R2) 20- Prelube Pressure Switch (R)

SECTION 2 SYSTEM Group 5 Electrical System Starting Circuit When the prelube operation completes, the engine starts as follows. 1. Voltage from battery (11) has been applied to terminals B in starter (L1) (12) and starter (L2) (13).

8. When ECM (L) detects that the engine speed input from crank speed sensor (17) is over 500 min-1, current from ECM (L) flows to engine protection relay (L) (18).

2. When the prelube operation completes, current from prelube pressure switch (L) (10) excites starter relay (L1) (8) and starter relay (L2) (9) at the same time. 3. Current from battery (11) flows to terminals S of starter (L1) (12) and starter (L2) (13) through, battery relays 1 to 4 (4 to 7), starter relay (L1) (8), and starter relay (L2) (9).

9. Engine protection relay (L) (18) is exited, and current flowing to starter relay (L1) (8) and starter relay (L2) (9) is stopped. 10. Therefore, the starting circuit is stopped.

4. The coils of starter (L1) (12) and starter (L2) (13) are excited, and terminal B is connected to terminal M. Consequently, when motor (a) rotates, pinion gear (b) rotates at the same time. Then, the engine starts.

12, 13, 24, 25

5. When the engine has started, the generating current from terminal AC of alternator (L) (14) flows and excites alternator signal relay 2 (L) (15). 6. The ground circuit in alternator signal relay 1 (L) (16) is disconnected and alternator signal relay 1 (L) (16) is turned OFF.

7. When alternator signal relay 1 (L) (16) is turned OFF, current from terminal M in key switch (1) flows to MCU. Therefore, MCU detects that alternator (L) (14) generates power.

TKEB-02-05-015

Motor

Pinion Gear

fNOTE: The illustration on T2-5-23 shows when engine start switch (L) (2) is ON.

TOKGB91-EN-00(20181003)

T2-5-22

SECTION 2 SYSTEM Group 5 Electrical System

ECM(L) 17

ECM(R) 29 3

23 16

MCU

7 13 25 1

TKGB-02-05-009

123456789-

Key Switch Engine Start Switch (L) Prelube Control Relay (L) Battery Relay 1 Battery Relay 2 Battery Relay 3 Battery Relay 4 Starter Relay (L1) Starter Relay (L2)

TOKGB91-EN-00(20181003)

101112131415161718-

Prelube Pressure Switch (L) Battery Starter (L1) Starter (L2) Alternator (L) Alternator Signal Relay 2 (L) Alternator Signal Relay 1 (L) Crank Speed Sensor (L) Engine Protection Relay (L)

192021222324252627-

T2-5-23

Engine Start Switch (R) Prelube Control Relay (R) Starter Relay (R1) Starter Relay (R2) Prelube Pressure Switch (R) Starter (R1) Starter (R2) Alternator (R) Alternator Signal Relay 2 (R)

28- Alternator Signal Relay 1 (R) 29- Crank Speed Sensor (R) 30- Engine Protection Relay (R)

SECTION 2 SYSTEM Group 5 Electrical System Charging Circuit (Key Switch: ON-Engine: Running) The alternators are installed in the right and left engines. The charging circuits of the right and left engines are same. The procedures for the charging circuit of the left engine are explained here. 1. When key switch (1) is in the ON position, terminal B is connected to terminals ACC and M in key switch (1). 2. Current from terminal M in key switch (1) flows to battery relays 1 to 4 (2 to 5) through fuse #11 in fuse box (cab 1) (11) and fuse #26 in fuse box 2 (12). Battery relays 1 to 4 (2 to 5) are kept ON. 3. Alternator (L) (6) turns and starts generating electricity with the left engine (L) running. 4. Current from terminal B in alternator (L) (6) flows to batteries (10) through slow blow fuse (200 A) (7), terminal (sub) (8), battery relays 1 to 4 (2 to 5), and terminal (main) (9). Then, batteries (10) are charged.

TOKGB91-EN-00(20181003)

T2-5-24

SECTION 2 SYSTEM Group 5 Electrical System

1 12

3 4

10 13 TKGB-02-05-010

1234-

Key Switch Battery Relay 1 Battery Relay 2 Battery Relay 3

TOKGB91-EN-00(20181003)

5678-

Battery Relay 4 Alternator (L) Slow Blow Fuse (200 A) Terminal (Sub)

9101112-

T2-5-25

Terminal (Main) Battery Fuse Box (Cab 1) Fuse Box 2

13- Alternator (R) 14- Slow Blow Fuse (200 A)

SECTION 2 SYSTEM Group 5 Electrical System Engine Stop Circuit Engine Stopping by using Emergency Engine Stop Switch 1. When the emergency engine stop switches 1 to 7 (9 to 15) are pushed, current which flows from terminal M in key switch (1) to ECM (L) and ECM (R) is blocked. 2. ECM (L) and ECM (R) control the electronic governor of the engine and stop supplying fuel. 3. The right and left engines are stopped. 4. At the same time, as current which flows to engine start switches (21, 22) is blocked, the right and left engines cannot start. 5. Only when the emergency stop switch 1 (9) is pushed, the air bleeding solenoid valve (23) of the hydraulic oil tank is activated and releases the pressure inside the hydraulic oil tank.

fNOTE: The illustration on T2-5-27 shows when the emergency engine stop switch 1 (9) is pushed.

Emergency Engine Stop Switch 1 (9) Emergency Engine Stop Switch 2 (10) Emergency Engine Stop Switch 3 (11) Emergency Engine Stop Switch 4 (12) Emergency Engine Stop Switch 5 (13) Emergency Engine Stop Switch 6 (14) Emergency Engine Stop Switch 7 (15)

TOKGB91-EN-00(20181003)

Position Right Console in Cab Pump Compartment (L) Engine Compartment (L) Left Side Engine Compartment (L) Right Side Engine Compartment (R) Left Side Engine Compartment (R) Right Side Pump Compartment (R)

T2-5-26

SECTION 2 SYSTEM Group 5 Electrical System 15 ECM(L)

ECM(R)

25 24

MCU

3 4 5

26 28

7 27 29 1

TKGB-02-05-011

123456789-

Key Switch Fuse Box (Cab 2) Fuse Box 2 Battery Relay 1 Battery Relay 2 Battery Relay 3 Battery Relay 4 Battery Emergency Engine Stop Switch 1

TOKGB91-EN-00(20181003)

10- Emergency Engine Stop Switch 2 11- Emergency Engine Stop Switch 3 12- Emergency Engine Stop Switch 4 13- Emergency Engine Stop Switch 5 14- Emergency Engine Stop Switch 6

15- Emergency Engine Stop Switch 7 16- Valve Limit Switch (Return) 17- Valve Limit Switch (L-Suction) 18- Valve Limit Switch (R-Suction) 19- Engine Stop Switch (R) 20- Engine Stop Switch (L) 21- Engine Start Switch (R) 22- Engine Start Switch (L) 23- Air Bleeding Solenoid Valve

T2-5-27

2425262728293031-

Slow Blow Fuse 4 Fuse Box 3 Starter (L1) Starter (L2) Starter (R1) Starter (R2) Alternator (L) Alternator (R)

SECTION 2 SYSTEM Group 5 Electrical System Engine Stopping by using Valve Limit Switch 1. Valve limit switches (16 to 18) are installed in the butterfly valves of the suction piping and return piping. When the butterfly valves are closed, valve limit switches (16 to 18) are turned OFF and current which flows from terminal M in key switch (1) to ECM (L) and ECM (R) is blocked. 2. ECM (L) and ECM (R) control the electronic governors of the engines and stop supplying fuel. 3. The right and left engines are stopped. 4. At the same time, as current which flows to engine start switches (21, 22) is blocked, the right and left engines cannot start.

fNOTE: The illustration on T2-5-29 shows when the valve limit switch (return) (16) is OFF.

TOKGB91-EN-00(20181003)

T2-5-28

SECTION 2 SYSTEM Group 5 Electrical System 15 ECM(L)

ECM(R)

25 24

MCU

3 4 5

26 28

7 27 29 1

TKGB-02-05-012

123456789-

Key Switch Fuse Box (Cab 2) Fuse Box 2 Battery Relay 1 Battery Relay 2 Battery Relay 3 Battery Relay 4 Battery Emergency Engine Stop Switch 1

TOKGB91-EN-00(20181003)

10- Emergency Engine Stop Switch 2 11- Emergency Engine Stop Switch 3 12- Emergency Engine Stop Switch 4 13- Emergency Engine Stop Switch 5 14- Emergency Engine Stop Switch 6

T2-5-29

2425262728293031-

Slow Blow Fuse 4 Fuse Box 3 Starter (L1) Starter (L2) Starter (R1) Starter (R2) Alternator (L) Alternator (R)

SECTION 2 SYSTEM Group 5 Electrical System Engine Stopping by using Engine Stop Switch The engine stop circuits by using the emergency engine stop switches are installed in the right and left engines. The engine stop circuits for the right and left engines are same. The procedures for the engine stop circuit of the left engine are explained here. 1. When engine stop switch (L) (20) is pushed, current which flows from terminal M in key switch (1) to ECM (L) is blocked. 2. ECM (L) controls the electronic governor of the left engine and stops supplying fuel. 3. The left engine is stopped.

fNOTE: The illustration on T2-5-31 shows when engine stop switch (L) (20) is pushed.

TOKGB91-EN-00(20181003)

T2-5-30

SECTION 2 SYSTEM Group 5 Electrical System 15 ECM(L)

ECM(R) 20

19 17

25 24

MCU

3 4 5

26 28

7 27 29 1

TKGB-02-05-013

123456789-

Key Switch Fuse Box (Cab 2) Fuse Box 2 Battery Relay 1 Battery Relay 2 Battery Relay 3 Battery Relay 4 Battery Emergency Engine Stop Switch 1

TOKGB91-EN-00(20181003)

10- Emergency Engine Stop Switch 2 11- Emergency Engine Stop Switch 3 12- Emergency Engine Stop Switch 4 13- Emergency Engine Stop Switch 5 14- Emergency Engine Stop Switch 6

T2-5-31

2425262728293031-

Slow Blow Fuse 4 Fuse Box 3 Starter (L1) Starter (L2) Starter (R1) Starter (R2) Alternator (L) Alternator (R)

SECTION 2 SYSTEM Group 5 Electrical System Surge Voltage Prevention Circuit The generating current from alternators (7, 8) flows to batteries (9) through battery relays 1 to 4 (3 to 6), and charges battery (9). When the right and left engines are stopped (engine stop switches (L, R) (13, 14): ON), battery relays 1 to 4 (3 to 6) are turned OFF. Then, the circuit in which current flows from alternators (7, 8) to batteries (9) is blocked. The right and left engines continue to rotate due to the inertia force just after engine stop switches (L, R) (13, 14) are pushed ON and alternators (7, 8) continue to generate electricity. At this time, when the generating current from alternators (7, 8) are blocked, surge voltage (voltage increase) arises in the circuit. The surge voltage prevention circuit is provided in order to prevent failures of the electronic components, such as MCU. Key Switch: ON 1. Current from batteries (9) always flows to terminals #1 and #3 of the delayed power off relay (2). 2. When key switch (1) is in the ON position, current from terminal M in key switch (1) flows to MCU and fuse #26 in fuse box 2 (11) through fuse #11 in fuse box (cab 1) (10). MCU recognizes the power ON state. 3. Current from fuse #26 in fuse box 2 (11) flows to terminals S of battery relays 1 to 4 (3 to 6). Battery relays 1 to 4 (3 to 6) are kept ON.

2. When current stops flowing to MCU, MCU keep ON the delayed power off relay (2). Battery relays 1 to 4 (3 to 6) are kept ON. 3. Consequently, while the engine rotates due to the inertia force, the generating current from terminal B of alternators (7, 8) flows to battery (9) and surge voltage does not arise in the circuit.

4. As long as current flows to MCU, MCU connects to the ground from terminal #2 of the delayed power off relay (2) and turns ON the delayed power off relay (2).

4. MCU turns OFF the delayed power off relay (2) (by disconnecting the ground circuit) when the illumination OFF delay set time (15 seconds to 10 minutes) has passed.

5. Current from terminal #5 of the delayed power off relay (2) flows to terminals S of battery relays 1 to 4 (3 to 6). Consequently, as battery relays 1 to 4 (3 to 6) are kept ON, current flows from terminal B of alternators (7, 8) to batteries (9), and charges batteries (9).

TOKGB91-EN-00(20181003)

Key Switch: ACC or OFF 1. When key switch (1) is set to the ACC or OFF position (current stops flowing to MCU), current from terminal M in key switch (1) flow to battery relays 1 to 4 (3 to 6) through fuse #26 in fuse box 2 (11) is blocked.

T2-5-32

SECTION 2 SYSTEM Group 5 Electrical System

ECM(L)

ECM(R)

MCU 1

3 4 5 6

9 7

1234-

Key Switch Delayed Power OFF Relay Battery Relay 1 Battery Relay 2

TOKGB91-EN-00(20181003)

TKGB-02-05-014

5678-

Battery Relay 3 Battery Relay 4 Alternator (L) Alternator (R)

9101112-

T2-5-33

Battery Fuse Box (Cab 1) Fuse Box 2 Fuse Box 1

13- Engine Stop Switch (L) 14- Engine Stop Switch (R)

SECTION 2 SYSTEM Group 5 Electrical System (Blank)

TOKGB91-EN-00(20181003)

T2-5-34

SECTION 2 SYSTEM Group 6 Air Conditioning System Outline Heater (15) warms air by absorbing heat from the warmed engine (4) coolant. The temperature is kept at the set temperature by adjusting evaporator (5) and heater (15). The air conditioner controller controls the air conditioning system. The air conditioner controller controls the damper operation by corresponding to the job site conditions such as ambient and cab inside air temperatures, operator's set-temperature, and the set-ventilation mode. In addition, the air conditioner controller displays the air conditioner system operation status on the liquid crystal panel of the air conditioner controller.

The air conditioning system consists of air conditioner unit (A), condenser unit (B), air conditioner compressor (1), air conditioner compressor motor (2), and air conditioner compressor motor pump (3). Configuration layout of the air conditioning system is illustrated below. Either fresh or re-circulated air is induced into air conditioner unit (A) by operating the fresh/re-circulated air damper servo motor (16). The induced air flows out of the vents through evaporator (5) or heater (15) by blower motor (11). Evaporator (5) is a device used to cool the air. Heater (15) is a device used to warm the air. In the air conditioning system, after the refrigerant is compressed by air conditioner compressor (1), it is sent to evaporator (5) in which the refrigerant expands to cool the air. Air conditioner compressor (1) is activated by the air conditioner compressor motor (2). The air conditioner compressor motor (2) is activated by pressure oil from the air conditioner compressor motor pump (3).

12 C

9 16 10

8 11

13 E 14

2 3 TKEB-05-07-001 AB1234-

Air Conditioner Unit Condenser Unit Air Conditioner Compressor Air Conditioner Compressor Motor Air Conditioner Compressor Motor Pump Engine

TOKGB91-EN-00(20181003)

CD5678910-

Cab Cab Bed Evaporator Air Conditioner Condenser Receiver Tank Expansion Valve Re-Circulated Air Filter Fresh Air Filter

E-

Engine Compartment

1112131415-

Blower Motor Frost Sensor Sight Glass High/Low Pressure Switch Heater

T2-6-1

16- Fresh/Re-Circulated Air Damper Servo Motor

SECTION 2 SYSTEM Group 6 Air Conditioning System Functions of Main Components The functions of the main components for the air conditioning system are described below.  Air Conditioner Compressor The air conditioner compressor draws refrigerant from the low-pressure circuit (between evaporator and compressor), compresses refrigerant, and sends the compressed refrigerant to the air conditioner condenser. (Refrigerant generates heat when compressed.)  Air Conditioner Condenser The air conditioner condenser cools hot and highpressure refrigerant.  Receiver Tank The receiver tank removes moisture from high-pressure refrigerant and stores refrigerant.  Expansion Valve The expansion valve atomizes high-pressure liquid refrigerant into low-pressure gas through an orifice. Then, the expansion valve adjusts the refrigerant flow rate.  Evaporator The evaporator vaporizes refrigerant and absorbs heat from atmosphere.  Heater Core The heater core circulates hot engine coolant and emits heat to atmosphere.  Blower Motor The blower motor sends air to the evaporator.

TOKGB91-EN-00(20181003)

T2-6-2

SECTION 2 SYSTEM Group 6 Air Conditioning System Functions of Main Electrical Parts The functions of the main electrical parts for the air conditioner are described below.  Air Conditioner Controller The Air Conditioner controller controls the air conditioning system. The Air Conditioner controller has the following functions.  The operator's instructions are input by the switches.  The air temperature is detected by the sensor.  The blower motor and air conditioner compressor are controlled by operating the relays.  The operating conditions of air conditioning system are displayed.  Power Transistor The power transistor is an electric switch to control blower motor voltage.  Blower Motor Relay The blower motor relay supplies 24 volts power to the blower motor when the air conditioner is operated.  Compressor Relay The compressor relay supplies 24 volts power to the air conditioner compressor clutch when the air conditioner is operated.  Frost Sensor The frost sensor detects the fin temperature which is cooled by the evaporator.  High/Low Pressure Switch The high/low pressure switch controls the air conditioner compressor clutch solenoid while detecting the air conditioner compressor circuit pressure. The high/low pressure switch consists of a pressure gauge and a switch. The pressure gauge detects the low pressure range (0.196 MPa to 0.216 MPa) and the surge pressure range (2.55 MPa to 3.14 MPa). When the circuit pressure decreases to the low pressure range or increases to the surge pressure range, the pressure gauge turns OFF the switch. Therefore, the air conditioner compressor operation stops.  Re-Circulated Air Temperature Sensor The re-circulated air temperature sensor detects the temperatures around the re-circulated air inlet as the interior air temperatures and converts them to the electrical resistance values.  Ambient Temperature Sensor The ambient temperature sensor detects the temperature at the side of the air conditioner condenser as the outdoor air temperature, and converts the temperature to the electrical resistance value.

TOKGB91-EN-00(20181003)

T2-6-3

SECTION 2 SYSTEM Group 6 Air Conditioning System 2

 Air Vent Damper Servo Motor The air vent damper servo motor opens or closes the vent louvers (3 places). The damper consists of a motor, link mechanism, and potentiometer. The motor opens or closes vent louvers via the link mechanism. The potentiometer converts the link movements (vent louvers strokes) to the voltage. Depending on the air conditioner controller MODE switch set position, vent louvers 1 to 3 are operated as shown below: MODE FACE VENT B/L FOOT

Vent Louver 1 Close Close Close Close

2 Close Open Open Close

3 Close Close Open Open

TKEB-05-07-006 TKEB-02-06-002

 Fresh/Re-Circulated Air Damper Servo Motor The fresh/re-circulated air damper servo motor opens or closes the fresh/re-circulated air selection louvers. The damper consists of a motor, link mechanism, and position sensing switch. The motor opens or closes the fresh/re-circulated air selection louvers via the link mechanism.  Air Mix Damper Servo Motor The air mix damper servo motor controls opening/ closing of the air mixing door in response to the set temperature. This servo motor consists of a motor, link mechanism, and potentiometer. The motor opens or closes the air mix door via the link mechanism. The potentiometer converts the link movements (the mix door strokes) to the voltage.

TOKGB91-EN-00(20181003)

T2-6-4

SECTION 2 SYSTEM Group 6 Air Conditioning System Electrical Circuit Diagram The illustration shows the circuit of air conditioner (rear). The circuits of air conditioner (right, left) are the same as the circuit of air conditioner (rear). 17 A

E F G H

B D 16

1 19

G H

C 4

3 11

8 12 7

ABCD1234-

Slow Blow Fuse 3 Slow Blow Fuse 2 Battery Key Switch ON Signal Air Conditioner Condenser (Rear) Air Conditioner Compressor (Rear) Air Conditioner Unit (Rear) Ambient Air Temperature Sensor (Rear)

EF56789-

TOKGB91-EN-00(20181003)

Air Conditioner Condenser Fan Motor Relay (Left) Air Conditioner Condenser Fan Motor Relay (Right) Air Conditioner Controller (Rear) Compressor Relay Re-Circulated Air Temperature Sensor Fresh/Re-Circulated Air Damper Servo Motor Frost Sensor

GH10111213141516-

T2-6-5

Air Conditioner Main Relay (Right) Air Conditioner Main Relay (Left) Air Mix Damper Servo Motor Air Vent Damper Servo Motor Blower Motor Relay Power Transistor Blower Motor High/Low Pressure Switch (Rear) Fuse Box (Cab 1)

TKEB-02-06-001

17- Fuse Box 2 18- Air Conditioner Condenser Fan Motor Relay (Rear) 19- Air Conditioner Main Relay (Rear) 20- Air Conditioner Condenser Fan Motor (Rear)

SECTION 2 SYSTEM Group 6 Air Conditioning System (Blank)

TOKGB91-EN-00(20181003)

T2-6-6

MEMO

TOKGB91-EN-00(20181003)

MEMO

TOKGB91-EN-00(20181003)

SECTION 3

COMPONENT OPERATION CONTENTS Group 1 Pump Device

Outline..................................................................................... T3-1-1 Main Pump............................................................................. T3-1-2 Oil Cooler Fan Motor Pump.............................................. T3-1-4 Regulator for Main Pump.................................................. T3-1-6 Regulator for Oil Cooler Fan Motor Pump................T3-1-14 Pump Control Solenoid Valve........................................T3-1-34 Pilot Pump, Air Conditioner Compressor Motor Pump, Pump Transmission Oil Pump, Spare Pump........T3-1-36 Pump Delivery Pressure Sensor....................................T3-1-36 Regulator Pressure (Flow Rate Control Pressure) Sensor......................T3-1-36 Contamination Sensor.....................................................T3-1-37

Solenoid Valve....................................................................... T3-6-7 Reducing Valve for Travel Mode Control..................... T3-6-8 Accumulator.......................................................................... T3-6-9

Group 7 Others (Undercarriage)

Swing Bearing....................................................................... T3-7-1 Accumulator.......................................................................... T3-7-2 Adjuster Cylinder................................................................. T3-7-3 Center Joint............................................................................ T3-7-4

Group 8 Others (Front Attachment)

Make-Up Valve...................................................................... T3-8-1 3-Spool Solenoid Valve Unit............................................. T3-8-4

Group 2 Swing Device

Outline..................................................................................... T3-2-1 Swing Motor.......................................................................... T3-2-2 Swing Parking Brake........................................................... T3-2-4 Swing Reduction Gear....................................................... T3-2-5 Valve Unit................................................................................ T3-2-6

Group 3 Control Valve

Outline..................................................................................... T3-3-1 Position of Valve and Section.......................................... T3-3-2 Pilot Port Position................................................................ T3-3-4 Hydraulic Circuit................................................................... T3-3-6 Main Relief Valve.................................................................. T3-3-8 Overload Relief Valve.......................................................... T3-3-8 Make-Up Valve...................................................................... T3-3-9

Group 4 Control Equipment

Outline..................................................................................... T3-4-1 Electric Control Lever......................................................... T3-4-2 EDQR Valve for Electric Control Lever........................... T3-4-6

Group 5 Travel Device

Outline..................................................................................... T3-5-1 Travel Motor........................................................................... T3-5-2 Travel Mode Control........................................................... T3-5-4 Brake Valve............................................................................. T3-5-8 Parking Brake.......................................................................T3-5-10 Travel Reduction Gear......................................................T3-5-11

Group 6 Others (Upperstructure)

Oil Cooler Fan Motor........................................................... T3-6-1 Air Conditioner Compressor Motor............................... T3-6-3 Folding Stairway Pump Unit............................................ T3-6-5 Pilot Relief Valve................................................................... T3-6-6

TOKGB91-EN-00(20181003)

KGB91T-3-1

(Blank)

TOKGB91-EN-00(20181003)

KGB91T-3-2

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Outline The pump devices are installed in the right and left engines. The pump device consists of pump transmission (18), 4-unit pump (25), 2-unit pumps (3 used) (19, 20, 21) or 2-unit pumps (3 used) (22, 23, 24). Pump transmission (18) distributes the engine output power by using gears and transmits to each pump. 2-unit pumps (6 used) (19, 20, 21, 22, 23, 24) are 2-tandem swash plate type variable displacement plunger pumps, and consist of main pumps L1 to L6, R1 to R6 (1 to 12). Each main pump (1 to 12) supplies high pressure oil.

Viewed from the pump transmission (18) side in 4-unit pump (25), the pumps are arranged as follows:  Oil cooler fan motor pump (13) (swash plate type variable displacement plunger pump)  Pilot pump (14) (gear pump)  Air conditioner compressor motor pump (15) (gear pump) or Spare pump (16) (gear pump)  Pump transmission oil pump (17) (gear pump)

Left Engine

Right Engine

19 1

22 7

18 13

3456-

5 6

TOKGB91-EN-00(20181003)

TKGB-03-01-001

Main Pump L1 (Pump Transmission Side) Main pump L2 (Pump End Side) Main Pump L3 (Pump Transmission Side) Main pump L4 (Pump End Side) Main Pump L5 (Pump Transmission Side) Main pump L6 (Pump End Side)

Main Pump R1 (Pump Transmission Side) 8- Main Pump R2 (Pump End Side) 9- Main Pump R3 (Pump Transmission Side) 10- Main Pump R4 (Pump End Side) 11- Main Pump R5 (Pump Transmission Side) 12- Main Pump R6 (Pump End Side)

13- Oil Cooler Fan Motor Pump (2 Used) 14- Pilot Pump (2 Used) 15- Air Conditioner Compressor Motor Pump 16- Spare Pump 17- Pump Transmission Oil Pump (2 Used) 18- Pump Transmission 19- 2-Unit Pump (Main Pumps L1, L2)

T3-1-1

TKGB-03-01-001

20- 2-Unit Pump (Main Pumps L3, L4) 21- 2-Unit Pump (Main Pumps L5, L6) 22- 2-Unit Pump (Main Pumps R1, R2) 23- 2-Unit Pump (Main Pumps R3, R4) 24- 2-Unit Pump (Main Pumps R5, R6) 25- 4-Unit Pump (2 Used)

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Main Pump

fNOTE: Main pumps L1 to L6, R1 to R6 are identical

The main pump is a 2-tandem swash plate type variable displacement plunger pump. Shafts (1, 2) are connected by coupling (9). The same type pumps are installed in shafts (1, 2). Cylinder blocks (7) are connected to shafts (1, 2) by a spline joint. Plungers (6) are inserted into cylinder block (7).

in structure but different in displacement. (Refer to GENERAL/Component Specifications T1-3-6.)

A 1

4 5

T117-02-01-002

A-

Main Pumps L1, L3, L5, R1, R3, R5

B-

Main Pumps L2, L4, L6, R2, R4, R6

123-

Shaft Shaft Servo Piston

45-

Shoe Plate Swash Plate

TOKGB91-EN-00(20181003)

67-

T3-1-2

Plunger (9 Used for Each) Cylinder Block

89-

Valve Plate Coupling

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Operational Principle

Increasing and Decreasing Flow Rate

1. Engine torque is transferred to shaft (2).

1. Changing inclination of swash plate (6) increases or decreases the pump delivery flow rate.

2. When shaft (2) turns, plungers (5) turn with cylinder block (4).

2. Servo piston (1) is moved by pressure oil from the regulator.

3. Plungers (5) slide on swash plate (6).

3. As swash plate (6) is connected to servo piston (1), the displacement angle of swash plate (6) is changed according to the movement of servo piston (1).

4. Plungers (5) reciprocate in the cylinder block (4) bore. 5. Hydraulic oil is drawn and delivered by this reciprocation.

4. Therefore, the strokes of plungers (5) are changed and the pump delivery flow rate increases or decreases.

2 3 4 5 6

12-

Servo Piston Shaft

TOKGB91-EN-00(20181003)

34-

Valve Plate Cylinder Block

T3-1-3

T142-02-01-001

Plunger (9 Used)

Swash Plate

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Oil Cooler Fan Motor Pump The oil cooler fan motor pump is a swash plate type variable displacement plunger pump. Cylinder block (6) is connected to shaft (2) by a spline joint, and plungers (5) are inserted into cylinder block (6). The oil cooler fan motor pump and main pumps L1 to L6, R1 to R6 are identical in structure and operational principle. (Refer to Main Pump Section T3-1-3.)

12-

Servo Piston Shaft

TOKGB91-EN-00(20181003)

34-

Swash Plate Shoe Plate

56-

T3-1-4

Plunger (9 Used) Cylinder Block

TKEB-03-01-005

Valve Plate

SECTION 3 COMPONENT OPERATION Group 1 Pump Device (Blank)

TOKGB91-EN-00(20181003)

T3-1-5

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Regulator for Main Pump The regulator is installed in the upper part of main pump (12) and controls the main pump flow rate. The flow rate control is performed by increasing or decreasing the flow rate control pressure Pi by the pump control solenoid valve (4). The own pump delivery pressure Pd acts on spool (2) via check valve (6), and always acts on small chamber (15) of servo piston (11).

When the pump control solenoid valve (4) is activated, primary pilot pressure Psv from pilot pump (13) is reduced and acts on piston (3) as flow rate control pressure Pi. Primary pilot pressure Psv from pilot pump (13) is combined with the own pump delivery pressure Pd through check valve (5).

5 Psv

Pi 3

8 9 10

2 1

Pd TKAB-03-01-007

TOKGB91-EN-00(20181003)

T3-1-6

SECTION 3 COMPONENT OPERATION Group 1 Pump Device

Psv 9

a 13

12 TKAB-03-01-008

Pd- Own Pump Delivery Pressure Pi- Flow Rate Control Pressure

Psv- Primary Pilot Pressure

1234-

5678-

9- Pin 10- Feedback Lever 11- Servo Piston 12- Main Pump

Sleeve Spool Piston Pump Control Solenoid Valve

TOKGB91-EN-00(20181003)

Check Valve Check Valve Spring Pin

T3-1-7

Displacement Angle Increase

Displacement Angle Decrease

13- Pilot Pump 14- Large Chamber 15- Small Chamber

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Control by Flow Rate Control Pressure of Pump Control Solenoid Valve

4. As servo piston (11) is moved, feedback lever (10) turns counterclockwise around pin (9).

 Minimum flow rate (Flow rate control pressure Pi is zero.) 1. When the flow rate control pressure Pi from the pump control solenoid valve (4) is zero, spool (2) is pushed to the left by spring (7).

5. As the end of feedback lever (10) is connected to sleeve (1) by pin (8), sleeve (1) is moved to the left. 6. Servo piston (11) moves until the open part between sleeve (1) and spool (2) is closed. Servo piston (11) stops when the open part is completely closed.

2. The own pump delivery pressure Pd acts on large chamber (14) of servo piston (11) via check valve (6), sleeve (1), and spool (2).

7. As described above, the pump displacement angle is minimized and the pump delivery flow rate is minimized.

3. The own pump delivery pressure Pd always acts on small chamber (15) of servo piston (11). Due to the difference in the pressure receiving areas, servo piston (11) is moved to the right. As servo piston (11) moves to the right, the swash plate turns clockwise

5 Psv

Pi 3

7 8 9

Pd 13

12 TKAB-03-01-009

TOKGB91-EN-00(20181003)

T3-1-8

SECTION 3 COMPONENT OPERATION Group 1 Pump Device

Psv

9 3

a 13

TKAB-03-01-010

Pd- Own Pump Delivery Pressure Pi- Flow Rate Control Pressure

Psv- Primary Pilot Pressure

1234-

5678-

9- Pin 10- Feedback Lever 11- Servo Piston 12- Main Pump

Sleeve Spool Piston Pump Control Solenoid Valve

TOKGB91-EN-00(20181003)

Check Valve Check Valve Spring Pin

T3-1-9

Displacement Angle Increase

Displacement Angle Decrease

13- Pilot Pump 14- Large Chamber 15- Small Chamber

SECTION 3 COMPONENT OPERATION Group 1 Pump Device  Flow Rate Increase (Flow rate control pressure Pi increases.) 1. The pump control solenoid valve (4) increases the flow rate control pressure Pi according to the signal from PFU (R) or PFU (L).

5. When servo piston (11) is moved, feedback lever (10) turns clockwise around pin (9). 6. As the end of feedback lever (10) is connected to sleeve (1) by pin (8), sleeve (1) is moved to the right.

2. Piston (3) moves spool (2) to the right by using the flow rate control pressure Pi until the flow rate control pressure Pi balances with the spring (7) force.

7. Servo piston (11) moves until the open part between sleeve (1) and spool (2) is closed. Servo piston (11) stops when the open part is completely closed.

3. As spool (2) is moved, large chamber (14) of servo piston (11) is connected to the hydraulic oil tank via spool (2).

8. As described above, the pump displacement angle increases and the pump delivery flow rate increases. The increased amount of the pump delivery flow rate is proportional to the increased amount of the flow rate control pressure Pi.

4. As the own pump delivery pressure Pd always acts on small chamber (15) of servo piston (11), servo piston (11) is moved to the left and pressure oil in large chamber (14) returns to the hydraulic oil tank. As servo piston (11) moves to the left, the swash plate turns counter clockwise

Psv 5

4 6 Pi

3 7 8 2

9 10

Pd 13

12 TKAB-03-01-035

TOKGB91-EN-00(20181003)

T3-1-10

SECTION 3 COMPONENT OPERATION Group 1 Pump Device

Psv

9 10 3 6

a 13

MP TKAB-03-01-011

Pd- Own Pump Delivery Pressure Pi- Flow Rate Control Pressure

Psv- Primary Pilot Pressure a- Displacement Angle Increase

1234-

5678-

9- Pin 10- Feedback Lever 11- Servo Piston 12- Main Pump

Sleeve Spool Piston Pump Control Solenoid Valve

TOKGB91-EN-00(20181003)

Check Valve Check Valve Spring Pin

T3-1-11

Displacement Angle Decrease

13- Pilot Pump 14- Large Chamber 15- Small Chamber

SECTION 3 COMPONENT OPERATION Group 1 Pump Device  Flow Rate Decrease (Flow rate control pressure Pi decreases.) 1. The pump control solenoid valve (4) decreases the flow rate control pressure Pi according to the signal from PFU (R) or PFU (L).

6. As servo piston (11) is moved to the right, feedback lever (10) turns counterclockwise around pin (9). 7. As the end of feedback lever (10) is connected to sleeve (1) by pin (8), sleeve (1) is moved to the left.

2. Spool (2) is moved to the left until the flow rate control pressure Pi balances with the spring (7) force.

8. Servo piston (11) moves until the open part between sleeve (1) and spool (2) is closed. Servo piston (11) stops when the open part is completely closed.

3. Pressure oil acting on piston (3) is returned to the hydraulic oil tank through the pump control solenoid valve (4).

9. As described above, the pump displacement angle decreases and the pump delivery flow rate decreases. The decreased amount of the pump delivery flow rate is proportional to the decreased amount of the flow rate control pressure Pi.

4. As spool (2) is moved, the own pump delivery pressure Pd acts on large chamber (14) of servo piston (11) via check valve (6), sleeve (1), and spool (2). 5. The own pump delivery pressure Pd always acts on small chamber (15) of servo piston (11). Due to the difference in the pressure receiving areas, servo piston (11) is moved to the right. As servo piston (11) moves to the right, the swash plate turns clockwise.

Psv

4 6 Pi

7 8

9 10

Pd 13

12 TKAB-03-01-009

TOKGB91-EN-00(20181003)

T3-1-12

SECTION 3 COMPONENT OPERATION Group 1 Pump Device

Psv

9 10 3 6

a 13

12 TKAB-03-01-013

Pd- Own Pump Delivery Pressure Pi- Flow Rate Control Pressure

Psv- Primary Pilot Pressure a- Displacement Angle Increase

1234-

5678-

9- Pin 10- Feedback Lever 11- Servo Piston 12- Main Pump

Sleeve Spool Piston Pump Control Solenoid Valve

TOKGB91-EN-00(20181003)

Check Valve Check Valve Spring Pin

T3-1-13

Displacement Angle Decrease

13- Pilot Pump 14- Large Chamber 15- Small Chamber

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Regulator for Oil Cooler Fan Motor Pump B

The regulator is installed in the upper part of the oil cooler fan motor pump (24) and controls the flow rate of the oil cooler fan motor pump (24). The flow rate control is performed by increasing or decreasing the flow rate control pressure Pi by the pump control solenoid valve (17). The own pump delivery pressure Pf always acts on compensating piston (1), spool (2), and small chamber (27) of servo piston (15). When the pump control solenoid valve (17) is activated, primary pilot pressure Pr from pilot pump (25) is reduced and acts on piston (22) as the flow rate control pressure Pi.

TKAB-03-01-015

17 Pr

22 2

Pf 25

Pf- Own Pump Delivery Pressure Pi- Flow Rate Control Pressure

Pr- Primary Pilot Pressure a- Displacement Angle Increase

Displacement Angle Decrease

1234567-

891011121314-

15161718192021-

Servo Piston Spool Pump Control Solenoid Valve Lever 1 Pin Spring Pin

Compensating Piston Spool Sleeve Lever 2 Pin Pin Pin

TOKGB91-EN-00(20181003)

Hole Inner Spring Outer Spring Compensating Rod Pin Feedback Lever Pin

T3-1-14

TKAB-03-01-014

222324252627-

Piston Hole Oil Cooler Fan Motor Pump Pilot Pump Large Chamber Small Chamber

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Section A

15 14 13 a

b 12 11 10

TKAB-03-01-016

Section B

TOKGB91-EN-00(20181003)

T3-1-15

TKAB-03-01-017

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Link Mechanism The movement of piston (22) is transmitted to lever 1 (18) via pin (21), and turns lever 1 (18) around pin (19) which is secured to supporting plug (d) The movement of compensating rod (11) is transmitted to lever 2 (4) via pin (12), and turns lever 2 (4) around pin (5) which is secured to housing (c) Pin (7) is installed in feedback lever (13). The both ends of pin (7) are inserted into holes (23, 8) of lever 1 (18) and lever 2 (4).

Therefore, when lever 1 (18) or lever 2 (4) turns, pin (7) comes in contact with the lever hole. Feedback lever (13) turns around pin (14) which is installed in servo piston (15). As servo piston (15) is moved, feedback lever (13) is moved via pin (14). At this time, as lever 1 (18) and lever 2 (4) do not turn, feedback lever (13) turns around pin (7).

c 5

4 8

13 6 7 18

19 21

14 22 15

Housing

Supporting Plug

2456-

Spool Lever 2 Pin Pin

781112-

Pin Hole Compensating Rod Pin

TOKGB91-EN-00(20181003)

T1J1-03-01-007

: Displacement Angle Decrease 13141518-

T3-1-16

Feedback Lever Pin Servo Piston Lever 1

: Displacement Angle Increase 19212223-

Pin Pin Piston Hole

SECTION 3 COMPONENT OPERATION Group 1 Pump Device (Blank)

TOKGB91-EN-00(20181003)

T3-1-17

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Control by Flow Rate Control Pressure of Pump Control Solenoid Valve for Oil Cooler Fan Motor Pump  Flow Rate Decrease (Flow rate control pressure Pi increases.) 1. When the pump control solenoid valve (17) is activated, the flow rate control pressure Pi acts on piston (22) via spool (16) according to the operation amount of the pump control solenoid valve (17).

9. As described above, the pump delivery flow rate is decreased according to the increased amount of the flow rate control pressure Pi.

fNOTE: (Refer to SYSTEM/Hydraulic System/Pilot Circuit.)

2. When the flow rate control pressure Pi increases, piston (22) is moved to the right until the flow rate control pressure Pi balances with the spring (20) force.

3. Piston (22) moves lever 1 (18) via pin (21). Lever 1 (18) turns counterclockwise around pin (19) which is secured to supporting plug (d). 4. Pin (7) which is installed in feedback lever (13) is inserted into hole (23) of lever 1 (18). Therefore, feedback lever (13) turns clockwise around pin (14) by turning lever 1 (18). Then, spool (2) is moved to the right. 5. As spool (2) is moved, the own pump delivery pressure Pf acts on large chamber (26) of servo piston (15) via spool (2). The own pump delivery pressure Pf also acts on small chamber (27). Due to the difference in the pressure receiving areas, servo piston (15) is moved to the right.

Pi Pi-

Flow Rate Control Pressure

Q-

Flow Rate

16 Pr Pi 17 22

6. The pump displacement angle decreases according to the movement of servo piston (15), and the pump delivery flow rate decreases. 7. As servo piston (15) is moved, feedback lever (13) is moved via pin (14). As piston (22) and lever 1 (18) do not move, feedback lever (13) turns counterclockwise around pin (7). Then, spool (2) is moved to the left.

2 13 1

8. When the open part between spool (2) and sleeve (3) is completely closed, the own pump delivery pressure Pf does not act on large chamber (26) of servo piston (15). Then, servo piston (15) is stopped moving.

TOKGB91-EN-00(20181003)

T3-1-18

Pf 25

14 24 TKAB-03-01-019

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Section A

Section B

15 14 13 a

b 12 11 10 9

TKAB-03-01-020

23 Pi

14 13

20 TKAB-03-01-021

TOKGB91-EN-00(20181003)

T3-1-19

SECTION 3 COMPONENT OPERATION Group 1 Pump Device

7 18

19 21

14 22 15

T1J1-03-01-007

Pf- Own Pump Delivery Pressure Pi- Flow Rate Control Pressure

Pr- Primary Pilot Pressure a- Displacement Angle Increase

bc-

Displacement Angle Decrease Housing

Supporting Plug

1234567-

891011121314-

15161718192021-

Servo Piston Spool Pump Control Solenoid Valve Lever 1 Pin Spring Pin

222324252627-

Piston Hole Oil Cooler Fan Motor Pump Pilot Pump Large Chamber Small Chamber

Compensating Piston Spool Sleeve Lever 2 Pin Pin Pin

TOKGB91-EN-00(20181003)

Hole Inner Spring Outer Spring Compensating Rod Pin Feedback Lever Pin

T3-1-20

SECTION 3 COMPONENT OPERATION Group 1 Pump Device (Blank)

TOKGB91-EN-00(20181003)

T3-1-21

SECTION 3 COMPONENT OPERATION Group 1 Pump Device  Flow Rate Increase (Flow rate control pressure Pi decreases.) 1. When the pump control solenoid valve (17) is activated, the flow rate control pressure Pi acts on piston (22) via spool (16) according to the operation amount of the pump control solenoid valve (17).

9. As described above, the pump delivery flow rate is increased according to the decreased amount of the flow rate control pressure Pi.

fNOTE: (Refer to SYSTEM/Hydraulic System/Pilot Circuit.)

2. When the flow rate control pressure Pi decreases, piston (22) is moved to the left until the flow rate control pressure Pi balances with the spring (20) force.

3. Piston (22) moves lever 1 (18) via pin (21). Lever 1 (18) turns clockwise around pin (19) which is secured to supporting plug (d). 4. Pin (7) which is installed in feedback lever (13) is inserted into hole (23) of lever 1 (18). Therefore, feedback lever (13) turns counterclockwise around pin (14) by turning lever 1 (18). Then, spool (2) is moved to the left.

Pi Pi-

Flow Rate Control Pressure

5. As spool (2) is moved, large chamber (26) of servo piston (15) is connected to the hydraulic oil tank via spool (2). As the own pump delivery pressure Pf acts on small chamber (27), servo piston (15) is moved to the left. 6. The pump displacement angle increases according to the movement of servo piston (15), and the pump delivery flow rate increases.

Q-

Flow Rate

16 Pr Pi 17 22

7. As servo piston (15) is moved, feedback lever (13) is moved via pin (14). As piston (22) and lever 1 (18) do not move, feedback lever (13) turns clockwise around pin (7). Then, spool (2) is moved to the right.

2 13

8. When the open part between spool (2) and sleeve (3) is completely closed, large chamber (26) of servo piston (15) is disconnected from the hydraulic oil tank. Then, servo piston (15) is stopped moving. 15 25

Pf 24 TKAB-03-01-022

TOKGB91-EN-00(20181003)

T3-1-22

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Section A

15 14 13 a

b 12 11 10 9

TKAB-03-01-023

Section B

23 Pi

TOKGB91-EN-00(20181003)

14 13

T3-1-23

TKAB-03-01-024

SECTION 3 COMPONENT OPERATION Group 1 Pump Device

7 18

19 21

14 22 15

T1J1-03-01-007

Pf- Own Pump Delivery Pressure Pi- Flow Rate Control Pressure

Pr- Primary Pilot Pressure a- Displacement Angle Increase

bc-

Displacement Angle Decrease Housing

Supporting Plug

1234567-

891011121314-

15161718192021-

Servo Piston Spool Pump Control Solenoid Valve Lever 1 Pin Spring Pin

222324252627-

Piston Hole Oil Cooler Fan Motor Pump Pilot Pump Large Chamber Small Chamber

Compensating Piston Spool Sleeve Lever 2 Pin Pin Pin

TOKGB91-EN-00(20181003)

Hole Inner Spring Outer Spring Compensating Rod Pin Feedback Lever Pin

T3-1-24

SECTION 3 COMPONENT OPERATION Group 1 Pump Device (Blank)

TOKGB91-EN-00(20181003)

T3-1-25

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Control by Own Pump Delivery Pressure

fNOTE: This control is performed only when the engine speed increases over the rated speed when starting.

 Flow Rate Decrease 1. When the own pump delivery pressure Pf increases from C to D, compensating piston (1) moves compensating rod (11) to the right until the own pump delivery pressure Pf balances with the force of outer spring (10) and inner spring (9).

2. Compensating rod (11) moves lever 2 (4) via pin (12). Lever 2 (4) turns counterclockwise around pin (5) which is secured to housing (c).

9. As described above, the pump delivery flow rate decreases from A to B.

3. Pin (7) which is installed in feedback lever (13) is inserted into hole (8) of lever 2 (4). Therefore, feedback lever (13) turns clockwise around pin (14) by turning lever 2 (4). Then, spool (2) is moved to the right.

Q A B

4. As spool (2) is moved, the own pump delivery pressure Pf acts on large chamber (26) of servo piston (15) via spool (2). The own pump delivery pressure Pf also acts on small chamber (27). Due to the difference in the pressure receiving areas, servo piston (15) is moved to the right. 5. The pump displacement angle decreases according to the movement of servo piston (15), and the pump delivery flow rate decreases.

C Pf- Own Pump Delivery Pressure

6. The own pump delivery pressure Pf acts on compensating piston (1). Then, even when servo piston (15) is moved, compensating rod (11) and lever 2 (4) do not move.

Q-

Pump Delivery Flow Rate

7. As servo piston (15) is moved, feedback lever (13) is moved via pin (14). As compensating rod (11) and lever 2 (4) do not move, feedback lever (13) turns counterclockwise around pin (7). Then, spool (2) is moved to the left.

3 2 13

9, 10 25

TOKGB91-EN-00(20181003)

T3-1-26

14 24

TKAB-03-01-025

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Section A

b 12

11 10

TKAB-03-01-026

24 c 5

4 8

2 d

T1J1-03-01-007

TOKGB91-EN-00(20181003)

T3-1-27

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Pf- Own Pump Delivery Pressure Pr- Primary Pilot Pressure

ab-

Displacement Angle Increase Displacement Angle Decrease

cd-

Housing Supporting Plug

12345-

678910-

Pin Pin Hole Inner Spring Outer Spring

1112131415-

Compensating Rod Pin Feedback Lever Pin Servo Piston

Compensating Piston Spool Sleeve Lever 2 Pin

TOKGB91-EN-00(20181003)

T3-1-28

24252627-

Oil Cooler Fan Motor Pump Pilot Pump Large Chamber Small Chamber

SECTION 3 COMPONENT OPERATION Group 1 Pump Device (Blank)

TOKGB91-EN-00(20181003)

T3-1-29

SECTION 3 COMPONENT OPERATION Group 1 Pump Device  Flow Rate Increase 1. When the own pump delivery pressure Pf decreases from D to C, compensating piston (1) moves compensating rod (11) to the left until the own pump delivery pressure Pf balances with the force of outer spring (10) and inner spring (9).

7. When the open part between spool (2) and sleeve (3) is completely closed, large chamber (26) of servo piston (15) is disconnected from the hydraulic oil tank. Then, servo piston (15) is stopped moving. 8. As described above, the pump delivery flow rate increases from B to A.

2. Compensating rod (11) moves lever 2 (4) via pin (12). Lever 2 (4) turns clockwise around pin (5) which is secured to housing (c). 3. Pin (7) which is installed in feedback lever (13) is inserted into hole (8) of lever 2 (4). Therefore, feedback lever (13) turns counterclockwise around pin (14) by turning lever 2 (4). Then, spool (2) is moved to the left.

Q A B

4. As spool (2) is moved, large chamber (26) of servo piston (15) is connected to the hydraulic oil tank via spool (2). As the own pump delivery pressure Pf acts on small chamber (27), servo piston (15) is moved to the left. 5. The pump displacement angle increases according to the movement of servo piston (15), and the pump delivery flow rate increases.

C Pf- Own Pump Delivery Pressure

6. As servo piston (15) is moved, feedback lever (13) is also moved via pin (14). As compensating rod (11) and lever 2 (4) do not move, feedback lever (13) turns clockwise around pin (7). Then, spool (2) is moved to the right.

Q-

Pump Delivery Flow Rate

2 13

9, 10 25

TOKGB91-EN-00(20181003)

T3-1-30

Pf 24

TKAB-03-01-027

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Section A

b 12

11 10

TKAB-03-01-028

24 c 5

4 8

2 d

T1J1-03-01-007

TOKGB91-EN-00(20181003)

T3-1-31

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Pf- Own Pump Delivery Pressure Pr- Primary Pilot Pressure

ab-

Displacement Angle Increase Displacement Angle Decrease

cd-

Housing Supporting Plug

12345-

678910-

Pin Pin Hole Inner Spring Outer Spring

1112131415-

Compensating Rod Pin Feedback Lever Pin Servo Piston

Compensating Piston Spool Sleeve Lever 2 Pin

TOKGB91-EN-00(20181003)

T3-1-32

24252627-

Oil Cooler Fan Motor Pump Pilot Pump Large Chamber Small Chamber

SECTION 3 COMPONENT OPERATION Group 1 Pump Device (Blank)

TOKGB91-EN-00(20181003)

T3-1-33

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Pump Control Solenoid Valve The pump control solenoid valve is installed on the regulators for main pumps L1 to L6, R1 to R6 and for the oil cooler fan motor pumps (2 used). The pump control solenoid valve supplies the flow rate control pressure to the regulator and controls the pump delivery flow rate. Operation  Neutral state 1. When in neutral, port Pi (7) is disconnected from output port (6) by spool (1). 2. Output port (6) is connected to port T (5) through the notch of spool (1).  Operating state 1. When current flows to solenoid (4) from PFU, solenoid (4) is excited and pushes spool (1). 2. As spool (1) moves to the left, port Pi (7) is connected to output port (6) through the notch of spool (1). 3. Pressure at output port (6) begins to increase. 4. Diameter B is larger than diameter A as for spool (1). 5. When pressure at output port (6) begins to increase, spool (1) is move to the left due to the force as Fsol > P1 × (B - A) + S1. 6. When pressure at output port (6) increases and the following formula exists Fsol =P1 × (B - A) + S1, then spool (1) is stopped. P1: Pressure at Output Port (6) A, B: Pressure Receiving Area of Spool (1) S1: Spring (3) Force (Force pushing spool (1) to the right) Fsol: Solenoid (4) Force

TOKGB91-EN-00(20181003)

T3-1-34

SECTION 3 COMPONENT OPERATION Group 1 Pump Device

Neutral state: 2

T1J1-03-01-032

Operating state: 2

12-

Spool Sleeve

TOKGB91-EN-00(20181003)

T1J1-03-01-033

34-

Spring Solenoid

56-

T3-1-35

Port T Output Port

Port Pi

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Pilot Pump, Air Conditioner Compressor Motor Pump, Pump Transmission Oil Pump, Spare Pump

The pilot pump, air conditioner compressor motor pump, pump transmission oil pump, and spare pump are gear pumps. As for the gear pump, drive gear (1) is driven by the engine via the pump transmission, which rotates driven gear (2) as they are meshed together.

b T137-02-03-005 1-

Drive Gear

Driven Gear

Suction Port

Delivery Port

Pump Delivery Pressure Sensor The pump delivery pressure sensor detects the pump delivery pressure, which is used in order to control various operations. When oil pressure is applied to diaphragm (6), diaphragm (6) is deformed. The deformation of diaphragm (6) is detected as electrical signals. 6

TKEB-03-01-002 345-

Ground Output Power Source (5 V)

Diaphragm (Pressure Receiving Area)

Regulator Pressure (Flow Rate Control Pressure) Sensor The regulator pressure (flow rate control pressure) sensor detects the pump regulator pressure, which is used in order to control various operations. When oil pressure is applied to diaphragm (7), diaphragm (7) is deformed. The deformation of diaphragm (7) is detected as electrical signals. 7

9 10 T1J1-03-01-029

78-

Diaphragm (Pressure Receiving Area) Ground

TOKGB91-EN-00(20181003)

9- Output 10- Power Source (5 V)

T3-1-36

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Contamination Sensor Contamination sensors (1) are respectively installed in 12 main pumps. Contamination sensors (1) change the current values according to the contamination level of hydraulic oil and detect abnormality of the main pumps. When hydraulic oil is contaminated by metal powder, metal powder adheres to magnet (4) of contamination sensor (1) and decreases the resistance value of contamination sensor (1) (terminal #2 (2) of the connector). CSU (Contamination Sensing Unit) identifies the resistance value of contamination sensor (1). When any one of the resistance values is less than the specified value, CSU turns on warning light LED (yellow) in the cab. At the same time, CSU outputs the signal to IDU by using the CAN communication. IDU displays the alarm on the display.

TKEB-03-01-003

1 1-

Contamination Sensor

The abnormal main pump can be identified by checking 12 indicators on the contamination sensor amplifier. 1

fNOTE: CSU is located in the control box. fNOTE: The contamination sensor is installed in the

2 3

following components as well as the main pump. Swing Motor: Upper part of each swing motor (4 used) Travel Motor: Upper part of the center joint (common to right and left travel motors (4 used))

4 23-

TOKGB91-EN-00(20181003)

T3-1-37

Terminal #2 Terminal #1

Magnet

TKEB-03-01-004

SECTION 3 COMPONENT OPERATION Group 1 Pump Device (Blank)

TOKGB91-EN-00(20181003)

T3-1-38

SECTION 3 COMPONENT OPERATION Group 2 Swing Device Outline The swing device consists of valve unit (1), swing motor (2), and swing reduction gear (3). Swing motor (2) is driven by pressure oil from the pump and transmits the rotation power to swing reduction gear (3).

Swing reduction gear (3) is a planetary gear type and converts swing motor (2) output into slow large torque to rotate the shaft. Therefore, the upperstructure is swing. The relief valve is installed in valve unit (1) and protects the swing circuit from being overloaded.

TKGB-03-02-001

Valve Unit

TOKGB91-EN-00(20181003)

Swing Motor

T3-2-1

Swing Reduction Gear

SECTION 3 COMPONENT OPERATION Group 2 Swing Device Swing Motor The swing motor consists of the parking brake (a) part and motor (b) part.

Motor (b) is a swash plate type axial plunger motor. Motor (b) consists of shaft (4), swash plate (3), shoes (2), plungers (5), rotor (6), valve plate (7), and housing (1). Shoe (2) is crimped to plunger (5). Plunger (5) is inserted into rotor (6). Rotor (6) is connected to shaft (4) by a spline joint.

Parking brake (a) is a wet-type spring set hydraulic released multi-disc brake. It consists of friction plates (8), plates (9), piston (10), and springs (11).

11 10 9 a 8

7 1

6 5

2 3

TKEB-03-02-001

Parking Brake

Motor

123-

Housing Shoe Swash Plate

456-

Shaft Plunger Rotor

TOKGB91-EN-00(20181003)

789-

T3-2-2

Valve Plate Friction Plate Plate

10- Piston 11- Spring

SECTION 3 COMPONENT OPERATION Group 2 Swing Device Operational Principle Swing speed varies depending on the amount of oil flow rate which is supplied to the swing motor. When pressure oil is supplied to port A (a), plungers (1) are pushed and shoes (2) slide along swash plate (3). Then, the rotation power occurs. This rotation power is transmitted to the swing reduction gear via shaft (4). Pressure oil from port B (b) returns to the hydraulic oil tank. The rotation direction depends on whether pressure oil is supplied to port A or port B.

2 3

Port A

Port B

Plunger

Shoe

TOKGB91-EN-00(20181003)

T115-02-03-003

T3-2-3

Swash Plate

Shaft

SECTION 3 COMPONENT OPERATION Group 2 Swing Device Swing Parking Brake The parking brake consists of coupling (4), friction plates (5), plates (6), piston (2), and springs (1). Coupling (4) is connected to shaft (3) by a spline joint. Plate (6) is connected to coupling (4) by a spline joint. Friction plate (5) is connected to casing (7) by a spline joint and is installed between plates (6). When the pilot shut-off lever is in the LOCK position, brake release pressure (b) does not act on piston chamber (a). Then, piston (2) is pushed down by the spring (1) force. As friction plate (5) and plate (6) are pushed to casing (7), shaft (3) does not rotate.

When the pilot shut-off lever is in the UNLOCK position, brake release pressure (b) acts on piston chamber (a). Then, the piston overcomes the spring (1) force and moves up. The friction force of friction plate (5) and plate (6) disappears and this allows shaft (3) to rotate.

1 2 a

3 e

f T18N-03-02-001

7 b

6 5

T144-03-02-002

Piston Chamber

Brake Release Pressure (2.6 MPa or More)

cd-

Swing Motor Pilot Shut-Off Solenoid Valve

ef-

Relief Valve (3.9 MPa) Pilot Pump

12-

Spring Piston

34-

Shaft Coupling

56-

Friction Plate Plate

Casing

TOKGB91-EN-00(20181003)

T3-2-4

SECTION 3 COMPONENT OPERATION Group 2 Swing Device Swing Reduction Gear The swing reduction gear is a two-stage planetary reduction gear. The shaft of the swing motor rotates the first stage sun gear (7). Therefore, rotating torque is transmitted to the second stage sun gear (5) after rotation speed is reduced between the first stage planetary gear (1) and first stage carrier (6). Then, the second stage sun gear (5) rotates. The rotation of the second stage sun gear (5) is transmitted to shaft (3) after rotation speed is reduced between the second stage planetary gear (2) and second stage carrier (4). Then, shaft (3) rotates. 7

1 6 2 5

T117-02-02-007

12-

First Stage Planetary Gear Second Stage Planetary Gear

TOKGB91-EN-00(20181003)

34-

Shaft Second Stage Carrier

56-

T3-2-5

Second Stage Sun Gear First Stage Carrier

First Stage Sun Gear

SECTION 3 COMPONENT OPERATION Group 2 Swing Device Valve Unit The valve unit consists of relief valves (2) and make-up valves (1).

When the pressure in the port AV (BV) (b) side increases further, the pressure in piston chamber (9) moves piston (6) to the left and the spring (5) force increases. When piston (6) reaches the stroke end, the spring (5) force stops increasing. When the pressure in the port AV (BV) (b) side increases over the spring (5) force, main poppet (4) is opened again and pressure oil from port AV (BV) (b) flows to port BV (AV) (c). As described above, main poppet (4) is opened in two stages and the shock in the circuit is reduced when starting or stopping swing operation.

Relief Valve Relief valve (2) prevents the swing circuit pressure from rising over the set pressure when starting or stopping swing operation. When the pressure in the port AV (BV) (b) side increases, the pressure in port AV (BV) (b) acts on pilot piston (7) through orifice (3) in main poppet (4) and piston chamber (9). When this force increases over the spring (8) force, pilot piston (7) is moved to the right and the pressure in piston chamber (9) decreases. The pressure difference is developed between the front and rear of main poppet (4). When the force generated in main poppet (4) increases over the spring (5) force, main poppet (4) is opened and pressure oil from port AV (BV) (b) flows to port BV (AV) (c). When pilot piston (7) reaches the stroke end, the pressure difference between the front and rear of main poppet (4) disappears and main poppet (4) is closed.

Make-Up Valve When stopping swing operation, the swing motor is driven by inertia force of the uppersfructure. The swing motor is turned forcibly in excess of oil flow rate form the pump. At this time, in order to avoid cavitation in the motor, the make-up valve draws hydraulic oil in make-up circuit (a) and compensates the lack of oil feed.

TOKGB91-EN-00(20181003)

T3-2-6

TKEB-03-02-002

SECTION 3 COMPONENT OPERATION Group 2 Swing Device Relief Valve (2)

T117-02-02-004

Make-Up Valve (1)

T117-02-02-005

Make-Up Circuit

Port AV (BV)

Port BV (AV) (Hydraulic Oil Tank Connecting Side)

123-

Make-Up Valve Relief Valve Orifice

456-

Main Poppet Spring Piston

789-

Pilot Piston Spring Piston Chamber

TOKGB91-EN-00(20181003)

T3-2-7

10- Poppet 11- Spring

SECTION 3 COMPONENT OPERATION Group 2 Swing Device (Blank)

TOKGB91-EN-00(20181003)

T3-2-8

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Outline The control valve controls the pressure, flow rate, and flow direction in the main circuit. Six control valves consists of four valve sections respectively. The spools are operated by pilot oil pressure. The main relief valve is equipped for the control valve. In addition, the overload relief valve and make-up valve are equipped for each section as required.

TOKGB91-EN-00(20181003)

T3-3-1

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Position of Valve and Section

fNOTE: The illustration shows the layout viewed from the machine front.

Control Valve 4 (Upper Right)

Control Valve 1 (Upper Left)

b 13

1 b

TKGB-03-03-005

TKGB-03-03-008

Control Valve 5 (Middle Right)

Control Valve 2 (Middle Left)

b TKGB-03-03-003

TKGB-03-03-006 Control Valve 6 (Lower Right)

Control Valve 3 (Lower Left)

21 b

b TKGB-03-03-008

TOKGB91-EN-00(20181003)

T3-3-2

TKGB-03-03-004

SECTION 3 COMPONENT OPERATION Group 3 Control Valve

ab-

Main Relief Valve Overload Relief Valve

Make-Up Valve

Control Valve 4 (Upper Right)

Control Valve 1 (Upper Left)

1234-

13141516-

Arm Section Bucket Open/Close Section Boom Raise/Bucket Tilt-In Section Left Travel Section

Bucket Section Arm Extend/Boom Lower Section Boom Section Swing Section

Control Valve 5 (Middle Right)

Control Valve 2 (Middle Left)

5678-

17181920-

Bucket Section Boom Section Arm Section Right Travel Section

Left Travel Section Boom Raise/Bucket Tilt-In Section Bucket Open/Close Section Arm Section

Control Valve 6 (Lower Right)

Control Valve 3 (Lower Left)

9101112-

21222324-

Bucket Section Arm Extend/Boom Lower Section Boom Section Swing Section

TOKGB91-EN-00(20181003)

T3-3-3

Right Travel Section Arm Section Boom Section Bucket Section

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Pilot Port Position

fNOTE: The illustration shows the layout viewed from the machine front.

Control Valve 1 (Upper Left)

Control Valve 4 (Upper Right)

TKGB-03-03-005

TKGB-03-03-008

Control Valve 2 (Middle Left)

Control Valve 5 (Middle Right)

TKGB-03-03-003

TKGB-03-03-006

Control Valve 3 (Lower Left)

Control Valve 6 (Lower Right)

TKGB-03-03-008

TOKGB91-EN-00(20181003)

T3-3-4

TKGB-03-03-004

SECTION 3 COMPONENT OPERATION Group 3 Control Valve

Control Valve 4 (Upper Right)

Control Valve 1 (Upper Left)

12345678-

2526272829303132-

Arm Extend Bucket Open Boom Raise Left Travel Reverse Arm Retract Bucket Close Bucket Tilt-In Left Travel Forward

Bucket Tilt-Out Boom Lower Boom Lower Swing Right Bucket Tilt-In Arm Extend Boom Raise Swing Left

Control Valve 5 (Middle Right)

Control Valve 2 (Middle Left)

910111213141516-

3334353637383940-

Bucket Tilt-In Boom Lower Arm Extend Right Travel Forward Bucket Tilt-Out Boom Raise Arm Retract Right Travel Reverse

Left Travel Forward Bucket Tilt-In Bucket Close Arm Retract Left Travel Reverse Boom Raise Bucket Open Arm Extend

Control Valve 6 (Lower Right)

Control Valve 3 (Lower Left)

1718192021222324-

4142434445464748-

Bucket Tilt-In Boom Lower Boom Lower Swing Right Bucket Tilt-Out Arm Extend Boom Raise Swing Left

TOKGB91-EN-00(20181003)

T3-3-5

Right Travel Reverse Arm Retract Boom Raise Bucket Tilt-Out Right Travel Forward Arm Extend Boom Lower Bucket Tilt-In

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Hydraulic Circuit Control valve 1 (upper left) (a) controls pressure oil from main pumps L5 and L6. Viewed from the port P side, the spools are arranged as follows: swing (16), boom (15), arm extend/boom lower (14), and bucket (13). Control valve 2 (middle left) (b) controls pressure oil from main pumps L3 and L4. Viewed from the port P side, the spools are arranged as follows: left travel (17), boom raise/ bucket tilt-in (18), bucket open/close (19), and arm (20). Control valve 3 (lower left) (c) controls pressure oil from main pumps L1 and L2. Viewed from the port P side, the spools are arranged as follows: right travel (21), arm (22), boom (23), and bucket (24). Control valve 4 (upper right) (d) controls pressure oil from main pumps R1 and R2. Viewed from the port P side, the spools are arranged as follows: left travel (4), boom raise/ bucket tilt-in (3), bucket open/close (2), and arm (1). Control valve 5 (middle right) (e) controls pressure oil from main pumps R3 and R4. Viewed from the port P side, the spools are arranged as follows: right travel (8), arm (7), boom (6), and bucket (5). Control valve 6 (lower right) (f ) controls pressure oil from main pumps R5 and R6. Viewed from the port P side, the spools are arranged as follows: swing (12), boom (11), arm extend/boom lower (10), and bucket (9).

TOKGB91-EN-00(20181003)

The circuit in the control valve consists of the combination tandem circuit and parallel circuit (g). As parallel circuit (g) is equipped as follows, various combined operations can be performed.  Control Valve 1 (Upper Left) (a) Swing (16) and Boom (15) Sections  Control Valve 2 (Middle Left) (b) Boom Raise/Bucket Tilt-In (18), Bucket Open/Close (19), and Arm (20) Sections  Control Valve 3 (Lower Left) (c) Arm (22), Boom (23), and Bucket (24) Sections  Control Valve 4 (Upper Right) (d) Boom Raise/Bucket Tilt-In (3), Bucket Open/Close (2), and Arm (1) Sections  Control Valve 5 (Middle Right) (e) Arm (7), Boom (6), and Bucket (5) Sections  Control Valve 6 (Lower Right) (f ) Swing (12) and Boom (11) Sections

T3-3-6

SECTION 3 COMPONENT OPERATION Group 3 Control Valve d

e P

P P

20 f

10 11

24 P

R4 R3

R1 R2

R3 R4

Front View of Main Pump (Right Engine)

L1 L2

L3 L4

R5 R6

L5 L6 Front View of Main Pump (Left Engine)

TKGB-03-03-001

ab-

Control Valve 1 (Upper Left) Control Valve 2 (Middle Left)

cd-

Control Valve 3 (Lower Left) Control Valve 4 (Upper Right)

ef-

Control Valve 5 (Middle Right) Control Valve 6 (Lower Right)

Parallel Circuit

123456-

Arm Bucket Open/Close Boom Raise/Bucket Tilt-In Left Travel Bucket Boom

789101112-

Arm Right Travel Bucket Arm Extend/Boom Lower Boom Swing

131415161718-

Bucket Arm Extend/Boom Lower Boom Swing Left Travel Boom Raise/Bucket Tilt-In

192021222324-

Bucket Open/Close Arm Right Travel Arm Boom Bucket

TOKGB91-EN-00(20181003)

T3-3-7

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Main Relief Valve

Overload Relief Valve

The main relief valve is located in port P (a) and prevents the main circuit pressure from exceeding the set pressure.

The overload relief valve is located in the actuator port and prevents the actuator circuit pressure from exceeding the set pressure. Operational principle of the overload relief valve is the same as that of the main relief valve.

1. Pressure in port P (a) is routed to pilot poppet (7) through orifice (2) in main poppet (1) and orifice (6) in seat (5). 2. When pressure in port P (a) increases over the spring (8) force, pilot poppet (7) is opened. Pressure oil flows along the outer circumference of sleeve (9) and flows to port T (b). 3. At this time, a pressure difference occurs between port P (a) and spring chamber (4) due to orifice (2). 4. When the force acting on main poppet (1) increases over the spring (3) due to this pressure difference, main poppet (1) is opened and pressure oil in port P (a) directly flows to port T (b). 5. When pressure in port P (a) decreases, main poppet (1) is closed again by the spring (3) force.

Port P

Port T

123-

Main Poppet Orifice Spring

456-

Spring Chamber Seat Orifice

TOKGB91-EN-00(20181003)

T145-02-03-001

789-

T3-3-8

Pilot Poppet Spring Sleeve

SECTION 3 COMPONENT OPERATION Group 3 Control Valve Make-Up Valve The make-up valve is located in actuator port (a). When the actuator circuit pressure decreases less than pressure in the hydraulic oil tank, the make-up valve supplies hydraulic oil from port T (b). 1. Pressure in actuator port (a) acts on poppet (1). 2. When pressure in actuator port (a) decreases less than pressure in the hydraulic oil tank, pressure oil in port T (b) opens poppet (1) and flows to the actuator port (a) side. 3. When pressure in actuator port (a) increases again, poppet (1) is closed by the spring (3) force and the pressure acting on poppet (1).

Actuator Port

Port T

Poppet

Sleeve

TOKGB91-EN-00(20181003)

TKGB-03-03-007

T3-3-9

Spring

SECTION 3 COMPONENT OPERATION Group 3 Control Valve (Blank)

TOKGB91-EN-00(20181003)

T3-3-10

SECTION 3 COMPONENT OPERATION Group 4 Control Equipment Outline On this machine, spool (11) in control valve (7) is operated by electric control lever (1), ELU (12), and EDQR valve (2) for electric control lever.

3 1 2

9 4

c 12 b 5 6

7 8

From Pilot Shut-Off Solenoid Valve

Port P

Port T

12-

Electric Control Lever EDQR Valve for Electric Control Lever Solenoid Valve

4567-

Spool Pilot Pump Actuator Control Valve

891011-

Spring Hydraulic Oil Tank Main Pump Spool

TOKGB91-EN-00(20181003)

T3-4-1

12- ELU

TKEB-03-04-001

SECTION 3 COMPONENT OPERATION Group 4 Control Equipment Electric Control Lever When moving the electric control lever, command current is sent from controller (1) to ELU according to the control lever stroke. Front Attachment, Swing

15~20°

1 X

a 1-

Controller

TOKGB91-EN-00(20181003)

To ELU

T3-4-2

TKGB-03-04-002

SECTION 3 COMPONENT OPERATION Group 4 Control Equipment Front Attachment, Swing

90%±2%

a 50%±1.5%

10%±2%

c d

2 3

1 e f

g h i

abc-

Short Zone About 3° Output Voltage Ratio Center of Electric Control Lever

#1 (Yellow)

TOKGB91-EN-00(20181003)

T18G-03-04-003

fg-

Resistor for Calibration Electrical Turning Angle (30°±5°)

hi-

Total Resistance (2 kΩ±15 %) + Direction on XY Axis

Mechanical Control Angle (±15° to ±20°) Short Zone

#2 (Red)

#3 (Green)

#4 (White)

T3-4-3

SECTION 3 COMPONENT OPERATION Group 4 Control Equipment Travel, Bucket Open/Close

12.4°±1° 12.4°±1°

1 a T18G-03-04-002 1-

Controller

TOKGB91-EN-00(20181003)

To ELU

T3-4-4

SECTION 3 COMPONENT OPERATION Group 4 Control Equipment Travel (Control Curve: 25±5°C) Control Torque

Output Voltage Ratio

N·m 16.0 15.3±2.3

100

Vout

12.0

50±5 20±7.5

8.0 6.5±1.0

12.4±1

4.0 0

80±7.5

12.4±1 deg T18M-03-04-004

a12.4±1

12.4±1 deg T18M-03-04-003

Output Voltage Ratio

Neutral Switch Voltage

deg T18G-03-04-006

Bucket Open/Close (Control Curve: 25±5°C) Control Torque

Output Voltage Ratio

N·m 16.0

100

12.0

9.3±1.4 8.0

v 80±7.5 50±5 20±7.5

4.0

12.4±1

12.4±1 deg T18M-03-04-004

3.9±0.6 0

Vout

a12.4±1

12.4±1 deg T18L-03-04-001

Output Voltage Ratio

Neutral Switch Voltage

deg T18G-03-04-006

TOKGB91-EN-00(20181003)

T3-4-5

SECTION 3 COMPONENT OPERATION Group 4 Control Equipment EDQR Valve for Electric Control Lever The EDQR (Electric Dual Quick Response) valve improves the response characteristics of the control valve spool when the control lever is operated.

The EDQR valve activates the proportional solenoid valve according to current flowing through ELU from the control lever. Then, the EDQR valve moves the spool by using secondary pilot pressure. The EDQR valve directly routes pressure oil from the pilot pump to the spool end of the control valve, and controls the spool end of the control valve.

EDQR Valve (Upper)

EDQR Valve (Lower)

TKGB-03-04-001

Port PP (From Pilot Shut-Off Solenoid Valve)

bc-

Port T1 (To Hydraulic Oil Tank) Port P1 (From Pilot Pump)

123-

Air Bleeding Solenoid Valve Swing Left Solenoid Valve Left Travel Forward Solenoid Valve Bucket Tilt-In Solenoid Valve Boom Lower Solenoid Valve

678-

Boom Raise Solenoid Valve Bucket Open Solenoid Valve Right Travel Forward Solenoid Valve Air Bleeding Solenoid Valve

45-

TOKGB91-EN-00(20181003)

TKGB-03-04-001

10- Right Travel Reverse Solenoid Valve 11- Left Travel Reverse Solenoid Valve 12- Arm Extend Solenoid Valve 13- Arm Retract Solenoid Valve

T3-4-6

14- Bucket Tilt-Out Solenoid Valve 15- Bucket Close Solenoid Valve 16- Swing Right Solenoid Valve

SECTION 3 COMPONENT OPERATION Group 4 Control Equipment Construction

fNOTE: The illustration shows the valve status when the

The EDQR valve consists of housing (1), solenoid valve (2), spool (9), spring (11), filter (3), and orifice (7).

control levers are in neutral.

D 3

1 d

4, 5 a

e A

8 7

10 11 A-A

B-B

C-C

ab-

Port PP Port T

cd-

Port P1 Port S

Port A

1234-

Housing Solenoid Valve (8 Used) Filter Plug (2 Used)

5678-

O-Ring (2 Used) Plug (14 Used) Orifice Plug (7 Used)

9101112-

Spool (7 Used) Plug (14 Used) Spring (7 Used) Plug (7 Used)

TOKGB91-EN-00(20181003)

T3-4-7

D-D TKEB-03-04-007

13- Plug (2 Used)

SECTION 3 COMPONENT OPERATION Group 4 Control Equipment Operation When control lever is in neutral

When control lever is operated

1. When the control lever is in neutral, solenoid valve (1) is not activated. Therefore, as spool (2) is pushed up by the spring (3) force, spool (2) completely blocks pressure oil from port P1 (c).

1. When the control lever is operated, spool (2) is pushed down by signal pressure (f ) from solenoid valve (1) according to the control lever stroke.

2. As output port (e) is connected to port T (b), pressure in output port (e) is equal to pressure in the hydraulic oil tank.

2. The pilot pump pressure oil from port P (c) flows to output port (e) through notch part (g) of spool (2), and pressure in output port (e) increases. 3. Pressure oil in output port (e) also flows to the spring (3) chamber through passage (h) of spool (2)

3. Therefore, the spool of the control valve is kept in neutral.

4. As section areas at the signal pressure (f ) side and spring (3) chamber are same, spool (2) is pushed up until pressure in the spring (3) chamber (spring (3) force: 0.15 MPa and pressure oil in output port (e)) balance with signal pressure (f ). 5. Pressure oil of the pressure according to signal pressure (f ) is supplied to the spool end of the control valve from the EDQR valve. 6. When the control lever is returned to the neutral position, signal pressure (f ) disappears and spool (2) is pushed up by the spring (3) force. 7. As output port (e) is connected to port T (b), pressure oil from the spool end of the control valve returns to the hydraulic oil tank through the EDQR valve and port T (b). 8. The spool of the control valve is returned to the neutral position.

TOKGB91-EN-00(20181003)

T3-4-8

SECTION 3 COMPONENT OPERATION Group 4 Control Equipment When control lever is in neutral

When control lever is operated

2 b

a d

h e

g 3 3 TKEB-03-04-004

Port PP (From Pilot Shut-Off Solenoid Valve) Port T (To Hydraulic Oil Tank)

cde-

Port P1 (From Pilot Pump) Port S (For Pressure Sensor) Output Port (Port A)

fgh-

Signal Pressure Notch Part Passage

Solenoid Valve

Spool

Spring

TOKGB91-EN-00(20181003)

T3-4-9

TKEB-03-04-005

SECTION 3 COMPONENT OPERATION Group 4 Control Equipment Proportional Solenoid Valve The proportional solenoid valve is controlled by the electric current signal through ELC from the electric control lever, and outputs pressure in proportion to the electric current.  Neutral state 1. Spring (2) pushes spool (1) to the right and output port S is connected to tank port T.

 Excited state 1. Solenoid (3) pushes spool (1) to the left by the force in proportion to the current value flowing through solenoid (3). 2. Pilot pressure oil from port P flows to output port S and pressure at output port S increases. 3. This pressure at output port S acts on stepped part (a) of spool (1). Spool (1) is pushed to the right due to difference in the pressure receiving area between stepped part (a). 4. When pressure at output port S increases and the force to push spool (1) to the right is balanced with the force to push spool (1) to the left due to solenoid (3), spool (1) is stopped moving and pressure at output port S stops increasing.

TKEB-03-04-006

Spool

TOKGB91-EN-00(20181003)

Spring

T3-4-10

Solenoid

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Outline The travel device consists of travel motors (6) (2 used) and travel reduction gear (7). Brake valves (1) (2 used) are separately installed from travel motors (6) (2 used). Travel motor (6) is driven by pressure oil from the pump and transmits the rotation power to travel reduction gear (7). Travel reduction gear (7) is a planetary-gear-type reduction gear, converts the travel motor (6) rotation power to a slow-large torque, and rotates the drive tumbler.

Brake valve (1) consists of the counterbalance valve and relief valve, protects the travel circuit from being overloaded, and prevents the machine from rollaway when traveling on a down slope.

12-

Brake Valve (2 Used) Travel Forward Piping (2 Used)

34-

Travel Reverse Piping (2 Used) Travel Mode Control Piping

56-

Drain Piping (2 Used) Travel Motor (2 Used)

TKGB-03-05-001

fNOTE: The illustration shows the travel device at the left side. The number is for one travel device.

TOKGB91-EN-00(20181003)

T3-5-1

Travel Reduction Gear

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Travel Motor The travel motor is a swash-plate type variable displacement axial plunger motor. The travel motor is equipped with parking brake (c) and travel mode selector valve (a). Plunger motor (b) consists of shaft (1), swash plate (2), shoes (7), plungers (4), rotor (3), valve plate (5), and housing (6). Shoe (7) is crimped to plunger (4). Plunger (4) is inserted into the bore of rotor (3). Rotor (3) is connected to shaft (1) by a spline joint.

ab-

Travel Mode Selector Valve Plunger Motor

TKEB-03-05-002

Parking Brake

12-

Shaft Swash Plate

TOKGB91-EN-00(20181003)

34-

Rotor Plunger

T117-03-01-002

56-

T3-5-2

Valve Plate Housing

Shoe

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Operational Principle 1. Travel speed varies depending on the amount of pressure oil which is supplied to the travel motor and on the displacement angle of thrust plate (2) of the swash plate.

4. This rotation power is transmitted to the reduction gear via shaft (1). 5. When rotor (3) rotates and plungers (5) reach the port B (b) side, pressure oil is returned to the hydraulic oil tank.

2. When pressure oil is supplied to port A (a) of valve plate (4), pressure oil enters one side of rotor (3) and pushes plungers (5).

6. Whether forward travel or reverse travel depends on whether pressure oil is supplied to port A (a) or port B (b).

3. As thrust plate (2) of the swash plate is inclined, shoes (6) slide along the swash plate due to this force and rotor (3) rotates.

TKEB-03-05-003

Port A

Port B

12-

Shaft Thrust Plate

34-

Rotor Valve Plate

TOKGB91-EN-00(20181003)

56-

T3-5-3

Plunger Shoe

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Travel Mode Control Slow Speed 1. Port PA and port PB of the travel mode selector valve (1) are connected to the travel main circuit. When travel operation either forward or reverse is performed, the main pressure is routed through port PA or port PB, pushes shuttle (4), and enters port P. 2. When the travel mode switch is OFF (slow speed), reduced pilot pressure (2.4 MPa (350 psi)) (a) acts on port PS of the travel mode selector valve (1). 3. Spool (3) is pushed to the left by pressure from port PS. As the spring (2) force overcomes this pressure, spool (3) is not shifted. 4. The main pressure in port PA or port PB acts on tilt piston (5) (slow speed side) through the notch of spool (3) and port SA. 5. The main pressure pushes tilt piston (5) (slow speed side) and maximizes the displacement angle of travel motor (7). Then, travel speed is changed to slow speed. 6. Pressure oil in tilt piston (6) (fast speed side) flows to port DR through port SB and the passage in spool (3), and returns to the hydraulic oil tank. (Refer to SYSTEM/Control System.)

TOKGB91-EN-00(20181003)

T3-5-4

SECTION 3 COMPONENT OPERATION Group 5 Travel Device

P TKEB-03-05-004

c 8 7 6

T118-03-06-002

Pilot Pressure from Reducing Valve (2.4 MPa)

From Port SA

To Port SB

123-

Travel Mode Selector Valve Spring Spool

456-

Shuttle Tilt Piston (Slow Speed Side) Tilt Piston (Fast Speed Side)

789-

Travel Motor Parking Brake Control Valve

TOKGB91-EN-00(20181003)

T3-5-5

T141-03-05-003

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Fast Speed 1. When the travel mode switch is ON (fast speed), pilot pressure (3.9 MPa (570 psi)) (a) which is not reduced acts on port PS of the travel mode selector valve (1). 2. Pilot pressure (a) overcomes spring (2) and pushes spool (3) to the left. 3. The main pressure in port PA or port PB acts on tilt piston (6) (fast speed side) through the notch of spool (3) and port SB. 4. The main pressure pushes tilt piston (6) (fast speed side) and minimizes the displacement angle of travel motor (7). Then, travel speed is changed to fast speed. 5. Pressure oil in tilt piston (5) (slow speed side) flows to port DR through port SA and the passage in spool (3), and returns to the hydraulic oil tank. (Refer to SYSTEM/Control System.)

TOKGB91-EN-00(20181003)

T3-5-6

SECTION 3 COMPONENT OPERATION Group 5 Travel Device

P TKEB-03-05-005

c 8 7 6

3 1

T118-03-06-002

Pilot Pressure from Reducing Valve (3.9 MPa)

To Port SA

From Port SB

123-

Travel Mode Selector Valve Spring Spool

456-

Shuttle Tilt Piston (Slow Speed Side) Tilt Piston (Fast Speed Side)

789-

Travel Motor Parking Brake Control Valve

TOKGB91-EN-00(20181003)

T3-5-7

T141-03-05-006

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Brake Valve The brake valve consists of counterbalance valve (10) and relief valves (11) (2 used). When Traveling 1. When pressure oil from control valve (12) is supplied to port AV, pressure oil flows through spool (5), opens check valve (4), and flows to port AM. 2. As returning oil from port BM is blocked by check valve (6) and spool (5), returning oil cannot flow to port BV.

Circuit Protection 1. When the circuit pressure increases over the set pressure, relief valve (11) is opened and high pressure oil is relieved to the low-pressure side. Then, the travel motor is protected from being overloaded. 2. Relief valve (11) buffers shock pressure developed by inertia force of the machine when stopping traveling.

3. Therefore, pressure in port AV gradually increases. Pressure oil acts on chamber (1) via orifice (3) and moves spool (5) to the right. 4. Returning oil from port BM flows to port BV through the notch of spool (5) and rotates travel motor (6).

3. When travel motor (13) draws pressure oil like a pump, check valve (4 or 6) is unseated (make-up operation) and prevents the cavitation.

When Descending a Slope 1. When the machine descends a slope, the travel motors are forcibly rotated by the machine self weight like a pump.

2. Pressure oil in port AM is drawn to travel motor (13) and pressure in port AV and chamber (1) decreases. 3. Therefore, as spool (5) returns to the left and returning oil from port BM is reduced by spool (5), oil pressure functions as the brake of travel motor (13).

3 4

7 6 10

4. This hydraulic brake is applied and prevents the machine from rollaway.

11 13 T141-03-05-004

TOKGB91-EN-00(20181003)

T3-5-8

SECTION 3 COMPONENT OPERATION Group 5 Travel Device

T144-03-05-002

1234-

Chamber Spring Orifice Check Valve

TOKGB91-EN-00(20181003)

5678-

Spool Check Valve Orifice Spring

9101112-

T3-5-9

Chamber Counterbalance Valve Relief Valve Control Valve

13- Travel Motor

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Parking Brake The parking brake is a wet-type spring set hydraulic released multi-disc brake. The brake is released when the brake release pressure oil is routed to piston chamber (a). The parking brake consists of coupling (5), friction plates (2), plates (3), piston (6), and springs (4). Coupling (5) is connected to shaft (1) by a spline joint. Plate (3) is connected to coupling (5) by a spline joint. Friction plates (2) are connected to casing (7) by a spline joint and are installed between plates (3). When brake is applied

When brake is released

1. When the pilot control shut-off lever is in the LOCK position, pilot pressure (b) does not act on piston chamber (a).

1. When the pilot control shut-off lever is in the UNLOCK position, pilot pressure (b) acts on piston chamber (a).

2. Therefore, piston (6) is pushed to the left by the spring (4) force.

2. Therefore, piston (6) pushes springs (4) and moves to the right.

3. As friction plates (2) and plates (3) are pushed to casing (7), shaft (1) does not rotate.

3. As friction plates (2) and plates (3) are released from casing (7), this allows shaft (1) to rotate. 2

3 b FR

a c 4

6 a

e b 5 6 f

T18N-03-02-001

7 T117-03-01-004 ab-

Piston Chamber Pilot Pressure (over 1.9 MPa)

Travel Motor

Pilot Control Shut-Off Solenoid Valve (UNLOCK Position)

ef-

Relief Valve (3.9 MPa) Pilot Pump

12-

Shaft Friction Plate

34-

Plate Spring

56-

Coupling Piston

Casing

TOKGB91-EN-00(20181003)

T3-5-10

SECTION 3 COMPONENT OPERATION Group 5 Travel Device Travel Reduction Gear The travel reduction gear consists of spur gear (7) and two-stage reduction planetary gear. Shaft (5) of travel motor (a) rotates spur gear (7) via pinion gear (6). Therefore, The rotation is transmitted to the first stage sun gear (4) after rotation speed is reduced. The first stage sun gear (4) rotates. The rotation of the first stage sun gear (4) is transmitted to the second stage sun gear (2) after rotation speed is reduced between the first stage planetary gears (8) and first stage carrier (3). Then, the second stage sun gear (2) rotates. The rotation of the second stage sun gear (2) is transmitted to drive tumbler (b) after rotation speed is reduced between the second stage planetary gears (9) and second stage carrier (1). 1

3 4

7 T141-03-05-001

Travel Motor

Drive Tumbler

123-

Second Stage Carrier Second Stage Sun Gear First Stage Carrier

456-

First Stage Sun Gear Shaft Pinion Gear

TOKGB91-EN-00(20181003)

789-

T3-5-11

Spur Gear First Stage Planetary Gear Second Stage Planetary Gear

SECTION 3 COMPONENT OPERATION Group 5 Travel Device (Blank)

TOKGB91-EN-00(20181003)

T3-5-12

SECTION 3 COMPONENT OPERATION Group 6 Others (Upperstructure) Oil Cooler Fan Motor The oil cooler fan motor is an inclined-shaft type, fixed displacement axial plunger motor. The oil cooler fan motor consists of drive disc (1), plate (2), center pin (3), plungers (4), rotor (5), valve plate (6), and housing (7). Plunger (4) is installed in drive disc (1) with plate (2). Plunger (4) is inserted into the rotor (5) bore. Drive disc (1) unites with the shaft.

TKGB-03-06-001

12-

Drive Disc Plate

TOKGB91-EN-00(20181003)

34-

Center Pin Plunger

56-

T3-6-1

Rotor Valve Plate

Housing

SECTION 3 COMPONENT OPERATION Group 6 Others (Upperstructure) Operational Principle The oil cooler fan motor rotation speed varies depending on the amount of pressure oil which is supplied to the oil cooler fan motor. When pressure oil is supplied to port AM of valve plate (6), pressure oil enters one side of rotor (5) and pushes plungers (4). Vertical component force (FV) of force (F) rotates drive disc (1). This rotation power is transmitted to the shaft which unites with the drive disc (1).

As drive disc (1) rotates, rotor (5) rotates. When plungers (4) reach the port BM side, pressure oil is returned to the hydraulic oil tank. Whether the rotational direction depends on whether pressure oil is supplied to port AM or port BM.

1 4 5 FV

AM BM

TKEB-03-06-001

Drive Disc

TOKGB91-EN-00(20181003)

Plunger

T3-6-2

Rotor

Valve Plate

SECTION 3 COMPONENT OPERATION Group 6 Others (Upperstructure) Air Conditioner Compressor Motor The air conditioner compressor motor is a swash-plate type, fixed displacement axial plunger motor. The motor consists of shaft (1), swash plate (3), shoes (2), plungers (4), rotor (5), valve plate (6), and housing (7). Shoe (2) is crimped onto plunger (4) which is inserted into the bore of rotor (5). Rotor (5) is connected to shaft (1) by a spline joint.

TKGB-03-06-002

12-

Shaft Shoe

TOKGB91-EN-00(20181003)

34-

Swash Plate Plunger

56-

T3-6-3

Rotor Valve Plate

Housing

SECTION 3 COMPONENT OPERATION Group 6 Others (Upperstructure) Operational Principle 1. The rotation speed varies depending on the amount of pressure oil which is supplied to the motor.

4. This rotation power is transmitted via shaft (1). 5. When rotor (5) rotates and plungers (4) reach the port B (b) side, pressure oil is returned to the hydraulic oil tank.

2. When pressure oil is supplied to port A (a) of valve plate (6), pressure oil enters one side of rotor (5) and pushes plungers (4).

6. Whether the rotational direction depends on whether pressure oil is supplied to port A (a) or port B (b).

3. As swash plate (3) is inclined, shoes (2) slide along swash plate (3) due to this force and rotor (5) rotates.

6 b

TKEB-03-05-003

Port A

Port B

12-

Shaft Shoe

34-

Swash Plate Plunger

TOKGB91-EN-00(20181003)

56-

T3-6-4

Rotor Valve Plate

SECTION 3 COMPONENT OPERATION Group 6 Others (Upperstructure) Folding Stairway Pump Unit The folding stairway pump unit consists of electric motor (1) and gear pump (2). The folding stairway pump unit is activated only while the retract switch or extend switch is pushed. Electric motor (1) is a 24 V-DC motor.

TKEB-03-06-002

Electric Motor

TOKGB91-EN-00(20181003)

Gear Pump

T3-6-5

SECTION 3 COMPONENT OPERATION Group 6 Others (Upperstructure) Pilot Relief Valve 1. Pressure oil acts on poppet (2).

The pilot relief valve is a direct operated relief valve. The pilot relief valve is installed in the pilot circuit and functions to regulate pressure oil to a constant pressure. The pilot relief valve consists of body (1), poppet (2), spring (3), guide (4), and plug (5).

2. When pressure acting on poppet (2) increases over the spring (3) force, poppet (2) is opened. 3. Pressure oil flows to port T (T) from port B (B). 4. Consequently, the pressure is kept constant.

TKEB-03-06-003

A-

Port A

B-

Port B

T-

Port T

12-

Body Poppet

34-

Spring Guide

Plug

TOKGB91-EN-00(20181003)

T3-6-6

SECTION 3 COMPONENT OPERATION Group 6 Others (Upperstructure) Solenoid Valve This solenoid valve is used for the following solenoid valves.  Pilot Shut-Off Solenoid Valve  Travel Mode Selector Solenoid Valve  Fast Filling Solenoid Valve The solenoid valve is an ON/OFF solenoid valve. The solenoid valve changes the output port according to the signal to the solenoid.  Neutral state Spool (2) is set in the neutral position by springs (1, 4).Port P (P) is connected to port A (A). Port T (T) is connected to port B (B).  Operating state When solenoid (3) is excited, spool (2) is pushed to the right. Port P (P) is connected to port B (B). Port T (T) is connected to port A (A).

B TKGB-03-06-003

A-

Port A

B-

Port B

P-

Port P

T-

Port T

Spring

Spool

Solenoid

Spring

TOKGB91-EN-00(20181003)

T3-6-7

SECTION 3 COMPONENT OPERATION Group 6 Others (Upperstructure) Reducing Valve for Travel Mode Control The reducing valve for travel mode control decreases primary pilot pressure to the specified pressure and supplies secondary pilot pressure to the travel mode selector valve. The reducing valve for travel mode control consists of housing (1), spool (2), spring (3), and plugs (4, 5, 6).

1. Pressure oil from input port (B) flows to output port (C) through spool (2). 2. When pressure in output port (C) increases over the spring (3) force, spool (2) is moved to the right. 3. As output port (C) is connected to tank port (A), pressure oil flows to tank port (A) from output port (C). 4. Pressure in output port (C) is decreased and becomes lower than pressure in input port (B). 5. When pressure oil flows to pilot port (D), spool (2) is moved to the left. Then, output port (C) is disconnected from tank port (A). Pressure in output port (C) is not decreased.

2 P

T 6

A-

Tank Port

B-

Input Port

C-

Output Port

12-

Housing Spool

34-

Spring Plug

56-

Plug Plug

TOKGB91-EN-00(20181003)

TKGB-03-06-004

T3-6-8

D-

Pilot Port

SECTION 3 COMPONENT OPERATION Group 6 Others (Upperstructure) Accumulator The accumulator is provided in the pilot circuit. The accumulator buffers fluctuations in oil pressure and maintains the pilot pressure for a short time period after the engine is stopped. The accumulator mainly consists of body (3), holder (4), nitrogen gas (N2) (1) and bladder (2).

 Pressure oil from the pilot pump is routed to the accumulator through port A and compresses bladder (2) until pressure oil balances with nitrogen gas (N2) (1) in bladder (2).

 When pressure oil is stopped supplying due to engine stopping, bladder (2) starts expanding and supplies accumulated pressure oil (B) to the pilot circuit through port A.

T105-02-10-003

TOKGB91-EN-00(20181003)

A-

Port A

B-

Accumulated Pressure Oil

12-

Nitrogen Gas (N2) Bladder

34-

Body Holder

T3-6-9

SECTION 3 COMPONENT OPERATION Group 6 Others (Upperstructure) (Blank)

TOKGB91-EN-00(20181003)

T3-6-10

SECTION 3 COMPONENT OPERATION Group 7 Others (Undercarriage) Swing Bearing The swing bearing supports the upperstructure on the undercarriage and allows the upperstructure to rotate smoothly. The swing bearing is a three-row-roller type bearing and consists of retaining ring (7), support ring (8), nose ring (4), three types of rollers (1, 2, 6), and seals (3, 5). Retaining ring (7) and support ring (8) are bolted to the upperstructure. Nose ring (4) is bolted to the undercarriage. The internal gear of nose ring (4) meshes with the pinion gear of the swing reduction gear.

8 7 4 6

12-

Radial Roller Support Roller

TOKGB91-EN-00(20181003)

34-

Seal Nose Ring

T115-03-03-001

56-

T3-7-1

Seal Retaining Roller

78-

Retaining Ring Support Ring

SECTION 3 COMPONENT OPERATION Group 7 Others (Undercarriage) Accumulator The accumulator consists of shell (2), bladder (3), gas valve (4), and oil port assembly (1). Shell (2) is filled with the hydraulic oil. The high pressure nitrogen gas is enclosed in bladder (3). Bladder (3) is contracted until the gas pressure in bladder (1) balances with pressure oil flowing through oil port assembly (1).

T115-03-03-003

Oil Port Assembly

TOKGB91-EN-00(20181003)

Shell

T3-7-2

Bladder

Gas Valve

SECTION 3 COMPONENT OPERATION Group 7 Others (Undercarriage) Adjuster Cylinder The adjuster cylinder consists of two single-acting pistons. Cushion piston (2) in the front part absorbs shock loads. Adjuster piston (1) in the rear part adjusts track sag. Cushion piston (2) accumulates pressure oil (d) in the piston chamber. When cushion piston (2) is pushed by external load, cushion piston (2) absorbs shock loads. Adjuster piston (1) adjusts track sag according to the amount of grease (b) in the piston chamber.

Travel stop valve (3) is installed in the stroke end of cushion piston (2). When cushion piston (2) is moved to the stroke end, travel stop valve (3) is shifted and generates signal pressure (c). Then, the travel operation is stopped. (Refer to SYSTEM/Hydraulic System/Travel Shock Absorbing/Travel Stop Circuit.)

1 b

2 d

TKEB-03-07-001

ab-

Rear Side Grease

cd-

Signal Pressure Pressure Oil

Front Side

Adjuster Piston

Cushion Piston

Travel Stop Valve

TOKGB91-EN-00(20181003)

T3-7-3

SECTION 3 COMPONENT OPERATION Group 7 Others (Undercarriage) Center Joint The center joint is a freely rotatable joint. When the upperstructure swings, the center joint eliminates twisting of hoses and supplies hydraulic oil to the travel motors. Body (1) is secured to the swing center of the upperstructure. Spindle (3) is secured to the undercarriage and can not swing.

Pressure oil flows to the right and left travel motors through spindle (3) and each oil port of spindle (3). Seal (2) is installed between body (1) and spindle (3), and prevents oil leaks from each oil port.

1 a 2 b c d

f 3

e g

ab-

Travel (Left Reverse) Travel (Right Forward)

cd-

Travel (Left Forward) Travel (Right Reverse)

ef-

Signal Pressure Drain

Body

Seal

Spindle

TOKGB91-EN-00(20181003)

T3-7-4

TKEB-03-07-002

Pilot Pressure

SECTION 3 COMPONENT OPERATION Group 8 Others (Front Attachment) Make-Up Valve Hydraulic Circuit Diagram

The make-up valve is located in the boom lower flow rate regenerative circuit between the boom cylinder bottom and rod sides. The make-up valve is activated when performing boom lower operation. The make-up valve consists of housing (1), cover (2), spool (3), check valve (4), spring (5), sleeve (6), poppet (7), check valve (8), and spring (9).

TKEB-03-08-001

3 b

c T18G-03-04-015

ABC-

Port A Port B Passage

Pi- Port Pi Dr- Port Dr a- To Hydraulic Oil Tank

From Boom Lower Make-Up Solenoid Valve To Cylinder Rod Side

123-

Housing Cover Spool

456-

789-

Poppet Check Valve Spring

TOKGB91-EN-00(20181003)

Check Valve Spring Sleeve

T3-8-1

From Cylinder Bottom Side

SECTION 3 COMPONENT OPERATION Group 8 Others (Front Attachment) Operation When pressure in port Pi is low  Pressure in port A (A) is higher than pressure in port B (B). 1. When pressure in port Pi is low, spool (3) is pushed to the right by spring (5).

 Pressure in port A (A) is lower than pressure in port B (B). 1. When pressure in port Pi is low, spool (3) is pushed to the right by spring (5).

2. Pressure oil in port A (A) flows through check valve (8) of poppet (7).

2. Pressure oil in port B (B) flows through check valve (4) of spool (3).

3. Pressure in passage (C) is equal to pressure in port A (A).

3. Pressure in passage (C) is equal to pressure in port B (B).

4. The port A (A) pressure receiving area of poppet (7) is smaller than the passage (C) pressure receiving area.

4. The port B (B) pressure receiving area of poppet (7) is smaller than the passage (C) pressure receiving area.

5. Poppet (7) is pushed to the right by pressure in passage (C).

6. Pressure oil does not flow to port B (B) from port A (A).

6. Pressure oil does not flow to port A (A) from port B (B).

3 Pi

B T18G-03-04-015

A-

Port A

B-

Port B

C-

Passage

34-

Spool Check Valve

57-

Spring Poppet

Check Valve

TOKGB91-EN-00(20181003)

T3-8-2

Pi-

Port Pi

SECTION 3 COMPONENT OPERATION Group 8 Others (Front Attachment) When spool (3) is moved by pressure in port Pi when performing boom lower operation 1. When pressure in port Pi is routed to the spool (3) end and increases over the spring (5) force, spool (3) is pushed to the left.

7. Port A (A) is connected to port B (B). Then, pressure oil flows to port B (B) from port A (A).

2. Pressure oil in passage (C) flows to port B (B) through spool (3) and variable orifice (D) of housing (1). 3. Pressure in passage (C) decreases and poppet (7) is moved to the left. Check valve (8) of poppet (7) is opened.

Pressure (b) Pressure Receiving Characteristic of Port Pi a mm

4. Pressure oil in port A (A) flows to passage (C) through check valve (8), poppet (7), and variable orifice (E) of sleeve (6). 5. Pressure in passage (C) depends on pressure oil flowing through variable orifices(D) and variable orifice (E) as the reduced amount of pressure oil depends on the position of poppet (7). 6. When the force to push poppet (7) to the right due to pressure in passage (C) is balanced with the force to push poppet (7) to the left due to pressure oil in port A (A), poppet (7) is stopped moving.

b MPa

TKEB-03-08-002 ab-

5 a

c mm

Stroke of Spool (3) Pressure in Port Pi

Stroke of Poppet (7)

3 Pi

1 F

D C E

ABC-

Port A Port B Passage

DE-

123-

Housing Cover Spool

456-

TOKGB91-EN-00(20181003)

Variable Orifice Variable Orifice Check Valve Spring Sleeve

F-

Pi-

Operation of Spool and Poppet Port Pi

789-

Poppet Check Valve Spring

T3-8-3

T18G-03-04-015

SECTION 3 COMPONENT OPERATION Group 8 Others (Front Attachment) 3-Spool Solenoid Valve Unit Hydraulic Circuit Diagram

The 3-spool solenoid valve unit consists of proportional solenoid valves (SA, SB, and SC). SA: This valve controls the make-up valve for boom. SB: Unused SC: This valve is used for air bleeding. Solenoid Valve SA (Boom Lower Make-Up Solenoid Valve) The boom lower make-up solenoid valve controls the make-up valve for boom according to the signal from ELU.

TKEB-03-08-003

TKEB-03-08-004

P-

From Pilot Pump

TOKGB91-EN-00(20181003)

D-

To Hydraulic Oil Tank

T3-8-4

MEMO

TOKGB91-EN-00(20181003)

MEMO

TOKGB91-EN-00(20181003)