Hitachi ZX250-7 300-7 ELECTRICAL CIRCUIT DIAGRAM MANUAL by www.heydownloads.com

PART NO.

TODFY50-EN-00

ZX250LC-7 • 250LCN-7 HYDRAULIC EXCAVATOR

Technical Manual Operational Principle

TECHNICAL MANUAL OPERATIONAL PRINCIPLE

250LC-7 250LCN-7

Hydraulic Excavator

URL:http://www.hitachi-c-m.com

TODFY50-EN-00

PRINTED IN JAPAN (K) 2020, 01

Service Manual consists of the following separate Part No. Technical Manual (Operational Principle) : Vol. No.TODFY50-EN Technical Manual (Troubleshooting) : Vol. No.TTDFY50-EN Workshop Manual : Vol. No.WDFY50-EN Engine Manual : Vol. No.ETDFY50-EN, EWDFY50-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. ● Be sure to thoroughly read this manual for correct product information and service procedures. ● 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 this form for usage.) •

Service Material Development Center Hitach Construction Machinery Co., Ltd.

•

TEL: 81-29-832-9673

•

FAX: 81-29-831-1162

• E-mail: HCM-TIC-GES@hitachi-kenki.com 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.

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 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 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 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. Each number contains the following information: ● Technical Manual: T 1-3-5 T

Technical Manual

Section Number

Group Number

Consecutive Page Number for Each Group

● Workshop Manual: W 1-3-2-5 W

Workshop Manual

Section Number

Group Number

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IN-1

INTRODUCTION 2

Sub Group Number

Consecutive Page Number for Each Group

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

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.

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

CAUTION Indicates potentially hazardous situation which could, if not avoided, result in personal injury or death. This is also provided before the indication of mass to draw attention to safety during handling of the machine.

IMPORTANT Indicates a situation which, if not conformed to the instructions, could result in damage to the machine. This header is given to matters that are important in terms of operation and management.

NOTE Indicates supplementary technical information or know-how.

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 Length

To Convert From

Into

Multiply By

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

0.10197

Pressure

MPa

kgf/cm2

10.197

MPa

psi

145.0

Volume

TODFY50-EN-00(10/01/2020)

IN-2

INTRODUCTION Quantity Power

To Convert From

Into

Multiply By

1.360

1.341

Temperature

°C

°F

°C×1.8+32

Velocity

km/h

mph

0.6214

min-1

rpm

1.0

L/min

US gpm

0.2642

mL/rev

cc/rev

1.0

Flow rate

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IN-3

INTRODUCTION MEMO

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IN-4

SYMBOL AND ABBREVIATION Symbol and Abbreviation Symbol/Abbreviation

Name

Meaning

Technical manual (Operational Technical manual (Operational principle). principle)

Technical manual (Trouble shooting)

Technical manual (Troubleshooting).

T/M

Technical manual

Technical manual.

W, W/M

Workshop manual

Workshop Manual (Mounting/dismounting, disassembly and assembly of devices).

Main Controller

Main Controller. MC controls the engine, pumps, and valves ac cording to the machine operation condition.

ECM

Engine Control Module

Engine Controller. ECM controls the fuel injection amount and others according to the machine operation condition.

VGS

Variable Geometry System con Variable Turbocharger Controller. VGS is a system for efficiently troller supercharging even when the engine speed is low and the ex haust energy is low. Through adjustment of the nozzle open ing of the turbine housing, the turbine rotation speed is opti mized, the low-speed torque and acceleration are improved, and the power consumption and PM are reduced.

GSM

Global System for Mobile com Communication Controller. GSM is one of wireless communica munications controller tion methods and is used in over 100 countries centering around Europe and Asia and serves as the de facto global standard for mobile phones.

GPS

Global Positioning System

Global Positioning System.

CAN

Controller Area Network

CAN communication. CAN is ISO Standards of the serial com munication protocol (rules).

A/C

Air Conditioner

Air conditioner.

OP, OPT

Option

Optional item.

MPDr.

Maintenance Pro Dr.

MPDr. is software for conducting troubleshooting, monitoring, and adjustment.

A/I

Auto-Idle

Auto-Idle.

Warming-Up

Warming up.

Low (Slow) Idle

Slow Idle Engine Speed

ATT

Attachment

Attachment. In this document, it refers to an optional part such as breaker, pulverizer, and crusher.

HI, Hi

High

Travel fast speed position.

LO, Lo

Low

Travel slow speed position.

DPF

Diesel Particulate Filter

DPF (Diesel Particulate Filter) is a filter to remove fine particles including harmful substances in the exhaust gas of the diesel engine. Exhaust fine particle removing device.

DPD

Diesel Particulate Diffuser

DPD (Diesel Particulate Diffuser) is an exhaust gas purifying device (one type of DPF) that removes PM (particulate matter) in the exhaust gas of the diesel engine. DPD collects and filters PM in the exhaust gas using a ceramic filter and, when the PM accumulation amount has become large, incinerates the accu mulated PM at once and regenerates the filter.

DOC

Diesel Oxidation Catalyst

Oxidation catalyst for diesel. DOC oxidizes the unburnt fuel and raises the exhaust temperature.

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SY-1

SYMBOL AND ABBREVIATION Symbol/Abbreviation

Name

Meaning

CSF

Catalyzed Soot Filter

Filter. The filter collects PM, and removes it by burning it by means of high-temperature exhaust gas whose temperature has been raised by oxidation catalyst. The catalyst is also ap plied on the filter, thus accelerating burning of PM.

Particulate Matter

Particulate matter.

EGR

Exhaust Gas Recirculation

The EGR re-circulates a part of exhaust gas into intake mani fold and mixes it with intake-air to lower the burn temperature and suppress the generation of NOx (nitrogen oxide).

Moment Limiter

ML crane.

HRV

Hose Rupture Valve

Hose rupture valve.

LLC

Long Life Coolant

Coolant.

SCR

Selective Catalytic Reduction

The urea SCR system injects DEF to NOx in the exhaust of en gine to remove NOx.

DCU

Dosing Control Unit

Urea SCR System Controller. DCU controls the DEF injection amount and others according to the machine operation condi tion.

S/M

Supply Module

DEF supply module. The DEF supply module supplies the pres surized DEF to dosing module (D/M). When the key switch is set to the OFF position, it sucks DEF from DEF circuit to return it.

D/M

Dosing Module

Dosing Module. The dosing module (D/M) injects DEF into the exhaust piping according to the signal from DCU.

NOx

Nitrogen Oxide

Nitrogen oxide.

DEF

Diesel Exhaust Fluid

Urea water. This is urea water with a concentration of 32.5% that is specified in ISO 22241.

PLCU

Performance Level Control Unit PLCU is a controller to control AFL.

PBLI

Push Button Low Idle

Push button low idle. PBLI is described as audio mute/onetouch idle switch in this manual.

AFL

Auxiliary Function Lever

AUX function lever.

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SY-2

CONTRASTING LIST OF PART NAME Contrasting List of Part Name between Technical Manual and Parts Catalog Part name in technical manual

Part name in parts catalog

Part No.

Fuel Sensor (float)

FLOAT

4660782

Hydraulic Oil Temperature Sensor

SENSOR

4697482

MAF/Intake-Air Temperature Sensor

SENSOR

4664861

Ambient Temperature Sensor

SENSOR

4405815

Coolant Temperature Sensor

SENSOR;THERMO

YA00010305

Common Rail Pressure Sensor

RAIL ASM; COMMON

8982446690

Fuel Temperature Sensor

SENSOR;FUEL TEMP

8980235810

Crank Speed Sensor

SENSOR

YA00010304

Engine Oil Pressure Sensor

SENSOR;PRES

4657942

EGR Cooler Outlet Temperature Sensor

SENSOR;THERMO

YA00001667

Intake Manifold Temperature Sensor

SENSOR;THERMO

YA00011515

Boost Pressure/Temperature Sensor

SENSOR;PRES

YA00001668

EGR Cooler Inlet Temperature Sensor

SENSOR;THERMO

YA00001666

Cam Angle Sensor

SENSOR;ANGLE

YA00011513

Differential Pressure Sensor

SENSOR;PRESSURE

YA00054794

Upstream NOx Sensor

SENSOR;NOX

YA00001705

Downstream NOx Sensor

SENSOR;NOX

YA00001705

DOC Outlet Exhaust Temperature Sensor

SENSOR;THERMO

YA00009436

DOC Inlet Exhaust Temperature Sensor

SENSOR;THERMO

YA00009435

SCR Exhaust Temperature Sensor

SENSOR;THERMO

YA00001706

Pump 1 Delivery Pressure Sensor

SENSOR;PRESSURE

4436271

Pump 2 Delivery Pressure Sensor

SENSOR;PRESSURE

4436271

Pump 3 Delivery Pressure Sensor

SENSOR;PRESSURE

4436271

Pump 1 Control Pressure Sensor

SENSOR;PRES.

4436536

Pump 2 Control Pressure Sensor

SENSOR;PRES.

4436536

Pump 3 Control Pressure Sensor

SENSOR;PRES.

4436536

Arm 1 Roll-In Pilot Pressure Sensor

SENSOR;PRESSURE

4436535

Arm 2 Roll-In Pilot Pressure Sensor

SENSOR;PRESSURE

4436535

Arm Roll-Out Pilot Pressure Sensor

SENSOR;PRESSURE

4436535

Bucket Roll-In Pilot Pressure Sensor

SENSOR;PRESSURE

4436535

Bucket Roll-Out Pilot Pressure Sensor

SENSOR;PRESSURE

4436535

Boom Raise Pilot Pressure Sensor

SENSOR;PRESSURE

4436535

Auxiliary 1 Pilot Pressure Sensor

SENSOR;PRESSURE

4436535

Auxiliary 2 Pilot Pressure Sensor

SENSOR;PRESSURE

4436535

Swing Pilot Pressure Sensor

SENSOR;PRESSURE

4436535

Travel Pilot Pressure Sensor

SENSOR;PRESSURE

4436535

Front Pilot Pressure Sensor

SENSOR;PRESSURE

4436535

DEF Quality Sensor

UNIT;UREA

YA00050269

DEF Tank Level Sensor

UNIT;UREA

YA00050269

DEF Tank Temperature Sensor

UNIT;UREA

YA00050269

TODFY50-EN-00(10/01/2020)

CO-1

CONTRASTING LIST OF PART NAME Part name in technical manual

Part name in parts catalog

Part No.

Engine Oil Monitoring Sensor

SENSOR;OIL

YA00046690

Hydraulic Oil Monitoring Sensor

SENSOR;OIL

YA00052887

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CO-2

SECTION AND GROUP CONTENTS

SECTION1 GENERAL Group1

Specifications

Group2

Component Layout

Group3

Component Specifications

SECTION2 SYSTEM TECHNICAL MANUAL ( O p e r a t i o n a l P r i n c i p l e )

Group1

Controller

Group2

Control System

Group3

Engine System

Group4

Hydraulic System

Group5

Electrical System

SECTION3 COMPONENT OPERATION Group1

Pump Device

Group2

Swing Device

Group3

Control Valve

Group4

Pilot Valve

Group5

Travel Device

Group6

Signal Control Valve

Group7

Others (Upperstructure)

Group8

Others (Undercarriage)

MEMO

TODFY50-EN-00(10/01/2020)

GENERAL Specifications............................................T1-1-1 Specifications of ZX250LC-7, 250LCN-7....................... T1-1-1 Specifications of ZX250LC-7, 250LCN-7 (2-Piece Boom) ................................................................................. T1-1-2 Working Ranges of ZX250LC-7, 250LCN-7.................. T1-1-3 Working Ranges of ZX250LC-7, 250LCN-7 (2-Piece Boom) ................................................................................. T1-1-4

Component Layout...................................T1-2-1 Main Component (Upperstructure) .............................. T1-2-1 Main Component (Undercarriage) ................................ T1-2-3 Main Component (Front Attachment) ......................... T1-2-3 Electrical System (Overview) ........................................... T1-2-4 Electrical System (Rear Tray) ............................................ T1-2-5 Electrical System (Switches)............................................. T1-2-6 Electrical System (Utility Space) ..................................... T1-2-7 Electrical System (Relays).................................................. T1-2-7 Engine Oil Monitoring Sensor ......................................... T1-2-8 Hydraulic Oil Monitoring Sensor.................................... T1-2-8 Engine ...................................................................................... T1-2-9 Aftertreatment Device .....................................................T1-2-10 Pump Device .......................................................................T1-2-10 Around Pump Device .......................................................T1-2-11 Control Valve .......................................................................T1-2-12 Signal Control Valve..........................................................T1-2-12 Swing Device.......................................................................T1-2-13 Travel Device .......................................................................T1-2-14 5-Spool Solenoid Valve Unit ..........................................T1-2-14 3-Spool Solenoid Valve Unit ..........................................T1-2-15 2-Spool Solenoid Valve Unit (For Aftertreatment Device Regeneration Control) .................................T1-2-15 DEF Tank................................................................................T1-2-16 DEF Supply Module...........................................................T1-2-16 Layout of Attachment Spec. Parts ...............................T1-2-17 Around Control Valve .......................................................T1-2-18 Control Valve Lower Side ................................................T1-2-18 Utility Space.........................................................................T1-2-19

Component Specifications.......................T1-3-1 Specifications of Engine .................................................... T1-3-1 Specifications of Engine Accessories............................ T1-3-3 Specifications of Hydraulic Component...................... T1-3-3 Specifications of Electrical Component....................... T1-3-5

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MEMO

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SYSTEM Controller ..................................................T2-1-1 Outline of Controller........................................................... T2-1-1 CAN Circuit ............................................................................. T2-1-1

Control System..........................................T2-2-1 Outline of Control System ................................................ T2-2-1 Engine Control ...................................................................... T2-2-1 Engine Control System Layout........................................ T2-2-2 Engine Protection Control ................................................ T2-2-3 Engine Control Dial Control ............................................. T2-2-5 ECO Control............................................................................ T2-2-7 Power Mode (ECO/PWR Mode) Switch Control ........ T2-2-9 ECO Mode Control.............................................................T2-2-11 Travel HP Mode Control...................................................T2-2-13 Auto-Idle Control ...............................................................T2-2-15 Hydraulic Oil Temperature Auto Warming-Up Control..............................................................................T2-2-17 Radiator Coolant Temperature Auto Warming-Up Control..............................................................................T2-2-19 Idle Speed-Up Control .....................................................T2-2-21 Idle Speed-Up Control (Pilot Shut-Off Lever)...........T2-2-23 Engine Speed Slow Down Control ..............................T2-2-25 Heater Control.....................................................................T2-2-27 One-Touch Idle Control....................................................T2-2-29 Attachment Operation Speed Increase Control (Option)............................................................................T2-2-31 Attachment Operation Speed Limit Control (Option)............................................................................T2-2-33 Pump Control ......................................................................T2-2-35 Pump Control System Layout........................................T2-2-36 Speed Sensing Control ....................................................T2-2-37 Swing Relief Cut Control .................................................T2-2-39 Pump Torque Decrease Control (Radiator Coolant Temperature) .................................................................T2-2-40 Pump Torque Decrease Control (Hydraulic Oil Temperature) .................................................................T2-2-42 Travel Torque-Up Control................................................T2-2-44 Pump Torque Restriction Control (During Engine Output Restriction)......................................................T2-2-46 Pump 1 Flow Rate Control..............................................T2-2-48 Pump 2 Flow Rate Control..............................................T2-2-50 Pump 3 Flow Rate Control..............................................T2-2-52 Pump 1 Flow Rate Limit Control (Option).................T2-2-54 Pump 2 Flow Rate Limit Control (Option).................T2-2-56 Pump 3 Flow Rate Limit Control (Option).................T2-2-58

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Valve Control (Standard) .................................................T2-2-60 Valve Control (Standard) System Layout...................T2-2-61 Power Digging Control ....................................................T2-2-62 Auto-Power Lift Control...................................................T2-2-64 Travel Motor Displacement Angle Control ...............T2-2-66 Arm Regenerative Cut Control......................................T2-2-68 Digging Regenerative Control ......................................T2-2-70 Arm 1 Flow Rate Control .................................................T2-2-72 Arm 2 Roll-In Pilot Cut Control......................................T2-2-74 Aftertreatment Device Manual Regeneration Control..............................................................................T2-2-76 Aftertreatment Device Auto Regeneration Control .............................................................................................T2-2-78 Pump 3 Center Bypass Shut-Out Control..................T2-2-80 Arm Roll-In Meter-Out Open Control .........................T2-2-82 Valve Control (Option) .....................................................T2-2-85 Valve Control (Option) System Layout .......................T2-2-86 Attachment Flow Rate Control .....................................T2-2-87 Auxiliary Flow Combiner Control.................................T2-2-89 Breaker 1 (HSB Breaker) Control ...................................T2-2-91 Auxiliary Overload Relief Valve Pressure Control .... .............................................................................................T2-2-93 Pump/Valve Coordination Control ..............................T2-2-95 Pump/Valve Coordination Control System Layout. .............................................................................................T2-2-96 Pump 3 Minimum Displacement Angle Hold Control during Digging Operation ........................T2-2-97 Other Control ................................................................... T2-2-100 Work Mode Control........................................................ T2-2-100 Auto Shut-Down Control ............................................. T2-2-100 Automatic Engine Stop Control at Low Temperature................................................................ T2-2-102 Hydraulic Oil Overheat Alarm Control .................... T2-2-103 Breaker Alarm Control (Option)................................. T2-2-104 Travel Alarm Control (Option) .................................... T2-2-105 Swing Alarm Control (Option).................................... T2-2-106 Overload Alarm Control (Option).............................. T2-2-108

Engine System ..........................................T2-3-1 Outline of ECM System ...................................................... T2-3-1 Fuel Injection Control......................................................... T2-3-2 Fuel Injection Amount Control ....................................... T2-3-3 Fuel Injection Timing Control.......................................... T2-3-5 Fuel Injection Rate Control............................................... T2-3-7 Fuel Injection Pressure Control....................................... T2-3-8 Fuel Injection Amount Correction Control...............T2-3-10

EGR Control..........................................................................T2-3-12 Preheating Control ............................................................T2-3-14 Variable Turbocharger Control .....................................T2-3-15 Alarm Control......................................................................T2-3-16 Urea SCR System ................................................................T2-3-16 DEF Injection Control .......................................................T2-3-17 Start-Up Control .................................................................T2-3-18 DEF Defrosting Control(DEF Tank)...............................T2-3-19 DEF Defrosting Control(DEF Piping) ...........................T2-3-20 DEF Thermal Control(DEF Tank) ...................................T2-3-21 DEF Thermal Control(DEF Piping)................................T2-3-22 After-Run Control...............................................................T2-3-23 Engine Output Restriction Control (INDUCEMENT) .............................................................................................T2-3-25 Insufficient DEF Level .......................................................T2-3-26 Malfunction of Urea SCR System/Malfunction of EGR System.....................................................................T2-3-26 Outline of Aftertreatment Device................................T2-3-27 Operation of Aftertreatment Device...........................T2-3-28 Aftertreatment Device Regeneration Control.........T2-3-29

Hydraulic System ......................................T2-4-1 Outline of Hydraulic System ............................................ T2-4-1 Pilot Circuit of Hydraulic System .................................... T2-4-1 Operation Control Circuit.................................................. T2-4-3 Pump Control Circuit (Refer to COMPONENT OPERATION/Pump Device.) ........................................ T2-4-5 Aftertreatment Device Regeneration Control Circuit (Refer to SYSTEM/Control System.)............ T2-4-7 Valve Control Circuit (Refer to COMPONENT OPERATION/Control Valve, Travel Device.)............ T2-4-8 Travel Motor Displacement Angle Control Circuit (Refer to COMPONENT OPERATION/Travel Device.).............................................................................T2-4-11 Swing Parking Brake Release Circuit (Refer to COMPONENT OPERATION/Swing Device.)..........T2-4-13 Main Circuit of Hydraulic System .................................T2-4-13 Neutral Circuit .....................................................................T2-4-16 Flow Combiner Circuit (Front Attachment)..............T2-4-17 Relief Circuit.........................................................................T2-4-19 Combined Operation Circuit .........................................T2-4-21 Flow Combiner Circuit .....................................................T2-4-22 Digging Regenerative Circuit ........................................T2-4-25 Arm Regenerative Cut Circuit........................................T2-4-27 Arm 1 Flow Rate Control Circuit ...................................T2-4-29 Arm 2 Roll-In Pilot Cut Control Circuit........................T2-4-31 Pump 3 Center Bypass Shut-Out Control Circuit..... .............................................................................................T2-4-33 Arm Roll-In Meter-Out Open Control Circuit ...........T2-4-35 Bucket Regenerative Cut Circuit...................................T2-4-37 Boom Lower Meter-In Cut Control ..............................T2-4-39 Boom Cylinder Bottom Pressure: High (With the Front Attachment above the Ground)..................T2-4-39 Boom Cylinder Bottom Pressure: Low (With the Track Raised off the Ground)....................................T2-4-40

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Pump 3 Minimum Displacement Angle Hold Control during Digging Operation Circuit ..........T2-4-42 Breaker/Pulverizer/Crusher Circuit of Hydraulic System (Option) ............................................................T2-4-43 Auxiliary Flow Combiner Circuit...................................T2-4-45 When Performing Single Operation of Auxiliary Flow Combiner Circuit................................................T2-4-45 When Performing Combined Operation of Auxiliary Flow Combiner Circuit .............................T2-4-47 Breaker 1 (HSB Breaker) Circuit .....................................T2-4-49 Breaker 2 (NPK Breaker) Circuit .....................................T2-4-50

Electrical System.......................................T2-5-1 Outline of Electrical System ............................................. T2-5-1 Main Circuit of Electrical System .................................... T2-5-1 Electric Power Circuit (Key Switch: OFF) ...................... T2-5-1 CAN Circuit ............................................................................. T2-5-3 Accessory Circuit (Key Switch: ACC).............................. T2-5-4 Starting Circuit (Key Switch: START).............................. T2-5-5 Charging Circuit (Key Switch: ON) ................................. T2-5-7 Alternator Operation .......................................................... T2-5-8 Regulator Operation........................................................... T2-5-9 Surge Voltage Prevention Circuit ................................... T2-5-9 Pilot Shut-Off Circuit (Key Switch: ON).......................T2-5-10 Auto Shut-Down Circuit/Automatic Engine Stop Circuit at Low Temperature ......................................T2-5-11 Engine Stop Circuit............................................................T2-5-13 Emergency Stop Circuit...................................................T2-5-14 Monitor Circuit of Electrical System ............................T2-5-16 Security Circuit....................................................................T2-5-17 Aerial Angle Circuit............................................................T2-5-18 Control Lever Automatic Pilot Shut-Off Circuit.......T2-5-18 Seat Belt Reminder Circuit..............................................T2-5-19 Radio Circuit.........................................................................T2-5-20 Air Conditioner Circuit .....................................................T2-5-21 Accessory Circuit................................................................T2-5-22 Work Light Circuit (Work Light: ON)............................T2-5-22 Work Light Circuit (Work Light and Boom Light: ON).....................................................................................T2-5-24 Wiper Circuit ........................................................................T2-5-26 Washer Circuit .....................................................................T2-5-28 Cab Light Circuit (Cab Light Switch: Door Interlocking Position (Key Switch: ON))................T2-5-30 Cab Light Circuit (Cab Light Switch: ON Position)... .............................................................................................T2-5-31

COMPONENT OPERATION Pump Device .............................................T3-1-1 Outline of Pump Device .................................................... T3-1-1 Outline of Main Pump........................................................ T3-1-2 Operational Principle of Main Pump ............................ T3-1-2 Increasing and Decreasing of Main Pump Delivery Flow Rate........................................................................... T3-1-3 Outline of Regulator ........................................................... T3-1-4 Regulator Control Function.............................................. T3-1-6 Control by Pump Control Pressure ................................ T3-1-7 Control by Own and Partner Pump Delivery Pressure (Regulators for Pump 1 and Pump 2) ... ............................................................................................... T3-1-7 Control by Own Pump Delivery Pressure (Pump 3 Regulator).......................................................................... T3-1-8 Control by Pilot Pressure from Torque Control Solenoid Valves ............................................................... T3-1-9 Control by Pilot Pressure from Maximum Pump Flow Rate Limit Control Solenoid Valves (Pump Flow Rate Limit Control) ............................................T3-1-11 Control by Pilot Pressure from Maximum Pump Flow Rate Limit Control Solenoid Valves (Pump Flow Rate Control)........................................................T3-1-12 Flow Rate Increase Control by Pump Control Pressure............................................................................T3-1-13 Flow Rate Decrease Control by Pump Control Pressure............................................................................T3-1-16 Flow Rate Decrease Control by Own and Partner Pump Delivery Pressure (Regulators for Pump 1 and Pump 2)...................................................................T3-1-19 Flow Rate Increase Control by Own and Partner Pump Delivery Pressure (Regulators for Pump 1 and Pump 2)...................................................................T3-1-22 Flow Rate Decrease Control by Own Pump Delivery Pressure (Pump 3 Regulator) ..................T3-1-25 Flow Rate Increase Control by Own Pump Delivery Pressure (Pump 3 Regulator) ..................T3-1-28 Flow Rate Decrease Control by Pilot Pressure from Torque Control Solenoid Valve................................T3-1-30 Flow Rate Control by Pilot Pressure from Maximum Pump Flow Rate Limit Control Solenoid Valves (Pumps 1, Pump 2, and Pump 3).........................................................................................T3-1-33 Outline of Maximum Flow Rate Limit Control Solenoid Valve and Torque Control Solenoid Valve..................................................................................T3-1-34 TODFY50-EN-00(10/01/2020)

Operation of Maximum Flow Rate Limit Control Solenoid Valve and Torque Control Solenoid Valve..................................................................................T3-1-34 Outline of Pilot Pump.......................................................T3-1-36 Outline of Pump Delivery Pressure Sensor...............T3-1-36 Outline of Pump Control Pressure Sensor ................T3-1-36

Swing Device.............................................T3-2-1 Outline of Swing Device.................................................... T3-2-1 Outline of Swing Reduction Gear .................................. T3-2-2 Outline of Swing Motor ..................................................... T3-2-3 Outline of Swing Parking Brake ...................................... T3-2-4 When Brake is Released of Swing Parking Brake...... T3-2-4 When Brake is Applied of Swing Parking Brake ........ T3-2-4 Outline of Valve Unit........................................................... T3-2-6 Operation of Make-Up Valve ........................................... T3-2-6 Outline of Swing Relief Valve........................................... T3-2-8 Low-Pressure Relief Operation (Shockless Function) of Swing Relief Valve................................. T3-2-8 High-Pressure Relief Operation (Overload Prevention) of Swing Relief Valve............................. T3-2-9 Outline of Swing Dampener Valve ................................ T3-2-9 Operation of Swing Dampener Valve.........................T3-2-10 Output Curve of Swing Dampener Valve: Between A and B (When Relieving)..........................................T3-2-10 Output Curve of Swing Dampener Valve: Operation of Combination Valve A between A and B (During Relief )...................................................T3-2-12 Output Curve of Swing Dampener Valve: Operation of Combination Valve B between A and B (During Relief )...................................................T3-2-14 Output Curve of Swing Dampener Valve: Between B and C (Pressure Begins to Decrease)..................T3-2-16 Output Curve of Swing Dampener Valve: Operation of Combination Valve A between B and C (Pressure Begins to Decrease) .....................T3-2-18 Output Curve of Swing Dampener Valve: Between C and D (Port BM Pressure Decreases)..................T3-2-20 Output Curve of Swing Dampener Valve: Operation of Combination Valve B between C and D (Port BM Pressure Decreases)......................T3-2-22 Output Curve of Swing Dampener Valve: Between D and E (During Aftershock).....................................T3-2-24 Output Curve of Swing Dampener Valve: Operation of Combination Valve A between D and E (During Aftershock).........................................T3-2-26

Output Curve of Swing Dampener Valve: Operation of Combination Valve B between D and E (During Aftershock).........................................T3-2-28

Control Valve.............................................T3-3-1 Outline of Control Valve .................................................... T3-3-1 Components in Control Valve ......................................... T3-3-2 Main Circuit of Control Valve .........................................T3-3-21 Pilot Operation Control Circuit of Control Valve.....T3-3-24 External Pilot Pressure Circuit of Control Valve.......T3-3-25 Operation of Flow Combiner Valve .............................T3-3-27 Outline of Main Relief Valve ...........................................T3-3-29 Relief Operation of Main Relief Valve .........................T3-3-29 Pressure Increasing Operation of Main Relief Valve .............................................................................................T3-3-30 Outline of Overload Relief Valve (With Make-Up Function) .........................................................................T3-3-31 Relief Operation of Overload Relief Valve.................T3-3-31 Make-Up Operation of Overload Relief Valve..........T3-3-32 Outline of Regenerative Valve.......................................T3-3-33 Operation of Boom Regenerative Valve ....................T3-3-33 Outline of Bucket Regenerative Valve........................T3-3-34 Operation When Performing Bucket Regenerative Operation ........................................................................T3-3-35 Operation When Performing Bucket Regenerative Cut Operation ................................................................T3-3-36 Operation When Performing Arm Regenerative Operation ........................................................................T3-3-38 Operation When Releasing Arm Regenerative Operation ........................................................................T3-3-41 Outline of Anti-Drift Valve ..............................................T3-3-43 Holding Operation of Anti-Drift Valve........................T3-3-43 Releasing Operation of Anti-Drift Valve.....................T3-3-44 Outline of Flow Rate Control Valve..............................T3-3-45 Normal Operation of Flow Rate Control Valve ........T3-3-45 Flow Rate Control Operation of Flow Rate Control Valve..................................................................................T3-3-46 Outline of Arm Roll-In Meter-Out Open Control Spool.................................................................................T3-3-47 Operation of Arm Roll-In Meter-Out Open Control Spool.................................................................................T3-3-47 Outline of Digging Regenerative Valve .....................T3-3-50 Operation of Digging Regenerative Valve................T3-3-50 Outline of Boom Lower Meter-In Cut Valve..............T3-3-51 Operation of Boom Lower Meter-In Cut Valve (With the Track off the Ground) ..............................T3-3-52 Operation of Boom Lower Meter-In Cut Valve (With the Front Attachment above the Ground) .............................................................................................T3-3-54 Outline of Auxiliary Flow Combiner Valve and Pump 1 Bypass Shut-Out Valve ...............................T3-3-57 Operation of Auxiliary Flow Combiner Valve and Pump 1 Bypass Shut-Out Valve (During Single Operation).......................................................................T3-3-57

TODFY50-EN-00(10/01/2020)

Operation of Auxiliary Flow Combiner Valve and Pump 1 Bypass Shut-Out Valve (During Combined Operation).................................................T3-3-59 Outline of Pump 3 Bypass Shut-Out Valve ...............T3-3-62 Operation of Pump 3 Bypass Shut-Out Valve ..........T3-3-62

Pilot Valve .................................................T3-4-1 Outline of Pilot Valve .......................................................... T3-4-1 Outline of Front Attachment/Swing Pilot Valve ....... T3-4-1 Outline of Travel Pilot Valve ............................................. T3-4-2 Outline of Auxiliary 1 and Positioning/Auxiliary 2 Pilot Valves........................................................................ T3-4-2 Operation of Front Attachment/Swing and Travel Pilot Valves........................................................................ T3-4-3 When Front Attachment/Swing and Travel Pilot Valves are in Neutral (Output Curve: A to B)......... T3-4-4 During Metering or Decompressing of Front Attachment/Swing and Travel Pilot Valves (Output Curve: C to D) .................................................. T3-4-6 Full Stroke of Front Attachment/Swing and Travel Pilot Valves (Output Curve: E to F)............................ T3-4-8 Operation of Auxiliary 1 and Positioning/Auxiliary 2 Pilot Valves ..................................................................T3-4-10 When Auxiliary 1 and Positioning/Auxiliary 2 Pilot Valves are in Neutral (Output Curve: A to B).......T3-4-10 During Metering or Decompressing of Auxiliary 1 and Positioning/Auxiliary 2 Pilot Valves (Output Curve: C to D) .................................................................T3-4-11 Outline of Shockless Function (Only Travel Pilot Valve) ................................................................................T3-4-13 Operation of Shockless Function .................................T3-4-13

Travel Device.............................................T3-5-1 Outline of Travel Device .................................................... T3-5-1 Outline of Travel Reduction Gear................................... T3-5-1 Outline of Travel Motor...................................................... T3-5-2 Operation of Travel Motor ................................................ T3-5-3 Outline of Parking Brake ................................................... T3-5-4 Operation of Parking Brake (When Parking Brake is Released) ....................................................................... T3-5-5 Operation of Parking Brake (When Parking Brake is Applied) ......................................................................... T3-5-6 Outline of Travel Brake Valve ........................................... T3-5-7 Operation of Counterbalance Valve (During Travel) ................................................................................. T3-5-8 Operation of Counterbalance Valve (When Descending a Slope) ...................................................T3-5-10 Outline of Travel Relief Valve .........................................T3-5-11 Operation of Travel Relief Valve (During Relief ) .....T3-5-11 Operation of Travel Relief Valve (During Make-Up) .............................................................................................T3-5-12 Outline of Travel Mode Control ....................................T3-5-14 Operation of Selecting Travel Mode (Slow Speed). .............................................................................................T3-5-14 Operation of Selecting Travel Mode (Fast Speed)... .............................................................................................T3-5-15

Signal Control Valve .................................T3-6-1 Outline of Signal Control Valve....................................... T3-6-1 Pilot Valve Side of Pilot Port ............................................. T3-6-1 Control Valve Side of Pilot Port ....................................... T3-6-2 Outline of Shuttle Valve..................................................... T3-6-4 Outline of Shockless Valve................................................ T3-6-7 Operation of Shockless Valve (During Boom Raise Operation)......................................................................... T3-6-7 Operation of Shockless Valve (During Boom Lower Operation or When Stopping Boom Raise Operation (Shock Reducing Operation))... ............................................................................................... T3-6-8 Operation of Pump 1 Flow Rate Control Valve, Pump 2 Flow Rate Control Valve, and Pump 3 Flow Rate Control Valve .............................................T3-6-11 Operation of Flow Combiner Valve Control Spool.. .............................................................................................T3-6-12 Operation of Swing Parking Brake Release Spool... .............................................................................................T3-6-12

Others (Upperstructure) ..........................T3-7-1 Outline of Pilot Shut-Off Solenoid Valve ..................... T3-7-1 Pilot Shut-Off Lever: LOCK Position............................... T3-7-2 Pilot Shut-Off Lever: UNLOCK Position......................... T3-7-2 Outline of Solenoid Valve ................................................. T3-7-3 Outline of 5-Spool Solenoid Valve Unit ....................... T3-7-3 Outline of 3-Spool Solenoid Valve Unit ....................... T3-7-4 Outline of 2-Spool Solenoid Valve Unit (For Aftertreatment Device Manual Regeneration Control) .............................................................................. T3-7-4 Outline of Auxiliary Control Solenoid Valve Unit (Option).............................................................................. T3-7-5 Outline of Proportional Solenoid Valve ....................... T3-7-6 Operation of Proportional Solenoid Valve (When in Neutral) ......................................................................... T3-7-6 Operation of Proportional Solenoid Valve (When Excited)............................................................................... T3-7-6 Outline of ON/OFF Solenoid Valve ................................ T3-7-8 Operation of ON/OFF Solenoid Valve (when in Neutral) .............................................................................. T3-7-8 Operation of ON/OFF Solenoid Valve (When in Operation)......................................................................... T3-7-8 Outline of Hose Rupture Valve........................................ T3-7-9 Operation of Hose Rupture Valve (When Control Lever is in Neutral) ......................................................... T3-7-9 Operation of Hose Rupture Valve (During Boom Lower Operation (Control Lever Stroke: Less than Half-Stroke)) .........................................................T3-7-10 Operation of Hose Rupture Valve (During Boom Lower Operation (Control Lever Stroke: More than Half-Stroke)) .........................................................T3-7-12 Outline of Pilot Relief Valve ............................................T3-7-15 Outline of Recirculation Valve .......................................T3-7-16

Others (Undercarriage) ............................T3-8-1 Outline of Swing Bearing .................................................. T3-8-1 TODFY50-EN-00(10/01/2020)

Outline of Center Joint....................................................... T3-8-2 Outline of Track Adjuster (Front Idler Integrated Type).................................................................................... T3-8-3

MEMO

TODFY50-EN-00(10/01/2020)

MEMO

TODFY50-EN-00(10/01/2020)

SECTION1 GENERAL Group1 Specifications Specifications of ZX250LC-7, 250LCN-7 A

B F

E D K J

MDFY-12-005-1 ja

Model

ZX250LC-7

ZX250LCN-7

Type of Front-End Attachment

2.96 m Arm

Bucket Capacity (Heaped)

PCSA 1.0, CECE 0.9

Counterweight Weight

Operating Weight

26500

26400

Base Machine Weight

20600

20500

Engine

−

ISUZU 4HK1

kW/min-1

ISO 14396: 140/2000

kW/min-1

ISO 9249: 132/2000

Engine Output

6200

A: Overall Width (Excluding Rear View Mirrors)

B: Cab Height

C: Rear End Swing Radius

3140

D: Minimum Ground Clearance

(*1) 460

E: Counterweight Clearance

(*2) 1050

F: Engine Cover Height

(*3) 2570

G: Overall Width of Upperstructure

2870

H: Undercarriage Length

4640

I: Undercarriage Width

J: Sprocket Center to Idler Center

3850

K: Track Shoe Width

600 (Grouser shoe)

Ground Pressure

kPa

Swing Speed

min-1

10.7

Travel Speed (fast/slow)

km/h

5.5/3.4

Gradeability

°(tanθ)

35 (0.70)

3190 3010

3190

2990

52.5

The dimensions do not include the height of the shoe lug.

TODFY50-EN-00(10/01/2020)

2990

T1-1-1

52.3

SECTION1 GENERAL Group1 Specifications *2 *3

The dimensions do not include the height of the shoe lug. The dimensions do not include the height of the shoe lug.

Specifications of ZX250LC-7, 250LCN-7 (2-Piece Boom) A

B F

E D K J

MDFY-12-005-1 ja

Model

ZX250LC-7 (2-Piece Boom)

ZX250LCN-7 (2-Piece Boom)

Type of Front-End Attachment

−

2.96 m Arm

Bucket Capacity (Heaped)

PCSA 1.0, CECE 0.9

Counterweight Weight

6200

Operating Weight

27100

27000

Base Machine Weight

20600

20500

Engine

−

ISUZU 4HK1

kW/min-1

ISO 14396: 140/2000

kW/min-1

ISO 9249: 132/2000

Engine Output A: Overall Width (Excluding Rear View Mirrors)

B: Cab Height

3010

C: Rear End Swing Radius

3140

D: Minimum Ground Clearance

(*1) 460

E: Counterweight Clearance

(*2) 1050

F: Engine Cover Height

(*3) 2570

G: Overall Width of Upperstructure

2870

H: Undercarriage Length

4640

I: Undercarriage Width

J: Sprocket Center to Idler Center

K: Track Shoe Width

Ground Pressure

kPa

Swing Speed

min-1

10.7

Travel Speed (fast/slow)

km/h

5.5/3.4

TODFY50-EN-00(10/01/2020)

3190

2990

3190

2990 3850 600 (Grouser shoe)

53.7

T1-1-2

53.6

SECTION1 GENERAL Group1 Specifications Model

ZX250LC-7 (2-Piece Boom)

Gradeability *1 *2 *3

°(tanθ)

ZX250LCN-7 (2-Piece Boom)

35 (0.70)

The dimensions do not include the height of the shoe lug. The dimensions do not include the height of the shoe lug. The dimensions do not include the height of the shoe lug.

Working Ranges of ZX250LC-7, 250LCN-7 G

C D

F A B

MDC1-12-002-1 ja

Item

2.96 m Front Attachment Backhoe

A: Maximum Digging Reach

10290

B: Maximum Digging Depth

(*1) 6960

C: Maximum Digging Height

(*2) 10160

D: Maximum Dumping Height

(*3) 7200

E: Overall Height

3110

F: Overall Length

10350

G: Minimum Swing Radius

3440

*1 *2 *3

The dimensions do not include the height of the shoe lug. The dimensions do not include the height of the shoe lug. The dimensions do not include the height of the shoe lug.

TODFY50-EN-00(10/01/2020)

T1-1-3

SECTION1 GENERAL Group1 Specifications Working Ranges of ZX250LC-7, 250LCN-7 (2-Piece Boom) G

C D

A B

MDC1-13-002-1 ja

Item

2.96 m Front Attachment Backhoe

A: Maximum Digging Reach

10430

B: Maximum Digging Depth

(*1) 6530

C: Maximum Digging Height

(*2) 11840

D: Maximum Dumping Height

(*3) 8720

E: Overall Height

3090

F: Overall Length

10420

G: Minimum Swing Radius

2310

*1 *2 *3

The dimensions do not include the height of the shoe lug. The dimensions do not include the height of the shoe lug. The dimensions do not include the height of the shoe lug.

TODFY50-EN-00(10/01/2020)

T1-1-4

SECTION1 GENERAL Group2 Component Layout Main Component (Upperstructure) 1

2 15

13 12 11 10 9

4 7

Upperstructure (1) TDFY-05-04-001-1 ja 1234-

Engine Signal Control Valve Control Valve Swing Device

TODFY50-EN-00(10/01/2020)

5678-

DEF Tank 3-Spool Solenoid Valve Unit 2-Spool Solenoid Valve Unit 5-Spool Solenoid Valve Unit

9101112-

T1-2-1

DEF Supply Module Fuel Main Filter Fuel Pre-Filter Pump Device

131415-

Engine Oil Filter Pilot Filter/Pilot Relief Valve Aftertreatment Device

SECTION1 GENERAL Group2 Component Layout 30

29 16 28

27 17 18 19

22 23

25 26

Upperstructure (2) 16171819-

Intercooler Radiator Oil Cooler Air Conditioner Condenser

TODFY50-EN-00(10/01/2020)

20212223-

Fuel Cooler Battery Air Cleaner Washer Tank

242526-

T1-2-2

Front Attachment/Swing Pilot Valve Pilot Shut-Off Solenoid Valve Travel Pilot Valve

27282930-

TDFY-05-04-002-1 ja Tool Box Fuel Tank Hydraulic Oil Tank Expansion Tank

SECTION1 GENERAL Group2 Component Layout Main Component (Undercarriage) 1

7 6

4 3 12-

Swing Bearing Center Joint

34-

Travel Device Lower Roller

56-

Upper Roller Track Adjuster

TDCN-01-02-011-1 ja Front Idler

Main Component (Front Attachment) A

2 1

3 3

4 2 7 5

6 TDC1-01-02-023-2 ja

A- 2-Piece Boom

TODFY50-EN-00(10/01/2020)

B- Mono Boom

T1-2-3

SECTION1 GENERAL Group2 Component Layout 12-

Bucket Cylinder Hose Rupture Valve (Arm)

Arm Cylinder

45-

Hose Rupture Valve (Position ing) Positioning Cylinder

67-

Hose Rupture Valve (Boom) Boom Cylinder

Electrical System (Overview) 22

20 19

18 17 16

15 3 14

4 5 13 24 12 6 11 7 8 10 9 1234567-

Rear View Camera (Refer to "Engine"T1-2-9) Camera Left Battery (Refer to "DEF Supply Mod ule"T1-2-16) (Refer to "Electrical System (Utility Space)"T1-2-7) (Refer to "Signal Control Valve"T1-2-12)

TODFY50-EN-00(10/01/2020)

89101112131415-

(Refer to "3-Spool Solenoid Valve Unit"T1-2-15) Wiper Motor Monitor Horn Work Light (Refer to "DEF Tank"T1-2-16) (Refer to "Swing De vice"T1-2-13) Fuel Sensor

1617-

181920-

T1-2-4

Hydraulic Oil Temperature Sensor (Refer to "2-Spool Solenoid Valve Unit (For Aftertreatment Device Regeneration Con trol)"T1-2-15) (Refer to "5-Spool Solenoid Valve Unit"T1-2-14) Camera Right Electric Fuel Pump

21222324-

TDFY-05-04-003-1 ja (Refer to "Around Pump De vice"T1-2-11) (Refer to "Aftertreatment De vice"T1-2-10) (Refer to "Control Valve"T1-2-12) (Refer to "Electrical System (Relays)"T1-2-7)

SECTION1 GENERAL Group2 Component Layout Electrical System (Rear Tray) 1

2 3 A

6 A

13 14

20 19

1234-

MC (Main Controller) Fuse Box 1 Fuse Box 2 MPDr. Connector (Download Connector Using Combined ly)

TODFY50-EN-00(10/01/2020)

56789-

DC-DC Converter PLCU (Option) GSM (Communication Con troller) Monitor Controller Pilot Shut-Off Relay (R12)

101112131415-

T1-2-5

Horn Relay (R10) Work Light Relay 2 (R8) Wiper Relay (R6) Starter Cut Relay (R4) ECM Main Relay (R2) Load Dump Relay (R1)

161718192021-

TDFY-05-04-004-1 ja Security Horn Relay (R3) Key Switch ON Cut Relay (R5) Work Light Relay 1 (R7) Washer Relay (R9) ACC Cut Relay (R11) Aerial Angle Controller

SECTION1 GENERAL Group2 Component Layout Electrical System (Switches)

16 3 őŖŔŉ

˩ˡ˪˱ Ŕņŕ

ůİŮŪůġ

˩˫ˠˡ

22 14

őŖŔŉ

䰙

信 ŕŖŏņ

˩˫ˠˡ

䩩

őŖŔŉ

ŔŐŖœńņ őŖŔŉ

őŖŔŉ

ŗŐōİőŘœȁ

łŖŕŐ İŐŇŇ

łŖŕŐ

ůİŮŪůġ

䢳䢴

ŐŇŇ

Ŋŏŕ

ŐŇŇ

ＯＦＦ

łń

Őŏ

Őŏ őŖŔŉġ

Ŕŕł œŕ

0 Ŋŏŕ

Őŏ

ŐŇŇ őŖŔŉ

24 8 1234567-

Home Switch Selector/Set Switch Engine Control Dial Power Mode Switch Source Switch/Tuning Switch Power Switch/Volume Control Switch Fresh/Re-circulated Air Damp er Switch

891011121314-

Numeric Keypad Key Switch Wiper/Washer Switch Work Light Switch Travel Mode Switch Auto-Idle Switch AUTO/OFF Switch / Blower Switch

151617181920-

Temperature Control Switch/ Mode Switch Return to Previous Screen Switch Audio Mute/One-Touch Idle Switch Power Digging Switch Aerial Angle Switch Manual Regeneration Switch

21222324-

TDFY-05-04-005-1 ja Pilot Shut-Off Lever Horn Switch Quick Wiper Switch Overhead Window Wiper/ Overhead Window Washer Switch (Option)

NOTE Audio mute/one-touch idle switch (17) can be set to OFF, engine idle mode, radio mute mode, or engine idle/radio mute mode by the MPDr.. (PBLI)

TODFY50-EN-00(10/01/2020)

T1-2-6

SECTION1 GENERAL Group2 Component Layout Electrical System (Utility Space) A a

1 A

TDFY-05-04-006-1 ja

a- Machine Front Side 12-

ECM (Engine Controller) DCU

Air Cleaner

45-

MAF/Intake-Air Temperature Sensor Air Cleaner Restriction Switch

67-

VGS Controller Battery Disconnect Switch

Electrical System (Relays) 1

6 2 5

3 TDFY-05-04-007-1 ja 12-

Ambient Temperature Sensor Starter Relay

TODFY50-EN-00(10/01/2020)

34-

Battery Relay Fusible Link (Black: 80A, 100A)

56-

T1-2-7

Glow Plug Relay Fusible Link (Red: 45 A)

SECTION1 GENERAL Group2 Component Layout Engine Oil Monitoring Sensor 1

TDFY-05-01-025-1 ja

a- Machine Front Side 1-

Engine Oil Monitoring Sensor

Hydraulic Oil Monitoring Sensor

TDFY-05-01-026-1 ja

a- Machine Front Side 1-

Hydraulic Oil Monitoring Sen sor

TODFY50-EN-00(10/01/2020)

T1-2-8

SECTION1 GENERAL Group2 Component Layout Engine 15 16 1

8 17

9 18 11

13 14

123456-

Overheat Switch Coolant Temperature Sensor Glow Plug Intake Throttle Common Rail Pressure Sensor Fuel Temperature Sensor

TODFY50-EN-00(10/01/2020)

7891011-

Crank Speed Sensor Supply Pump Engine Oil Pressure Sensor EGR Cooler Outlet Tempera ture Sensor EGR Valve

121314-

T1-2-9

Intake Manifold Temperature Sensor Boost Pressure/Temperature Sensor Injector

15161718-

TDFY-05-04-023-1 ja EGR Cooler Inlet Temperature Sensor VGS Actuator Engine Oil Level Switch Cam Angle Sensor

SECTION1 GENERAL Group2 Component Layout Aftertreatment Device 9

2 3

4 a

10 TDFY-05-04-015-1 ja

a- Machine Front Side 123-

Differential Pressure Sensor Downstream NOx Sensor Controller Downstream NOx Sensor

Upstream NOx Sensor Con troller Dosing Module Upstream NOx Sensor

56-

78-

DOC Outlet Exhaust Tempera ture Sensor DOC Inlet Exhaust Tempera ture Sensor

910-

SCR Exhaust Temperature Sensor Differential Pressure Detec tion Port

Pump Device 1

4 15

10 14 12 9 13 7

5 8 TDFY-05-04-016-1 ja

TODFY50-EN-00(10/01/2020)

T1-2-10

SECTION1 GENERAL Group2 Component Layout 123456-

Pilot Pump Pump 1 Pump 3 Pump 2 Pump 2 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

78910-

Pump 1 Delivery Pressure Sensor Pump 1 and 2 Torque Control Solenoid Valve Maximum Pump 2 Flow Rate Limit Control Solenoid Valve Pump 3 Torque Control Sole noid Valve

11121314-

Pump 1 Control Pressure Sen sor Pump 3 Control Pressure Sen sor Pump 2 Control Pressure Sen sor Maximum Pump 3 Flow Rate Limit Control Solenoid Valve

15-

Maximum Pump 1 Flow Rate Limit Control Solenoid Valve

Around Pump Device

3 TDFY-05-04-017-1 ja

12-

Electric Fuel Pump Fuel Main Filter

TODFY50-EN-00(10/01/2020)

34-

Fuel Pre-Filter Engine Oil Filter

T1-2-11

Pilot Filter/Pilot Relief Valve

SECTION1 GENERAL Group2 Component Layout Control Valve 2

6 5 TDFY-05-04-026-1 ja

a- Machine Front Side 12-

Main Relief Valve (For P3) Arm 2 Roll-In Pilot Pressure Sensor

34-

Bucket Roll-In Pilot Pressure Sensor Main Relief Valve (For P1, P2)

56-

Travel Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor

78-

Arm Roll-Out Pilot Pressure Sensor Boom Raise Pilot Pressure Sensor

Signal Control Valve 2

Control Valve Side TDFY-05-04-026-2 ja

TODFY50-EN-00(10/01/2020)

T1-2-12

SECTION1 GENERAL Group2 Component Layout a- Machine Front Side 1-

Travel Pilot Pressure Sensor

Swing Pilot Pressure Sensor

A A

3 a 4 7

TDFY-05-04-027-1 ja

a- Pilot Valve Side 12-

Auxiliary 2 Pilot Pressure Sen sor Shockless Valve

Pump 3 Flow Rate Control Valve

45-

Pump 2 Flow Rate Control Valve Flow Combiner Valve Control Spool

67-

Swing Parking Brake Release Spool Pump 1 Flow Rate Control Valve

Swing Device

1 2

TDAA-01-02-009-1 ja 1-

Swing Relief Valve

TODFY50-EN-00(10/01/2020)

Front Pilot Pressure Sensor

T1-2-13

SECTION1 GENERAL Group2 Component Layout Travel Device 1

1 T1HD-01-02-001-2 ja 1-

Counterbalance Valve

Travel Motor Displacement Angle Control Valve

Travel Relief Valve

5-Spool Solenoid Valve Unit SC

TDAA-03-07-001-2 ja

SC- 5-Spool Solenoid Valve Unit (SC) SF- 5-Spool Solenoid Valve Unit (SF) SE- 5-Spool Solenoid Valve Unit (SE)

TODFY50-EN-00(10/01/2020)

SD- 5-Spool Solenoid Valve Unit (SD) SI- 5-Spool Solenoid Valve Unit (SI)

T1-2-14

SECTION1 GENERAL Group2 Component Layout 3-Spool Solenoid Valve Unit 1

SK3 SK2 SK1 TDFY-05-01-019-2 ja

SK1- 3-Spool Solenoid Valve Unit (SK1) SK2- 3-Spool Solenoid Valve Unit (SK2) 1-

SK3- 3-Spool Solenoid Valve Unit (SK3)

Arm 1 Roll-In Pilot Pressure Sensor

2-Spool Solenoid Valve Unit (For Aftertreatment Device Regeneration Control) SZ

TDAA-03-07-002-2 ja

SZ- 2-Spool Solenoid Valve Unit (SZ)

TODFY50-EN-00(10/01/2020)

SJ- 2-Spool Solenoid Valve Unit (SJ)

T1-2-15

SECTION1 GENERAL Group2 Component Layout DEF Tank 1

5 6

8 123-

DEF Sensor Unit DEF Tank Coolant Hose (To Engine)

Coolant Hose (From DEF Sup ply Module)

56-

DEF Hose (To DEF Supply Module) DEF Hose (From DEF Supply Module)

78-

TDFY-05-04-019-1 ja DEF Tank Level Sensor DEF Tank Temperature/DEF Quality Sensor

DEF Supply Module 1

3 TDFY-05-04-020-1 ja

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T1-2-16

SECTION1 GENERAL Group2 Component Layout 1-

DEF Supply Module

Coolant Control Valve

DEF Supply Module Main Fil ter

Layout of Attachment Spec. Parts

4,5

(Refer to "Utility Space"T1-2-19)

TODFY50-EN-00(10/01/2020)

Auxiliary 1 Pilot Valve

T1-2-17

(Refer to "Around Control Valve"T1-2-18)

TDFY-05-04-021-2 ja (Refer to "Control Valve Lower Side"T1-2-18)

SECTION1 GENERAL Group2 Component Layout Around Control Valve 1

5 123-

Signal Control Valve Breaker Relief Solenoid Valve Swing Device

45-

Selector Valve Control Sole noid Valve Selector Valve

Auxiliary Control Solenoid Valve Unit

TDFY-05-04-025-1 ja Auxiliary 1 Pilot Pressure Sen sor

Control Valve Lower Side 2 a

1 TDFY-05-04-022-1 ja

a- Machine Front Side 1-

Auxiliary 1 Overload Relief Valve

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Control Valve

T1-2-18

SECTION1 GENERAL Group2 Component Layout Utility Space 1

TDFY-05-04-024-1 ja 1-

Accumulator (Pilot Circuit)

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Check Valve

T1-2-19

SECTION1 GENERAL Group2 Component Layout MEMO

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T1-2-20

SECTION1 GENERAL Group3 Component Specifications Specifications of Engine Manufacturer

ISUZU

Model

4HK1

Type

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

Cyl. No.- Bore × Stroke

4-115 mm×125 mm

Piston Displacement

5193 cm3

Rated Output

134 kW/1900 min-1 Travel HP Mode: 140 kW/2000 min-1

Compression Ratio

16.3

Dry Weight

552 kg

Firing Order

1-3-4-2

Rotation Direction

Clockwise (Viewed from fan side)

Cooling System

Cooling Fan

Dia. 650 mm, 5 Blades, Synthetic Resin, HF Type, Unequal Pitch, Fan Ring with Safety Net

Fan Pulley Ratio

Belt Driven Rotation Ratio : 1.01

Thermostat

Cracking Temperature at Atmospheric Pressure: No.1: 76.5 °C, No.2: 82 °C Full Open (Stroke: 8 mm or more): No.1: 90 °C, No.2: 95 °C

Water Pump

Centrifugal Type

Lubrication Pump Type

Gear Pump

Oil Filter

Full-Flow Paper Element Type with Bypass

Oil Cooler

Water Cooled Integral 5-Stage Type

Motor

Magnetic Pinion Shift Reduction Type

Voltage/Output

24 V/5 kW

Preheat System

Method

Glow Plug (24V, QOS II Type)

Engine Stop System

Method

Fuel Shut-Off (Electronic Control)

Alternator

Method

Regulator Integrated AC Type, Brushless

Voltage/Output

24 V/60 A

Supercharging System

Type

Exhaust-Turbocharger Type RHF55V Type with Lubrication, Water-Cooled Type

Fuel System

Type

Common Rail Type HP3 Type

Governor

Electronic All Speed Control

Injection Nozzle

Electrical Multi-Hole Injector (G3 Type)

Lubrication System

Starting System

IMPORTANT This list shows design specifications, which are not servicing standards. Performance

Without Fan

With Fan

Fuel Consumption Ra tio

210 g/kW·h at 140 kW/(at Full Load: 2000 min-1)

221 g/kW·h at 132 kW/(at Full Load: 2000 min-1)

207 g/kW·h at 134 kW/(at Working Load: 1900 min-1)

217 g/kW·h at 127 kW/(at Working Load: 1900 min-1)

Maximum Output Tor 676 N·m at 1800 min-1 que

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T1-3-1

SECTION1 GENERAL Group3 Component Specifications Compression Pressure 3.04 MPa at 200 min-1 Valve Clearance (In take/Exhaust)

0.4/0.4 mm (when Cool)

No Load Speed

Slow: 800 min-1 Fast: 1900 min-1

Engine Performance Curve (4HK1) Test Condition: 1. In conformity with JIS D0006 (Performance Test Method for Diesel Engine Used for Construction Machinery) under standard atmospheric pressure. 2. Equipped with the alternator and without the fan. N·m

g/kW·h

min-1

TDC2-01-03-001 ja

N- Engine Speed P- Output

TODFY50-EN-00(10/01/2020)

q- Fuel Consumption Ratio T- Torque

T1-3-2

SECTION1 GENERAL Group3 Component Specifications Specifications of Engine Accessories Radiator Assembly

Type

Parallel Type Radiator

Oil Cooler

Air-Tight Test Pressure

0.1 MPa

Expansion Tank

Total Capacity

8.4 L

Cap Opening Pressure

90 kPa

Fuel Cooler Battery

Battery (Large Capacity)

1.5 MPa

Intercooler 0.25 MPa

Fin Shape

Wavy Fin

Capacity

0.2 L

Type

115E41L

Voltage

12 V

Capacity

88 Ah or more (5-Hour Rate), 93 Ah or more (20-Hour Rate)

CCA

E41, 610 A

Type

170F51-MF

Voltage

12 V

Capacity

120 Ah or more (5-Hour Rate), 126 Ah or more (20-Hour Rate)

CCA

F51, 925A

Specifications of Hydraulic Component Pump Device

Drive Gear Ratio

Main Pump (P1, P2): 1.147, Main Pump (P3): 1, Pilot Pump: 1.114

Main Pump

Type

Bent-Axis Type Variable Displacement Axial Plunger Pump

Theoretical Displacement

(P1, P2): 102.7 cm3/rev (P3): 102 cm3/rev

Rated Pressure

34.3 MPa

Regulator

Type

Hydraulic Pressure Operated Type

Pilot Pump

Type

Fixed Displacement Type Gear Pump

Theoretical Displacement

16.8 cm3/rev

Type

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

Main Relief Set Pressure

Normal: 34.3 MPa at 150 L/min

Control Valve

Power Digging: 38.0 MPa at 150 L/min Swing Device Swing Motor Valve Unit Swing Parking Brake

Overload Relief Set Pressure

39.2 MPa at 50 L/min (Boom, Arm, Bucket)

Type

Two-Stage Reduction Planetary Gear

Reduction Gear Ratio

21.75

Type

Swash-Plate Type, Fixed Displacement Axial Plunger Motor

Theoretical Displacement

129.2 cm3/rev

Type

Non Counterbalance Valve Type

Relief Set Pressure

32.4 MPa at 40 L/min

Type

Wet-Type Spring Set Hydraulic Released Multi-Disc Brake

Release Pressure

1.9 to 2.8 MPa

TODFY50-EN-00(10/01/2020)

T1-3-3

SECTION1 GENERAL Group3 Component Specifications Travel Device

Type

Three-Stage Reduction Planetary Gear

Reduction Gear Ratio

64.863

Type

Swash-Plate Type Variable Displacement Axial Plunger Motor

Theoretical Displacement (Fast/Slow)

75.7/122.5 cm3/rev

Type

Counterbalance Valve Type

Relief Set Pressure

34.8 MPa

Type

Wet-Type Spring Set Hydraulic Released Multi-Disc Brake

Release Starting Pressure

0.97±0.07 MPa

Front Attachment/Swing Pilot Valve

Plunger Stroke

Ports 1, 3: 6.5 mm

Travel Pilot Valve

Plunger Stroke

Ports 1, 2, 3, 4: 4.6 mm

5-Spool Solenoid Valve Unit

Type

5-Spool Proportional Solenoid Valve

Rated Voltage

24 VDC

Coil Resistance

22 Ω

2-Spool Solenoid Valve Unit (Aftertreatment De vice Regeneration Con trol)

Type

2-Spool Proportional Solenoid Valve

Rated Voltage

24 VDC

Coil Resistance

22 Ω

3-Spool Solenoid Valve Unit

Type

3-Spool Proportional Solenoid Valve

Rated Voltage

24 VDC

Coil Resistance

22 Ω

Auxiliary Flow Combiner Control Solenoid Valve (Option)

Rated Voltage

24 VDC

Coil Resistance

22 Ω

Auxiliary Flow Rate Con trol Solenoid Valve (Op tion)

Rated Voltage

24 VDC

Coil Resistance

22 Ω

Signal Control Valve

Rated Pressure

3.72 MPa

Pilot Shut-Off Solenoid Valve

Type

ON/OFF Solenoid Valve

Rated Voltage

24 VDC

Coil Resistance

49 Ω

Cracking Pressure

490 kPa at 5 L/min

Travel Motor

Travel Brake Valve Travel Parking Brake

Oil Cooler Bypass Check Valve Cylinder (Mono Boom)

Ports 2, 4: 8.0 mm

Boom

Arm

Bucket

Rod Outer Diameter

90 mm

100 mm

90 mm

Tube Inner Diameter

125 mm

140 mm

130 mm

Stroke

1390 mm

1610 mm

1075 mm

Fully Retracted Length 1990 mm

2177 mm

1632 mm

Plating Thickness

30 μm

TODFY50-EN-00(10/01/2020)

30 μm

T1-3-4

SECTION1 GENERAL Group3 Component Specifications Cylinder (2-Piece Boom)

Boom

Arm

Bucket

Positioning

Rod Outer Diame 90 mm ter

100 mm

90 mm

100 mm

Tube Inner Diame 125 mm ter

140 mm

130 mm

150 mm

Stroke

1390 mm

1610 mm

1075 mm

1327 mm

Fully Retracted Length

1990 mm

2177 mm

1632 mm

1910 mm

30 μm

Plating Thickness 30 μm Hose Rupture Valve

Relief Set Pressure

40.5+1.00 MPa at 0.5±0.1 L/min

Specifications of Electrical Component Battery Relay

Voltage/Current

24 V/100 A

Starter Relay

Voltage

24 V

Glow Plug Relay

Voltage

24 V

Hydraulic Oil Temperature Operating Temperature Sensor

-30 to 120 °C

Air Cleaner Restriction Switch

Operating Pressure

6.2±0.6 kPa

Horn

Voltage/Current

24 V/2.5+0.5-1 A

Sound Pressure

113±5 dB (A) at 2 m

Work Light

LED 12 to 24V, 20W

Cab Light

LED 24 V/0.03 A

Refrigerant

HFC134 a

Cooling Ability

4.5 kW or more

Cool Air Volume

550 m3/h or more

Heating Ability

5.4 kW or more

Warm Air Volume

340 m3/h or more

Temperature Adjusting Sys tem

Electronic Type

Refrigerant Quantity

850±50 g

Compressor Oil Quantity

160 cm3

Illumination Air Conditioner

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T1-3-5

SECTION1 GENERAL Group3 Component Specifications MEMO

TODFY50-EN-00(10/01/2020)

T1-3-6

TODFY50-EN-00(10/01/2020)

SECTION2 SYSTEM Group1 Controller Outline of Controller The following controllers are provided in this machine in order to control the functions. Each controller excluding the communication controller communicates by using the CAN circuit and sends or receives the required signal. Controller

Control

Comment on Control

MC controls the engine, pumps, and valves.

T2-2

ECM

ECM controls the actual engine speed.

T2-3

VGS Controller

The VGS controller controls the engine turbocharger.

T2-3

DCU

DCU controls the DEF injection amount.

T2-3

Monitor Controller

The monitor controller displays the operating information and alarms on T2-5, T5-2 the monitor. The monitor controller controls the wipers and work lights.

Air Conditioner Controller

The air conditioner controller controls the air conditioner.

T2-5, T5-7

Radio Controller

The radio controller controls the radio.

T2-5

Communication Controller

The communication controller sends the mails and operating informa tion.

T5-3

Aerial Angle Controller

The aerial angle controller controls the composition/display switching of T2-5 camera images.

Switch Box Controller

The switch box controller sends the information on each switch.

T2-2, T2-5

PLCU (Option)

PLCU (Option) controls AFL.

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

CAN Circuit CAN (Controller Area Network) is ISO Standards of the serial communication protocol. This machine has seven networks (CAN bus (4)) that consist of Power-CAN (1), Body-CAN (5), ISO-CAN (18), Local-CAN (20), IF-CAN (26), PL-CAN (22), and OPT-CAN (27). Power-CAN (1) and ISO-CAN (18) are used for the engine control. Body- CAN (5) is used for the accessories. Local-CAN (20) is used for the urea SCR system. IF-CAN (26) is used for communication. PL-CAN (22) is used for the AFL. OPT-CAN (27) is used for the oil monitoring sensor. CAN bus (4) consists of two harnesses, CAN-H (High) (2) and CAN-L (Low) (3). Each controller judges the CAN bus (4) level due to the potential difference between CAN-H (High) (2) and CAN-L (Low) (3). Each controller arranges the CAN bus (4) level and sends the signal and data to other controllers. Termination resistors (120 Ω) (17) are installed to both ends of CAN bus (4).

TODFY50-EN-00(10/01/2020)

T2-1-1

SECTION2 SYSTEM Group1 Controller 2 4 3 17

6 VGS

18 9

17 19 DCU

26 17

17 1

7 ECM

24 17

11 MPDr.

17 5 16

8 MC

17 27

22 17 17

25 PLCU

30 SW-BOX

17 29

14 28

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Power- CAN CAN-H (High) CAN-L (Low) CAN Bus Body- CAN VGS Controller (Variable Tur bo Controller) ECM (Engine Controller)

TODFY50-EN-00(10/01/2020)

89101112131415-

MC (Main Controller) Communication Controller Monitor Controller MPDr. Aerial Angle Controller Radio Controller Air Conditioner Controller Monitor Control Unit

1617181920212223-

T2-1-2

Information Control Unit Termination Resistor (120 Ω) ISO-CAN DCU Local-CAN DEF Sensor Unit PL-CAN Upstream NOx Sensor

24252627282930-

TDFY-02-01-001-1 ja Downstream NOx Sensor PLCU (Option) IF-CAN OPT-CAN Engine Oil Monitoring Sensor Hydraulic Oil Monitoring Sen sor Switch Box Controller

SECTION2 SYSTEM Group2 Control System Outline of Control System MC is used in order to control the machine operations. Signals from the engine control dial, various sensors, and various switches are sent to MC and processed in the logic circuit. MC sends the signal equivalent to the target engine speed to ECM by using CAN communication in order to control the engine. (Refer to SYSTEM/Engine System.) In addition, MC drives the solenoid valve unit and torque control solenoid valve in order to control the pump and valve.

Engine Control The engine control consists of the followings. ● Engine Protection Control ● Engine Control Dial Control ● ECO Control ● Power Mode (ECO/PWR Mode) Switch Control ● ECO Mode Control ● Travel HP Mode Control ● Auto-Idle Control ● Hydraulic Oil Temperature Auto Warming-Up Control ● Radiator Coolant Temperature Auto Warming-Up Control ● Idle Speed-Up Control ● Idle Speed-Up Control (Pilot Shut-Off Lever) ● Engine Speed Slow Down Control ● Heater Control ● One-Touch Idle Control ● Attachment Operation Speed Increase Control (Option) ● Attachment Operation Speed Limit Control (Option)

TODFY50-EN-00(10/01/2020)

T2-2-1

SECTION2 SYSTEM Group2 Control System Engine Control System Layout 30

32 11

MODE

27 34

39 SW-BOX 13

12 40

38 37 36 9 8 7 6 5 4 3 2 1

14 35 DCU

10 MC

15 ECM

18 19 26

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Hydraulic Oil Temperature Sensor Boom Raise Pilot Pressure Sensor Arm 1 Roll-In Pilot Pressure Sensor Bucket Roll-In Pilot Pressure Sensor Swing Pilot Pressure Sensor Travel Pilot Pressure Sensor Front Pilot Pressure Sensor Auxiliary 1 Pilot Pressure Sen sor (Option) Auxiliary 2 Pilot Pressure Sen sor (Option)

TODFY50-EN-00(10/01/2020)

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MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

2223242526272829303132-

T2-2-2

Pump 2 Delivery Pressure Sensor Pump 2 Control Pressure Sen sor Pump 3 Control Pressure Sen sor Pump 1 Control Pressure Sen sor Auto Shut-Down Signal Travel Mode Switch Slow Speed Position Fast Speed Position Auto-Idle Switch Power Mode Switch Engine Control Dial

333435363738394041-

TDFY-02-02-001-1 ja Key Switch Pilot Shut-Off Switch DCU Arm Roll-Out Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Arm 2 Roll-In Pilot Pressure Sensor Switch Box Controller Audio Mute/One-Touch Idle Switch Engine Oil Pressure Sensor

SECTION2 SYSTEM Group2 Control System Engine Protection Control Purpose: The engine protection control controls increasing the engine speed and promotes the circulation of the engine oil immediately after the engine starts. Therefore, the engine (turbocharger) is protected from being damaged.

TDC1-02-02-047-1 ja

A- Engine Speed B- Engine Control Dial Position C- Slow Idle Speed Position

D- Fast Idle Speed Position E- 1000 min-1 or Slow Idle Speed F- Fast Idle Speed

Operation: 1. When the engine starts, MC (10) receives the signals from coolant temperature sensor (16), hydraulic oil temperature sensor (1), and engine oil pressure sensor (41). MC (10) sends the signal equivalent to the target engine speed according to the received signals to ECM (15) by using CAN communication (14). 2. ECM (15) sets the engine speed to 1000 min-1 or slow idle speed and holds it for 3 to 10 seconds. 3. When the engine starts and the specified time is passed, MC (10) deactivates the engine protection control. 4. ECM (15) slowly returns the engine speed to the speed according to other engine controls.

NOTE The priority is given to the engine protection control. Therefore, the engine speed does not change even if engine control dial (32) is operated at the engine protection control. Other controls are activated after the engine protection control is deactivated.

TODFY50-EN-00(10/01/2020)

T2-2-3

SECTION2 SYSTEM Group2 Control System 30

32 11

MODE

27 34

39 SW-BOX 13

12 40

38 37 36 9 8 7 6 5 4 3 2 1

14 35 DCU

10 MC

15 ECM

18 19 26

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TODFY50-EN-00(10/01/2020)

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MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

2223242526272829303132-

T2-2-4

333435363738394041-

TDFY-02-02-002-1 ja Key Switch Pilot Shut-Off Switch DCU Arm Roll-Out Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Arm 2 Roll-In Pilot Pressure Sensor Switch Box Controller Audio Mute/One-Touch Idle Switch Engine Oil Pressure Sensor

SECTION2 SYSTEM Group2 Control System Engine Control Dial Control Purpose: The engine control dial control controls the engine speed according to the rotation angle of engine control dial (32).

TDC1-02-02-048-1 ja

A- Engine Speed B- Engine Control Dial Position C- Slow Idle Speed Position

D- Fast Idle Speed Position E- Fast Idle Speed F- Slow Idle Speed

Operation: 1. Switch box controller (39) receives the signals of the rotation angle (the required engine speed) of engine control dial (32) and sends the signals to MC (10) by using CAN communication (14). MC (10) sends the signal equivalent to the target engine speed according to the received signals to ECM (15) by using CAN communication (14). 2. ECM (15) controls the engine speed according to CAN communication (14).

TODFY50-EN-00(10/01/2020)

T2-2-5

SECTION2 SYSTEM Group2 Control System 30

32 11

MODE

27 34

39 SW-BOX 13

12 40

38 37 36 9 8 7 6 5 4 3 2 1

14 35 DCU

10 MC

15 ECM

18 19 26

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TODFY50-EN-00(10/01/2020)

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MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

2223242526272829303132-

T2-2-6

3334353637383940-

TDFY-02-02-003-1 ja Key Switch Pilot Shut-Off Switch DCU Arm Roll-Out Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Arm 2 Roll-In Pilot Pressure Sensor Switch Box Controller Audio Mute/One-Touch Idle Switch

SECTION2 SYSTEM Group2 Control System ECO Control Purpose: The ECO control reduces the engine speed by 100 min-1 from the fast idle speed when all control levers are in neutral. Therefore, the fuel consumption and noise level can be reduced.

TDC1-02-02-049-1 ja

A- Engine Speed B- Engine Control Dial Position C- Slow Idle Speed Position D- Fast Idle Speed Position

E- Fast Idle Speed F- ECO Speed G- Slow Idle Speed

Operation: 1. When all following conditions exist and all the control levers are set to the neutral position [travel pilot pressure sensor (6) and front pilot pressure sensor (7): OFF], MC (10) sends the signal to ECM (15) by using CAN communication (14) after one second. •

Engine control dial (32): Fast idle position

•

Power mode switch (31): PWR

2. ECM (15) reduces the engine speed by 100 min-1 from the fast idle speed.

NOTE The ECO control is deactivated by MPDr. (11) temporarily or completely. The ECO control is activated again when key switch (33) is turned OFF with the ECO control deactivated temporarily. (ECO Control Suspend) The ECO control is always deactivated with the ECO control deactivated completely. (ECO Control Selection) NOTE When the engine speed is set slower than the fast idle speed by 100 min-1 by engine control dial (32), the engine speed does not change. And the ECO control is done regardless of whether the auto-idle control is done or not. The fast idle speed can be corrected by MPDr. (11). (PWR Mode Speed)

TODFY50-EN-00(10/01/2020)

T2-2-7

SECTION2 SYSTEM Group2 Control System 30

32 11

MODE

27 34

39 SW-BOX 13

12 40

38 37 36 9 8 7 6 5 4 3 2 1

14 35 DCU

10 MC

15 ECM

18 19 26

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TODFY50-EN-00(10/01/2020)

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MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

2223242526272829303132-

T2-2-8

3334353637383940-

TDFY-02-02-004-1 ja Key Switch Pilot Shut-Off Switch DCU Arm Roll-Out Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Arm 2 Roll-In Pilot Pressure Sensor Switch Box Controller Audio Mute/One-Touch Idle Switch

SECTION2 SYSTEM Group2 Control System Power Mode (ECO/PWR Mode) Switch Control Purpose: The power mode (ECO/PWR mode) switch control shifts the power mode (ECO/PWR mode) by operating power mode switch (31). Operation: 1. Switch box controller (39) receives the signal from power mode switch (31). 2. Switch box controller (39) sends the received signals to MC (10) by using CAN communication (14). 3. MC (10) shifts the power mode according to the setting of “Power Mode Selection“ and ”Power Mode Memory Selection” on MPDr. (11) by pushing power mode switch (31). (Refer to the table.) 4. MC (10) sends the signal equivalent to the target engine speed according to the received signals to ECM (15) by using CAN communication (14). 5. ECM (15) controls the engine speed according to CAN communication (14). 6. At the same time, MC (10) sends the control mode of power mode to monitor controller (12) by using CAN communication (14). 7. Monitor controller (12) displays the control mode of power mode on monitor (13). Power Mode Selection

Power Mode at the Mo ment When Key Switch is Turned OFF

Power Mode When Key Switch is ON Next Time Power Mode Memory Se lection: OFF

Power Mode Memory Se lection: ON

ECO, PWR Mode Selection (Default) ECO

ECO

PWR

ECO

PWR

ECO mode: Fixed

ECO

PWR mode: Fixed

PWR

TODFY50-EN-00(10/01/2020)

T2-2-9

SECTION2 SYSTEM Group2 Control System 30

32 11

MODE

27 34

39 SW-BOX 13

12 40

38 37 36 9 8 7 6 5 4 3 2 1

14 35 DCU

10 MC

15 ECM

18 19 26

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TODFY50-EN-00(10/01/2020)

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MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

2223242526272829303132-

T2-2-10

3334353637383940-

TDFY-02-02-005-1 ja Key Switch Pilot Shut-Off Switch DCU Arm Roll-Out Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Arm 2 Roll-In Pilot Pressure Sensor Switch Box Controller Audio Mute/One-Touch Idle Switch

SECTION2 SYSTEM Group2 Control System ECO Mode Control Purpose: The ECO mode control lowers the engine speed in order to reduce fuel consumption. According to the pump control pressure, pilot pressure, and average pump delivery pressure, the ECO mode control lowers the engine speed that is set by engine control dial (32).

TDC1-02-02-050-1 ja

A- Engine Speed B- Engine Control Dial Position C- Slow Idle Speed Position D- Fast Idle Speed Position

E- Fast Idle Speed F- ECO Mode Speed G- Slow Idle Speed

Operation: 1. When all following conditions exist, the ECO mode control is activated. •

Required engine speed signal from engine control dial (32): Faster than the engine speed set by the ECO mode control

• Power mode switch (31): ECO mode position 2. When the ECO mode control is activated, according to the following conditions, MC (10) sends the signal equivalent to the target engine speed to ECM (15) by using CAN communication (14). Engine speed reduced condition: Deceleration ratio of the engine speed at the ECO mode is controlled by the pump control pressure or average pump delivery pressure. The priority is given to the control by the average pump delivery pressure more than the pump control pressure for the deceleration ratio of the engine speed. The evaluation specifications are shown in the table. •

Evaluation by control lever operation ratio (pump control pressure) Condition

Deceleration Ratio of Engine Speed

Control lever operation: Short stroke (Pump control Large pressure: Low) Control lever operation: Long stroke (Pump control Small pressure: High) •

Evaluation by average pump delivery pressure Condition

Deceleration Ratio of Engine Speed

Average pump delivery pressure: High (high load)

Large

Average pump delivery pressure: Low (low load)

Small

TODFY50-EN-00(10/01/2020)

T2-2-11

SECTION2 SYSTEM Group2 Control System NOTE When conducting a high-load work, set the mode to the PWR mode. 3. ECM (15) reduces the engine speed from the required engine speed by engine control dial (32). 4. The engine speed becomes the required engine speed by engine control dial (32) when performing travel or swing operation.

NOTE The ECO mode control during travel operation can be made operable or inoperable by MPDr. (11). The selected setting can be saved even if key switch (33) is turned OFF. (ECO Mode Travel Speed Increase Selection) 5. Therefore, the swing return operation becomes fast and the proper travelling power is obtained. 29

32 11

MODE

27 34

39 SW-BOX 13

12 40

38 37 36 9 8 7 6 5 4 3 2 1

14 35 DCU

10 MC

15 ECM

18 19 26

TDFY-02-02-006-1 ja

TODFY50-EN-00(10/01/2020)

T2-2-12

SECTION2 SYSTEM Group2 Control System 1-

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MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

2223242526272829303132-

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Key Switch Pilot Shut-Off Switch DCU Arm Roll-Out Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Arm 2 Roll-In Pilot Pressure Sensor Switch Box Controller Audio Mute/One-Touch Idle Switch

Travel HP Mode Control Purpose: The travel HP mode control increases the engine speed and makes the travel speed faster when performing the travel single operation.

TDC1-02-02-051-1 ja

A- Engine Speed B- Engine Control Dial Position C- Slow Idle Speed Position D- Fast Idle Speed Position

E- Travel HP Mode Speed F- Fast Idle Speed G- Slow Idle Speed

Operation: 1. When all following conditions exist, MC (10) sends the signal equivalent to the target engine speed to ECM (15) by using CAN communication (14). •

Engine control dial (32): Fast idle position

•

Travel mode switch (27): Fast speed

•

Travel pilot pressure sensor (6): Outputting signal

• Delivery pressure of pumps 1 and 2: The delivery pressure of either pump is high. (Reference: 19 MPa) 2. ECM (15) increases the engine speed to the travel HP mode speed and makes the travel speed faster.

NOTE The travel HP mode control can be made operable or inoperable by MPDr. (11). The selected setting can be saved even if key switch (33) is turned OFF. (Travel HP Mode Control Selection)

TODFY50-EN-00(10/01/2020)

T2-2-13

SECTION2 SYSTEM Group2 Control System 30

32 11

MODE

27 34

39 SW-BOX 13

12 40

38 37 36 9 8 7 6 5 4 3 2 1

14 35 DCU

10 MC

15 ECM

18 19 26

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MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

2223242526272829303132-

T2-2-14

3334353637383940-

TDFY-02-02-007-1 ja Key Switch Pilot Shut-Off Switch DCU Arm Roll-Out Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Arm 2 Roll-In Pilot Pressure Sensor Switch Box Controller Audio Mute/One-Touch Idle Switch

SECTION2 SYSTEM Group2 Control System Auto-Idle Control Purpose: The auto-idle control reduces the engine speed when all control levers are in neutral. Therefore, the fuel consumption and noise level can be reduced.

TDC1-02-02-052-1 ja

A- Engine Speed B- Engine Control Dial Position C- Slow Idle Speed Position D- Fast Idle Speed Position

E- Fast Idle Speed F- Auto-Idle Speed G- Slow Idle Speed

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

Coolant temperature: 10 °C or more

•

Auto-idle switch (30): ON position

Control lever: All control levers are held in the neutral position [travel pilot pressure sensor (6) and front pilot pressure sensor (7): OFF] beyond 3.5 seconds 2. When the auto-idle control is activated, MC (10) sends the signal equivalent to the auto-idle speed to ECM (15) by using CAN communication (14). 3. ECM (15) changes the engine speed into the auto-idle speed. 4. When any one of the following condition exists, the auto-idle control is deactivated. •

•

Control lever: Any control lever is operated [travel pilot pressure sensor (6) and front pilot pressure sensor (7): ON]

•

When power mode switch (31) is operated

•

When engine control dial (32) is operated

• Coolant temperature: 5 °C or less 5. MC (10) returns the signal sending to ECM (15) into the signal equivalent to the target engine speed set by engine control dial (32) immediately.

NOTE The auto-idle speed can be adjusted by MPDr. (11). (AI Speed) NOTE The auto-idle control is disabled during aftertreatment device auto regeneration. When aftertreatment device auto regeneration is performed at the auto-idle control, the auto-idle control is kept until the auto-idle control is deactivated.

TODFY50-EN-00(10/01/2020)

T2-2-15

SECTION2 SYSTEM Group2 Control System 30

32 11

MODE

27 34

39 SW-BOX 13

12 40

38 37 36 9 8 7 6 5 4 3 2 1

14 35 DCU

10 MC

15 ECM

18 19 26

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MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

2223242526272829303132-

T2-2-16

3334353637383940-

TDFY-02-02-008-1 ja Key Switch Pilot Shut-Off Switch DCU Arm Roll-Out Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Arm 2 Roll-In Pilot Pressure Sensor Switch Box Controller Audio Mute/One-Touch Idle Switch

SECTION2 SYSTEM Group2 Control System Hydraulic Oil Temperature Auto Warming-Up Control Purpose: The hydraulic oil temperature auto warming-up control automatically warms up the hydraulic system.

TDC1-02-02-053-1 ja

A- Engine Speed B- Engine Control Dial Position C- Slow Idle Speed Position D- Fast Idle Speed Position

E- Fast Idle Speed F- Auto Warming-Up Speed G- Slow Idle Speed

Operation: 1. MC (10) receives the signal from hydraulic oil temperature sensor (1). 2. When all following conditions exist, MC (10) sends the signal equivalent to the target engine speed to ECM (15) by using CAN communication (14). •

Engine control dial (32): Below auto warming-up speed position

• When key switch (33) is in the ON or START position and hydraulic oil temperature is -20 to 0 °C 3. ECM (15) increases the engine speed to the auto warming-up speed. 4. When any one the following conditions exists, MC (10) deactivates the hydraulic oil temperature auto warming-up control. •

When 12 minutes passed after setting key switch (33) to ON position

•

When 12 minutes passed after setting key switch (33) to START position

• Hydraulic oil temperature: 2 °C or more 5. ECM (15) returns the engine speed to the engine speed set by engine control dial (32).

NOTE The engine slow idle speed and auto warming-up speed can be adjusted by MPDr. (11). (Li Speed, Hydraulic Oil Temperature WU Speed)

IMPORTANT When adjusting the slow idle speed, deactivate the auto warming-up control by using MPDr. (11). Or wait the adjustment until 12 minutes after the engine starts.

NOTE The hydraulic oil temperature auto warming-up control is deactivated by MPDr. (11) temporarily or completely. The hydraulic oil temperature auto warming-up control is activated again when key switch (33) is turned OFF with the hydraulic oil temperature auto warming-up control deactivated temporarily. (Hydraulic Oil/Coolant Temperature Auto Warming-up Control Casual Deactivation) The hydraulic oil temperature auto warming-up control is always deactivated with the hydraulic oil temperature auto warming-up control deactivated completely. (Hydraulic oil temperature WU control selection)

TODFY50-EN-00(10/01/2020)

T2-2-17

SECTION2 SYSTEM Group2 Control System 30

32 11

MODE

27 34

39 SW-BOX 13

12 40

38 37 36 9 8 7 6 5 4 3 2 1

14 35 DCU

10 MC

15 ECM

18 19 26

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MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

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T2-2-18

3334353637383940-

TDFY-02-02-009-1 ja Key Switch Pilot Shut-Off Switch DCU Arm Roll-Out Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Arm 2 Roll-In Pilot Pressure Sensor Switch Box Controller Audio Mute/One-Touch Idle Switch

SECTION2 SYSTEM Group2 Control System Radiator Coolant Temperature Auto Warming-Up Control Purpose: The radiator coolant temperature auto warming-up control automatically warms up the engine.

TDC1-02-02-053-1 ja

A- Engine Speed B- Engine Control Dial Position C- Slow Idle Speed Position D- Fast Idle Speed Position

E- Fast Idle Speed F- Auto Warming-Up Speed G- Slow Idle Speed

(min-1) 1400

1200

G -18

50 (° C) TDFY-02-02-053-1 ja

G- Slow Idle Speed Operation: 1. ECM (15) receives the signal from coolant temperature sensor (16). 2. When key switch (33) is in the ON or START position, MC (10) receives the signal of coolant temperature sensor (16) from ECM (15). MC (10) sends the signal equivalent to the target engine speed according to the received signals to ECM (15) by using CAN communication (14). 3. ECM (15) increases the engine speed to the auto warming-up speed. 4. When the coolant temperature increases beyond the specified value, MC (10) deactivates the radiator coolant temperature auto warming-up control. 5. ECM (15) returns the engine speed to the engine speed set by engine control dial (32).

NOTE The slow idle speed can be adjusted by MPDr. (11). (Li Speed)

IMPORTANT When adjusting the slow idle speed, deactivate the auto warming-up control by using MPDr. (11). Or wait the adjustment until 12 minutes after the engine starts.

TODFY50-EN-00(10/01/2020)

T2-2-19

SECTION2 SYSTEM Group2 Control System NOTE The radiator coolant temperature auto warming-up control can be deactivated temporarily by MPDr. (11). Once key switch (33) is turned OFF, the radiator coolant temperature auto warming-up control is effective again. (Hydraulic Oil/ Coolant Temperature Auto Warming-Up Control Casual Deactivation) NOTE If the hydraulic oil temperature auto warming-up control and radiator coolant temperature auto warming-up control are activated at the same time, MC (10) selects the control which the target engine speed is faster. MC (10) sends the signal to ECM (15) by using CAN communication (14). The radiator coolant temperature auto warming-up speed is changed due to the coolant temperature. Even if the engine speed becomes the slow idle speed with the coolant temperature beyond 50 °C, when the coolant temperature decreases, the engine speed increases again. 29

32 11

MODE

27 34

39 SW-BOX 13

12 40

38 37 36 9 8 7 6 5 4 3 2 1

14 35 DCU

10 MC

15 ECM

18 19 26

TDFY-02-02-010-1 ja

TODFY50-EN-00(10/01/2020)

T2-2-20

SECTION2 SYSTEM Group2 Control System 1-

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MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

2223242526272829303132-

3334353637383940-

Idle Speed-Up Control Purpose: The idle speed-up control prevents the engine from hunting when the engine runs at slow speed.

TDC1-02-02-055-1 ja

A- Engine Speed B- Engine Control Dial Position C- Slow Idle Speed Position D- Fast Idle Speed Position

E- Fast Idle Speed F- Idle Speed-Up Speed G- Slow Idle Speed

Operation: 1. When all following conditions exist, MC (10) sends the signal equivalent to the target engine speed to ECM (15) by using CAN communication (14). •

Engine speed: Between slow idle speed and idle speed-up speed

• Control lever: When a control lever (travel or front attachment) is operated 2. ECM (15) increases the engine speed to the idle speed-up speed.

TODFY50-EN-00(10/01/2020)

T2-2-21

SECTION2 SYSTEM Group2 Control System 30

32 11

MODE

27 34

39 SW-BOX 13

12 40

38 37 36 9 8 7 6 5 4 3 2 1

14 35 DCU

10 MC

15 ECM

18 19 26

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MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

2223242526272829303132-

T2-2-22

3334353637383940-

TDFY-02-02-011-1 ja Key Switch Pilot Shut-Off Switch DCU Arm Roll-Out Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Arm 2 Roll-In Pilot Pressure Sensor Switch Box Controller Audio Mute/One-Touch Idle Switch

SECTION2 SYSTEM Group2 Control System Idle Speed-Up Control (Pilot Shut-Off Lever) Purpose: When engine control dial (32) is in the slow idle position and the pilot shut-off lever is in the UNLOCK position, the idle speed-up control (pilot shut-off lever) increases the engine speed by 100 min-1 from the slow idle speed. Therefore, the engine stall is prevented during a control lever operation. (When the pilot shut-off lever is in the LOCK position, this control reduces the engine speed to the slow idle speed in order to reduce fuel consumption and noise level.)

TDC1-02-02-056-1 ja

A- Engine Speed B- Engine Control Dial Position C- Slow Idle Speed Position D- Fast Idle Speed Position

E- Fast Idle Speed F- Idle Speed-Up Speed G- Slow Idle Speed

Operation: 1. MC (10) receives the signal from pilot shut-off switch (34). 2. When all following conditions exist, MC (10) sends the signal equivalent to the target engine speed to ECM (15) by using CAN communication (14). •

Engine control dial (32): Slow idle position

•

Pilot shut-off switch (34): OFF (Pilot shut-off lever: UNLOCK Position)

3. ECM (15) increases the engine speed to the idle speed-up speed (slow idle speed +100 min-1). 4. When the pilot shut-off lever is in LOCK position [pilot shut-off switch (34): ON], MC (10) sends the signal of the target engine speed equivalent to the slow idle speed to ECM (15) by using CAN communication (14). 5. ECM (15) changes the engine speed to the slow idle speed according to CAN communication (14).

TODFY50-EN-00(10/01/2020)

T2-2-23

SECTION2 SYSTEM Group2 Control System 30

32 11

MODE

27 34

39 SW-BOX 13

12 40

38 37 36 9 8 7 6 5 4 3 2 1

14 35 DCU

10 MC

15 ECM

18 19 26

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MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

2223242526272829303132-

T2-2-24

3334353637383940-

TDFY-02-02-012-1 ja Key Switch Pilot Shut-Off Switch DCU Arm Roll-Out Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Arm 2 Roll-In Pilot Pressure Sensor Switch Box Controller Audio Mute/One-Touch Idle Switch

SECTION2 SYSTEM Group2 Control System Engine Speed Slow Down Control Purpose: The engine speed slow down control gradually reduces the engine speed to the slow idle speed when the auto shutdown control is performed. Therefore, the loads of the engine and hydraulic actuator can be reduced.

TDC1-02-02-057-1 ja

A- Engine Speed B- Time

C- Slow Idle Speed

Operation: 1. MC (10) saves the engine speed at the moment when the auto shut-down control is performed. 2. MC (10) sends the signal that the engine speed gradually reduces from the saved engine speed to ECM (15) by using CAN communication (14). 3. ECM (15) changes the engine speed to the slow idle speed according to CAN communication (14). 4. Then, the auto shut-down control stops the engine. (Refer to "Auto Shut-Down Control"T2-2-100.)

TODFY50-EN-00(10/01/2020)

T2-2-25

SECTION2 SYSTEM Group2 Control System 30

32 11

MODE

27 34

39 SW-BOX 13

12 40

38 37 36 9 8 7 6 5 4 3 2 1

14 35 DCU

10 MC

15 ECM

18 19 26

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TODFY50-EN-00(10/01/2020)

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MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

2223242526272829303132-

T2-2-26

3334353637383940-

TDFY-02-02-014-1 ja Key Switch Pilot Shut-Off Switch DCU Arm Roll-Out Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Arm 2 Roll-In Pilot Pressure Sensor Switch Box Controller Audio Mute/One-Touch Idle Switch

SECTION2 SYSTEM Group2 Control System Heater Control Purpose: The heater control increases the engine speed at the low temperature, and increases the rising temperature speed of the heater in the cab.

TDC1-02-02-058-1 ja

A- Engine Speed B- Engine Control Dial Position C- Slow Idle Speed Position

D- Fast Idle Speed Position E- Fast Idle Speed F- Slow Idle Speed

Operation: 1. Set engine control dial (32) to the fast idle position after the engine starts. 2. When all following conditions exist, MC (10) sends the signal equivalent to the target engine speed to ECM (15) by using CAN communication (14). •

Coolant temperature: less than 5 °C

•

Control lever: When all control lever (travel or front attachment) are in the neutral position.

• Pilot shut-Off Switch (34): ON (Pilot shut-off lever: LOCK Position) 3. ECM (15) increases the engine speed beyond the fast idle speed. 4. If the heater control and other engine control are activated at the same time, MC (10) deactivates the heater control and gives priority to other engine control.

NOTE The heater control can be made operable or inoperable by MPDr. (11). The selected setting can be saved even if key switch (33) is turned OFF. (Heater Control Selection)

TODFY50-EN-00(10/01/2020)

T2-2-27

SECTION2 SYSTEM Group2 Control System 30

32 11

MODE

27 34

39 SW-BOX 13

12 40

38 37 36 9 8 7 6 5 4 3 2 1

14 35 DCU

10 MC

15 ECM

18 19 26

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TODFY50-EN-00(10/01/2020)

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MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

2223242526272829303132-

T2-2-28

3334353637383940-

TDFY-02-02-015-1 ja Key Switch Pilot Shut-Off Switch DCU Arm Roll-Out Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Arm 2 Roll-In Pilot Pressure Sensor Switch Box Controller Audio Mute/One-Touch Idle Switch

SECTION2 SYSTEM Group2 Control System One-Touch Idle Control Purpose: The one-touch idle control reduces the engine speed when the audio mute/one-touch idle switch is pushed. Therefore, the noise level can be reduced.

TDC1-02-02-047-1 ja

A- Engine Speed B- Engine Control Dial Position C- Slow Idle Speed Position

D- Fast Idle Speed Position E- Slow Idle Speed F- Fast Idle Speed

Operation: 1. When audio mute/one-touch idle switch (40) is pushed, monitor controller (12) sends the signal for audio mute/onetouch idle switch (40) in the ON position to MC (10) by using CAN communication (14). 2. MC (10) sends the signal of the target engine speed equivalent to the slow idle speed to ECM (15) by using CAN communication (14) regardless of the angle (required engine speed) of engine control dial (32). 3. ECM (15) changes the engine speed to the slow idle speed. 4. When any one of the following condition exists, the one-touch idle control is deactivated. •

Control lever: Any control lever is operated [travel pilot pressure sensor (6) and front pilot pressure sensor (7): ON]

•

When power mode switch (31) is operated

• When engine control dial (32) is operated 5. MC (10) returns the signal sending to ECM (15) into the signal equivalent to the target engine speed set by engine control dial (32) immediately.

NOTE Audio mute/one-touch idle switch (40) can be set to OFF, engine idle mode, radio mute mode, or engine idle/radio mute mode by MPDr. (11). (PBLI)

TODFY50-EN-00(10/01/2020)

T2-2-29

SECTION2 SYSTEM Group2 Control System 30

32 11

MODE

27 34

39 SW-BOX 13

12 40

38 37 36 9 8 7 6 5 4 3 2 1

14 35 DCU

10 MC

15 ECM

18 19 26

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TODFY50-EN-00(10/01/2020)

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MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

2223242526272829303132-

T2-2-30

3334353637383940-

TDFY-02-02-045-1 ja Key Switch Pilot Shut-Off Switch DCU Arm Roll-Out Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Arm 2 Roll-In Pilot Pressure Sensor Switch Box Controller Audio Mute/One-Touch Idle Switch

SECTION2 SYSTEM Group2 Control System Attachment Operation Speed Increase Control (Option) Purpose: When the attachment is operated, the attachment operation speed increase control increases the engine speed by the amount of the setting speed. This control is activated when the engine speed to a faster (+) attachment operating speed set by MPDr. (11) when the attachment is operated.

TDC1-02-02-059-1 ja

A- Engine Speed B- Engine Control Dial Position C- Slow Idle Speed Position

D- Fast Idle Speed Position E- Fast Idle Speed F- Slow Idle Speed

Operation: 1. When all following conditions exist and the attachment is operated, MC (10) sends the signal equivalent to the target engine speed set by MPDr. (11) to ECM (15) by using CAN communication (14). •

MPDr. (11): The fast idle speed is set to a faster (+) attachment operating speed.

•

Engine control dial (32): Fast idle position

•

Power mode switch (31): PWR

•

When performing auxiliary operation

•

Work mode: Attachment mode

• The attachment selected by using monitor (13) is set to faster (+) by MPDr. (11). 2. ECM (15) increases the engine speed to the amount of the attachment operating speed set by MPDr. (11).

NOTE The fast idle speed can be adjusted by MPDr. (11). When the fast idle speed is preset to a slower speed, the fast idle speed will not be increased when operating the attachment. (PWR Mode Speed) NOTE Even if the attachment is not operated, the increased engine speed can be kept for a specified time by MPDr. (11). (ATT Speed Deceleration Waiting Time)

TODFY50-EN-00(10/01/2020)

T2-2-31

SECTION2 SYSTEM Group2 Control System 30

32 11

MODE

27 34

39 SW-BOX 13

12 40

38 37 36 9 8 7 6 5 4 3 2 1

14 35 DCU

10 MC

15 ECM

18 19 26

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MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

2223242526272829303132-

T2-2-32

3334353637383940-

TDFY-02-02-016-1 ja Key Switch Pilot Shut-Off Switch DCU Arm Roll-Out Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Arm 2 Roll-In Pilot Pressure Sensor Switch Box Controller Audio Mute/One-Touch Idle Switch

SECTION2 SYSTEM Group2 Control System Attachment Operation Speed Limit Control (Option) Purpose: When the attachment is operated, the attachment operation speed limit control reduces the engine speed by the amount of the setting speed. This control is activated when the engine speed to a slower (-) attachment operating speed set by MPDr. (11) when the attachment is operated.

TDC1-02-02-060-1 ja

A- Engine Speed B- Engine Control Dial Position C- Slow Idle Speed Position

D- Fast Idle Speed Position E- Fast Idle Speed F- Slow Idle Speed

Operation: 1. When all following conditions exist and the attachment mode is selected, MC (10) sends the signal equivalent to the target engine speed set by MPDr. (11) to ECM (15) by using CAN communication (14). •

MPDr. (11): The fast idle speed is set to a slower (-) attachment operating speed.

•

Work mode: Attachment mode

• The attachment selected by using monitor (13) is set to slower (-) by MPDr. (11). 2. ECM (15) reduces the engine speed by the amount of the speed set by MPDr. (11).

TODFY50-EN-00(10/01/2020)

T2-2-33

SECTION2 SYSTEM Group2 Control System 30

32 11

MODE

27 34

39 SW-BOX 13

12 40

38 37 36 9 8 7 6 5 4 3 2 1

14 35 DCU

10 MC

15 ECM

18 19 26

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TODFY50-EN-00(10/01/2020)

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MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

2223242526272829303132-

T2-2-34

3334353637383940-

TDFY-02-02-017-1 ja Key Switch Pilot Shut-Off Switch DCU Arm Roll-Out Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Arm 2 Roll-In Pilot Pressure Sensor Switch Box Controller Audio Mute/One-Touch Idle Switch

SECTION2 SYSTEM Group2 Control System Pump Control The pump control consists of the followings. ● Speed Sensing Control ● Swing Relief Cut Control ● Pump Torque Decrease Control (Radiator Coolant Temperature) ● Pump Torque Decrease Control (Hydraulic Oil Temperature) ● Travel Torque-Up Control ● Pump Torque Restriction Control (During Engine Output Restriction) ● Pump 1 Flow Rate Control ● Pump 2 Flow Rate Control ● Pump 3 Flow Rate Control ● Pump 1 Flow Rate Limit Control (Option) ● Pump 2 Flow Rate Limit Control (Option) ● Pump 3 Flow Rate Limit Control (Option)

TODFY50-EN-00(10/01/2020)

T2-2-35

SECTION2 SYSTEM Group2 Control System Pump Control System Layout 29

30 11

MODE

38 SW-BOX

31 12 37 34 33 9 8 7 6 5 4 3 2 1

14 32 DCU

10 MC 15 ECM

20 16

18 19

17 REG.

REG.

35 36 26 27 28 123456789-

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MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

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T2-2-36

Pump 2 Delivery Pressure Sensor Pump 2 Control Pressure Sen sor Pump 3 Control Pressure Sen sor Pump 1 Control Pressure Sen sor Pump 1 and 2 Torque Control Solenoid Valve Pump 3 Torque Control Sole noid Valve Maximum Pump 2 Flow Rate Limit Control Solenoid Valve Power Mode Switch

303132333435363738-

TDFY-02-02-018-1 ja Engine Control Dial Key Switch DCU Arm Roll-Out Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Maximum Pump 1 Flow Rate Limit Control Solenoid Valve Maximum Pump 3 Flow Rate Limit Control Solenoid Valve Arm 2 Roll-In Pilot Pressure Sensor Switch Box Controller

SECTION2 SYSTEM Group2 Control System 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 so that the engine output 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.

TDC1-02-02-061-1 ja

P- Pressure

Q- Flow Rate

Operation: 1. The target engine speed can be set by engine control dial (30). 2. ECM (15) receives the signals from cam angle sensor (18) and crank speed sensor (19). 3. ECM (15) calculates them and sends the actual engine speed to MC (10) by using CAN communication (14). 4. MC (10) calculates the difference in the speed between the target engine speed and actual engine speed that is received through CAN communication (14) from ECM (15). 5. MC (10) sends the signals to pump 1 and 2 torque control solenoid valve (26) and pump 3 torque control solenoid valve (27). 6. Pump 1 and 2 torque control solenoid valve (26) and pump 3 torque control solenoid valve (27) supplies the pilot pressure to the regulators according to the signals, and reduces the pump delivery flow rate. 7. If the load of engine (17) increases and the actual engine speed becomes slower than the target engine speed, the pump displacement angle is reduced so that the pump flow rate will be reduced. Therefore, the load of engine (17) is reduced and the engine stall is prevented.

TODFY50-EN-00(10/01/2020)

T2-2-37

SECTION2 SYSTEM Group2 Control System 29

30 11

MODE

38 SW-BOX

31 12 37 34 33 9 8 7 6 5 4 3 2 1

14 32 DCU

10 MC 15 ECM

20 16

18 19

17 REG.

REG.

35 36 26 27 28 123456789-

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MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

2223242526272829-

T2-2-38

303132333435363738-

TDFY-02-02-019-1 ja Engine Control Dial Key Switch DCU Arm Roll-Out Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Maximum Pump 1 Flow Rate Limit Control Solenoid Valve Maximum Pump 3 Flow Rate Limit Control Solenoid Valve Arm 2 Roll-In Pilot Pressure Sensor Switch Box Controller

SECTION2 SYSTEM Group2 Control System Swing Relief Cut Control Purpose: The swing relief cut control reduces the pump 3 delivery flow rate when starting swing operation, and reduces energy consumption. Operation: 1. When all following conditions exist, MC (10) activates pump 3 torque control solenoid valve (27). •

Swing pilot pressure sensor (5): High-pressure

• Pump 3 delivery pressure sensor (21): High-pressure 2. Pump 3 torque control solenoid valve (27) delivers the pilot pressure according to the signal to the regulator and reduces pump 3 delivery flow rate. 29

30 11

MODE

38 SW-BOX

31 12 37 34 33 9 8 7 6 5 4 3 2 1

14 32 DCU

10 MC 15 ECM

20 16

18 19

17 REG.

REG.

35 36 26 27 28 TDFY-02-02-020-1 ja

TODFY50-EN-00(10/01/2020)

T2-2-39

SECTION2 SYSTEM Group2 Control System 123456789-

101112131415161718192021-

MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

2223242526272829-

303132333435363738-

Engine Control Dial Key Switch DCU Arm Roll-Out Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Maximum Pump 1 Flow Rate Limit Control Solenoid Valve Maximum Pump 3 Flow Rate Limit Control Solenoid Valve Arm 2 Roll-In Pilot Pressure Sensor Switch Box Controller

Pump Torque Decrease Control (Radiator Coolant Temperature) Purpose: When the target engine speed is the ECO mode engine speed or faster and coolant temperature increases, the pump torque decrease control (radiator coolant temperature) reduces the pump flow rate. Therefore, pump driving torque is decreased so that the engine overheating is prevented. Operation: 1. When the target engine speed is the ECO mode engine speed or faster and coolant temperature increases, MC (10) activates pump 1 and 2 torque control solenoid valve (26) and pump 3 torque control solenoid valve (27). 2. Pump 1 and 2 torque control solenoid valve (26) and pump 3 torque control solenoid valve (27) supplies the pilot pressure to the regulators according to the signals, and reduces the pump delivery flow rate. 3. Therefore, the engine overheating is prevented when the coolant temperature increases.

NOTE The pump torque decrease control (radiator coolant temperature) can be made operable or inoperable by MPDr. (11). (Pump Torque Decrease Control Selection (Radiator Coolant Temperature))

TODFY50-EN-00(10/01/2020)

T2-2-40

SECTION2 SYSTEM Group2 Control System 29

30 11

MODE

38 SW-BOX

31 12 37 34 33 9 8 7 6 5 4 3 2 1

14 32 DCU

10 MC 15 ECM

20 16

18 19

17 REG.

REG.

35 36 26 27 28 123456789-

TODFY50-EN-00(10/01/2020)

101112131415161718192021-

MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

2223242526272829-

T2-2-41

303132333435363738-

TDFY-02-02-021-1 ja Engine Control Dial Key Switch DCU Arm Roll-Out Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Maximum Pump 1 Flow Rate Limit Control Solenoid Valve Maximum Pump 3 Flow Rate Limit Control Solenoid Valve Arm 2 Roll-In Pilot Pressure Sensor Switch Box Controller

SECTION2 SYSTEM Group2 Control System Pump Torque Decrease Control (Hydraulic Oil Temperature) Purpose: The pump torque decrease control (hydraulic oil temperature) reduces the pump delivery flow rate when hydraulic oil temperature becomes high or low. At high temperature, pump driving torque is decreased so that the engine overheating is prevented. At low temperature, the viscosity of hydraulic oil increases so that the hydraulic component response becomes slower. Consequently, at low temperature, pump driving torque is decreased for stable front attachment operating speed. Operation: 1. When hydraulic oil temperature becomes high or low, MC (10) activates the pump 1 and 2 torque control solenoid valve (26) and the pump 3 torque control solenoid valve (27). 2. Pump 1 and 2 torque control solenoid valve (26) and pump 3 torque control solenoid valve (27) supplies the pilot pressure to the regulators according to the signals, and reduces the pump delivery flow rate. 3. Therefore, at high hydraulic oil temperature, the engine overheating is prevented. At low temperature, the front attachment operating speed becomes stable.

NOTE During the pump torque decrease control (hydraulic oil temperature), the adjustment of the pump driving torque side by monitor (13) or MPDr. (11) is disabled. (Front Attachment Speed Control at High Load (ECO), Front Attachment Speed Adjustment (PWR))

TODFY50-EN-00(10/01/2020)

T2-2-42

SECTION2 SYSTEM Group2 Control System 29

30 11

MODE

38 SW-BOX

31 12 37 34 33 9 8 7 6 5 4 3 2 1

14 32 DCU

10 MC 15 ECM

20 16

18 19

17 REG.

REG.

35 36 26 27 28 123456789-

TODFY50-EN-00(10/01/2020)

101112131415161718192021-

MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

2223242526272829-

T2-2-43

303132333435363738-

TDFY-02-02-046-1 ja Engine Control Dial Key Switch DCU Arm Roll-Out Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Maximum Pump 1 Flow Rate Limit Control Solenoid Valve Maximum Pump 3 Flow Rate Limit Control Solenoid Valve Arm 2 Roll-In Pilot Pressure Sensor Switch Box Controller

SECTION2 SYSTEM Group2 Control System Travel Torque-Up Control Purpose: When the travel operation is performed with the engine running at slow speed, normally, the hydraulic pump delivers the pressure oil at the flow rate corresponding to point A on the P-Q curve in illustration C. At this time, if any difference exists between pump 1 and pump 2 flow rate, the machine will mistrack. In order to prevent mistracking, when traveling the machine with the engine running at slow speed, the pump P-Q curve is raised and the pump delivers the pressure oil at the flow rate corresponding to point B (maximum flow rate). In addition, when the travel operation is made with the engine running at fast speed, the pump P-Q curve is raised in order to improve the travel function. Q B b

a P

C TDC1-02-02-062-1 ja

P- Pressure Q- Flow Rate

a- Normal P-Q Curve b- Increased Torque P-Q Curve

Operation: 1. When all following conditions MC (10) calculates the signals from pump 1 delivery pressure sensor (20) and pump 2 delivery pressure sensor (22). •

Engine control dial (30): Slow speed

•

Travel pilot pressure sensor (6): Outputting signal

• Front pilot pressure sensor (7): No signal 2. MC (10) sends the signal to pump 1 and 2 torque control solenoid valve (26). 3. Pump 1 and 2 torque control solenoid valve (26) supplies the pilot pressure to the regulators according to the signals, and increases the pump delivery flow rate.

TODFY50-EN-00(10/01/2020)

T2-2-44

SECTION2 SYSTEM Group2 Control System 29

30 11

MODE

38 SW-BOX

31 12 37 34 33 9 8 7 6 5 4 3 2 1

14 32 DCU

10 MC 15 ECM

20 16

18 19

17 REG.

REG.

35 36 26 27 28 123456789-

TODFY50-EN-00(10/01/2020)

101112131415161718192021-

MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

2223242526272829-

T2-2-45

303132333435363738-

TDFY-02-02-022-1 ja Engine Control Dial Key Switch DCU Arm Roll-Out Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Maximum Pump 1 Flow Rate Limit Control Solenoid Valve Maximum Pump 3 Flow Rate Limit Control Solenoid Valve Arm 2 Roll-In Pilot Pressure Sensor Switch Box Controller

SECTION2 SYSTEM Group2 Control System Pump Torque Restriction Control (During Engine Output Restriction) Purpose: The pump torque restriction control (during engine output restriction) decreases pump driving torque according to the step of engine output restriction. Operation: 1. When any following conditions exist and a specified time has passed, MC (10) activates pump 1 and 2 torque control solenoid valve (26) and pump 3 torque control solenoid valve (27). •

DEF level is severely low

•

Uera SCR system is abnormal

• EGR system is abnormal 2. Pump 1 and 2 torque control solenoid valve (26) and pump 3 torque control solenoid valve (27) supplies the pilot pressure to the regulators according to the signals, and reduces the pump delivery flow rate.

TODFY50-EN-00(10/01/2020)

T2-2-46

SECTION2 SYSTEM Group2 Control System 29

30 11

MODE

38 SW-BOX

31 12 37 34 33 9 8 7 6 5 4 3 2 1

14 32 DCU

10 MC 15 ECM

20 16

18 19

17 REG.

REG.

35 36 26 27 28 123456789-

TODFY50-EN-00(10/01/2020)

101112131415161718192021-

MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

2223242526272829-

T2-2-47

303132333435363738-

TDFY-02-02-040-1 ja Engine Control Dial Key Switch DCU Arm Roll-Out Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Maximum Pump 1 Flow Rate Limit Control Solenoid Valve Maximum Pump 3 Flow Rate Limit Control Solenoid Valve Arm 2 Roll-In Pilot Pressure Sensor Switch Box Controller

SECTION2 SYSTEM Group2 Control System Pump 1 Flow Rate Control Purpose: The pump 1 flow rate control changes the pump 1 flow rate which is required according to each stroke of the boom, arm, bucket, travel, and swing control levers. Therefore, the fuel consumption is reduced.

TDC1-02-02-045-1 ja

A- Control Level Operation

Q- Flow Rate

Operation: 1. When the control lever is operated, MC (10) receives the signals from pilot pressure sensors (boom raise (2), arm rollout (33), arm 1 roll-in (3), arm 2 roll-in (37), bucket roll-in (4), bucket roll-out (34), travel (6) and swing (5)). 2. MC (10) activates maximum pump 1 flow rate limit control solenoid valve (35) according to the control lever stroke and controls the pump 1 flow rate.

TODFY50-EN-00(10/01/2020)

T2-2-48

SECTION2 SYSTEM Group2 Control System 29

30 11

MODE

38 SW-BOX

31 12 37 34 33 9 8 7 6 5 4 3 2 1

14 32 DCU

10 MC 15 ECM

20 16

18 19

17 REG.

REG.

35 36 26 27 28 123456789-

TODFY50-EN-00(10/01/2020)

101112131415161718192021-

MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

2223242526272829-

T2-2-49

303132333435363738-

TDFY-02-02-041-1 ja Engine Control Dial Key Switch DCU Arm Roll-Out Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Maximum Pump 1 Flow Rate Limit Control Solenoid Valve Maximum Pump 3 Flow Rate Limit Control Solenoid Valve Arm 2 Roll-In Pilot Pressure Sensor Switch Box Controller

SECTION2 SYSTEM Group2 Control System Pump 2 Flow Rate Control Purpose: The pump 2 flow rate control changes the pump 2 flow rate which is required according to each stroke of the boom, arm, travel, and swing control levers. Therefore, the fuel consumption is reduced.

TDC1-02-02-045-1 ja

A- Control Level Operation

Q- Flow Rate

Operation: 1. When the control lever is operated, MC (10) receives the signals from pilot pressure sensors (boom raise (2), arm rollout (33), arm 1 roll-in (3), arm 2 roll-in (37), travel (6), and swing (5)). 2. MC (10) activates maximum pump 2 flow rate limit control solenoid valve (28) according to the control lever stroke and controls the pump 2 flow rate.

TODFY50-EN-00(10/01/2020)

T2-2-50

SECTION2 SYSTEM Group2 Control System 29

30 11

MODE

38 SW-BOX

31 12 37 34 33 9 8 7 6 5 4 3 2 1

14 32 DCU

10 MC 15 ECM

20 16

18 19

17 REG.

REG.

35 36 26 27 28 123456789-

TODFY50-EN-00(10/01/2020)

101112131415161718192021-

MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

2223242526272829-

T2-2-51

303132333435363738-

TDFY-02-02-042-1 ja Engine Control Dial Key Switch DCU Arm Roll-Out Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Maximum Pump 1 Flow Rate Limit Control Solenoid Valve Maximum Pump 3 Flow Rate Limit Control Solenoid Valve Arm 2 Roll-In Pilot Pressure Sensor Switch Box Controller

SECTION2 SYSTEM Group2 Control System Pump 3 Flow Rate Control Purpose: The pump 3 flow rate control changes the pump 3 flow rate which is required according to each stroke of the boom and swing control levers. Therefore, the fuel consumption is reduced.

TDC1-02-02-045-1 ja

A- Control Level Operation

Q- Flow Rate

Operation: 1. When the control lever is operated, MC (10) receives the signals from pilot pressure sensors (boom raise (2) and swing (5)). 2. MC (10) activates maximum pump 3 flow rate limit control solenoid valve (36) according to the control lever stroke and controls the pump 3 flow rate.

TODFY50-EN-00(10/01/2020)

T2-2-52

SECTION2 SYSTEM Group2 Control System 29

30 11

MODE

38 SW-BOX

31 12 37 34 33 9 8 7 6 5 4 3 2 1

14 32 DCU

10 MC 15 ECM

20 16

18 19

17 REG.

REG.

35 36 26 27 28 123456789-

TODFY50-EN-00(10/01/2020)

101112131415161718192021-

MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

2223242526272829-

T2-2-53

303132333435363738-

TDFY-02-02-043-1 ja Engine Control Dial Key Switch DCU Arm Roll-Out Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Maximum Pump 1 Flow Rate Limit Control Solenoid Valve Maximum Pump 3 Flow Rate Limit Control Solenoid Valve Arm 2 Roll-In Pilot Pressure Sensor Switch Box Controller

SECTION2 SYSTEM Group2 Control System Pump 1 Flow Rate Limit Control (Option) Purpose: The pump 1 flow rate limit control limits the maximum flow rate of pump 1 when a attachment (mainly a vibrating hammer) is used. Then, the limited pressure oil from pump 1 is combined with pressure oil from pump 2, and the combined pressure oil is delivered to the actuator. (Refer to SYSTEM/Hydraulic System.)

TDC1-02-02-046-1 ja

P- Pressure

Q- Flow Rate

Operation: 1. When the attachment is used with the travel control lever set in neutral, MC (10) receives the signal from the auxiliary 1 pilot pressure sensor (8) (Option). 2. MC (10) activates maximum pump 1 flow rate limit control solenoid valve (35) according to the attachment operation and controls the maximum flow rate of pump 1.

NOTE The pump 1 delivery flow rate can be limited by MPDr. (11). (Pump 1 Maximum Flow Rate)

TODFY50-EN-00(10/01/2020)

T2-2-54

SECTION2 SYSTEM Group2 Control System 29

30 11

MODE

38 SW-BOX

31 12 37 34 33 9 8 7 6 5 4 3 2 1

14 32 DCU

10 MC 15 ECM

20 16

18 19

17 REG.

REG.

35 36 26 27 28 123456789-

TODFY50-EN-00(10/01/2020)

101112131415161718192021-

MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

2223242526272829-

T2-2-55

303132333435363738-

TDFY-02-02-023-1 ja Engine Control Dial Key Switch DCU Arm Roll-Out Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Maximum Pump 1 Flow Rate Limit Control Solenoid Valve Maximum Pump 3 Flow Rate Limit Control Solenoid Valve Arm 2 Roll-In Pilot Pressure Sensor Switch Box Controller

SECTION2 SYSTEM Group2 Control System Pump 2 Flow Rate Limit Control (Option) Purpose: The pump 2 flow rate limit control limits the maximum flow rate of pump 2 when a attachment (mainly a hydraulic breaker) is used.

TDC1-02-02-046-1 ja

P- Pressure

Q- Flow Rate 06 32 PM

ECO

50.0 h

Pump Flow Rate

150 -

TDFY-05-02-040 en_GB

Operation: 1. When the attachment is used with the travel control lever set in neutral, MC (10) receives the signal from the auxiliary 1 pilot pressure sensor (8) (Option). 2. MC (10) activates maximum pump 2 flow rate limit control solenoid valve (28) according to the attachment control operation and controls the maximum flow rate of pump 2.

NOTE The pump 2 delivery flow rate can be limited by MPDr. (11). (Pump 2 Maximum Flow Rate) NOTE The pump 2 flow rate can be adjusted finely by using monitor (13) when the auxiliary flow combiner solenoid valve is not activated.

TODFY50-EN-00(10/01/2020)

T2-2-56

SECTION2 SYSTEM Group2 Control System 29

30 11

MODE

38 SW-BOX

31 12 37 34 33 9 8 7 6 5 4 3 2 1

14 32 DCU

10 MC 15 ECM

20 16

18 19

17 REG.

REG.

35 36 26 27 28 123456789-

TODFY50-EN-00(10/01/2020)

101112131415161718192021-

MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

2223242526272829-

T2-2-57

303132333435363738-

TDFY-02-02-024-1 ja Engine Control Dial Key Switch DCU Arm Roll-Out Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Maximum Pump 1 Flow Rate Limit Control Solenoid Valve Maximum Pump 3 Flow Rate Limit Control Solenoid Valve Arm 2 Roll-In Pilot Pressure Sensor Switch Box Controller

SECTION2 SYSTEM Group2 Control System Pump 3 Flow Rate Limit Control (Option) Purpose: The pump 3 flow rate limit control limits the maximum flow rate of pump 3 when a fully 360-degree rotating type attachment is used.

TDC1-02-02-046-1 ja

P- Pressure

Q- Flow Rate

Operation: 1. When the attachment is used with the travel control lever set in neutral, MC (10) receives the signal from the auxiliary 2 pilot pressure sensor (9) (Option). 2. MC (10) activates maximum pump 3 flow rate limit control solenoid valve (36) according to the attachment control operation and controls the maximum flow rate of pump 3.

NOTE The pump 3 delivery flow rate can be limited by MPDr. (11). (Pump 3 Maximum Flow Rate)

TODFY50-EN-00(10/01/2020)

T2-2-58

SECTION2 SYSTEM Group2 Control System 29

30 11

MODE

38 SW-BOX

31 12 37 34 33 9 8 7 6 5 4 3 2 1

14 32 DCU

10 MC 15 ECM

20 16

18 19

17 REG.

REG.

35 36 26 27 28 123456789-

TODFY50-EN-00(10/01/2020)

101112131415161718192021-

MC MPDr. Monitor Controller Monitor CAN ECM Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

2223242526272829-

T2-2-59

303132333435363738-

TDFY-02-02-025-1 ja Engine Control Dial Key Switch DCU Arm Roll-Out Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Maximum Pump 1 Flow Rate Limit Control Solenoid Valve Maximum Pump 3 Flow Rate Limit Control Solenoid Valve Arm 2 Roll-In Pilot Pressure Sensor Switch Box Controller

SECTION2 SYSTEM Group2 Control System Valve Control (Standard) The valve control consists of the followings. ● Power Digging Control ● Auto-Power Lift Control ● Travel Motor Displacement Angle Control ● Arm Regenerative Cut Control ● Digging Regenerative Control ● Arm 1 Flow Rate Control ● Arm 2 Roll-In Pilot Cut Control ● Aftertreatment Device Manual Regeneration Control ● Aftertreatment Device Auto Regeneration Control ● Pump 3 Center Bypass Shut-Out Control ● Arm Roll-In Meter-Out Open Control

TODFY50-EN-00(10/01/2020)

T2-2-60

SECTION2 SYSTEM Group2 Control System Valve Control (Standard) System Layout 44

43 MODE

13 12 41

15 54 SW-BOX

16 ECM

11 MC

50 49 10 9 8 7 6 5 4 3 2 1

48 DCU 23

20 21

22 31

SI SE SF SC SD

SZ SJ

51 SK3

SK2

53 SK1

35 P2

P3 P1 TDFY-02-02-026-1 ja

TODFY50-EN-00(10/01/2020)

T2-2-61

SECTION2 SYSTEM Group2 Control System 123456789101112-

1314151617181920212223242526-

MPDr. Monitor Controller Monitor ECM Manual Regeneration Switch Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 and 2 Torque Control Solenoid Valve Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 2 Control Pressure Sen sor

272829303132333435363738394041-

Pump 3 Control Pressure Sen sor Pump 1 Control Pressure Sen sor 5-Spool Solenoid Valve Unit Main Relief Valve (For P1, 2) Digging Regenerative Valve Control Valve Arm 2 Flow Rate Control Valve Pump 1 Bypass Shut-Out Valve Main Relief Valve (For P3) Arm 1 Flow Rate Control Valve Travel Motor Displacement Angle Control Valve Arm Regenerative Valve 2-Spool Solenoid Valve Unit Power Digging Switch Travel Mode Switch

4243444546474849505152535455-

Slow Speed Position Fast Speed Position Power Mode Switch Engine Control Dial Key Switch Pilot Shut-Off Switch DCU Bucket Roll-Out Pilot Pressure Sensor Arm 2 Roll-In Pilot Pressure Sensor 3-Spool Solenoid Valve Unit Pump 3 Bypass Shut-Out Valve Arm Roll-In Meter-Out Open Control Spool Switch Box Controller Differential Pressure Sensor

Power Digging Control Purpose: The power digging control increases the digging force by temporarily increasing the relief pressure. Operation: 1. For maximum eight seconds after power digging switch (40) is turned ON, MC (11) continuously activates 5-spool solenoid valve unit (29) (SI). 2. When 5-spool solenoid valve unit (29) (SI) is activated, the pilot pressure acts on main relief valves (30, 35) and increases the relief pressure. (Refer to COMPONENT OPERATION/Control Valve.)

TODFY50-EN-00(10/01/2020)

T2-2-62

SECTION2 SYSTEM Group2 Control System

43 MODE

13 12 41

15 54 SW-BOX

16 ECM

48 DCU 23

40 19

50 49 10 9 8 7 6 5 4 3 2 1

11 MC

20 21

22 31

SI SE SF SC SD

SZ SJ

51 39 SK3

SK2

53 SK1

35 P2

P3 P1 TDFY-02-02-027-1 ja

TODFY50-EN-00(10/01/2020)

T2-2-63

SECTION2 SYSTEM Group2 Control System 1-

23456789101112-

1314151617181920212223242526-

272829303132333435363738394041-

42434445464748495051525354-

Auto-Power Lift Control Purpose: The auto-power lift control increases the relief pressure when raising the boom. Operation: 1. When all following conditions exist, MC (11) activates 5-spool solenoid valve unit (29) (SI). •

Boom raise pilot pressure sensor (2): Specified pressure or higher (Reference: 1.7 MPa or more)

•

Pump 1 delivery pressure sensor (23): High (Reference: 31.5 MPa or more)

• Arm 1 roll-in pilot pressure sensor (3): Specified pressure or lower (Reference: 2.7 MPa or less) 2. When 5-spool solenoid valve unit (29) (SI) is activated, the pilot pressure acts on main relief valves (30, 35) and increases the relief pressure. (Refer to COMPONENT OPERATION/Control Valve.)

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

TODFY50-EN-00(10/01/2020)

T2-2-64

SECTION2 SYSTEM Group2 Control System

43 MODE

13 12 41

15 54 SW-BOX

16 ECM

48 DCU 23

40 19

50 49 10 9 8 7 6 5 4 3 2 1

11 MC

20 21

22 31

SI SE SF SC SD

SZ SJ

51 39 SK3

SK2

53 SK1

35 P2

P3 P1 TDFY-02-02-028-1 ja

TODFY50-EN-00(10/01/2020)

T2-2-65

SECTION2 SYSTEM Group2 Control System 123456789101112-

1314151617181920212223242526-

272829303132333435363738394041-

42434445464748495051525354-

Travel Motor Displacement Angle Control Purpose: The travel motor displacement angle control controls the travel mode. Operation: •

Slow speed 1. When travel mode switch (41) is in slow speed position (42), the travel motor displacement angle is kept in the maximum angle so that the travel speed is slow.

•

Fast speed 1. When all following conditions exist, MC (11) shifts 5-spool solenoid valve unit (29) (SI). •

Travel mode switch (41): Fast speed (43)

•

Travel pilot pressure sensor (6): Outputting signal

•

Front pilot pressure sensor (7): OFF

•

Pump 1 delivery pressure sensor (23), pump 2 delivery pressure sensor (25): The delivery pressure of either pump is low. (Reference: less than 24 MPa)

Pump 1 control pressure sensor (28), pump 2 control pressure sensor (26): Either pump control pressure is high. (Reference: 2.2 MPa or more) 2. When 5-spool solenoid valve unit (29) (SI) is shifted, the pilot pressure acts on travel motor displacement angle control valve (37). The travel motor is fixed at the minimum displacement angle and the travel speed increases. •

NOTE When one side track link is raised off the ground and is rotated, the pump control pressure at the one side increases so that the raised track link rotates at fast speed. When the machine is traveling at the fast speed and even if the front attachment is operated (front pilot pressure sensor (7): ON), the travel mode is kept at the fast speed.

TODFY50-EN-00(10/01/2020)

T2-2-66

SECTION2 SYSTEM Group2 Control System

43 MODE

13 12 41

15 54 SW-BOX

16 ECM

48 DCU 23

40 19

50 49 10 9 8 7 6 5 4 3 2 1

11 MC

20 21

22 31

SI SE SF SC SD

SZ SJ

51 39 SK3

SK2

53 SK1

35 P2

P3 P1 TDFY-02-02-029-1 ja

TODFY50-EN-00(10/01/2020)

T2-2-67

SECTION2 SYSTEM Group2 Control System 1-

23456789101112-

1314151617181920212223242526-

272829303132333435363738394041-

Pump 3 Control Pressure Sen sor Pump 1 Control Pressure Sen sor 5-Spool Solenoid Valve Unit Main Relief Valve (For P1, 2) Digging Regenerative Valve Control Valve Arm 2 Flow Rate Control Valve Pump 1 Bypass Shut-Out Valve Main Relief Valve (P3) Arm 1 Flow Rate Control Valve Travel Motor Displacement Angle Control Valve Arm Regenerative Valve 2-Spool Solenoid Valve Unit Power Digging Switch Travel Mode Switch

42434445464748495051525354-

Arm Regenerative Cut Control Purpose: According to other operating conditions and working condition, the arm regenerative control shifts arm regenerative valve (38) when performing the arm roll-in operation. Therefore, this control controls the proper operation according to the pump load. Operation: 1. When the following input conditions exist, MC (11) activates 5-spool solenoid valve unit (29) (SC). •

Engine control dial (45)

•

Pump 1 delivery pressure sensor (23)

•

Pump 2 delivery pressure sensor (25)

•

Pump 3 delivery pressure sensor (24)

•

Boom raise pilot pressure sensor (2)

•

Arm 1 roll-in pilot pressure sensor (3)

•

Bucket roll-in pilot pressure sensor (4)

•

Bucket roll-out pilot pressure sensor (49)

•

Swing pilot pressure sensor (5)

•

Travel pilot pressure sensor (6)

•

Auxiliary 1 Pilot Pressure Sensor (8) (Option)

• Auxiliary 2 Pilot Pressure Sensor (9) (Option) 2. Pressure oil from the pilot pump flows through 5-spool solenoid valve unit (29) (SC) and shifts arm regenerative valve (38). 3. Pressure oil from the arm cylinder rod side flows to the hydraulic oil tank. 4. The pressure at the arm cylinder rod side decreases and improves the digging force (arm). Also, the oil passage pressure loss is reduced in order to reduce fuel consumption.

TODFY50-EN-00(10/01/2020)

T2-2-68

SECTION2 SYSTEM Group2 Control System

43 MODE

13 12 41

15 54 SW-BOX

16 ECM

48 DCU 23

40 19

50 49 10 9 8 7 6 5 4 3 2 1

11 MC

20 21

22 31

SI SE SF SC SD

SZ SJ

51 39 SK3

SK2

53 SK1

35 P2

P3 P1 TDFY-02-02-030-1 ja

TODFY50-EN-00(10/01/2020)

T2-2-69

SECTION2 SYSTEM Group2 Control System 1-

23456789101112-

1314151617181920212223242526-

272829303132333435363738394041-

42434445464748495051525354-

Digging Regenerative Control Purpose: The digging regenerative control increases the arm roll-in speed when operating digging (boom raise and arm roll-in). Operation: 1. When all following conditions exist, MC (11) activates 5-spool solenoid valve unit (29) (SF). •

Work mode: Bucket, Others, Thumb, Tilting Rotator, or Tilting Bucket

•

Pump 1 delivery pressure sensor (23), pump 2 delivery pressure sensor (25): High-pressure (Reference: 22 MPa or more)

•

Arm 1 roll-in pilot pressure sensor (3): Specified pressure or higher (Reference: 2.7 MPa or more)

• Boom raise pilot pressure sensor (2): Specified pressure or lower (Reference: less than 2.0 MPa) 2. When 5-spool solenoid valve unit (29) (SF) is activated, the pilot pressure shifts digging regenerative valve (31). 3. Pressure oil from the boom cylinder rod side is combined with pressure oil from pump 2. The combined pressure oil flows to the arm 1 spool. 4. Pressure oil from the arm 1 spool is combined with pressure oil from the arm 2 spool. The combined pressure oil flows to the arm cylinder bottom side. Therefore, speed of arm roll-in increases.

TODFY50-EN-00(10/01/2020)

T2-2-70

SECTION2 SYSTEM Group2 Control System

43 MODE

13 12 41

15 54 SW-BOX

16 ECM

48 DCU 23

40 19

50 49 10 9 8 7 6 5 4 3 2 1

11 MC

20 21

22 31

SI SE SF SC SD

SZ SJ

51 39 SK3

SK2

53 SK1

35 P2

P3 P1 TDFY-02-02-031-1 ja

TODFY50-EN-00(10/01/2020)

T2-2-71

SECTION2 SYSTEM Group2 Control System 123456789101112-

1314151617181920212223242526-

272829303132333435363738394041-

42434445464748495051525354-

Arm 1 Flow Rate Control Purpose: The arm 1 flow rate control restricts pressure oil flowing to arm 1 and delivers more pressure oil to other actuators (boom raise, attachment) when performing combined operation of arm and other actuators (boom raise, attachment). Therefore, the operating speed of other actuators (boom raise, attachment) except arm 1 is maintained. Operation: 1. MC (11) activates 5-spool solenoid valve unit (29) (SE) when performing combined operation of arm and other actuators (boom raise, attachment). 2. When 5-spool solenoid valve unit (29) (SE) is activated, the pilot pressure shifts arm 1 flow rate control valve (36). 3. Pressure oil which flows to the arm 1 spool from pump 2 is restricted by arm 1 flow rate control valve (36). 4. As pressure oil flow rate which flows to arm 1 from pump 2 is decreased and pressure oil which flows to other actuators increases, the operating speed of other actuators (boom raise, attachment) is maintained.

NOTE The degrees of priority to arm operation can be adjusted by monitor (15). (Priority (Arm Roll-In), Priority (Arm Roll-Out))

TODFY50-EN-00(10/01/2020)

T2-2-72

SECTION2 SYSTEM Group2 Control System

43 MODE

13 12 41

15 54 SW-BOX

16 ECM

48 DCU 23

40 19

50 49 10 9 8 7 6 5 4 3 2 1

11 MC

20 21

22 31

SI SE SF SC SD

SZ SJ

51 39 SK3

SK2

53 SK1

35 P2

P3 P1 TDFY-02-02-032-1 ja

TODFY50-EN-00(10/01/2020)

T2-2-73

SECTION2 SYSTEM Group2 Control System 1-

23456789101112-

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272829303132333435363738394041-

42434445464748495051525354-

Arm 2 Roll-In Pilot Cut Control Purpose: The arm 2 roll-in pilot cut control controls arm 2 roll-in pilot pressure according to other operating conditions and working conditions when performing the combined operation of front attachment. Therefore, the operating speed of other actuators (bucket, boom raise) except arm 2 is maintained. Operation: 1. When all following conditions exist, MC (11) activates 3-spool solenoid valve unit (51) (SK1). •

Pump 1, 2 delivery pressure: Specified pressure or higher, Combined operation of arm roll-in and bucket

•

Combined operation of attachment and arm roll-in

•

Combined operation of swing, boom raise, and arm roll-in (When the boom raise speed priority is in Auto1 or Auto2)

• Pump 3 delivery pressure: High, Combined operation of arm roll-in and boom raise 2. The 3-spool solenoid valve unit (51) (SK1) reduces arm 2 roll-in pilot pressure. 3. As the pressure oil from pump 1 flows to the spools except arm 2, the operating speed of other actuators is maintained.

NOTE The degrees of priority to boom operation can be selected by monitor (15). (Boom Raise Speed Priority) For pump 3 delivery pressure in the boom raise speed priority (Auto2), its setting value can be adjusted by MPDr. (13).

TODFY50-EN-00(10/01/2020)

T2-2-74

SECTION2 SYSTEM Group2 Control System

43 MODE

13 12 41

15 54 SW-BOX

16 ECM

48 DCU 23

40 19

50 49 10 9 8 7 6 5 4 3 2 1

11 MC

20 21

22 31

SI SE SF SC SD

SZ SJ

51 39 SK3

SK2

53 SK1

36 a

35 P2

P3 P1 TDFY-02-02-033-2 ja

a- Arm Roll-In Pilot Pressure

TODFY50-EN-00(10/01/2020)

T2-2-75

SECTION2 SYSTEM Group2 Control System 1-

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42434445464748495051525354-

Aftertreatment Device Manual Regeneration Control Purpose: The aftertreatment device manual regeneration control regenerates the aftertreatment device manually when all following conditions exist. •

Aftertreatment device manual regeneration request is displayed on monitor (15)

• Manual regeneration switch (17): ON position As this control increases the pump load during regeneration, the load is applied to the engine. Therefore, this control assists to increase the exhaust temperature up to the temperature that a catalyst in the aftertreatment device is activated. Operation: 1. MC (11) receives the aftertreatment device regeneration signal from ECM (16) by using CAN communication (12). 2. When all following conditions exist, MC (11) activates 2-spool solenoid valve unit (39) (SZ), (SJ), and pump 1 and 2 torque control solenoid valve (22). •

Engine control dial (45): Slow idle speed position

•

Pilot Shut-Off Switch (47): ON position (Pilot shut-off lever: LOCK Position)

• Manual regeneration switch (17): ON position 3. When 2-spool solenoid valve unit (39) (SZ) and pump 1 and 2 torque control solenoid valve (22) are activated, the pilot pressure acts on the pump 1 regulator and increases pump 1 delivery flow rate. 4. When 2-spool solenoid valve unit (39) (SJ) is activated, the pilot pressure shifts pump 1 bypass shut-out valve (34). 5. When pump 1 bypass shut-out valve (34) is shifted, the neutral circuit of pump 1 is partially blocked and the neutral circuit pressure of pump 1 increases. 6. MC (11) receives the signal of the neutral circuit pressure of pump 1 from pump 1 delivery pressure sensor (23). 7. In order to set the neutral circuit pressure of pump 1 to the target delivery pressure (8.0 MPa), MC (11) activates 2spool solenoid valve unit (39) (SJ) according to the signal from pump 1 delivery pressure sensor (23). 8. Therefore, the exhaust temperature increases by increasing the load to the engine.

TODFY50-EN-00(10/01/2020)

T2-2-76

SECTION2 SYSTEM Group2 Control System

43 MODE

13 12 41

15 54 SW-BOX

16 ECM

48 DCU 23

40 19

50 49 10 9 8 7 6 5 4 3 2 1

11 MC

20 21

22 31

SI SE SF SC SD

SZ SJ

51 39 SK3

SK2

53 SK1

35 P2

P3 P1 TDFY-02-02-034-1 ja

TODFY50-EN-00(10/01/2020)

T2-2-77

SECTION2 SYSTEM Group2 Control System 123456789101112-

Hydraulic Oil Temperature Sensor Boom Raise Pilot Pressure Sensor Arm 1 Roll-In Pilot Pressure Sensor Bucket Roll-In Pilot Pressure Sensor Swing Pilot Pressure Sensor Travel Pilot Pressure Sensor Front Pilot Pressure Sensor Auxiliary 1 Pilot Pressure Sensor (Option) Auxiliary 2 Pilot Pressure Sensor (Option) Arm Roll-Out Pilot Pressure Sensor MC CAN

1314151617181920212223242526-

MPDr. Monitor Controller Monitor ECM Manual Regeneration Switch Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Pump 1 and 2 Torque Con trol Solenoid Valve Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 2 Control Pressure Sensor

27282930313233343536373839-

Pump 3 Control Pressure Sensor Pump 1 Control Pressure Sensor 5-Spool Solenoid Valve Unit Main Relief Valve (For P1, 2) Digging Regenerative Valve Control Valve Arm 2 Flow Rate Control Valve Pump 1 Bypass Shut-Out Valve Main Relief Valve (For P3) Arm 1 Flow Rate Control Valve Travel Motor Displacement Angle Control Valve Arm Regenerative Valve 2-Spool Solenoid Valve Unit

404142434445464748495051525354-

Power Digging Switch Travel Mode Switch Slow Speed Position Fast Speed Position Power Mode Switch Engine Control Dial Key Switch Pilot Shut-Off Switch DCU Bucket Roll-Out Pilot Pres sure Sensor Arm 2 Roll-In Pilot Pressure Sensor 3-Spool Solenoid Valve Unit Pump 3 Bypass Shut-Out Valve Arm Roll-In Meter-Out Open Control Spool Switch Box Controller

Aftertreatment Device Auto Regeneration Control Purpose: The aftertreatment device auto regeneration control regenerates the aftertreatment device automatically. As this control increases the pump load during regeneration, the load is applied to the engine. Therefore, this control assists to increase the exhaust temperature up to the temperature that a catalyst in the aftertreatment device is activated. Operation: 1. MC (11) receives the aftertreatment device regeneration signal from ECM (16) by using CAN communication (12). 2. When all following conditions exist, MC (11) activates 2-spool solenoid valve unit (39) (SZ), (SJ), and pump 1 and 2 torque control solenoid valve (22). •

15 hours passed after the completion of the previous regeneration

•

The output signal from differential pressure sensor (55) at a certain pressure level or more before 15 hours pass after the completion of the previous regeneration

Control lever: All control levers are held in the neutral position [travel pilot pressure sensor (6) and front pilot pressure sensor (7): OFF] beyond 3.5 seconds 3. When 2-spool solenoid valve unit (39) (SZ) and pump 1 and 2 torque control solenoid valve (22) are activated, the pilot pressure acts on the pump 1 regulator and increases pump 1 delivery flow rate. 4. When 2-spool solenoid valve unit (39) (SJ) is activated, the pilot pressure shifts pump 1 bypass shut-out valve (34). 5. When pump 1 bypass shut-out valve (34) is shifted, the neutral circuit of pump 1 is partially blocked and the neutral circuit pressure of pump 1 increases. 6. MC (11) receives the signal of the neutral circuit pressure of pump 1 from pump 1 delivery pressure sensor (23). 7. In order to set the neutral circuit pressure of pump 1 to the target delivery pressure (8.0 MPa), MC (11) activates 2spool solenoid valve unit (39) (SJ) according to the signal from pump 1 delivery pressure sensor (23). 8. Therefore, the exhaust temperature increases by increasing the load to the engine. •

TODFY50-EN-00(10/01/2020)

T2-2-78

SECTION2 SYSTEM Group2 Control System

43 MODE

13 12 41

15 54 SW-BOX

16 ECM

48 DCU 23

55 19

50 49 10 9 8 7 6 5 4 3 2 1

11 MC

20 21

22 31

SI SE SF SC SD

SZ SJ

51 39 SK3

SK2

53 SK1

35 P2

P3 P1 TDFY-02-02-050-1 ja

TODFY50-EN-00(10/01/2020)

T2-2-79

SECTION2 SYSTEM Group2 Control System 1-

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4243444546474849505152535455-

Pump 3 Center Bypass Shut-Out Control Purpose: The pump 3 center bypass shut-out control controls the pump 3 delivery flow rate by the pump 3 flow rate control when performing boom raise operation. At the same time, MC (11) activates the pump 3 bypass shut-out valve (52) in order to reduce fuel consumption by decreasing the amount of pressure oil returning from the pump 3 neutral circuit into the hydraulic oil tank as much as possible. Operation: 1. When all following conditions exist, MC (11) activates 3-spool solenoid valve unit (51) (SK3). •

Boom raise pilot pressure sensor (2): Outputting signal

•

Swing pilot pressure sensor (5): No signal

• Auxiliary 2 pilot pressure sensor (9): No signal 2. When 3-spool solenoid valve unit (51) (SK3) is activated, the pilot pressure shifts pump 3 bypass shut-out valve (52). 3. When the pump 3 bypass shut-out valve (52) is shifted, the pump 3 neutral circuit is restricted. 4. Therefore, the amount of pressure oil returning from the pump 3 neutral circuit into the hydraulic oil tank is reduced.

TODFY50-EN-00(10/01/2020)

T2-2-80

SECTION2 SYSTEM Group2 Control System

43 MODE

13 12 41

15 54 SW-BOX

16 ECM

48 DCU 23

40 19

50 49 10 9 8 7 6 5 4 3 2 1

11 MC

20 21

22 31

SI SE SF SC SD

SZ SJ

51 a

39 SK3

SK2

53 SK1

35 P2

P3 P1 TDFY-02-02-047-1 ja

a- Primary Pilot Pressure From Pilot Pump

TODFY50-EN-00(10/01/2020)

T2-2-81

SECTION2 SYSTEM Group2 Control System 1-

23456789101112-

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42434445464748495051525354-

Arm Roll-In Meter-Out Open Control Purpose: The arm roll-in meter-out open control increases the arm roll-in meter-out opening when performing arm roll-in operation. Therefore, pressure loss of the arm roll-in meter-out side is reduced in order to reduce fuel consumption when performing arm roll-in operation. Operation: 1. When all following conditions exist, MC (11) activates 5-spool solenoid valve unit (29) (SD). •

Pump 2 delivery pressure: High, Combined operation of arm roll-in and bucket (when performing digging operation)

• Arm roll-in operation above the ground (in arm regenerative control) 2. When 5-spool solenoid valve unit (29) (SD) is activated, the pilot pressure shifts arm roll-in meter-out open control spool (53). 3. The arm roll-in meter-out opening increases so that pressure loss of the arm roll-in meter-out side is reduced when performing arm roll-in operation.

TODFY50-EN-00(10/01/2020)

T2-2-82

SECTION2 SYSTEM Group2 Control System

43 MODE

13 12 41

15 54 SW-BOX

16 ECM

48 DCU 23

40 19

50 49 10 9 8 7 6 5 4 3 2 1

11 MC

20 21

22 31

SI SE SF SC SD

SZ SJ

51 39 SK3

SK2

53 SK1

35 P2

P3 P1 TDFY-02-02-048-1 ja

TODFY50-EN-00(10/01/2020)

T2-2-83

SECTION2 SYSTEM Group2 Control System 123456789101112-

TODFY50-EN-00(10/01/2020)

1314151617181920212223242526-

272829303132333435363738394041-

T2-2-84

42434445464748495051525354-

SECTION2 SYSTEM Group2 Control System Valve Control (Option) The valve control (option) consists of the followings. ● Attachment Flow Rate Control ● Auxiliary Flow Combiner Control ● Breaker 1 (HSB Breaker) Control ● Auxiliary Overload Relief Valve Pressure Control

NOTE This control is for only the machine with the option parts equipped.

TODFY50-EN-00(10/01/2020)

T2-2-85

SECTION2 SYSTEM Group2 Control System Valve Control (Option) System Layout 12 11

14 2 3 4 5 6 7 8 9 40 41

13 17

15 ECM

16 22

10 MC

23 24 25 26

31 32

33 34 30 29 35 36

28 39

38 37 P2

P1 TDFY-02-02-035-1 ja

TODFY50-EN-00(10/01/2020)

T2-2-86

SECTION2 SYSTEM Group2 Control System 1-

2345678910-

1112131415161718192021-

CAN MPDr. Monitor Controller Monitor ECM Engine Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor Pump 2 Delivery Pressure Sensor Pump 2 Control Pressure Sen sor Pump 3 Control Pressure Sen sor

2223242526272829-

Pump 1 Control Pressure Sen sor Auxiliary Control Solenoid Valve Unit Auxiliary Flow Combiner Con trol Solenoid Valve Auxiliary Flow Rate Control Solenoid Valve Auxiliary Flow Combiner Valve Control Valve Pump 1 Bypass Shut-Out Valve Auxiliary Flow Rate Control Valve

303132333435363738394041-

Auxiliary 1 Overload Relief Valve Travel Pilot Pressure Attachment Accumulator Control Valve Accumulator (High Pressure) Accumulator (Low Pressure) Breaker Relief Solenoid Valve Selector Valve Pilot Pump Selector Valve Control Sole noid Valve Bucket Roll-Out Pilot Pressure Sensor Arm 2 Roll-In Pilot Pressure Sensor

Attachment Flow Rate Control Purpose: When performing the combined operation of attachment and other actuators, the attachment flow rate control restricts pressure oil flowing to auxiliary 1 and delivers more pressure oil to other actuators. Therefore, the operating speed of actuators except auxiliary is maintained. Operation: 1. When any following conditions exist, MC (10) activates auxiliary flow rate control solenoid valve (25). •

Pump 3 delivery pressure: Low, Combined operation of swing, arm roll-in, and boom raise

•

During travel operation

•

Combined operation of arm roll-out and attachment when pulverizer or crusher is selected on the work mode

•

Combined operation of arm roll-in and attachment (when adjusting priority (arm roll-in))

• Combined operation of arm roll-out and attachment (when adjusting priority (arm roll-out)) 2. When auxiliary flow rate control solenoid valve (25) is activated, the pilot pressure shifts auxiliary flow rate control valve (29). 3. Pressure oil (P2) which flows to the auxiliary 1 spool from pump 2 is restricted by auxiliary flow rate control valve (29). 4. As pressure oil (P2) from pump 2 flows to the spools except auxiliary 1, the operating speed of other actuators is maintained.

TODFY50-EN-00(10/01/2020)

T2-2-87

SECTION2 SYSTEM Group2 Control System 12 11

14 2 3 4 5 6 7 8 9 40 41

13 17

15 ECM

16 22

10 MC

23 24 25 26

31 32

33 34 30 29 35 36

28 39

38 37 P2

P1 TDFY-02-02-036-1 ja

TODFY50-EN-00(10/01/2020)

T2-2-88

SECTION2 SYSTEM Group2 Control System 1-

2345678910-

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2223242526272829-

303132333435363738394041-

Auxiliary Flow Combiner Control Purpose: The auxiliary flow combiner control combines pressure oil (P1) from pump 1 with pressure oil (P2) from pump 2. The combined pressure oil flows to the attachment. Therefore, the attachment operating speed becomes fast. When performing the combined operation of travel and attachment, pressure oil (P1) from pump 1 is not combined with pressure oil (P2) from pump 2. The auxiliary flow combiner control maintains the travel operating speed. Operation: 1. When any following conditions exist, MC (10) shifts the auxiliary flow combiner control solenoid valve (24). •

When using the pulverizer or crusher

• 2 Pumps Combined Flow is ON by using MPDr. (12). 2. When the auxiliary flow combiner control solenoid valve (24) is shifted, the pilot pressure from the attachment pilot valve shifts the auxiliary flow combiner valve (26) and pump 1 bypass shut-out valve (28). 3. Pressure oil (P1) from pump 1 is combined with pressure oil (P2) from pump 2 through auxiliary flow combiner valve (26). The combined pressure oil flows to the attachment and the attachment operating speed increases. 4. Travel pilot pressure (31) is routed to auxiliary flow combiner valve (26) when performing the combined operation of travel and attachment. 5. As auxiliary flow combiner valve (26) is not shifted, pressure oil (P1) from pump 1 is not combined with pressure oil (P2) from pump 2 so that the travel operating speed is maintained.

TODFY50-EN-00(10/01/2020)

T2-2-89

SECTION2 SYSTEM Group2 Control System 12 11

14 2 3 4 5 6 7 8 9 40 41

13 17

15 ECM

16 22

10 MC

23 24 25 26

31 32

33 34 30 29 35 36

28 39

38 37 P2

P1 TDFY-02-02-037-1 ja

TODFY50-EN-00(10/01/2020)

T2-2-90

SECTION2 SYSTEM Group2 Control System 12345678910-

1112131415161718192021-

2223242526272829-

303132333435363738394041-

Breaker 1 (HSB Breaker) Control Purpose: When breaker 1 (HSB breaker) is used, the breaker 1 control decreases the breaker circuit pressure and prevents the breaker from being damaged. Operation: 1. When breaker 1 is selected, MC (10) activates selector valve control solenoid valve (39). 2. Pressure oil from pilot pump (38) is routed to selector valve (37) through selector valve control solenoid valve (39). 3. Selector valve (37) is shifted by pressure oil from pilot pump (38) and the return circuit of breaker is connected to the hydraulic oil tank. 4. MC (10) activates breaker relief solenoid valve (36) at the same time. 5. The main circuit of breaker is connected to the hydraulic oil tank by breaker relief solenoid valve (36). This decreases the breaker circuit pressure and prevents the breaker from being damaged.

TODFY50-EN-00(10/01/2020)

T2-2-91

SECTION2 SYSTEM Group2 Control System 12 11

14 2 3 4 5 6 7 8 9 40 41

13 17

15 ECM

16 22

10 MC

23 24 25 26

31 32

30 29 36

28 39

38 37 P2

P1 TDFY-02-02-038-1 ja

TODFY50-EN-00(10/01/2020)

T2-2-92

SECTION2 SYSTEM Group2 Control System 12345678910-

1112131415161718192021-

2223242526272829-

303132333435363738394041-

Auxiliary Overload Relief Valve Pressure Control Purpose: The auxiliary overload relief valve pressure control adjusts the relief pressure according to the settings when auxiliary 1 overload relief valve (30) is equipped. Operation: 1. When the pulverizer or crusher is used, MC (10) shifts the solenoid valve which is equipped with auxiliary 1 overload relief valve (30) according to the pressure set by MPDr. (12). 2. The set pressure of auxiliary 1 overload relief valve (30) can be adjusted.

NOTE The relief pressure can be adjusted by monitor (14). NOTE The breaker relief solenoid valve (36) is also activated when operating the pulverizer or crusher.

TODFY50-EN-00(10/01/2020)

T2-2-93

SECTION2 SYSTEM Group2 Control System 12 11

14 2 3 4 5 6 7 8 9 40 41

13 17

15 ECM

16 22

10 MC

23 24 25 26

31 32

33 34 30 29 35 36

28 39

38 37 P2

P1 TDFY-02-02-039-1 ja

TODFY50-EN-00(10/01/2020)

T2-2-94

SECTION2 SYSTEM Group2 Control System 12345678910-

1112131415161718192021-

2223242526272829-

Pump/Valve Coordination Control The pump/valve coordination control consists of the following: ● Pump 3 Minimum Displacement Angle Hold Control during Digging Operation

TODFY50-EN-00(10/01/2020)

T2-2-95

303132333435363738394041-

SECTION2 SYSTEM Group2 Control System Pump/Valve Coordination Control System Layout 44

MODE

13 12 15 54 SW-BOX

50 49 10 9 8 7 6 5 4 3 2 1

16 ECM

48 DCU 23

19 11 MC

20 21

22 31

SI SE SF SC SD

SZ SJ

51 39 SK3

SK2

SK1

35 P2

P3 P1 TDFY-02-02-049-1 ja

TODFY50-EN-00(10/01/2020)

T2-2-96

SECTION2 SYSTEM Group2 Control System 1-

2345678910-

1112131415161718192021222324-

MC CAN MPDr. Monitor Controller Monitor ECM Manual Regeneration Switch Coolant Temperature Sensor Engine Cam Angle Sensor Crank Speed Sensor Maximum Pump 3 Flow Rate Limit Control Solenoid Valve Pump 1 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

252627282930313233343536-

Pump 2 Delivery Pressure Sensor Pump 2 Control Pressure Sen sor Pump 3 Control Pressure Sen sor Pump 1 Control Pressure Sen sor 5-Spool Solenoid Valve Unit Main Relief Valve (For P1, 2) Digging Regenerative Valve Control Valve Arm 2 Flow Rate Control Valve Pump 1 Bypass Shut-Out Valve Main Relief Valve (For P3) Arm 1 Flow Rate Control Valve

383944454647484950515254-

Arm Regenerative Valve 2-Spool Solenoid Valve Unit Power Mode Switch Engine Control Dial Key Switch Pilot Shut-Off Switch DCU Bucket Roll-Out Pilot Pressure Sensor Arm 2 Roll-In Pilot Pressure Sensor 3-Spool Solenoid Valve Unit Pump 3 Bypass Shut-Out Valve Switch Box Controller

Pump 3 Minimum Displacement Angle Hold Control during Digging Operation Purpose: The pump 3 minimum displacement angle hold control during digging operation holds the displacement angle of pump 3 to the minimum during digging operation so that pump 1 and pump 2 are used at the maximum displacement angle. Therefore, the pumps are used within their highly efficient range in order to reduce fuel consumption. Operation: 1. When following conditions exist, MC (11) activates maximum pump 3 flow rate limit control solenoid valve (22) and 3spool solenoid valve unit (51) (SK2). Pump 1, 2 delivery pressure: High, Combined operation of arm roll-in, bucket roll-in, and boom raise (precision operation) 2. 3-spool solenoid valve unit (51) (SK2) decreases boom 3 raise pilot pressure. 3. At the same time, the maximum pump 3 flow rate limit control solenoid valve (22) sends pilot pressure to the regulator according to the signals. 4. Therefore, the displacement angle of pump 3 is held to the minimum and pump 1 and pump 2 are used at the maximum displacement angle so that the hydraulic component efficiency is improved and fuel consumption is reduced. •

TODFY50-EN-00(10/01/2020)

T2-2-97

SECTION2 SYSTEM Group2 Control System

MODE

13 12 15 54 SW-BOX

16 ECM

48 DCU 23

50 49 10 9 8 7 6 5 4 3 2 1

11 MC

20 21

22 31

SI SE SF SC SD

SZ SJ

51 39 a

SK3

SK2

SK1

35 P2

P3 P1 TDFY-02-02-051-1 ja

a- Boom Raise Pilot Pressure

TODFY50-EN-00(10/01/2020)

T2-2-98

SECTION2 SYSTEM Group2 Control System 12345678910-

TODFY50-EN-00(10/01/2020)

1112131415161718192021222324-

252627282930313233343536-

T2-2-99

383944454647484950515254-

SECTION2 SYSTEM Group2 Control System Other Control The other control consists of the followings. ● Work Mode Control ● Auto Shut-Down Control ● Automatic Engine Stop Control at Low Temperature ● Hydraulic Oil Overheat Alarm Control ● Breaker Alarm Control (Option) ● Travel Alarm Control (Option) ● Swing Alarm Control (Option) ● Overload Alarm Control (Option)

Work Mode Control The work mode control consists of attachment mode 1 to 16. The mode can be selected by the attachment. •

In response to the attachment control operation, increasing/decreasing of engine speed (refer to "Attachment Operation Speed Increase Control (Option)"T2-2-31 to "Attachment Operation Speed Limit Control (Option)"T2-2-33), increasing/decreasing of pump flow rate (refer to "Pump 1 Flow Rate Limit Control (Option)"T2-2-54 to "Pump 3 Flow Rate Limit Control (Option)"T2-2-58), and valve selection (refer to "Attachment Flow Rate Control"T2-2-87 to "Auxiliary Overload Relief Valve Pressure Control"T2-2-93) are controlled. The increasing/decreasing settings are made by MPDr..

NOTE As the attachment mode, one to sixteen attachment modes can be selected by MPDr. • Unset • Bucket 1 to 5 • Breaker 1 to 5 • Pulverizer 1 to 5 • Crusher 1 to 5 • Vibrating Hammer 1 to 5 • Others 1 to 5 • Grapple 1 to 5 • Clamshell 1 to 5 • Thumb 1 to 5 • Tilting Rotator 1 to 5 • Tilting Bucket 1 to 5

Auto Shut-Down Control Purpose: The auto shut-down control automatically stops the engine in order to reduce the fuel consumption when the operation is not performed in a specified time. Operation: 1. When all following conditions exist, MC (2) sends the auto shut-down signal to monitor controller (5) by using CAN communication (3). •

Pilot shut-off switch (15): ON position (Pilot shut-off lever: LOCK Position)

•

Auto shut-down: ON

TODFY50-EN-00(10/01/2020)

T2-2-100

SECTION2 SYSTEM Group2 Control System •

Overheat alarm: OFF

•

Coolant temperature: 60 to 100 °C

•

Manual regeneration switch (9): OFF position

•

Abnormal communication of ECM (8) or monitor controller (5): None

• Overload alarm switch (16): OFF 2. Monitor controller (5) displays the auto shut-down notice on monitor (6) and sounds buzzer (7) once before 30 seconds for the auto shut-down enable time set by monitor (6). Monitor controller (5) sounds buzzer (7) continuously before 15 seconds. (intermittent sound) 3. MC (2) decreases the engine speed to the slow idle speed after the auto shut-down enable time is over. (Refer to "Engine Speed Slow Down Control"T2-2-25.) 4. When the engine speed is decreased to the slow idle speed, MC (2) turns OFF battery relay (13). Therefore, the engine stops. (Refer to SYSTEM / Electrical System.)

NOTE The auto shut-down ON/OFF can be selected and the time when the auto shut-down control is activated can be set by monitor (6). NOTE Return the key switch to the OFF or ACC position and reset it to the START position, and the engine can restart.

TODFY50-EN-00(10/01/2020)

T2-2-101

SECTION2 SYSTEM Group2 Control System 4 14

1 SW-BOX

6 5

7 3 2 MC

9 8 ECM

12345-

Switch Box Controller MC CAN MPDr. Monitor Controller

678910-

Monitor Buzzer ECM Manual Regeneration Switch Coolant Temperature Sensor

11121314-

Engine Pump 1 Delivery Pressure Sensor Battery Relay Engine Control Dial

1516-

TDFY-02-02-044-1 ja Pilot Shut-Off Switch Overload Alarm Switch

Automatic Engine Stop Control at Low Temperature Purpose: The automatic engine stop control at low temperature automatically stops the engine when the machine is left for a long time, with the engine running at less than -20 °C. Therefore, the aftertreatment device is protected from being damaged. Operation: 1. When all following conditions exist, MC (2) sends the auto shut-down signal to monitor controller (5) by using CAN communication (3). •

Pilot shut-off switch (15): ON (60 minutes) (Pilot shut-off lever: LOCK Position)

•

Ambient temperature or intake-air temperature: -20 °C or less

TODFY50-EN-00(10/01/2020)

T2-2-102

SECTION2 SYSTEM Group2 Control System 2. Monitor controller (5) displays the auto shut-down notice on monitor (6) and sounds buzzer (7) once before 30 seconds for the auto shut-down enable time set by monitor (6). Monitor controller (5) sounds buzzer (7) continuously before 15 seconds. (intermittent sound) 3. MC (2) decreases the engine speed to the slow idle speed after the auto shut-down enable time is over. (Refer to "Engine Speed Slow Down Control"T2-2-25.) 4. When the engine speed is decreased to the slow idle speed, MC (2) turns OFF battery relay (13). Therefore, the engine stops. (Refer to SYSTEM / Electrical System.)

NOTE This control is activated regardless of the auto shut-down setting (ON/OFF). NOTE Return the key switch to the OFF or ACC position and reset it to the START position, and the engine can restart. 1

6 5 4 15

7 2

MC 3

8 ECM

1234-

Ambient Temperature Sensor MC CAN Air Conditioner Controller

5678-

Monitor Controller Monitor Buzzer ECM

91113-

MAF/Intake-Air Temperature Sensor Engine Battery Relay

15-

TDFY-02-02-052-1 ja Pilot Shut-Off Switch

Hydraulic Oil Overheat Alarm Control Purpose: The hydraulic oil overheat alarm control sounds buzzer (7) when the hydraulic oil temperature exceeds the specified value. TODFY50-EN-00(10/01/2020)

T2-2-103

SECTION2 SYSTEM Group2 Control System Operation: 1. MC (2) receives the signal from hydraulic oil temperature sensor (1). 2. When the oil temperature is kept high for a specified time, MC (2) sends the signal to monitor controller (5) by using CAN communication (3). 3. Monitor controller (5) sounds buzzer (7) and also displays the hydraulic oil overheat alarm on monitor (6). 4. When the oil temperature decreases, monitor controller (5) stops buzzer (7) and turns off the hydraulic oil overheat alarm on monitor (6).

NOTE The temperature, evaluation time, buzzer, and warning icon of the hydraulic oil overheat control can be made operable or inoperable by MPDr. (4). 1 4

7 1-

Hydraulic Oil Temperature Sensor

23-

MC CAN

45-

MPDr. Monitor Controller

TDAA-02-02-010-1 ja 67-

Monitor Buzzer

Breaker Alarm Control (Option) Purpose: The breaker alarm control sounds buzzer (7) when the breaker is used in a specified time continuously. Operation: 1. When the following conditions exist in a specified time continuously, MC (2) sends the signal to monitor controller (5) by using CAN communication (3). •

Work mode: Breaker 1 to 5

• Auxiliary 1 pilot pressure sensor (1) (Option): Outputting signal 2. Monitor controller (5) sounds buzzer (7).

NOTE The breaker alarm control can be made operable or inoperable by MPDr. (4) or monitor (6).

TODFY50-EN-00(10/01/2020)

T2-2-104

SECTION2 SYSTEM Group2 Control System 1 4

7 1-

Auxiliary 1 Pilot Pressure Sen sor (Option)

23-

MC CAN

45-

MPDr. Monitor Controller

TDAA-02-02-010-1 ja 67-

Monitor Buzzer

Travel Alarm Control (Option) Purpose: The travel alarm control sounds buzzer (5) when performing the travel operation. Operation: 1. MC (2) receives the signal from travel pilot pressure sensor (1) when the travel operation is performed. 2. As long as MC (2) receives this signal, MC (2) sends the signal to travel alarm device (3) and sounds buzzer (5).

NOTE After traveling continuously for over 13 seconds, buzzer (5) can be deactivated by travel alarm deactivation switch (4).

TODFY50-EN-00(10/01/2020)

T2-2-105

SECTION2 SYSTEM Group2 Control System 1

5 TDAA-02-02-011-1 ja 12-

Travel Pilot Pressure Sensor MC

Travel Alarm Device

Travel Alarm Deactivation Switch

Buzzer

Swing Alarm Control (Option) Purpose: The swing alarm control sounds buzzer (5) and turns on beacon light (6) when performing the swing operation. Operation: 1. MC (2) receives the signal from swing pilot pressure sensor (1) when the swing operation is performed. 2. As long as MC (2) receives this signal, MC (2) sends the signal to swing alarm relay (3), sounds buzzer (5), and turns on beacon light (6).

NOTE Buzzer (5) can be deactivated by swing alarm deactivation switch (4).

TODFY50-EN-00(10/01/2020)

T2-2-106

SECTION2 SYSTEM Group2 Control System

6 12-

Swing Pilot Pressure Sensor MC

TODFY50-EN-00(10/01/2020)

Swing Alarm Relay

T2-2-107

Swing Alarm Deactivation Switch

56-

TDAA-02-02-012-1 ja Buzzer Beacon Light

SECTION2 SYSTEM Group2 Control System Overload Alarm Control (Option) Purpose: The overload alarm control sounds buzzer (8) and displays the overload alarm when boom raise operation such as hoisting is overloaded. Operation: 1. When all following conditions exist, MC (2) sends the signal to monitor controller (6). •

Overload alarm: Enable

•

Boom bottom pressure sensor (3): Outputting signal beyond the specified pressure

• Overload alarm switch (1): ON position 2. As long as receiving the signal from MC (2), monitor controller (6) connects terminal #D7 to the ground inside. 3. Monitor controller (6) sounds buzzer (8) and displays the overload alarm on monitor (7).

NOTE The alarm pressure setting (Tipping Threshold Boom CYL Bottom Pressure) of load in MC (2) can be adjusted by MPDr. (5). 3

4 7 2

6 D7

8 TDAA-02-02-013-1 ja 12-

Overload Alarm Switch MC

TODFY50-EN-00(10/01/2020)

Boom Bottom Pressure Sen sor

456-

T2-2-108

CAN MPDr. Monitor Controller

78-

Monitor Buzzer

SECTION2 SYSTEM Group3 Engine System Outline of ECM System ECM (19) receives the signals from sensors and MC (30). ECM (19) processes and activates two-way valve (20), suction control valve (26), and EGR motor (16) in order to control supply pump (24), injector (21), and the EGR valve. Supply pump (24) is activated by the engine and produces high-pressure fuel. Common rail (23) distributes high-pressure fuel produced by supply pump (24) to injector (21) in each engine cylinder. Injector (21) injects high-pressure fuel from common rail (23). 6

5 28

12 13 14

33 DCU

34 15 16

17 19 ECM 18

30 MC 22

CAN 27 29 26

21 23

24 25

1234567-

TODFY50-EN-00(10/01/2020)

891011121314151617-

Crank Speed Sensor Cam Angle Sensor Coolant Temperature Sensor Boost Pressure Sensor Boost Temperature Sensor Engine Oil Pressure Sensor Intake Manifold Temperature Sensor EGR Motor Position Sensor EGR Motor Intake Throttle Position Sen sor

181920212223242526272829-

T2-3-1

Intake Throttle ECM Two-Way Valve Injector Common Rail Pressure Sensor Common Rail Supply Pump Fuel Tank Suction Control Valve Fuel Temperature Sensor Differential Pressure Sensor Engine Oil Level Switch

3031323334-

TDFY-02-03-001-1 ja MC VGS Controller VGS Actuator DCU Atmospheric Pressure Sensor (Inside of ECM)

SECTION2 SYSTEM Group3 Engine System Fuel Injection Control ECM (19) detects the engine running condition according to the signals from each sensor and MC (30). ECM (19) controls fuel injection amount, injection pressure, injection timing, and injection rate according to the engine running condition. The fuel injection control consists of the followings. •

Fuel Injection Amount Control

•

Fuel Injection Timing Control

•

Fuel Injection Rate Control

•

Fuel Injection Pressure Control 6

5 28

12 13 14

33 DCU

34 15 16

17 19 ECM 18

30 MC 22

CAN 27 29 26

21 23

24 25

1234567-

TODFY50-EN-00(10/01/2020)

891011121314151617-

181920212223242526272829-

T2-3-2

3031323334-

TDFY-02-03-001-1 ja MC VGS Controller VGS Actuator DCU Atmospheric Pressure Sensor (Inside of ECM)

SECTION2 SYSTEM Group3 Engine System Fuel Injection Amount Control Purpose: The fuel injection amount control controls the fuel injection amount properly. Operation: 1. ECM (19) detects the engine speed according to the signals from crank speed sensor (8) and cam angle sensor (9). 2. MC (29) calculates the target engine speed according to the signals from engine control dial (41), sensors, and switches. MC (29) sends the signal equivalent to the calculated target engine speed to ECM (19). (Refer to SYSTEM/ Control System.) 3. ECM (19) mainly controls fuel injection amount by turning two-way valve (20) in injector (21) ON/OFF according to the engine speed and the signal from MC (29). 6

51 50 49 48 47 46 45

44 43 42

5 28

12 13

31 14

57 54 DCU

30 53 17 19 ECM

29 MC

CAN 32 41 40

56 SW-BOX

MODE

39 26

35 33

23 21

34 25

TDFY-02-03-004-1 ja

TODFY50-EN-00(10/01/2020)

T2-3-3

SECTION2 SYSTEM Group3 Engine System 1234567891011121314-

EGR Cooler Inlet Temperature Sensor EGR Cooler Outlet Tempera ture Sensor Intake Air Temperature Sensor MAF Sensor Intercooler Inlet Temperature Sensor DOC Inlet Exhaust Tempera ture Sensor DOC Outlet Exhaust Tempera ture Sensor Crank Speed Sensor Cam Angle Sensor Coolant Temperature Sensor Boost Pressure Sensor Boost Temperature Sensor Engine Oil Pressure Sensor Intake Manifold Temperature Sensor

TODFY50-EN-00(10/01/2020)

151617181920212223242526272829303132-

EGR Motor Position Sensor EGR Motor Intake Throttle Position Sen sor Intake Throttle ECM Two-Way Valve Injector Common Rail Pressure Sensor Common Rail Supply Pump Fuel Tank Suction Control Valve Fuel Temperature Sensor Differential Pressure Sensor MC VGS Controller VGS Actuator Monitor Controller

333435363738394041424344-

T2-3-4

Pump 2 Delivery Pressure Sensor Pump 2 Control Pressure Sen sor Pump 3 Delivery Pressure Sensor Pump 3 Control Pressure Sen sor Pump 1 Delivery Pressure Sensor Pump 1 Control Pressure Sen sor Auto-Idle Switch Power Mode Switch Engine Control Dial Arm Roll-Out Pilot Pressure Sensor Auxiliary 2 Pilot Pressure Sen sor (Option) Auxiliary 1 Pilot Pressure Sen sor (Option)

45464748495051525354555657-

Front Pilot Pressure Sensor Travel Pilot Pressure Sensor Swing Pilot Pressure Sensor Bucket Roll-Out Pilot Pressure Sensor Bucket Roll-In Pilot Pressure Sensor Arm 1 Roll-In Pilot Pressure Sensor Boom Raise Pilot Pressure Sensor Hydraulic Oil Temperature Sensor Engine Oil Level Switch DCU Atmospheric Pressure Sensor (Inside of ECM) Switch Box Controller Arm 2 Roll-In Pilot Pressure Sensor

SECTION2 SYSTEM Group3 Engine System Fuel Injection Timing Control Purpose: The fuel injection timing control controls the fuel injection timing properly. Operation: 1. ECM calculates the fuel injection timing according to the engine speed and fuel injection amount. 2. ECM turns two-way valve (2) in the injector ON/OFF according to fuel injection timing.

TODFY50-EN-00(10/01/2020)

T2-3-5

SECTION2 SYSTEM Group3 Engine System 1 9

1 2

8 7

5 10 11

9 8

7 5

123-

From ECM Two-Way Valve Returning to Fuel Tank

TODFY50-EN-00(10/01/2020)

456-

Orifice A Control Chamber Nozzle

789-

T2-3-6

From Common Rail Valve Electromagnetic Coil

101112-

TDC1-02-03-002-1 ja Hydraulic Piston Spring Orifice B

SECTION2 SYSTEM Group3 Engine System Fuel Injection Rate Control Purpose: The fuel injection rate control controls the fuel injection timing and fuel injection amount, and sets proper combustion in the engine cylinder. Operation: 1. The injector injects small amount of fuel (pilot injection) first and ignites. 2. After igniting, the injector makes second fuel injection (main injection). 3. ECM turns two-way valve (2) in the injector ON/OFF. Consequently, ECM controls the proper fuel injection timing and fuel injection amount. Operation of Fuel Injection: 1. Fuel pressure is always applied to nozzle (6) in the injector. 2. When turning ON electromagnetic coil (9) in two-way valve (2), high-pressure fuel in control chamber (5) returns to the fuel tank through orifice A (4). 3. As the pressure in control chamber (5) decreases, hydraulic piston (10) is raised and nozzle (6) is opened so that the injection starts. 4. When turning OFF electromagnetic coil (9) in two-way valve (2), valve (8) is closed and the circuit to the fuel tank is closed. High-pressure fuel from the common rail flows to control chamber (5) through orifice B (12). 5. As high-pressure fuel flows to control chamber (5), the pressure difference occurs to the upper and lower parts of hydraulic piston (10). Hydraulic piston (10) is lowered by this pressure difference.As nozzle (6) is closed, the injection stops.

TODFY50-EN-00(10/01/2020)

T2-3-7

SECTION2 SYSTEM Group3 Engine System 1

8 7

5 10 11

9 8

7 5

123-

From ECM Two-Way Valve Returning to Fuel Tank

456-

Orifice A Control Chamber Nozzle

789-

From Common Rail Valve Electromagnetic Coil

Fuel Injection Pressure Control Purpose: The fuel injection pressure control controls the fuel injection pressure properly. TODFY50-EN-00(10/01/2020)

T2-3-8

101112-

TDC1-02-03-002-1 ja Hydraulic Piston Spring Orifice B

SECTION2 SYSTEM Group3 Engine System Operation: 1. ECM (19) calculates fuel injection amount according to the engine speed and the signals from MC (29). (Refer to "Fuel Injection Amount Control"T2-3-3) 2. Common rail pressure sensor (22) sends the signals according to pressure in common rail (23) to ECM (19). 3. ECM (19) calculates the proper fuel pressure in common rail (23) according to the engine speed, fuel injection amount, and the signals of the common rail pressure sensor (22). 4. ECM (19) activates suction control valve (26) in supply pump (24) and supplies the proper amount of fuel to common rail (23). 5. Fuel according to fuel pressure in common rail (23) is supplied to injector (21) from common rail (23) so that fuel injection pressure is controlled. 6

51 50 49 48 47 46 45

44 43 42

5 28

12 13

31 14

57 54 DCU

30 53 17 19 ECM

29 MC

CAN 32 41 40

56 SW-BOX

MODE

39 26

35 33

23 21

34 25

TDFY-02-03-005-1 ja

TODFY50-EN-00(10/01/2020)

T2-3-9

SECTION2 SYSTEM Group3 Engine System 1234567891011121314-

151617181920212223242526272829303132-

333435363738394041424344-

45464748495051525354555657-

Fuel Injection Amount Correction Control Purpose: The fuel injection amount correction control properly corrects the fuel injection amount and the proper fuel injection timing. Operation: 1. When the engine starts, if the engine speed is lower than the engine start correction speed, ECM (19) corrects the fuel injection amount. (Start Correction) 2. In addition, ECM (19) corrects fuel injection amount according to the signals from atmospheric pressure sensor (34) (inside of ECM). (High Altitude Correction) 3. ECM (19) controls two-way valve (20) in injector (21) and controls the proper fuel injection amount.

TODFY50-EN-00(10/01/2020)

T2-3-10

SECTION2 SYSTEM Group3 Engine System 6

5 28

12 13 14

33 DCU

34 15 16

17 19 ECM 18

30 MC 22

CAN 27 29 26

21 23

24 25

1234567-

TODFY50-EN-00(10/01/2020)

891011121314151617-

181920212223242526272829-

T2-3-11

3031323334-

TDFY-02-03-002-1 ja MC VGS Controller VGS Actuator DCU Atmospheric Pressure Sensor (Inside of ECM)

SECTION2 SYSTEM Group3 Engine System EGR Control Purpose: The EGR control re-circulates a part of exhaust gas into intake manifold (12), and mixes it with intake-air. Therefore, combustion temperature is lowered and generation of oxide of nitrogen (NOx) is controlled. Operation: •

EGR gas amount control 1. ECM (13) decides EGR gas amount according to engine speed, fuel flow rate, intake manifold temperature, coolant temperature, atmospheric pressure, and intake-air temperature. 2. ECM (13) activates EGR motor (10), opens EGR valve (8), and sends EGR gas to intake manifold (12) in response to engine condition. EGR gas and intake-air will mix in intake manifold (12). 3. At the same time, ECM (13) detects the opening amount of EGR valve (8) by using EGR motor position sensor (9).

•

EGR gas cooling 1. EGR gas is cooled by EGR cooler (6) in the EGR gas passage. 2. Cooled EGR gas and intake-air are mixed so that combustion temperature is lowered and NOx is generated lower than normal EGR gas.

NOTE EGR: Exhaust Gas Recirculation NOTE The MAF (Mass Air Flow) sensor forms an integral part with the intake-air temperature sensor. The MAF (Mass Air Flow) sensor detects intake-air amount from the air cleaner.

TODFY50-EN-00(10/01/2020)

T2-3-12

SECTION2 SYSTEM Group3 Engine System 2

3 21 5 6 4 7 22 8

12 9 11

13 14

20 15

19 18 17 16 123456-

From Air Cleaner To Intercooler Exhaust (To Aftertreatment Device) Engine Outlet of Coolant EGR Cooler

TODFY50-EN-00(10/01/2020)

789101112-

Inlet of Coolant EGR Valve EGR Motor Position Sensor EGR Motor Intake-Air (From Suction In tercooler) Intake Manifold

1314151617-

T2-3-13

ECM Atmospheric Pressure Sensor MAF/Intake-Air Temperature Sensor Intake Manifold Temperature Sensor Common Rail Pressure Sensor

1819202122-

TDC2-02-03-013-1 ja Coolant Temperature Sensor Cam Angle Sensor Crank Speed Sensor EGR Cooler Inlet Temperature Sensor EGR Cooler Outlet Tempera ture Sensor

SECTION2 SYSTEM Group3 Engine System Preheating Control Purpose: The preheating control controls glow plugs (8) which allows easier cold weather starting, reduces white smoke and noise at start up. And the preheating control adjusts length of time the glow plugs (8) are used to stabilize engine idle after start up. Operation: 1. ECM (3) receives the signals from intake-air temperature sensor (1) and coolant temperature sensor (2). 2. When the key switch is set to the ON position, current from terminal M (4) in the key switch flows to glow plug relay (7). 3. ECM (3) turns glow plug relay ON according to the signals from intake-air temperature sensor (1) and coolant temperature sensor (2). 4. ECM (3) controls time for current continuity to glow plug relay (7) so that, time for current continuity of glow plug (8) is controlled. 1

5 3

16 6

8 TDAA-02-03-010-1 ja 12-

Intake-Air Temperature Sen sor Coolant Temperature Sensor

TODFY50-EN-00(10/01/2020)

345-

ECM From Key Switch Terminal M Fuse Box

678-

T2-3-14

From Battery Glow Plug Relay Glow Plug

SECTION2 SYSTEM Group3 Engine System Variable Turbocharger Control Purpose: The variable turbocharger control controls the opening of nozzle inside of the turbine housing according to the engine speed and load. The inlet opening area of turbocharger and, the turbine speed are changed according to the opening of nozzle and supercharging pressure is controlled properly. Consequently, efficient turbocharging is obtained even the engine is running in slow speed.

TODFY50-EN-00(10/01/2020)

T2-3-15

SECTION2 SYSTEM Group3 Engine System Alarm Control Operation: 1. ECM (5) receives the signals from engine oil pressure sensor (3), boost temperature sensor (2), fuel temperature sensor (4), and common rail pressure sensor (9). 2. ECM (5) sends the signals to monitor controller (7) according to the signals from each sensor by using CAN communication (6). 3. Monitor controller (7) displays each alarm on monitor (1). 9 2 3 4 6 1 5

12-

Monitor Boost Temperature Sensor

34-

Engine Oil Pressure Sensor Fuel Temperature Sensor

56-

ECM CAN

79-

TDC4-02-03-009-1 ja Monitor Controller Common Rail Pressure Sensor

Urea SCR System The urea SCR system injects DEF into the exhaust of engine (1) to convert NOx into nitrogen and water. Therefore, the urea SCR system reduces NOx from exhaust gas. DCU (22) controls the urea SCR system. DCU (22) drives DEF supply module (20) and dosing module (8) according to the signals from sensors and ECM (24) to control following functions. DEF supply module (20) pumps DEF from DEF tank (14) to dosing module (8). Dosing module (8) injects DEF according to the signal from DCU (22). ● DEF Injection Control ● Start-Up Control ● DEF Defrosting Control ● DEF Thermal Control ● After-Run Control

TODFY50-EN-00(10/01/2020)

T2-3-16

SECTION2 SYSTEM Group3 Engine System 10

1 8 23 27

Local-CAN

11 12

18 13

22 DCU

24 ECM

ISO-CAN 19

DEF Pressure Sensor DEF Supply Module Tempera ture Sensor DEF Supply Module Coolant Control Valve DCU Differential Pressure Sensor ECM Monitor Controller MC

27-

17 16 15

26 MC

Power-CAN 1234567-

Engine DOC (Diesel Oxidation Cata lyst) DOC Inlet Exhaust Tempera ture Sensor DOC Outlet Exhaust Tempera ture Sensor Upstream NOx Sensor SCR Catalyst SCR Exhaust Temperature Sensor

891011121314151617-

29 Dosing Module Upstream NOx Sensor Con troller Filter (CSF) DEF Piping DEF Sensor Unit Controller DEF Sensor Unit DEF Tank DEF Tank Level Sensor DEF Tank Temperature Sensor DEF Quality Sensor

181920212223242526-

282930313233-

TDFY-02-03-008-1 ja Differential Pressure Detec tion Port Coolant Piping MAF/Intake-Air Temperature Sensor Reverting Valve Downstream NOx Sensor Downstream NOx Sensor Controller Heating Wire

DEF Injection Control Purpose: The DEF injection control controls the proper injection amount of DEF. Operation: 1. Upstream NOx sensor (5) detects the concentration of NOx in exhaust gas. 2. Upstream NOx sensor controller (9) sends the signals from upstream NOx sensor (5) to DCU (22) by using Local-CAN. 3. MAF/intake-air temperature sensor (29) detects intake-air flow rate from the air cleaner. 4. ECM (24) sends the signal from MAF/intake-air temperature sensor (29) to DCU (22) by using ISO-CAN. 5. DCU (22) controls dosing module (8) and sets a proper DEF injection amount according to the signal.

TODFY50-EN-00(10/01/2020)

T2-3-17

SECTION2 SYSTEM Group3 Engine System 10

1 8 23 27

Local-CAN

11 12

18 13

22 DCU

24 ECM

ISO-CAN 19

DEF Pressure Sensor DEF Supply Module Tempera ture Sensor DEF Supply Module Coolant Control Valve DCU Differential Pressure Sensor ECM Monitor Controller MC

27-

17 16 15

26 MC

Power-CAN 1234567-

Engine DOC (Diesel Oxidation Cata lyst) DOC Inlet Exhaust Tempera ture Sensor DOC Outlet Exhaust Tempera ture Sensor Upstream NOx Sensor SCR Catalyst SCR Exhaust Temperature Sensor

891011121314151617-

29 Dosing Module Upstream NOx Sensor Con troller Filter (CSF) DEF Piping DEF Sensor Unit Controller DEF Sensor Unit DEF Tank DEF Tank Level Sensor DEF Tank Temperature Sensor DEF Quality Sensor

181920212223242526-

282930313233-

TDFY-02-03-009-1 ja Differential Pressure Detec tion Port Coolant Piping MAF/Intake-Air Temperature Sensor Reverting Valve Downstream NOx Sensor Downstream NOx Sensor Controller Heating Wire

Start-Up Control Purpose: The start-up control increases pressure of DEF for injection. Operation: 1. SCR exhaust temperature sensor (7) detects the inlet temperature of SCR catalyst (6). 2. DCU (22) activates DEF supply module (20) when the inlet temperature of SCR catalyst (6) becomes the specified value or higher. 3. DEF supply module (20) supplies the pressurized DEF to dosing module (8).

TODFY50-EN-00(10/01/2020)

T2-3-18

SECTION2 SYSTEM Group3 Engine System 10

1 8 23 27

Local-CAN

11 12

18 13

22 DCU

24 ECM

ISO-CAN 19

DEF Pressure Sensor DEF Supply Module Tempera ture Sensor DEF Supply Module Coolant Control Valve DCU Differential Pressure Sensor ECM Monitor Controller MC

27-

17 16 15

26 MC

Power-CAN 1234567-

Engine DOC (Diesel Oxidation Cata lyst) DOC Inlet Exhaust Tempera ture Sensor DOC Outlet Exhaust Tempera ture Sensor Upstream NOx Sensor SCR Catalyst SCR Exhaust Temperature Sensor

891011121314151617-

29 Dosing Module Upstream NOx Sensor Con troller Filter (CSF) DEF Piping DEF Sensor Unit Controller DEF Sensor Unit DEF Tank DEF Tank Level Sensor DEF Tank Temperature Sensor DEF Quality Sensor

181920212223242526-

282930313233-

TDFY-02-03-010-1 ja Differential Pressure Detec tion Port Coolant Piping MAF/Intake-Air Temperature Sensor Reverting Valve Downstream NOx Sensor Downstream NOx Sensor Controller Heating Wire

DEF Defrosting Control(DEF Tank) Purpose: The DEF defrosting control circulates coolant and defrosts DEF when DEF may freeze. Operation: 1. When the detected temperature of the DEF tank temperature sensor (16), the DEF supply module temperature sensor (19), or MAF/intake-air temperature sensor (29) is below the specified value, DCU (22) opens coolant control valve (21). 2. Heated coolant from engine (1) flows into DEF tank (14) through coolant control valve (21) and DEF supply module (20). 3. Coolant is circulated and DEF is defrosted. TODFY50-EN-00(10/01/2020)

T2-3-19

SECTION2 SYSTEM Group3 Engine System 4. DCU (22) performs start-up control when a predetermined time has elapsed. (Refer to "Start-Up Control"T2-3-18) 5. When the DEF pressure that has increased because of the start-up control reaches a certain level or higher, DCU (22) closes cooler control valve (21). 10

1 8 23 27

Local-CAN

11 12

18 13

22 DCU

24 ECM

ISO-CAN 19

DEF Pressure Sensor DEF Supply Module Tempera ture Sensor DEF Supply Module Coolant Control Valve DCU Differential Pressure Sensor ECM Monitor Controller MC

27-

17 16 15

26 MC

Power-CAN 1234567-

Engine DOC (Diesel Oxidation Cata lyst) DOC Inlet Exhaust Tempera ture Sensor DOC Outlet Exhaust Tempera ture Sensor Upstream NOx Sensor SCR Catalyst SCR Exhaust Temperature Sensor

891011121314151617-

29 Dosing Module Upstream NOx Sensor Con troller Filter (CSF) DEF Piping DEF Sensor Unit Controller DEF Sensor Unit DEF Tank DEF Tank Level Sensor DEF Tank Temperature Sensor DEF Quality Sensor

181920212223242526-

282930313233-

TDFY-02-03-011-1 ja Differential Pressure Detec tion Port Coolant Piping MAF/Intake-Air Temperature Sensor Reverting Valve Downstream NOx Sensor Downstream NOx Sensor Controller Heating Wire

DEF Defrosting Control(DEF Piping) Purpose: The DEF defrosting control heats heating wires (b, c, d) and defrosts DEF when DEF may freeze. Operation: 1. When the detected temperature of the DEF tank temperature sensor (10) or MAF/intake-air temperature sensor (3) is below the specified value, DCU (5) turns ON SCR control relay (1). TODFY50-EN-00(10/01/2020)

T2-3-20

SECTION2 SYSTEM Group3 Engine System 2. Current from fuse #35 flows through SCR control relay (1) to heater (2). 3. Heater (2) heats heating wires (b, c, d) to warm the DEF piping. 4. DCU (5) turns OFF SCR control relay (1) when DEF temperature increases to their specified value or higher. 5. Therefore, the ground circuit in heater (2) is disconnected and heater (1) stops heating. a 1 A2 B2

A1 B3

b c d 148

102

230 241 101

Local-CAN

5 DCU

4 ECM

7 ISO-CAN 8 6

9 10 11 TDFY-02-03-014-1 ja

a- From Fuse #35 b- Heating Wire (for DEF Tank) 123-

SCR Control Relay Heater MAF/Intake-Air Temperature Sensor

c- Heating Wire (Returning to DEF Tank) d- Heating Wire (for Dosing Module) 4567-

ECM DCU DEF Tank DEF Sensor Unit Controller

891011-

DEF Sensor Unit DEF Quality Sensor DEF Tank Temperature Sensor DEF Tank Level Sensor

DEF Thermal Control(DEF Tank) Purpose: The DEF thermal control circulates coolant and defrosts DEF when DEF or intake-air temperature is below the specified value. Operation: 1. When the detected temperature of the DEF tank temperature sensor (16) or MAF/intake-air temperature sensor (29) is below the specified value, DCU (22) opens coolant control valve (21).

TODFY50-EN-00(10/01/2020)

T2-3-21

SECTION2 SYSTEM Group3 Engine System 2. Heated coolant from engine (1) flows into DEF tank (14) through coolant control valve (21) and DEF supply module (20). 3. By this means, coolant is circulated and DEF is kept warm. 4. DCU (22) closes coolant control valve (21) when DEF and intake-air temperature increases to their specified value or higher. 10

1 8 23 27

Local-CAN

11 12

18 13

22 DCU

24 ECM

ISO-CAN 19

DEF Pressure Sensor DEF Supply Module Tempera ture Sensor DEF Supply Module Coolant Control Valve DCU Differential Pressure Sensor ECM Monitor Controller MC

27-

17 16 15

26 MC

Power-CAN 1234567-

Engine DOC (Diesel Oxidation Cata lyst) DOC Inlet Exhaust Tempera ture Sensor DOC Outlet Exhaust Tempera ture Sensor Upstream NOx Sensor SCR Catalyst SCR Exhaust Temperature Sensor

891011121314151617-

29 Dosing Module Upstream NOx Sensor Con troller Filter (CSF) DEF Piping DEF Sensor Unit Controller DEF Sensor Unit DEF Tank DEF Tank Level Sensor DEF Tank Temperature Sensor DEF Quality Sensor

181920212223242526-

282930313233-

TDFY-02-03-012-1 ja Differential Pressure Detec tion Port Coolant Piping MAF/Intake-Air Temperature Sensor Reverting Valve Downstream NOx Sensor Downstream NOx Sensor Controller Heating Wire

DEF Thermal Control(DEF Piping) Purpose: The DEF thermal control heats heating wires (b, c, d) and defrosts DEF when DEF or intake-air temperature is below the specified value.

TODFY50-EN-00(10/01/2020)

T2-3-22

SECTION2 SYSTEM Group3 Engine System Operation: 1. When the detected temperature of the DEF tank temperature sensor (10) or MAF/intake-air temperature sensor (3) is below the specified value, DCU (5) turns ON SCR control relay (1). 2. Current from fuse #35 flows through SCR control relay (1) to heater (2). 3. Heater (2) heats heating wires (b, c, d) to keep the DEF piping warm. 4. DCU (5) turns OFF SCR control relay (1) when DEF temperature increases to their specified value or higher. 5. Therefore, the ground circuit in heater (2) is disconnected and heater (1) stops heating. a 1 A2 B2

A1 B3

b c d 148

102

230 241 101

Local-CAN

5 DCU

4 ECM

7 ISO-CAN 8 6

9 10 11 TDFY-02-03-014-1 ja

a- From Fuse #35 b- Heating Wire (for DEF Tank) 123-

SCR Control Relay Heater MAF/Intake-Air Temperature Sensor

c- Heating Wire (Returning to DEF Tank) d- Heating Wire (for Dosing Module) 4567-

ECM DCU DEF Tank DEF Sensor Unit Controller

891011-

DEF Sensor Unit DEF Quality Sensor DEF Tank Temperature Sensor DEF Tank Level Sensor

After-Run Control Purpose: The after-run control returns DEF from DEF piping (11) to DEF tank (14) when the key switch is set to the OFF position. This prevents DEF from freezing and crystallizing in the piping.

TODFY50-EN-00(10/01/2020)

T2-3-23

SECTION2 SYSTEM Group3 Engine System Operation: 1. When the key switch is set to the OFF position, DCU (22) turns ON reverting valve (30) and flow direction of DEF is changed. 2. DEF supply module (20) returns DEF from DEF piping (11) to DEF tank (14). 3. DCU (22) turns OFF DEF supply module (20) when the specified time (5 minutes) has passed. 4. Then, DCU (22) is turned OFF. 10

1 8 23 27

Local-CAN

11 12

18 13

22 DCU

24 ECM

ISO-CAN 19

DEF Pressure Sensor DEF Supply Module Tempera ture Sensor DEF Supply Module Coolant Control Valve DCU Differential Pressure Sensor ECM Monitor Controller MC

27-

17 16 15

26 MC

Power-CAN 1234567-

Engine DOC (Diesel Oxidation Cata lyst) DOC Inlet Exhaust Tempera ture Sensor DOC Outlet Exhaust Tempera ture Sensor Upstream NOx Sensor SCR Catalyst SCR Exhaust Temperature Sensor

TODFY50-EN-00(10/01/2020)

891011121314151617-

29 Dosing Module Upstream NOx Sensor Con troller Filter (CSF) DEF Piping DEF Sensor Unit Controller DEF Sensor Unit DEF Tank DEF Tank Level Sensor DEF Tank Temperature Sensor DEF Quality Sensor

181920212223242526-

T2-3-24

282930313233-

TDFY-02-03-013-1 ja Differential Pressure Detec tion Port Coolant Piping MAF/Intake-Air Temperature Sensor Reverting Valve Downstream NOx Sensor Downstream NOx Sensor Controller Heating Wire

SECTION2 SYSTEM Group3 Engine System Engine Output Restriction Control (INDUCEMENT) Purpose: When DEF level becomes low, or malfunction occurs on the urea SCR system or EGR system, the engine output restriction control displays the alarm on the monitor and sounds the buzzer. When the machine is continuously operated under this state, the engine output restriction control gradually decreases the engine torque and speed. Operation: 1. Signals from the urea SCR system are sent from DCU (33) to ECM (19) by using CAN communication. 2. When any one of the following conditions is met, ECM (19) decreases the engine torque. •

DEF level: 5% or less

•

Urea SCR system: Abnormal, certain time has elapsed

• EGR System: Abnormal, certain time has elapsed 3. In addition, ECM (19) sets the engine speed to the slow idle position according to the level of DEF and elapsed time from the system error occurrence. 4. When the machine recovers to the normal condition, ECM (19) controls the engine torque and speed according to the other engine controls. 6

5 28

12 13

14 33 DCU

34 15 16

17 19 ECM 18

30 MC 22

CAN 27 29 26

21 23

24 25

TDFY-02-03-003-1 ja

TODFY50-EN-00(10/01/2020)

T2-3-25

SECTION2 SYSTEM Group3 Engine System 123456-

EGR Cooler Inlet Temperature Sensor EGR Cooler Outlet Tempera ture Sensor Intake-Air Temperature Sen sor MAF Sensor Intercooler Inlet Temperature Sensor DOC Inlet Exhaust Tempera ture Sensor

789101112131415-

DOC Outlet Exhaust Tempera ture Sensor Crank Speed Sensor Cam Angle Sensor Coolant Temperature Sensor Boost Pressure Sensor Boost Temperature Sensor Engine Oil Pressure Sensor Intake Manifold Temperature Sensor EGR Motor Position Sensor

16171819202122232425-

EGR Motor Intake Throttle Position Sen sor Intake Throttle ECM Two-Way Valve Injector Common Rail Pressure Sensor Common Rail Supply Pump Fuel Tank

262728293031323334-

Suction Control Valve Fuel Temperature Sensor Differential Pressure Sensor Engine Oil Level Switch MC VGS Controller VGS Actuator DCU Atmospheric Pressure Sensor (Inside of ECM)

Insufficient DEF Level 1. When the DEF level becomes 10% or lower, the engine output restriction control level is set to step 1. 2. An alarm is displayed on the monitor and the buzzer sounds once. 3. Then, the engine output restriction control level is set to the step 2 or step 3 depending on the remaining level of DEF. Engine Output Restriction Step 1 Control Level

Step 2

Step 3

DEF Level

10 % or less

5% or less

Engine Torque

No restriction

Restriction

Engine Speed

No restriction

Slow Idle

Buzzer

Sounds once

Sounds once/One second

Sounds continuously

Monitor Screen

 ˫

06 32 PM

50.0 h

81.3 MHz

TDFY-02-03-015 ja

 ˫

81.3 MH

TDFY-02-03-016 ja

 ˫

81.3 MH

TDFY-02-03-017 ja

Malfunction of Urea SCR System/Malfunction of EGR System 1. When malfunction occurs (first time) on the urea SCR system or EGR system, the engine output restriction control level is set to the step 1. 2. An alarm is displayed on the monitor and the buzzer sounds once. 3. Then, the engine output restriction control level is set to the step 2 or step 3 according to the elapsed time. 4. When malfunction of the urea SCR system or EGR system occurs, the ECM monitors the system condition for 40 hours after the recovery. 5. When malfunction occurs (second time) during this 40 hours after the recovery, the engine output restriction control level starts from the step 2 and transitional period to the step 3 is shortened.

NOTE The transitional period of the engine output restriction control level differs between the urea SCR system malfunction and EGR system malfunction.

TODFY50-EN-00(10/01/2020)

T2-3-26

SECTION2 SYSTEM Group3 Engine System Engine Output Restric Step 1 tion Control Level

Step 2

Step 3

Malfunction of the - (Restriction starts.) Urea SCR System (First Time)

3 hours after starting the step 1 3.5 hours after starting the step 2

Malfunction of the Urea SCR System (Sec ond Time) (Within 40 Hours)

- (Restriction starts.)

Malfunction of the EGR - (Restriction starts.) System (First Time)

36 hours after starting the step 100 hours after starting the 1 step 2

Malfunction of the EGR System (Second Time) (Within 40 Hours)

- (Restriction starts.)

5 hours after starting the step 2

0.5 hours after starting the step 2

Engine Torque

No restriction

Restriction

Engine Speed

No restriction

Slow Idle

Buzzer

Sounds once

Sounds once/One second

Monitor Screen

 ˫

Sounds continuously

06 32 PM

50.0 h

 ˫

81.3 MHz

TDFY-02-03-018 ja

81.3 MHz

TDFY-02-03-019 ja

 ˫

81.3 MHz

TDFY-02-03-020 ja

Outline of Aftertreatment Device Aftertreatment device (16) consists of the diesel oxidation catalyst (DOC) block, filter (CSF) (14), and the SCR catalyst block. SCR catalyst 1 (11), SCR catalyst 2 (12), and the diesel oxidation catalyst (DOC) 2 (13) convert NOx in exhaust gas into nitrogen and water by a chemical reaction of NOx and DEF. Thus NOx is reduced from exhaust gas. Filter (14) removes fine particles (PM) in exhaust gas. Diesel oxidation catalyst (DOC) 1 (15) oxidizes unburnt fuel and raises exhaust temperature. Filter (14) traps PM, then burns and removes the PM using high temperature exhaust gas that was heated by diesel oxidation catalyst. Catalyst is applied onto filter (14). This promotes PM burning. DOC inlet exhaust temperature sensor (8) detects the exhaust temperature at upper stream of diesel oxidation catalyst (DOC) 1 (15). DOC outlet exhaust temperature sensor (7) detects the exhaust temperature at down stream of diesel oxidation catalyst (DOC) 1 (15). The differential pressure sensor (1) measures the differential pressure before and after filter (14) in order to detect the amount of trapped PM. Upstream NOx sensor (6) detects the concentration of NOx upstream of SCR catalyst 1 (11). Downstream NOx sensor (3) detects the concentration of NOx downstream of SCR catalyst 2 (12). Dosing module (5) injects DEF into aftertreatment device (16). SCR exhaust temperature sensor (9) detects the exhaust temperature at the upper stream of SCR catalyst 1 (11).

TODFY50-EN-00(10/01/2020)

T2-3-27

SECTION2 SYSTEM Group3 Engine System 16

11 12

2 3

4 a

14 TDFY-05-04-015-5 ja

a- Machine Front Side 1234-

Differential Pressure Sensor Downstream NOx Sensor Controller Downstream NOx Sensor Upstream NOx Sensor Con troller

5678-

Dosing Module Upstream NOx Sensor DOC Outlet Exhaust Tempera ture Sensor DOC Inlet Exhaust Tempera ture Sensor

9101112-

SCR Exhaust Temperature Sensor Differential Pressure Detec tion Port SCR Catalyst 1 SCR Catalyst 2

13141516-

Diesel Oxidation Catalyst (DOC) 2 Filter (CSF) Diesel Oxidation Catalyst (DOC) 1 Aftertreatment Device

Operation of Aftertreatment Device 1. Exhaust gas combusted in the engine cylinders passes through the diesel oxidation catalyst (DOC) 1 (15) in aftertreatment device (16) and flows to filter (CSF) (14). 2. Diesel oxidation catalysts (DOC) 1 (15) reduce harmful substances contained in exhaust gas such as carbon monoxide by initiating a chemical reaction. 3. When the exhaust gas passes through filter (14), the PM is filtered out by filter (14). 4. PM that was filtered out by filter (14) accumulates inside filter (14). 5. The accumulated PM is removed when aftertreatment device (16) is regenerated, and is discharged as CO2. (Refer to "Aftertreatment Device Regeneration Control"T2-3-29) 6. DCU (17) controls dosing module (5) according to the signals from upstream NOx sensor (6). 7. Dosing module (5) injects DEF into aftertreatment device (16). 8. At this time, DEF breaks down into ammonia (NH3) and carbon dioxide (CO2). 9. SCR catalysts 1 (11), SCR catalysts 2 (12) initiate a chemical reaction of ammonia (NH3) and NOx in exhaust gas so that NOx is broken down into nitrogen and water. 10. Oxidation catalyst (DOC) 2 (13) breaks down ammonia (NH3) into nitrogen (N2) and water (H2O). 11. As a result, NOx is reduced from exhaust gas and any remaining ammonia (NH3) is removed.

TODFY50-EN-00(10/01/2020)

T2-3-28

SECTION2 SYSTEM Group3 Engine System

10 6 A 4 2 15 7

1 14 Local-CAN

18 ECM

17 DCU ISO-CAN

14 c CO2

TDFY-02-03-006-1 ja

a- Filtering b- Accumulation 12345-

Differential Pressure Sensor Downstream NOx Sensor Controller Downstream NOx Sensor Upstream NOx Sensor Con troller Dosing Module

c- Regeneration 6789-

Upstream NOx Sensor DOC Outlet Exhaust Tempera ture Sensor DOC Inlet Exhaust Tempera ture Sensor SCR Exhaust Temperature Sensor

1011121314-

Differential Pressure Detec tion Port SCR Catalyst 1 SCR Catalyst 2 Diesel Oxidation Catalyst (DOC) 2 Filter (CSF)

15161718-

Diesel Oxidation Catalyst (DOC) 1 Aftertreatment Device DCU ECM

Aftertreatment Device Regeneration Control Purpose: The Aftertreatment device regeneration control mixes unburnt fuel with exhaust gas, and initiates oxidation of unburnt fuel by using the diesel oxidation catalysts (DOC). This process increases exhaust gas temperature and performs TODFY50-EN-00(10/01/2020)

T2-3-29

SECTION2 SYSTEM Group3 Engine System regeneration. Aftertreatment device (16) regeneration includes self regeneration and forced regeneration. Forced regeneration includes auto regeneration and manual regeneration. •

NH3 reset: NH3 reset resets error between actual value and calculated value of NH3 adsorbed to the SCR catalyst.

•

Elimination of HC Poisoning: When activity of the diesel oxidation catalysts (DOC) is low in a cold weather, NH3 adsorption to the SCR catalyst may be blocked due to unburnt fuel (HC). Elimination of HC poisoning is performed by increasing the exhaust temperature.

•

Removal of white deposition: When the machine is operated with low exhaust temperature for long period of time, part of injected DEF may create white deposition. White deposition is removed by increasing the exhaust temperature.

•

Elimination of Sulfur Poisoning: When sulfur compound contained in fuel adheres to the diesel oxidation catalysts (DOC), the catalyst performance deteriorates. Elimination of Sulfur poisoning is performed by increasing the exhaust temperature.

•

Removal of PM: PM accumulated in filter (CSF) (14) is burnt and removed using heat of exhaust gas.

Operation (Self Regeneration): 1. Auto regeneration uses high temperature exhaust gas to perform regeneration without using the diesel oxidation catalyst (DOC) 1(15) function. 2. A higher exhaust temperature at the filter (CSF) (14) inlet results in greater activation of the catalyst, increasing the amount of regeneration. Operation (Forced Regeneration): 1. ECM (18) injects fuel (post injection (20)) to exhaust gas in engine cylinder (19), and exhaust gas mixed with unburnt fuel is supplied to diesel oxidation catalyst (DOC) (1) (12). 2. Diesel oxidation catalyst (DOC) 1 (12) oxidizes unburnt fuel and raises exhaust temperature. 3. Therefore, exhaust temperature of the outlet of diesel oxidation catalyst (DOC) 1 (12) raises up to about 600 °C and regeneration is carried out. Auto-Regeneration: •

The regeneration is automatically carried out every 15 hours. (Regeneration time: About 7 minutes (Regeneration Time)

•

When the output signal from differential pressure sensor (1) reaches a certain pressure level or more before 15 hours pass after the completion of the previous regeneration, forced regeneration is automatically carried out. (Differential pressure regeneration)

Manual Regeneration: •

When Manual Regeneration Request is displayed on the monitor, the regeneration is manually carried out by setting the engine control dial to the slow idle position, turning the pilot shut-off lever to the LOCK position, and by pushing the manual regeneration switch to the ON position. (Regeneration time: About 30 minutes)

TODFY50-EN-00(10/01/2020)

T2-3-30

SECTION2 SYSTEM Group3 Engine System

10 6

4 2 15 7

14 1

18 ECM

Local-CAN 17 DCU

ISO-CAN

23 TDFY-02-03-007-1 ja

a- Fuel Injection Amount

TODFY50-EN-00(10/01/2020)

T2-3-31

SECTION2 SYSTEM Group3 Engine System 123456-

Differential Pressure Sensor Downstream NOx Sensor Controller Downstream NOx Sensor Upstream NOx Sensor Con troller Dosing Module Upstream NOx Sensor

TODFY50-EN-00(10/01/2020)

78910-

DOC Outlet Exhaust Tempera ture Sensor DOC Inlet Exhaust Tempera ture Sensor SCR Exhaust Temperature Sensor Differential Pressure Detec tion Port

111213141516-

T2-3-32

SCR Catalyst 1 SCR Catalyst 2 Diesel Oxidation Catalyst (DOC) 2 Filter (CSF) Diesel Oxidation Catalyst (DOC) 1 Aftertreatment Device

17181920212223-

DCU ECM Cylinder Post Injection Main Injection Pilot Injection Multi Injection

SECTION2 SYSTEM Group4 Hydraulic System Outline of Hydraulic System The hydraulic system mainly consists of the pilot circuit, main circuit, and breaker/pulverizer/crusher circuit. Pilot Circuit: Power Source Pilot Pump

Related Device

Supplied to

Pilot Valve Pump Regulator 5-Spool Solenoid Valve Unit 2-Spool Solenoid Valve Unit 3-Spool Solenoid Valve Unit Signal Control Valve

Operation Control Circuit Pump Control Circuit Aftertreatment Device Regeneration Control Circuit Valve Control Circuit Travel Motor Displacement Angle Control Circuit Swing Parking Brake Release Circuit

Main Circuit: Power Source Main Pump

Related Device

Supplied to

Control Valve

Motor Cylinder

Breaker/Pulverizer/Crusher Circuit (Option): Power Source

Related Device

Supplied to

Pilot Pump

Pilot Valve Auxiliary Control Solenoid Valve Unit Selector Valve Control Sole noid Valve

Auxiliary Flow Combiner Circuit Auxiliary Flow Rate Control Circuit Accumulator Control Valve Control Circuit Selector Valve Control Circuit

Main Pump

Control Valve

Attachment (Option) Breaker Relief Control Valve Control Circuit

Pilot Circuit of Hydraulic System Pressure oil from the pilot pump is used in order to operate the following circuits. •

Operation Control Circuit

•

Pump Control Circuit

•

Aftertreatment Device Regeneration Control Circuit

•

Valve Control Circuit

•

Travel Motor Displacement Angle Control Circuit

•

Swing Parking Brake Release Circuit

TODFY50-EN-00(10/01/2020)

T2-4-1

SECTION2 SYSTEM Group4 Hydraulic System 7

42 41

40 14 43

11 44

15 36

17 SA SU SX

SK1 SK2

37 35

SK3

SC SF

25 46

32 33

P3 P2

33 29 31

30 TDFY-02-04-001-1 ja

TODFY50-EN-00(10/01/2020)

T2-4-2

SECTION2 SYSTEM Group4 Hydraulic System 123456789101112-

Travel Pilot Valve Pilot Valve (Left) Pilot Valve (Right) Auxiliary 1 Pilot Valve Positioning/Auxiliary 2 Pilot Valve Operation Control Circuit Swing Parking Brake Release Circuit Swing Motor Pump Control Circuit Pump 1 and 2 Torque Control Solenoid Valve Pump 3 Torque Control Sole noid Valve Maximum Pump 2 Flow Rate Limit Control Solenoid Valve

1314151617181920212223242526-

Regulator Spool Flow Combiner Valve Boom Anti-Drift Valve Arm Bottom Anti-Drift Valve Arm Rod Anti-Drift Valve Pump 1 Bypass Shut-Out Valve Auxiliary Flow Combiner Valve Arm Regenerative Valve Digging Regenerative Valve Arm 1 Flow Rate Control Valve Arm Roll-In Meter-Out Open Control Spool Main Relief Valve Control Valve

2728293031323334353637383940-

Hydraulic Oil Tank Suction Filter Pilot Pump Pilot Filter Pilot Relief Valve Valve Control Circuit Travel Motor Travel Motor Displacement Angle Control Circuit 5-Spool Solenoid Valve Unit 2-Spool Solenoid Valve Unit Aftertreatment Device Regen eration Control Circuit Hose Rupture Valve (Position ing) Hose Rupture Valve (Arm) Hose Rupture Valve (Boom)

41424344454647-

Signal Control Valve Pilot Shut-Off Solenoid Valve Maximum Pump 1 Flow Rate Limit Control Solenoid Valve Maximum Pump 3 Flow Rate Limit Control Solenoid Valve 3-Spool Solenoid Valve Unit Pump 3 Bypass Shut-Out Valve Auxiliary 2 Hydraulic Pressure Source Selector Spool

Operation Control Circuit 1. The pilot valve controls pressure oil from pilot pump (B1) and moves the spool in control valve (B0). 2. Signal control valve (A9) and 3-spool solenoid valve unit (B2) are provided between the pilot valve and control valve (B0). Shockless valve (A8) is provided in the boom raise circuit in signal control valve (A9). 3. Shockless valve (A8) restricts returning oil from control valve (B0) when stopping the boom raise operation and dampens the quick spool movement in control valve (B0). (Refer to COMPONENT OPERATION/Signal Control Valve.)

TODFY50-EN-00(10/01/2020)

T2-4-3

SECTION2 SYSTEM Group4 Hydraulic System A0

A8 A9

9 10 11 12 4

3 2

8 7 6 5 13 14 15 16

10 12 11 9

3 1 B1

B0 4

16 1234A0A1A2A3-

Boom Raise Boom Lower Arm Roll-Out Arm Roll-In Travel (Left) Travel (Right) Swing Arm

TODFY50-EN-00(10/01/2020)

5678A4A5A6A7-

Swing Left Swing Right Bucket Roll-In Bucket Roll-Out Boom Bucket Auxiliary 1 Positioning/Auxiliary 2

6 9101112A8A9B0B1-

T2-4-4

Travel Left Forward Travel Left Reverse Travel Right Forward Travel Right Reverse Shockless Valve Signal Control Valve Control Valve Pilot Pump

13141516B2-

TDFY-02-04-003-1 ja Auxiliary 1 Auxiliary 1 Positioning Raise/Auxiliary 2 Positioning Lower/Auxiliary 2 3-Spool Solenoid Valve Unit

SECTION2 SYSTEM Group4 Hydraulic System Pump Control Circuit (Refer to COMPONENT OPERATION/Pump Device.) •

Pump Delivery Flow Rate Control by Pump Control Pressure Pi (23) 1. The pilot pressure from the pilot valve is selected by shuttle valve (10) in signal control valve (11). Then, pump 1 flow rate control valve (16), pump 2 flow rate control valve (14), and pump 3 flow rate control valve (13) in signal control valve (11) are shifted. 2. Pilot pressure oil from pilot pump (26) flows to the regulators in pump 1 (20), pump 2 (22), and pump 3 (21) as pump control pressure Pi (23) through maximum pump flow rate limit control solenoid valves (27, 24, 28). 3. The regulators increase or decrease the pump delivery flow rate according to pump control pressure Pi (23).

NOTE The boom lower pilot pressure is routed to pump 1 flow rate control valve (16) through control valve (17) with the track raised off the ground. The auxiliary 1 pilot pressure is routed to pump 1 flow rate control valve (16) through auxiliary flow combiner control solenoid valve (12) (option). •

Pump Control by Torque Control Solenoid Valve 1. The pilot pressure from pilot pump (26) is controlled by torque control solenoid valves (18, 25) and becomes torque control pressure Ppc (19). 2. Torque control pressure Ppc (19) flows to the regulators in pump 1 (20), pump 2 (22), and pump 3 (21). 3. The regulators increase or decrease the pump delivery flow rate according to torque control pressure Ppc (19). Supplied to

Pilot Pressure is Supplied to

Pump 1 Flow Rate Control Valve (16)

Boom Raise (6), Boom Lower (5), Arm (4), Bucket (7), Travel (Right) (2), Auxili ary 1 (8)

Pump 2 Flow Rate Control Valve (14)

Boom Raise (6), Arm(4), Travel (Left) (1), Auxiliary 1(8)

Pump 3 Flow Rate Control Valve (13)

Boom Raise (6), Swing(3) Positioning/Auxiliary 2 (9)

TODFY50-EN-00(10/01/2020)

T2-4-5

SECTION2 SYSTEM Group4 Hydraulic System 1

10 11

12 16 14

15 18

20 21 22

26 23

28 TDFY-02-04-002-1 ja

TODFY50-EN-00(10/01/2020)

T2-4-6

SECTION2 SYSTEM Group4 Hydraulic System 12345678910-

Travel (Left) Travel (Right) Swing Arm Boom Lower Boom Raise Bucket Auxiliary 1 Positioning/Auxiliary 2 Shuttle Valve

111213141516-

Signal Control Valve Auxiliary Flow Combiner Con trol Solenoid Valve (Option) Pump 3 Flow Rate Control Valve Pump 2 Flow Rate Control Valve Boom Lower Pilot Pressure Pump 1 Flow Rate Control Valve

1718192021222324-

Control Valve Pump 3 Torque Control Sole noid Valve Torque Control Pressure Ppc Pump 1 Pump 3 Pump 2 Pump Control Pressure Pi Maximum Pump 2 Flow Rate Limit Control Solenoid Valve

25262728-

Pump 1 and 2 Torque Control Solenoid Valve Pilot Pump Maximum Pump 1 Flow Rate Limit Control Solenoid Valve Maximum Pump 3 Flow Rate Limit Control Solenoid Valve

Aftertreatment Device Regeneration Control Circuit (Refer to SYSTEM/Control System.) Purpose: As the aftertreatment device regeneration control circuit increases the pump load when performing aftertreatment device manual regeneration, the load is applied to the engine. Therefore, the exhaust temperature increases up to the temperature that a catalyst in the aftertreatment device is activated. •

Valve Control 1. When the conditions for aftertreatment device manual regeneration control exist, MC shifts 2-spool solenoid valve unit (1) (SJ). 2. Pilot pressure oil shifts pump 1 bypass shut-out valve (3). 3. As neutral circuit (2) in pump 1 (4) is partially blocked, the pressure of pump 1 (4) increases.

•

Pump 1 (4) Delivery Flow Rate Control 1. When the conditions for aftertreatment device manual regeneration control exist, MC shifts 2-spool solenoid valve unit (1) (SZ) and pump 1 and 2 torque control solenoid valve (5). 2. Pilot pressure oil is supplied to the regulator in pump 1 (4).The regulator in pump 1 (4) increases the delivery flow rate. 3. Therefore, as the pump load increases, the load is applied to the engine. Consequently, the engine exhaust temperature increases and the aftertreatment device is regenerated.

TODFY50-EN-00(10/01/2020)

T2-4-7

SECTION2 SYSTEM Group4 Hydraulic System SZ 1

6 12-

2-Spool Solenoid Valve Unit Neutral Circuit

5 3-

Pump 1 Bypass Shut-Out Valve

Pump 1

56-

TDFY-02-04-004-1 ja Pump 1 and 2 Torque Control Solenoid Valve Pilot Pump

Valve Control Circuit (Refer to COMPONENT OPERATION/Control Valve, Travel Device.) ● The pilot pressure from the pilot pump controls the following valves and spools through 5-spool solenoid valve unit (23) (SI, SD, SE, SF, SC), 2-spool solenoid valve unit (24) (SJ), 3-spool solenoid valve unit (25) (SK3), and flow combiner valve control spool (7) in signal control valve (6). •

Boom Lower Pilot Pressure (8): Boom Anti-Drift Valve (15)

•

Arm Roll-Out Pilot Pressure (9): Arm Bottom Anti-Drift Valve (21)

TODFY50-EN-00(10/01/2020)

T2-4-8

SECTION2 SYSTEM Group4 Hydraulic System •

Arm Roll-In Pilot Pressure (10): Arm Rod Anti-Drift Valve (22)

•

5-spool Solenoid Valve Unit (23) (SI): Main Relief Valve (11, 17) (Increasing the Set Pressure)

•

5-spool Solenoid Valve Unit (23) (SD): Arm Roll-In Meter-Out Open Control Spool (13)

•

5-spool Solenoid Valve Unit (23) (SE): Arm 1 Flow Rate Control Valve (19)

•

5-Spool Solenoid Valve Unit (23) (SF): Digging Regenerative Valve (14)

•

5-Spool Solenoid Valve Unit (23) (SC): Arm Regenerative Valve (20)

•

2-Spool Solenoid Valve Unit (24) (SJ): Pump 1 Bypass Shut-Out Valve (16)

•

3-Spool Solenoid Valve Unit (25) (SK3): Pump 3 Bypass Shut-Out Valve (26)

•

Flow Combiner Valve Control Spool (7) (Travel (Right) Pilot Pressure): Flow Combiner Valve (2)

TODFY50-EN-00(10/01/2020)

T2-4-9

SECTION2 SYSTEM Group4 Hydraulic System 1

24 7 11

22 23 21 SI SD SE

13 14

SF SC 20

15 16

SK3

19 26

18 1234567-

Travel Right Reverse Travel Right Forward Arm Roll-In Arm Roll-Out Boom Lower Signal Control Valve Flow Combiner Valve Control Spool

TODFY50-EN-00(10/01/2020)

891011121314-

Boom Lower Pilot Pressure Arm Roll-Out Pilot Pressure Arm Roll-In Pilot Pressure Main Relief Valve (P1, P2) Flow Combiner Valve Arm Roll-In Meter-Out Open Control Spool Digging Regenerative Valve

151617181920-

T2-4-10

Boom Anti-Drift Valve Pump 1 Bypass Shut-Out Valve Main Relief Valve (P3) Travel Motor Displacement Angle Control Valve Arm 1 Flow Rate Control Valve Arm Regenerative Valve

212223242526-

TDFY-02-04-005-1 ja Arm Bottom Anti-Drift Valve Arm Rod Anti-Drift Valve 5-Spool Solenoid Valve Unit 2-Spool Solenoid Valve Unit 3-Spool Solenoid Valve Unit Pump 3 Bypass Shut-Out Valve

SECTION2 SYSTEM Group4 Hydraulic System Travel Motor Displacement Angle Control Circuit (Refer to COMPONENT OPERATION/Travel Device.) 1. The pilot pressure from 5-spool solenoid valve unit (23) (SI) controls travel motor displacement angle control valve (18). 2. The travel motor displacement angle control circuit and pressure-increase circuits of main relief valves (11, 17) are common circuit. 3. Therefore, when the travel is at fast speed, pressure in main relief valves (11, 17) increases.

TODFY50-EN-00(10/01/2020)

T2-4-11

SECTION2 SYSTEM Group4 Hydraulic System 1

24 7 11

22 23 21 SI SD SE

13 14

SF SC 20

15 16

SK3

19 26

18 1234567-

Travel (Right Reverse) Travel (Right Forward) Arm Roll-In Arm Roll-Out Boom Lower Signal Control Valve Flow Combiner Valve Control Spool

TODFY50-EN-00(10/01/2020)

891011121314-

Boom Lower Pilot Pressure Arm Roll-Out Pilot Pressure Arm Roll-In Pilot Pressure Main Relief Valve (For P1, P2) Flow Combiner Valve Arm Roll-In Meter-Out Open Control Spool Digging Regenerative Valve

151617181920-

T2-4-12

Boom Anti-Drift Valve Pump 1 Bypass Shut-Out Valve Main Relief Valve (For P3) Travel Motor Displacement Angle Control Valve Arm 1 Flow Rate Control Valve Arm Regenerative Valve

212223242526-

TDFY-02-04-005-1 ja Arm Bottom Anti-Drift Valve Arm Rod Anti-Drift Valve 5-Spool Solenoid Valve Unit 2-Spool Solenoid Valve Unit 3-Spool Solenoid Valve Unit Pump 3 Bypass Shut-Out Valve

SECTION2 SYSTEM Group4 Hydraulic System Swing Parking Brake Release Circuit (Refer to COMPONENT OPERATION/Swing Device.) 1. When operating the front attachment or swing, the pilot pressure from the pilot valve is selected by shuttle valve (8) in signal control valve (7). And this pilot pressure shifts swing parking brake release spool (9). 2. Consequently, pilot pressure SH from pilot pump (11) is supplied to swing motor (10) and releases the swing parking brake. 1

SH 9

10 123-

Swing Arm Boom

456-

Bucket Auxiliary 1 Positioning/Auxiliary 2

78-

Signal Control Valve Shuttle Valve

91011-

TDFY-02-04-022-1 ja Swing Parking Brake Release Spool Swing Motor Pilot Pump

Main Circuit of Hydraulic System 1. The main pump draws hydraulic oil from hydraulic oil tank (23) and delivers it to control valve (6). 2. Pressure oil from pump 1 (19) flows to travel (right) spool (11), bucket spool (12), arm 2 spool (13), and boom 1 spool (14) through pump 1 side (B) in control valve (6). TODFY50-EN-00(10/01/2020)

T2-4-13

SECTION2 SYSTEM Group4 Hydraulic System 3. Pressure oil from pump 2 (21) flows to boom 2 spool (10), arm 1 spool (9), auxiliary 1 spool (8), and travel (left) spool (7) through pump 2 side (D) in control valve (6). 4. Pressure oil from pump 3 (20) flows to swing spool (18), boom 3 spool spool (17), and positioning/auxiliary 2 spool (16) through pump 3 side (E) in control valve (6). 5. Delivered hydraulic oil is supplied to the motors or cylinders in response to the spool operation of control valve (6). 6. Returning oil from the motors or cylinders returns to hydraulic oil tank (23) through control valve (6) and oil cooler (25). 7. When the oil temperature is low (high viscosity) and the oil flow resistance increases in oil cooler (25), bypass check valve (24) is opened and hydraulic oil directly returns to hydraulic oil tank (23). A D

TDFY-02-04-006-1 ja

A- Machine Front Side B- Pump 1 Side 6-

D- Pump 2 Side E- Pump 3 Side

Control Valve

TODFY50-EN-00(10/01/2020)

T2-4-14

SECTION2 SYSTEM Group4 Hydraulic System 2

3 28 6

17 26

21 5

24 TDAA-02-04-008-2 ja

B- Pump 1 Side D- Pump 2 Side 1234567-

Travel Motor (Left) Travel Motor (Right) Bucket Cylinder Boom Cylinder Swing Motor Control Valve Travel (Left) Spool

TODFY50-EN-00(10/01/2020)

E- Pump 3 Side 891011121314-

Auxiliary 1 Spool Arm 1 Spool Boom 2 Spool Travel (Right) Spool Bucket Spool Arm 2 Spool Boom 1 Spool

16171819202122-

T2-4-15

Positioning/Auxiliary 2 Spool Boom 3 Spool Swing Spool Pump 1 Pump 3 Pump 2 Suction Filter

232425262728-

Hydraulic Oil Tank Bypass Check Valve Oil Cooler Positioning Cylinder Arm Cylinder Attachments

SECTION2 SYSTEM Group4 Hydraulic System Neutral Circuit 1. When the control lever is in neutral, pressure oil from the main pump returns to hydraulic oil tank (24) through the control valve. 2. Parallel circuits (8, 32, 19) are provided in each circuit of pump 1 (23), pump 2 (21), and pump 3 (22) so that the combined operation becomes possible. 3

38 1

5 35 34

7 8 12

10 32 11 31 13 29 15

27 14

26 16

21 TDFY-02-04-007-1 ja

TODFY50-EN-00(10/01/2020)

T2-4-16

SECTION2 SYSTEM Group4 Hydraulic System 12345678910-

Main Relief Valve (For P1, P2) Flow Combiner Circuit (Arm) Travel Motor (Right) Travel (Right) Spool Bucket Spool Bucket Cylinder Overload Relief Valve Parallel Circuit (Pump 1) Arm 2 Spool Neutral Circuit (Pump 1)

11121314151617181920-

Boom 1 Spool Boom Cylinder Overload Relief Valve Boom 3 Spool Swing Motor Swing Spool Main Relief Valve (For P3) Flow Combiner Circuit (P3) Parallel Circuit (Pump 3) Neutral Circuit (Pump 3)

21222324252627293031-

Pump 2 Pump 3 Pump 1 Hydraulic Oil Tank Overload Relief Valve Positioning/Auxiliary 2 Spool Positioning Cylinder Neutral Circuit (Pump 2) Arm Cylinder Boom 2 Spool

32333435363738-

Parallel Circuit (Pump 2) Arm 1 Spool Overload Relief Valve Auxiliary 1 Spool Attachment Travel (Left) Spool Travel Motor (Left)

Flow Combiner Circuit (Front Attachment) 1. When performing of boom raise operations, and pressure oil from three pumps (pump 1 (23), pump 2 (21), pump 3 (22)) is combined. 2. When performing arm and boom lower operation, pressure oil from pump 3 (22) is not combined, but pressure oil from pump 1 (23) and pump 2 (21) is combined.

TODFY50-EN-00(10/01/2020)

T2-4-17

SECTION2 SYSTEM Group4 Hydraulic System 3

38 1

5 35 34

7 8 12

10 32 11 31 13 29 15

27 14

26 16

23 12345678910-

Main Relief Valve (P1, P2) Flow Combiner Circuit (Arm) Travel Motor (Right) Travel (Right) Spool Bucket Spool Bucket Cylinder Overload Relief Valve Parallel Circuit (Pump 1) Arm 2 Spool Neutral Circuit (Pump 1)

TODFY50-EN-00(10/01/2020)

11121314151617181920-

Boom 1 Spool Boom Cylinder Overload Relief Valve Boom 3 Spool Swing Motor Swing Spool Main Relief Valve (P3) Flow Combiner Circuit (P3) Parallel Circuit (Pump 3) Neutral Circuit (Pump 3)

21222324252627293031-

T2-4-18

Pump 2 Pump 3 Pump 1 Hydraulic Oil Tank Overload Relief Valve Positioning/Auxiliary 2 Spool Positioning Cylinder Neutral Circuit (Pump 2) Arm Cylinder Boom 2 Spool

32333435363738-

TDFY-02-04-007-1 ja Parallel Circuit (Pump 2) Arm 1 Spool Overload Relief Valve Auxiliary 1 Spool Attachment Travel (Left) Spool Travel Motor (Left)

SECTION2 SYSTEM Group4 Hydraulic System Relief Circuit 1. Main relief valves (1, 17) are provided in the main circuit. 2. Main relief valves (1, 17) prevent the pressure in main circuit from exceeding the set pressure when the spool is operated (when the control lever is operated). 3. Overload relief valves (7, 13, 25, 34) are provided in the actuator circuit (between the control valve and the actuator) of boom, arm, bucket, and positioning (only the machine with 2-piece boom attached). 4. Overload relief valves (7, 13, 25, 34) prevent the pressure caused by external force in the actuator circuit from exceeding the set pressure. 5. Overload relief valves (7, 13, 25, 34) have make-up function. When the pressure in the actuator circuit decreases, overload relief valves (7, 13, 25, 34) draw pressure oil from hydraulic oil tank (24) and prevent cavitation from occurring.

TODFY50-EN-00(10/01/2020)

T2-4-19

SECTION2 SYSTEM Group4 Hydraulic System 3

38 1

5 35 34

7 8 12

10 32 11 31 13 29 15

27 14

26 16

23 12345678910-

TODFY50-EN-00(10/01/2020)

11121314151617181920-

Boom 1 Spool Boom Cylinder Overload Relief Valve Boom 3 Spool Swing Motor Swing Spool Main Relief Valve (For P3) Flow Combiner Circuit (P3) Parallel Circuit (Pump 3) Neutral Circuit (Pump 3)

21222324252627293031-

T2-4-20

Pump 2 Pump 3 Pump 1 Hydraulic Oil Tank Overload Relief Valve Positioning/Auxiliary 2 Spool Positioning Cylinder Neutral Circuit (Pump 2) Arm Cylinder Boom 2 Spool

32333435363738-

TDFY-02-04-007-1 ja Parallel Circuit (Pump 2) Arm 1 Spool Overload Relief Valve Auxiliary 1 Spool Attachment Travel (Left) Spool Travel Motor (Left)

SECTION2 SYSTEM Group4 Hydraulic System Combined Operation Circuit •

Swing, Boom Raise 1. When the boom is raised while swinging, the pilot pressure shifts swing spool (6), boom 1 spool (2), boom 2 spool (12), and boom 3 spool (5). 2. Pressure oil from pump 1 (9) flows to boom cylinders (3) through parallel circuit (1) and boom 1 spool (2) and raises the boom. 3. Pressure oil from pump 2 (7) flows to boom cylinders (3) through parallel circuit (11) and boom 2 spool (12), and raises the boom. 4. Pressure oil from pump 3 (8) flows to swing motor (4) through swing spool (6) and swings the machine. At the same time, pressure oil from pump 3 (8) flows through parallel circuit (10) and boom 3 spool (5), is combined with pressure oil from pump 1 (9) and pump 2 (7), and flows to boom cylinders (3) so that the boom is raised.

TODFY50-EN-00(10/01/2020)

T2-4-21

SECTION2 SYSTEM Group4 Hydraulic System

2 12 11 4 5

9 123-

Parallel Circuit (Pump 1) Boom 1 Spool Boom Cylinder

456-

Swing Motor Boom 3 Spool Swing Spool

7 789-

Pump 2 Pump 3 Pump 1

101112-

TDFY-02-04-008-1 ja Parallel Circuit (Pump 3) Parallel Circuit (Pump 2) Boom 2 Spool

Flow Combiner Circuit Purpose: The flow combiner circuit shifts flow combiner valve (4) when performing combined operation of travel and front attachment or combined operation of travel and swing, and the machine can travel straight. TODFY50-EN-00(10/01/2020)

T2-4-22

SECTION2 SYSTEM Group4 Hydraulic System •

Travel, Boom Raise 1. When performing combined operation boom raise and travel, pilot pressure shifts travel (right) spool (3), travel (left) spool (2), boom 1 spool (7), boom 2 spool (13), and boom 3 spool (9). 2. At the same time, the travel (right) pilot pressure shifts the flow combiner valve control spool in the signal control valve. Therefore, primary pilot pressure (5) from the pilot pump is routed to flow combiner valve (4) through the signal control valve and shifts flow combiner valve (4). 3. Pressure oil from pump 1 (12) flows through travel (right) spool (3) and activates travel motor (right) (6). 4. At the same time, pressure oil from pump 1 (12) flows to travel (left) spool (2) through flow combiner valve (4) and activates travel motor (left) (1). 5. Pressure oil from pump 2 (10) flows to boom cylinder (8) through boom 2 spool (13) and raises the boom. 6. Pressure oil from pump 3 (11) flows through boom 3 spool (9), is combined with pressure oil from pump 2 (10), and raises the boom. 7. Pressure oil from pump 2 (10) and pressure oil from pump 3 (11) are used for the boom. Pressure oil from pump 1 (12) is equally supplied to both right and left travel motors and the machine can travel straight.

NOTE As the travel (right) circuit is a tandem circuit, pressure oil from pump 1 (12) does not flow to boom 1 spool (7).

TODFY50-EN-00(10/01/2020)

T2-4-23

SECTION2 SYSTEM Group4 Hydraulic System 6

1 2

12 1234-

Travel Motor (Left) Travel (Left) Spool Travel (Right) Spool Flow Combiner Valve

TODFY50-EN-00(10/01/2020)

Primary Pilot Pressure from Pi lot Pump (From Flow Combin er Valve Control Spool) Travel Motor (Right)

78910-

T2-4-24

Boom 1 Spool Boom Cylinder Boom 3 Spool Pump 2

111213-

TDFY-02-04-009-1 ja Pump 3 Pump 1 Boom 2 Spool

SECTION2 SYSTEM Group4 Hydraulic System Digging Regenerative Circuit Purpose: The digging regenerative circuit increases the arm roll-in speed when performing the digging operation. •

Arm Roll-In, Boom Raise 1. When performing the combined operation of arm roll-in and boom raise, the pilot pressure shifts arm 1 spool (17), arm 2 (4), boom 1 spool (7), boom 2 spool (13), and boom 3 spool (8). 2. Pressure oil from pump 1 (11) flows to arm cylinder (18) through neutral circuit (2), parallel circuit (3), and arm 2 spool (4), and rolls in the arm. At the same time, pressure oil from pump 1 (11) flows through parallel circuit (3), flows to boom cylinder (6) through boom 1 spool (7), and raises the boom at the same time. 3. Pressure oil from pump 2 (9) flows through parallel circuit (14) and boom 2 spool (13), is combined with pressure oil from pump 1 (11), flows to boom cylinders (6), and raises the boom. At the same time, pressure oil from pump 2 (9) flows through arm 1 spool (17), is combined with pressure oil from pump 1 (11), flows to arm cylinder (18), and rolls in the arm. 4. Pressure oil from pump 3 (10) flows through boom 3 spool (8), is combined with pressure oil from pump 1 (11) and pump 2 (9), flows to boom cylinder (6), and raises the boom. 5. At this time, when the pump delivery pressure becomes high, MC activates 5-spool solenoid valve unit (SF). (Refer to SYSTEM/Control System.) 6. Pressure oil from the pilot pump flows through 5-spool solenoid valve unit (SF) and shifts digging regenerative valve (1). 7. Returning oil from the boom cylinder (6) rod side flows to arm 1 spool (17) through boom 1 spool (7) and digging regenerative valve (1). 8. Pressure oil from pump 1 (11) and pump 2 (9), and returning oil from the boom cylinder (6) rod side are combined, and flows to arm cylinder (18) so that the arm roll-in speed increases.

TODFY50-EN-00(10/01/2020)

T2-4-25

SECTION2 SYSTEM Group4 Hydraulic System 1

4 17 5 6

13 7 14

11 1234-

Digging Regenerative Valve Neutral Circuit (Pump 1) Parallel Circuit (Pump 1) Arm 2 Spool

TODFY50-EN-00(10/01/2020)

567-

Pilot Pressure from 5-Spool Solenoid Valve Unit (SF) Boom Cylinder Boom 1 Spool

891011-

T2-4-26

Boom 3 Spool Pump 2 Pump 3 Pump 1

13141718-

TDFY-02-04-010-1 ja Boom 2 Spool Parallel Circuit (Pump 2) Arm 1 Spool Arm Cylinder

SECTION2 SYSTEM Group4 Hydraulic System Arm Regenerative Cut Circuit Purpose: The arm regenerative cut circuit shifts the arm regenerative valve according to other operating conditions and working conditions when performing the arm roll-in operation. Therefore, the arm regenerative cut circuit controls to become a correct operation according to the pump load. •

Arm Roll-In, Boom Raise 1. When performing the combined operation of arm roll-in and boom raise, the pilot pressure shifts arm 1 spool (16), arm 2 (3), boom 1 spool (5), boom 2 spool (11), and boom 3 spool (6). 2. Pressure oil from pump 1 (9) flows to arm cylinder (17) through neutral circuit (1), parallel circuit (2), and arm 2 spool (3), and rolls in the arm. At the same time, pressure oil from pump 1 (9) flows through parallel circuit (2), flows to boom cylinder (4) through boom 1 spool (5), and raises the boom at the same time. 3. Pressure oil from pump 2 (7) flows through parallel circuit (12) and boom 2 spool (11), is combined with pressure oil from pump 1 (9), flows to boom cylinders (4), and raises the boom. At the same time, pressure oil from pump 2 (7) flows through arm 1 spool (16), is combined with pressure oil from pump 1 (9), flows to arm cylinder (17), and rolls in the arm. 4. Pressure oil from pump 3 (8) flows through boom 3 spool (6), is combined with pressure oil from pump 1 (9) and pump 2 (7), flows to boom cylinder (4), and raises the boom. 5. At this time, MC activates 5-spool solenoid valve unit (SC) according to pump delivery pressure. (Refer to SYSTEM/ Control System.) 6. Pressure oil from the pilot pump flows through 5-spool solenoid valve unit (SC) and shifts arm regenerative valve (13). 7. When pump delivery pressure is low, arm regenerative valve (13) is closed and returning oil from the arm cylinder (17) rod side is divided into two directions. One flows to the hydraulic oil tank through arm 1 spool (16). The other flows through check valve (15), is combined with pressure oil from pump 2 (7), flows to arm cylinder (17), and rolls in the arm. 8. When pump delivery pressure becomes high, arm regenerative valve (13) is shifted and all returning oil from the arm cylinder (17) rod side flows to the hydraulic oil tank through arm 1 spool (16) and arm regenerative valve (13). (Arm Regenerative Cut Circuit) 9. Therefore, the pressure at arm cylinder (17) rod side decreases and the digging force is improved.

TODFY50-EN-00(10/01/2020)

T2-4-27

SECTION2 SYSTEM Group4 Hydraulic System

16 15 14

13 11 5 12

9 12345-

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

TODFY50-EN-00(10/01/2020)

678911-

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

7 12131415-

T2-4-28

Parallel Circuit (Pump 2) Arm Regenerative Valve Pilot Pressure from 5-Spool Solenoid Valve Unit (SC) Check Valve

1617-

TDFY-02-04-011-1 ja Arm 1 Spool Arm Cylinder

SECTION2 SYSTEM Group4 Hydraulic System Arm 1 Flow Rate Control Circuit Purpose: The arm 1 flow rate control circuit restricts the circuit of low load when performing combined operation so that more pressure oil can be delivered to the actuator of high load. Therefore, the actuator of high load is given priority to operate. •

Arm Roll-In, Attachment 1. When performing the combined operation of arm roll-in and attachment (15), the pilot pressure shifts arm 1 spool (13), arm 2 spool (5), and auxiliary 1 spool (1). 2. At this time, MC activates 5-spool solenoid valve unit (SE). (Refer to SYSTEM/Control System.) 3. Pressure oil from the pilot pump flows through 5-spool solenoid valve unit (SE) and shifts selector valve (2) of the arm 1 flow rate control valve. 4. Pressure oil from pump 1 (9) flows to arm cylinder (14) through neutral circuit (4), parallel circuit (16), and arm 2 spool (5), and rolls in the arm. 5. Pressure oil from pump 2 (7) flows to poppet valve (3) of the arm 1 flow rate control valve and auxiliary 1 spool (1) through parallel circuit (11). 6. As the back pressure of poppet valve (3) is blocked by selector valve (2), pressure oil from pump 2 (7) is restricted by poppet valve (3). 7. Consequently, pressure oil from pump 2 (7) flows to attachment (15) through auxiliary 1 spool (1) preferentially.Therefore, the attachment operating speed increases.

TODFY50-EN-00(10/01/2020)

T2-4-29

SECTION2 SYSTEM Group4 Hydraulic System 1

4 15

14 13

9 123-

Auxiliary 1 Spool Arm 1 Flow Rate Control Valve (Selector Valve) Arm 1 Flow Rate Control Valve (Poppet Valve)

TODFY50-EN-00(10/01/2020)

45789-

Neutral Circuit (Pump 1) Arm 2 Spool Pump 2 Pump 3 Pump 1

11121314-

T2-4-30

Parallel Circuit (Pump 2) Pilot Pressure from 5-Spool Solenoid Valve Unit (SE) Arm 1 Spool Arm Cylinder

1516-

TDFY-02-04-012-1 ja Attachment Parallel Circuit (Pump 1)

SECTION2 SYSTEM Group4 Hydraulic System Arm 2 Roll-In Pilot Cut Control Circuit Purpose: The arm 2 roll-in pilot cut control circuit restricts the circuit of low load when performing combined operation so that more pressure oil can be delivered to the actuator of high load. Therefore, the actuator of high load is given priority to operate.

NOTE As an example, the combined operation of arm roll-in and bucket roll-in is explained here. 1. When performing combined operation of arm roll-in and bucket roll-in, the pilot pressure shifts arm 1 spool (14), and bucket spool (5). 2. At this time, MC activates 3-spool solenoid valve unit (SK1). (Refer to SYSTEM/Control System.) 3. Pressure oil from pump 2 (9) flows to arm cylinder (15) through parallel circuit (13) and arm 1 spool (14), and rolls-in the arm. 4. Pressure oil from pump 1 (11) flows to bucket cylinder (8) through neutral circuit (4) and bucket spool (5), and rolls in the bucket. 5. At the same time, pressure oil from pump 1 (11) flows to arm cylinder (15) through parallel circuit (3) and arm 2 spool (7). 6. Pilot pressure to arm 2 spool (7) is reduced by the 3-spool solenoid valve unit (SK1). 7. Pressure oil from pump 1 (11) preferetially flows to bucket cylinder (8) and the bucket roll-in speed increases. 8. When delivery pressure from pump 2 (9) becomes high, MC deactivates the pressure decrease control of the 3-spool solenoid valve unit (SK1). 9. Pressure oil from pump 1 (11) flows to the arm cylinder and the digging force (arm) increases.

TODFY50-EN-00(10/01/2020)

T2-4-31

SECTION2 SYSTEM Group4 Hydraulic System 3

8 5

11 345-

Parallel Circuit (Pump 1) Neutral Circuit (Pump 1) Bucket Spool

TODFY50-EN-00(10/01/2020)

67-

Pilot Pressure from 3-Spool Solenoid Valve Unit (SK1) Arm 2 Spool

891011-

T2-4-32

Bucket Cylinder Pump 2 Pump 3 Pump 1

131415-

TDFY-02-04-013-1 ja Parallel Circuit (Pump 2) Arm 1 Spool Arm Cylinder

SECTION2 SYSTEM Group4 Hydraulic System Pump 3 Center Bypass Shut-Out Control Circuit Purpose: The pump 3 center bypass shut-out control circuit controls the pump 3 delivery flow rate by the pump 3 flow rate control when performing boom raise operation. At the same time MC activates the pump 3 bypass shut-out valve (19) in order to reduce fuel consumption by decreasing the amount of pressure oil returning from the pump 3 neutral circuit into the hydraulic oil tank as much as possible. •

Arm Roll-In, Boom Raise (at High Load) 1. When performing the combined operation of arm roll-in and boom raise, the pilot pressure shifts arm 1 spool (17), arm 2 (4), boom 1 spool (7), boom 2 spool (13), and boom 3 spool (8). 2. Pressure oil from pump 1 (11) flows to arm cylinder (18) through neutral circuit (2), parallel circuit (3), and arm 2 spool (4), and rolls in the arm. At the same time, pressure oil from pump 1 (11) flows through parallel circuit (3), flows to boom cylinder (6) through boom 1 spool (7), and raises the boom at the same time. 3. Pressure oil from pump 2 (9) flows through parallel circuit (14) and boom 2 spool (13), is combined with pressure oil from pump 1 (11), flows to boom cylinders (6), and raises the boom. At the same time, pressure oil from pump 2 (9) flows through arm 1 spool (17), is combined with pressure oil from pump 1 (11), flows to arm cylinder (18), and rolls in the arm. 4. Pressure oil from pump 3 (10) flows through boom 3 spool (8), is combined with pressure oil from pump 1 (11) and pump 2 (9), flows to boom cylinder (6), and raises the boom. 5. At this time, MC activates 3-spool solenoid valve unit (SK3). (Refer to SYSTEM/Control System.) 6. Pressure oil from the pilot pump flows through 3-spool solenoid valve unit (SK3) and shifts pump 3 bypass shutout valve (19). 7. Therefore, the amount of pressure oil returning from the pump 3 neutral circuit into the hydraulic oil tank is reduced.

NOTE When performing combined operation of arm roll-in and boom raise above the ground, the load is low and pressure oil from pump 1 (11) and pump 2 (9) flows to arm cylinder (18).

TODFY50-EN-00(10/01/2020)

T2-4-33

SECTION2 SYSTEM Group4 Hydraulic System 1

4 17 5 6

13 7 14 19

SK3 11

9 TDFY-02-04-023-1 ja

12345-

Digging Regenerative Valve Neutral Circuit (Pump 1) Parallel Circuit (Pump 1) Arm 2 Spool Pilot Pressure from 5-Spool Solenoid Valve Unit (SF)

TODFY50-EN-00(10/01/2020)

67891011-

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

1314171819-

T2-4-34

Boom 2 Spool Parallel Circuit (Pump 2) Arm 1 Spool Arm Cylinder Pump 3 Bypass Shut-Out Valve

SECTION2 SYSTEM Group4 Hydraulic System Arm Roll-In Meter-Out Open Control Circuit Purpose: The arm roll-in meter-out open control circuit shifts the arm roll-in meter-out open control spool (12) during arm roll-in operation. Therefore, the arm roll-in meter-out open control circuit increases the arm roll-in meter-out opening during arm roll-in operation.

NOTE As an example, the combined operation of arm roll-in and bucket roll-in is explained here. 1. When performing combined operation of arm roll-in and bucket roll-in, the pilot pressure shifts 1 arm 1 spool (14), arm 2 spool (7), and bucket spool (5). 2. Pressure oil from pump 1 (11) flows to bucket cylinder (8) through neutral circuit (4), parallel circuit (3), and bucket spool (5), and rolls in the bucket. At the same time, pressure oil from pump 1 (11) flows to arm cylinder (15) through parallel circuit (3), and arm 2 spool (7), and rolls in the arm. 3. Pressure oil from pump 2 (9) flows through arm 1 spool (17), is combined with pressure oil from pump 1 (11), flows to arm cylinder (15), and rolls in the arm. 4. When pump 2 delivery pressure is high, MC activates the 5-spool solenoid valve unit (SD). (Refer to SYSTEM/Control System.) 5. Pressure oil from the pilot pump flows through 5-spool solenoid valve unit (SD) and shifts arm roll-in meter-out open control spool (12). 6. Therefore, the arm roll-in meter-out opening increases.

TODFY50-EN-00(10/01/2020)

T2-4-35

SECTION2 SYSTEM Group4 Hydraulic System 3

8 5

7 6 15

14 12 13

9 TDFY-02-04-024-1 ja

3456-

Parallel Circuit (Pump 1) Neutral Circuit (Pump 1) Bucket Spool Pilot Pressure from 5-Spool Solenoid Valve Unit (SD)

TODFY50-EN-00(10/01/2020)

7891011-

Arm 2 Spool Bucket Cylinder Pump 2 Pump 3 Pump 1

12131415-

T2-4-36

Arm Roll-In Meter-Out Open Control Spool Parallel Circuit (Pump 2) Arm 1 Spool Arm Cylinder

SECTION2 SYSTEM Group4 Hydraulic System Bucket Regenerative Cut Circuit Purpose: When the load is high at bucket roll-in operation, the bucket regeneration cut circuit flows back pressure oil at the bucket cylinder (3) rod side to hydraulic oil tank (5) without regeneration for the bottom side. Therefore, the pressure at bucket cylinder (3) rod side decreases and the digging force is improved. •

Regeneration Cut (Pump 1 (4) delivery pressure: High) 1. When the load becomes heavy at bucket roll-in operation, bucket regeneration cut valve (1) is shifted by pressure oil from pump 1 (4). 2. Returning oil from the cylinder rod side flows to hydraulic oil tank (5) through bucket spool (2) and bucket regeneration cut valve (1). 3. The pressure at bucket cylinder (3) rod side decreases and the digging force is improved.

•

Regeneration (Pump 1 (4)) delivery pressure: Low) 1. Pressure oil from pump 1 (4) is routed to bucket regeneration cut valve (1). 2. When the load is light at bucket roll-in operation, bucket regeneration cut valve (1) is not shifted. 3. As returning oil from the cylinder rod side is restricted by bucket regeneration cut valve (1), the pressure at cylinder rod side is higher than the pressure at cylinder bottom side. 4. Pressure oil from the cylinder rod side pushes to open the check valve in bucket spool (2) and flows to the cylinder bottom side. 5. The regeneration is done like this and the cylinder speed increases.

TODFY50-EN-00(10/01/2020)

T2-4-37

SECTION2 SYSTEM Group4 Hydraulic System

1 3 2 6

4 1-

Bucket Regeneration Cut Valve

TODFY50-EN-00(10/01/2020)

23-

Bucket Spool Bucket Cylinder

45-

T2-4-38

Pump 1 Hydraulic Oil Tank

TDFY-02-04-014-1 ja Bucket Regenerative Valve

SECTION2 SYSTEM Group4 Hydraulic System Boom Lower Meter-In Cut Control Purpose: When performing the boom lower operation with the front attachment above the ground, the boom lower meter-in cut control stops pressure oil which flows to boom cylinder from the pump. The boom falls due to the own weight by the boom regenerative circuit and pressure oil from the pump is used for other actuators. Therefore, other actuators are preferentially operated. The meter-in cut control is deactivated with the track raised off the ground. Therefore, the boom is given priority to operate and the jack-up force increases.

NOTE As an example, the combined operation of boom lower and arm roll-out is explained here.

Boom Cylinder Bottom Pressure: High (With the Front Attachment above the Ground) 1. When performing combined operation of boom lower and arm roll-out, the arm roll-out pilot pressure shifts arm 1 spool (13), and arm 2 spool (1). 2. When boom lower operation is done, boom lower meter-in cut valve (2) is shifted by the boom cylinder (3) bottom pressure. 3. Boom lower pilot pressure (14) is blocked by boom lower meter-in cut valve (2). As the pilot pressure is not routed, boom 1 spool (4) does not move. 4. Pressure oil in the boom cylinder (3) bottom side flows to the boom cylinder (3) rod side through boom regenerative valve (6) of boom 3 spool (5) due to boom own weight. 5. As all pressure oil from pump 1 (9) and pressure oil from pump 2 (7) are used for arm cylinder (12), arm roll-out speed increases.

NOTE The illustration shows during combined operation of boom lower and arm roll-out.

TODFY50-EN-00(10/01/2020)

T2-4-39

SECTION2 SYSTEM Group4 Hydraulic System

1 2

13 12

3 4

14 6

9 123-

Arm 2 Spool Boom Lower Meter-In Cut Valve Boom Cylinder

4567-

Boom 1 Spool Boom 3 Spool Boom Regenerative Valve Pump 2

891112-

Pump 3 Pump 1 Boom 2 Spool Arm Cylinder

1314-

TDFY-02-04-015-1 ja Arm 1 Spool Boom Lower Pilot Pressure

Boom Cylinder Bottom Pressure: Low (With the Track Raised off the Ground) 1. When the boom lower operation is done with the bucket set on the ground, the boom cylinder (3) bottom pressure becomes low and boom lower meter-in cut valve (1) is not shifted. TODFY50-EN-00(10/01/2020)

T2-4-40

SECTION2 SYSTEM Group4 Hydraulic System 2. Boom lower pilot pressure (8) acts on boom 3 spool (4). Then, boom lower pilot pressure (8) acts on boom 1 spool (2) and boom 2 spool (7) through boom lower meter-in cut valve (1). Therefore, each spool is moved. 3. Pressure oil from pump 1 (6) flows through boom 1 spool (2). Pressure oil from pump 2 (5) flows through boom 2 spool (7), is combined with pressure oil from boom 1 spool (2), and flows to the boom cylinder (3) rod side.

1 3 2

7 4

5 TDFY-02-04-016-1 ja

12-

Boom Lower Meter-In Cut Valve Boom 1 Spool

TODFY50-EN-00(10/01/2020)

345-

Boom Cylinder Boom 3 Spool Pump 2

678-

T2-4-41

Pump 1 Boom 2 Spool Boom Lower Pilot Pressure

SECTION2 SYSTEM Group4 Hydraulic System Pump 3 Minimum Displacement Angle Hold Control during Digging Operation Circuit Purpose: The pump 3 minimum displacement angle hold control circuit during digging operation holds the displacement angle of pump 3 to the minimum during digging operation so that pump 1 and pump 2 are used at the maximum displacement angle. Therefore, the pumps are used within their highly efficient range in order to reduce fuel consumption. •

Arm Roll-In, Boom Raise 1. When performing the combined operation of arm roll-in and boom raise, the pilot pressure shifts arm 1 spool (17), arm 2 (4), boom 1 spool (7), boom 2 spool (13), and boom 3 spool (8). 2. Pressure oil from pump 1 (11) flows to arm cylinder (18) through neutral circuit (2), parallel circuit (3), and arm 2 spool (4), and rolls in the arm. At the same time, pressure oil from pump 1 (11) flows through parallel circuit (3), flows to boom cylinder (6) through boom 1 spool (7), and raises the boom at the same time. 3. Pressure oil from pump 2 (9) flows through parallel circuit (14) and boom 2 spool (13), is combined with pressure oil from pump 1 (11), flows to boom cylinders (6), and raises the boom. At the same time, pressure oil from pump 2 (9) flows through arm 1 spool (17), is combined with pressure oil from pump 1 (11), flows to arm cylinder (18), and rolls in the arm. 4. Pressure oil from pump 3 (10) flows through boom 3 spool (8), is combined with pressure oil from pump 1 (11) and pump 2 (9), flows to boom cylinder (6), and raises the boom. 5. At this time, when the pump delivery pressure becomes high, MC activates 3-spool solenoid valve unit (SK2). (Refer to SYSTEM/Control System.) 6. Therefore, pilot pressure to boom 3 spool (8) is reduced.

TODFY50-EN-00(10/01/2020)

T2-4-42

SECTION2 SYSTEM Group4 Hydraulic System 1

4 17 5 6

13 7 14

SK2

11 1234-

Digging Regenerative Valve Neutral Circuit (Pump 1) Parallel Circuit (Pump 1) Arm 2 Spool

567-

Pilot Pressure from 5-Spool Solenoid Valve Unit (SF) Boom Cylinder Boom 1 Spool

891011-

Boom 3 Spool Pump 2 Pump 3 Pump 1

13141718-

TDFY-02-04-025-1 ja Boom 2 Spool Parallel Circuit (Pump 2) Arm 1 Spool Arm Cylinder

Breaker/Pulverizer/Crusher Circuit of Hydraulic System (Option) Valve Control Circuit (Refer to COMPONENT OPERATION/Control Valve.) •

The pilot pressure from the pilot valve, auxiliary control solenoid valve unit (4), and selector valve control solenoid valve (11) control the following valves.

TODFY50-EN-00(10/01/2020)

T2-4-43

SECTION2 SYSTEM Group4 Hydraulic System •

Travel Pilot Pressure: Auxiliary Flow Combiner Valve (7)

•

Auxiliary Flow Rate Control Solenoid Valve (6): Auxiliary Flow Rate Control Valve (9)

•

Auxiliary Flow Combiner Control Solenoid Valve (5) (Auxiliary 1 Pilot Pressure): Auxiliary Flow Combiner Valve (7), Pump 1 Bypass Shut-Out Valve (8)

•

Selector Valve Control Solenoid Valve (11): Selector Valve (12), Accumulator Control Valve (13) 1

4 5 7 6 13

12 11

9 TDFY-02-04-017-1 ja

TODFY50-EN-00(10/01/2020)

T2-4-44

SECTION2 SYSTEM Group4 Hydraulic System 1234-

Travel (Left) Travel (Right) Auxiliary 1 Auxiliary Control Solenoid Valve Unit

56-

Auxiliary Flow Combiner Con trol Solenoid Valve Auxiliary Flow Rate Control Solenoid Valve

789-

Auxiliary Flow Combiner Valve Pump 1 Bypass Shut-Out Valve Auxiliary Flow Rate Control Valve

10111213-

Pilot Pump Selector Valve Control Sole noid Valve Selector Valve Accumulator Control Valve

Auxiliary Flow Combiner Circuit When pulverizer or crusher is selected on the work mode or 2 Pumps Combined Flow is set ON by MPDr., MC activates the auxiliary flow combiner control solenoid valve. Therefore, the auxiliary flow combiner valve is shifted. (Refer to SYSTEM/ Control System.)

When Performing Single Operation of Auxiliary Flow Combiner Circuit The auxiliary flow combiner valve combines pressure oil from both pump 1 (8) and pump 2 (7) when performing attachment (9) single operation. Therefore, the attachment (9) operating speed increases. 1. Attachment pilot pressure (2) shifts auxiliary flow combiner valve (1) and pump 1 bypass shut-out valve (6) through auxiliary flow combiner control solenoid valve (3) when performing single operation of attachment (9). 2. When pump 1 bypass shut-out valve (6) is shifted, neutral circuit (5) of pump 1 (8) is blocked. 3. Pressure oil from pump 1 (8) flows to auxiliary 1 spool (10) through auxiliary flow combiner valve (1). 4. Consequently, pressure oil in both pump 1 (8) and pump 2 (7) are combined and operating speed of attachment (9) increases.

NOTE Attachment pilot pressure (2) shifts the pump 1 flow rate control valve in signal control valve through auxiliary flow combiner control solenoid valve (3) when operating attachment (9). Therefore, the displacement angle of pump 1 (8) increases and the pump delivery flow rate increases. (Refer to COMPONENT OPERATION/ Pump Device, Signal Control Valve.)

TODFY50-EN-00(10/01/2020)

T2-4-45

SECTION2 SYSTEM Group4 Hydraulic System 2

10 9

7 TDFY-02-04-018-1 ja

123-

Auxiliary Flow Combiner Valve Attachment Pilot Pressure Auxiliary Flow Combiner Con trol Solenoid Valve

TODFY50-EN-00(10/01/2020)

456-

To Pump 1 Flow Rate Control Valve Neutral Circuit (Pump 1) Pump 1 Bypass Shut-Out Valve

78910-

T2-4-46

Pump 2 Pump 1 Attachment Auxiliary 1 Spool

SECTION2 SYSTEM Group4 Hydraulic System When Performing Combined Operation of Auxiliary Flow Combiner Circuit When performing the combined operation of attachment (14) and travel, auxiliary flow combiner valve (18) is not shifted. Therefore, the travel operating speed is maintained. 1. When attachment (14) is operated, attachment pilot pressure (3) shifts auxiliary 1 spool (13) and acts on port SM in auxiliary flow combiner valve (18) through auxiliary flow combiner control solenoid valve (4). 2. When travel is operated at the same time, pilot pressure (16) from the signal control valve acts on port SN in auxiliary flow combiner valve (18). 3. Pressure oil from port SM acts on auxiliary flow combiner valve (18) to the open direction and pressure oil from port SN and the spring force act on auxiliary flow combiner valve (18) to the close direction. 4. As the force acts on auxiliary flow combiner valve (18) to the close direction is larger, auxiliary flow combiner valve (18) is kept closed. Pressure oil from pump 1 (10) is blocked by auxiliary flow combiner valve (18). 5. MC activates auxiliary flow rate control solenoid valve (1) during the combined operation of attachment (14) and travel. (Refer to SYSTEM/Control System.) 6. Pressure oil (2) from the pilot pump flows to selector valve (12) of the auxiliary flow rate control valve and shifts selector valve (12). 7. Therefore, as pressure oil which flows to auxiliary 1 spool (13) from pump 2 (9) is restricted by poppet valve (11) of the auxiliary flow rate control valve, pressure oil from pump 2 (9) flows to travel (left) spool (17). 8. Consequently, as pressure oil from pump 2 (9) is not combined with pressure oil from pump 1 (10) and flows to travel (left) spool (17), the travel operating speed is maintained.

NOTE The priority (command signal to auxiliary flow rate control solenoid valve (1)) of combined operation of attachment and travel can be adjusted on the monitor.

TODFY50-EN-00(10/01/2020)

T2-4-47

SECTION2 SYSTEM Group4 Hydraulic System 1

18 SM

SN 14

13 12 11

9 TDFY-02-04-019-1 ja

TODFY50-EN-00(10/01/2020)

T2-4-48

SECTION2 SYSTEM Group4 Hydraulic System 1-

Auxiliary Flow Rate Control Solenoid Valve Pressure Oil from Pilot Pump Attachment Pilot Pressure Auxiliary Flow Combiner Con trol Solenoid Valve To Pump 1 Flow Rate Control Valve

2345-

67891011-

Travel (Right) Spool Travel Motor (Right) Pump 1 Bypass Shut-Out Valve Pump 2 Pump 1 Auxiliary Flow Rate Control Valve (Poppet Valve)

121314151617-

Auxiliary Flow Rate Control Valve (Selector Valve) Auxiliary 1 Spool Attachment Travel Motor (Left) Travel Pilot Pressure Travel (Left) Spool

18-

Auxiliary Flow Combiner Valve

Breaker 1 (HSB Breaker) Circuit 1. Pressure oil from pump 2 (10) flows to breaker (2) through auxiliary 1 spool (1). 2. When breaker 1 is selected or the following conditions for attachment adjustment is set by MPDr., MC activates selector valve control solenoid valve (6) and breaker relief solenoid valve (5). •

Selector Valve Control: O/T

• Relief Valve Selection: Breaker relief is enabled. 3. Pressure oil from pilot pump (7) flows through selector valve control solenoid valve (6) and shifts selector valve (9). Selector valve (9) connects return circuit (3) of breaker (2) to hydraulic oil tank (8). 4. The back pressure when performing breaker (2) operation is reduced and breaker (2) is prevented from being damaged. 5. When breaker relief solenoid valve (5) is activated, main circuit (4) of breaker (2) is connected to hydraulic oil tank (8) and decreases the breaker circuit pressure. 6. Consequently, pressure oil from pump 2 (10) is optimized by breaker relief solenoid valve (5) and flows to breaker (2).

TODFY50-EN-00(10/01/2020)

T2-4-49

SECTION2 SYSTEM Group4 Hydraulic System

3 4

5 6

10 123-

Auxiliary 1 Spool Breaker Return Circuit

45-

Main Circuit Breaker Relief Solenoid Valve

67-

Selector Valve Control Sole noid Valve Pilot Pump

8910-

TDFY-02-04-020-1 ja Hydraulic Oil Tank Selector Valve Pump 2

Breaker 2 (NPK Breaker) Circuit 1. When breaker 2 is selected or the following conditions for attachment adjustment is set by MPDr., MC activates selector valve control solenoid valve (7). •

Selector Valve Control: O/T

TODFY50-EN-00(10/01/2020)

T2-4-50

SECTION2 SYSTEM Group4 Hydraulic System 2. Pressure oil from pilot pump (8) acts on selector valve (10) and accumulator control valve (6) through selector valve control solenoid valve (7). 3. Pressure oil from selector valve control solenoid valve (7) shifts selector valve (10). Selector valve (10) connects return circuit (5) of breaker (4) to hydraulic oil tank (9). 4. The back pressure when performing breaker (4) operation is reduced and breaker (4) is prevented from being damaged. 5. At the same time, accumulator control valve (6) is shifted and accumulators (2, 3) are connected to the high-pressure side and low-pressure side circuits in breaker (4). 6. The shock of oil pressure is buffered and the pulsation is reduced when performing breaker (4) operation.

11 TDFY-02-04-021-1 ja

TODFY50-EN-00(10/01/2020)

T2-4-51

SECTION2 SYSTEM Group4 Hydraulic System 123-

Auxiliary 1 Spool Accumulator (Low-Pressure Side) Accumulator (High-Pressure Side)

TODFY50-EN-00(10/01/2020)

4567-

Breaker Return Circuit Accumulator Control Valve Selector Valve Control Sole noid Valve

891011-

T2-4-52

Pilot Pump Hydraulic Oil Tank Selector Valve Pump 2

SECTION2 SYSTEM Group5 Electrical System Outline of Electrical System The electrical circuit is broadly divided into the main circuit, monitor circuit, accessory circuit, and control circuit. •

The main circuit consists of the engine and the accessory related circuits.

•

The monitor circuit displays the machine operating conditions. The monitor circuit consists of the monitor controller, monitor, relays, and switches.

•

The accessory circuit controls the various lights, the wiper, and the washer. The accessory circuit consists of the monitor controller, relays, and switches.

•

The control circuit controls the engine, pump, and valve. The control circuit consists of the actuators such as solenoid valves, MC, ECM, sensors, and switches. (Refer to SYSTEM/Control System.)

Main Circuit of Electrical System The major functions and circuits in the main circuit are as follows. •

The electric power circuit supplies electrical power to all electrical systems in the machine. {Key Switch, Battery, Fuses (Fuse Box, Fusible Link)}

•

The CAN circuit performs communication between each controller.

•

The accessory related circuit is operated when the key switch is in the ACC position.

•

The starting circuit starts the engine. (Key Switch, Starter, Starter Relay)

•

The charging circuit supplies electric power to the batteries and charges them. {Alternator, (Regulator)}

•

The surge voltage prevention circuit prevents the occurrence of serge voltage developed when stopping the engine. (Load Dump Relay)

•

The pilot shut-off circuit controls the pilot shut-off solenoid valve according to the pilot shut-off lever position. The pilot shut-off solenoid valve controls the pilot pressure oil that flows from the pilot pump to the pilot valve. (Pilot Shut-off Solenoid Valve, Pilot Shut-Off Lever)

•

The auto shut-down circuit/automatic engine stop circuit at low temperature automatically stops the engine when the specified conditions exist. (MC, ACC Cut Relay, Key Switch ON Cut Relay)

•

The engine stop circuit (key switch: OFF) stops the engine by using ECM. (MC, ECM)

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

TODFY50-EN-00(10/01/2020)

T2-5-1

SECTION2 SYSTEM Group5 Electrical System Battery (1) Fusible Link (2)

Battery Key Switch (5) Terminal B Disconnect Load Dump Relay (4) Switch (3) Fuel Filling Device (26) Fuse Box 1 (6)

Terminal #8

ECM Main Relay (Power) (21)

Terminal #9

Monitor Controller (Backup Power) (12) Switch Panel (13) Cab Light (14) Radio (Backup Power) (15) Security Horn (Power) (16) Security Horn Relay (Power) (17) GSM (Power) (18)

Fuse Box 2 (7)

TODFY50-EN-00(10/01/2020)

Terminal #10

MC (Power) (11)

Terminal #19

Horn Relay (Power) (22)

Terminal #20

Option (27)

Terminal #34

DCU (Power) (23)

Terminal #35

SCR Control Relay (24)

Terminal #36

GSM (25)

T2-5-2

Battery Disconnect Switch Indicator (28)

SECTION2 SYSTEM Group5 Electrical System B

KEY̲SW

H OFF ACC ON START

L R11 1 3 ACC̲CUT

3 R

R AVX

8f 2f 2f

W AV WB AEX B

27+ 2 YR 36+ 2 RW

32+ 5

22+

32- 10A 21- 10A

22- 10A

W 38+ 5

39- 5A 26- 5A 27- 10A 36- 5A 23- 20A

37- 10A

YG 5 W

34+ 3 R 25+ 2 YB

28+ 24+

WR G L 7+ 1.25 14+ 3 18+ 3

4+ 5 W 8+ 3 R

16+ 2 YB

1+ 5 W

19+ 3 R 13+ 2 G

15+ 3 W

11+ 5 W

R R

FUSE̲BOX2

2 2 2 5 4

16 12 11 3 15 8 2 1 19 13

8 19

4 9 10 17 6 20 5 7 14 18

35 34

38- 10A

31- 5A

33- 10A

282435342529-

20A 10A 5A 5A 20A 5A 5A 5A 5A 5A

R1 2 5 4 LOAD DUMP R4 STARTER CUT

10A 10A 20A 20A 5A 10A

1 3

L WR 1 3

2 YB

5A 10A 5A 20A 10A 30A 15A 20A 10A 5A

FUEL̲FILLING/P

DIODE3 A AVSS

2 5 4

9 10 20

25 WL GLOW̲PLUG RELAY

4 2

3 1

5 BY AEX 1 ENG̲4

GLOW̲PLUG

W W

C B S E

AEX AEX

2 4

W AV

1 3

1.5

FLOAT̲SW

R AV

FORK̲10

0.85 2

1.5 1.5 10A

W SF-3 2 B

B S

1 2

BOX;CONTROL

A E

STARTER

B B

1.5

BATTERY̲RELAY

1.5 1.5

5 R 2 W B S 1

B 1 B 2

AVSS AVXS

STOP

3 R 2 W 5 W

AVXS AVXS AEX AEX

60 -

BATTERY

1 59 2

W W W LY

1.5 1.5

AVXS

5 5 0.85 0.85

60 R -

1 2

R W W

2 G

R5 KEY̲ON̲CUT

3 R 3 B

AVXS

DIODE1 A K 2 W AVSS

3 RW

5 W

2 B

3 R

2 RW

AVSS

61 13

AVXS

DIODE5 2 B AVSS A K

DISCONNECT̲SW

1 3

2 5 4

AEX

B R

RW LY

START

L 3 L

3 W

5 1 4 3

3f W 3f W 3f L 2f WR

W5 1 4 3

OFF

B G1 G2 ACC M ST

STARTER̲RELAY

26 ACG B 8 R 2 0.85 L 3 0.85

W W LY

SF-3 AEX AEX

27 28

REGULATOR

ALTERNATOR

12 13 14 15 16 17 18 124567-

Battery Fusible Link Load Dump Relay Key Switch Fuse Box 1 Fuse Box 2

1112131415-

MC (Power) Monitor Controller (Backup Power) Switch Panel Cab Light Radio (Backup Power)

161718212223-

Security Horn (Power) Security Horn Relay (Power) GSM (Power) ECM Main Relay (Power) Horn Relay (Power) DCU (Power)

2425262728-

TDFY-02-05-001-1 ja SCR Control Relay GSM Fuel Filling Device Option Battery Disconnect Switch In dicator

TODFY50-EN-00(10/01/2020)

T2-5-3

SECTION2 SYSTEM Group5 Electrical System 2 4 3 17

6 VGS

18 9

17 19 DCU

26 17

17 1

7 ECM

24 17

11 MPDr.

17 5 16

8 MC

17 27

22 17 17

25 PLCU

30 SW-BOX

17 29

14 28

1234567-

Power- CAN CAN-H (High) CAN-L (Low) CAN Bus Body- CAN VGS Controller (Variable Tur bo Controller) ECM (Engine Controller)

89101112131415-

MC (Main Controller) Communication Controller Monitor Controller MPDr. Aerial Angle Controller Radio Controller Air Conditioner Controller Monitor Control Unit

1617181920212223-

Information Control Unit Termination Resistor (120 Ω) ISO-CAN DCU Local-CAN DEF Sensor Unit PL-CAN Upstream NOx Sensor

24252627282930-

TDFY-02-01-001-1 ja Downstream NOx Sensor PLCU (Option) IF-CAN OPT-CAN Engine Oil Monitoring Sensor Hydraulic Oil Monitoring Sen sor Switch Box Controller

Accessory Circuit (Key Switch: ACC) 1. When key switch (2) is set to the ACC position, terminal B is connected to the terminal ACC in key switch (2). 2. The circuit from the terminal ACC in key switch (2) is connected as shown below and makes each accessory operation possible.

TODFY50-EN-00(10/01/2020)

T2-5-4

SECTION2 SYSTEM Group5 Electrical System Key Switch (2) Terminal ACC

ACC Cut Relay (3)

Fuse Box 1 (4)

Terminal Radio (6) #13 Terminal Monitor Controller (5) #14 Terminal Auxiliary (7) #15

B G1 G2 ACC M ST

B ACC KEY̲SW

H OFF ACC ON START

3 5 1 4 3

L 3 L

3 W

R11 1 3 ACC̲CUT

ACC

3f W 3f W 3f L 2f WR

W5 1 4 3

Fuse Box 1 (4)

3 R

5 R 2 W B S 1

A E

8f 2f 2f

W AV WB AEX B

YG WR G L 7+ 1.25 14+ 3 18+ 3

4+ 5 W 8+ 3 R

16+ 2 YB

1+ 5 W

19+ 3 R 13+ 2 G

15+ 3 W

11+ 5 W

R1 2 5 4 LOAD DUMP R4 STARTER CUT

16 12 11 3 15 8 2 1 19 13

4 9 10 17 6 20 5 7 14 18

WL 2 GLOW̲PLUG RELAY

4 2

5 BY AEX 1 ENG̲4

GLOW̲PLUG

W W

B S E

3 1

AEX AEX

2 4

1 3

DIODE5 2 B AVSS A K

R AVX

1 3

2 YB

W AV

R AV

FORK̲10

B S

W SF-3 2 B

STARTER

2 5 4

BATTERY̲RELAY

1 3

DIODE3 A AVSS

2 5 4

20A 10A 5A 5A 20A 5A 5A 5A 5A 5A

2 B

AVSS

W W W LY

60 -

BATTERY

5 5 0.85 0.85

60 R +

AVXS AVXS AEX AEX

AVSS AVXS

3 R 2 W 5 W

5A 10A 5A 20A 10A 30A 15A 20A 10A 5A

1 59 2

R R

AVXS

2 G

2 2

R W W

2 5 4

2 RW

DIODE1 A K 2 W AVSS

3 R

61 13

AVXS

L WR

AEX

0.85 2

DISCONNECT̲SW

RW LY

R5 KEY̲ON̲CUT

3 RW

1 3

STARTER̲RELAY

ACG E

B 8 R 2 0.85 L 3 0.85

W W LY

SF-3 AEX AEX

REGULATOR

ALTERNATOR

TDFY-02-05-002-1 ja 12-

Battery Key Switch

34-

ACC Cut Relay Fuse Box 1

56-

Monitor Controller Radio

Auxiliary

Starting Circuit (Key Switch: START) 1. When key switch (7) is set to the START position, terminal B is connected to the terminals M and ST in key switch (7). 2. Current from the terminal M excites battery relay (4) through key switch ON cut relay (9). Current from battery (1) is routed to terminal B of starter (2) and terminal B of starter relay (3) through battery relay (4). 3. Current from terminal M of key switch (7) flows as follows as a signal indicating that key switch (7) is in the ON position or START position. Key Switch (7) Terminal M

Fuse #18

Monitor Controller (11)

Key Switch ON Cut Relay (9)

Fuse #17

ECM (13) DCU (20) MC (12)

4. When ECM (13) receives this signal, ECM (15) turns ON ECM main relay (14). 5. Current from battery (1) flows to ECM (13) through fuse #8 and ECM main relay (14), and the ECM (13) main power is turned ON. TODFY50-EN-00(10/01/2020)

T2-5-5

SECTION2 SYSTEM Group5 Electrical System 6. At the same time, current from fuse #8 flows through ECM main relay (14) and fuse #24 to DEF sensor unit (19), upstream NOx sensor (15), and downstream NOx sensor (16). 7. ECM (13) controls the condition of the engine to be able to start. 8. Current from the terminal ST flows to terminal S in starter relay (3) through starter cut relay (5). 9. Current flows to the coil in starter relay (3) and starter relay (3) is turned ON. 10. Current flows to terminal S in starter (2) from terminal C in starter relay (3). 11. The relay in starter (2) is turned ON so that the starter motor rotates. 7

B M

START 1

24 18 10

S C B S

12 MC

20 DCU

15 12345-

13 ECM

16 19

Battery Starter Starter Relay Battery Relay Starter Cut Relay

TODFY50-EN-00(10/01/2020)

6791011-

Fuse Box 1 Key Switch Key Switch ON Cut Relay Fuse Box 2 Monitor Controller

1213141516-

T2-5-6

MC ECM ECM Main Relay Upstream NOx Sensor Downstream NOx Sensor

1920-

TDFY-02-05-003-1 ja DEF Sensor Unit DCU

SECTION2 SYSTEM Group5 Electrical System Charging Circuit (Key Switch: ON) 1. After the engine starts and key switch (3) is released key switch (3) is returned to the ON position. 2. Terminal B is connected to the terminals ACC and M in key switch (3) with key switch (3) set in the ON position. 3. Alternator (5) starts generating electricity with the engine running. Current from terminal B in alternator (5) flows to batteries (1) through battery relay (2) and charges batteries (1). 4. Current from terminal L in alternator (5) flows to monitor controller (4). 5. Monitor controller (4) detects the alternator (5) generating electricity according to the electric source from alternator (5) and deletes the alternator alarm on the monitor. ACC

B G1 G2 ACC M ST

L 3 L

3 W

R11 1 3 ACC̲CUT

5 1 4 3

3f W 3f W 3f L 2f WR

W5 1 4 3

KEY̲SW

H OFF ACC ON START

3 R

5 R 2 W B S 1

A E

8f 2f 2f

W AV WB AEX B

YG WR G L 7+ 1.25 14+ 3 18+ 3

16+ 2 YB

4+ 5 W 8+ 3 R

19+ 3 R 13+ 2 G

15+ 3 W

1+ 5 W

11+ 5 W

16 12 11 3 15 8 2 1 19 13

4 9 10 17 6 20 5 7 14 18

W AV

2 GLOW̲PLUG RELAY

4 2

5 BY AEX 1 ENG̲4

GLOW̲PLUG

W W

B S E

3 1

AEX AEX

2 4

2 5 4

R1 2 5 4 LOAD DUMP R4 STARTER CUT

DIODE5 2 B AVSS A K

R AVX

1 3

R AV

FORK̲10

B S

W SF-3 2 B

STARTER

1 3

BATTERY̲RELAY

2 YB

20A 10A 5A 5A 20A 5A 5A 5A 5A 5A

DIODE3 A AVSS

2 5 4

1 3

2 B

AVSS

BATTERY

W W W LY

5 5 0.85 0.85

AVXS AVXS AEX AEX

60 R

AVSS AVXS

5A 10A 5A 20A 10A 30A 15A 20A 10A 5A

3 R 2 W 5 W

R R

1 59 2

2 2

AVXS

2 G

DIODE1 A K 2 W AVSS

R W W

2 5 4

2 RW

3 R

L WR

AVXS

R5 KEY̲ON̲CUT

DISCONNECT̲SW

3 RW

0.85 2

1 3

STARTER̲RELAY

B ACG B 8 R 2 0.85 L 3 0.85

W W LY

SF-3 AEX AEX

L REGULATOR

ALTERNATOR

4 5 TDFY-02-05-004-1 ja

12-

Battery Battery Relay

TODFY50-EN-00(10/01/2020)

34-

Key Switch Monitor Controller

T2-5-7

Alternator

SECTION2 SYSTEM Group5 Electrical System Alternator Operation ● Alternator (5) consists of field coil FC, stator coil SC, and diodes D. ● Regulator (6) consists of transistors T1, T2, Zener diode ZD, and resistances R1 to R6, RF. ● Terminal M (4) in the key switch is connected to base B of transistor T1 through R, RF, (R), and R1. ● When battery relay (2) is in the ON position, the battery (1) voltage is applied to base B of transistor T1 in regulator (6), and collector C is connected to emitter E. Therefore, field coil FC is grounded through transistor T1. ● At the beginning, no current is flowing to field coil FC. When the rotor starts rotating, the alternate current is generated in stator coil SC due to the rotor remnant magnetism. ● When current flows to field coil FC, the rotor is further magnetized and the generating voltage increases. Then, current flowing to field coil FC increases. Therefore, the generating voltage increases further and batteries (1) start charging. 3

(R)

TDAA-02-05-004-1 ja 12-

Battery Battery Relay

TODFY50-EN-00(10/01/2020)

34-

To Key Switch Terminal B From Key Switch Terminal M

56-

T2-5-8

Alternator Regulator

SECTION2 SYSTEM Group5 Electrical System Regulator Operation ● When the generating voltage increases more than the set voltage of Zener diode ZD, current flows to base B of transistor T2 and collector C is connected to emitter E. ● Current flowing to base B of transistor T1 disappears due to the transistor T2 operation, and transistor T1 is turned OFF. ● No current flows to filed coil FC and the generating voltage at stator coil SC decreases. ● When the generating voltage decreases lower than the set voltage of Zener diode ZD, transistor T2 is turned OFF and transistor T1 is turned ON again. ● Current flows to field coil FC and the generating voltage at stator coil SC increases. The above operation is repeated and the alternator (5) generating voltage is kept constant. 3

TDAA-02-05-003-1 ja 12-

Battery Battery Relay

34-

To Key Switch Terminal B From Key Switch Terminal M

56-

Alternator Regulator

Surge Voltage Prevention Circuit 1. When the engine is stopped (key switch (4): OFF), current from terminal M in key switch (4) disappears and battery relay (2) is turned OFF. 2. The engine continues to rotate due to the inertia force just after key switch (4) is turned OFF and alternator (5) continues to generate electricity. 3. As the generating current cannot flow to battery (1), surge voltage arises in the circuit and failures of the electronic components, such as controller, possibly cause. In order to prevent the occurrence of surge voltage, the surge voltage prevention circuit is provided. 4. When alternator (5) is generating electricity, the generating current from alternator (5) terminal L flows to terminal #A23 of monitor controller (6). Monitor controller (6) connects terminal #B30 to the ground. 5. Therefore, current flows to the exciting circuit in load dump relay (3) and load dump relay (3) is turned ON. 6. Consequently, even if key switch (4) is set to the OFF position with the engine running, current from battery (1) continues to excite battery relay (2) through load dump relay (3).

TODFY50-EN-00(10/01/2020)

T2-5-9

SECTION2 SYSTEM Group5 Electrical System 7. In addition, when a specified time has passed since alternator (5) stops generating electricity, monitor controller (6) disconnects terminal #B30 from the ground. Therefore, battery relay (2) is turned OFF. M B G1 G2 ACC M ST

4 KEY̲SW

H OFF ACC ON START

L 3 L

3 W

R11 1 3 ACC̲CUT

5 1 4 3

3f W 3f W 3f L 2f WR

W5 1 4 3

OFF

3 R

5 R 2 W B S 1

1 3

2 5 4

A E

8f 2f 2f

W AV WB AEX B

YG WR G L 7+ 1.25 14+ 3 18+ 3

16+ 2 YB

4+ 5 W 8+ 3 R

19+ 3 R 13+ 2 G

15+ 3 W

1+ 5 W

11+ 5 W

16 12 11 3 15 8 2 1 19 13

4 9 10 17 6 20 5 7 14 18

W AV

2 GLOW̲PLUG RELAY

4 2

5 BY AEX 1 ENG̲4

GLOW̲PLUG

W W

B S E

3 1

AEX AEX

2 4

R1 2 5 4 LOAD DUMP R4 STARTER CUT

DIODE5 2 B AVSS A K

R AVX

1 3

R AV

FORK̲10

B S

W SF-3 2 B

STARTER

BATTERY̲RELAY

2 YB

20A 10A 5A 5A 20A 5A 5A 5A 5A 5A

DIODE3 A AVSS

2 5 4

1 3

2 B

AVSS

BATTERY

W W W LY

5 5 0.85 0.85

AVXS AVXS AEX AEX

60 R

L WR

AVSS AVXS

3 R 2 W 5 W

5A 10A 5A 20A 10A 30A 15A 20A 10A 5A

1 59 2

R R

AVXS

2 G

DIODE1 A K 2 W AVSS

R W W

2 5 4

2 RW

2 2

3 R

0.85 2

AVXS

R5 KEY̲ON̲CUT

DISCONNECT̲SW

3 RW

1 3

STARTER̲RELAY

ACG B 8 R 2 0.85 L 3 0.85

W W LY

SF-3 AEX AEX

A23

B30

REGULATOR

ALTERNATOR

6 5 TDFY-02-05-005-1 ja

12-

Battery Battery Relay

34-

Load Dump Relay Key Switch

56-

Alternator Monitor Controller

Pilot Shut-Off Circuit (Key Switch: ON) 1. When the pilot shut-off lever is set to the UNLOCK position, pilot shut-off switch (5) is turned OFF. 2. Current from the terminal M in key switch (6) flows to fuse #25. 3. Current from fuse #25 flows through pilot shut-off switch (5) and pilot shut-off relay (2) to the pilot shut-off solenoid valve (3). 4. Therefore, pilot shut-off solenoid valve (3) is turned ON and pressure oil from the pilot pump is supplied to the pilot valve. • Neutral Engine Start Circuit 1. When the pilot shut-off lever is set to the UNLOCK position, the coil of starter cut relay (4) is connected to the ground. 2. Therefore, starter cut relay (4) is excited. 3. When starter cut relay (4) is excited, the circuit between terminal ST in key switch (6) and terminal S of starter relay (10) is disconnected. 4. Therefore, when the pilot shut-off lever is in the UNLOCK position, even if key switch (6) is set to the START position, the starter does not rotate and the engine does not start.

TODFY50-EN-00(10/01/2020)

T2-5-10

SECTION2 SYSTEM Group5 Electrical System NOTE When the pilot shut-off lever is set to the UNLOCK position, current stops flowing to terminal #F18 of MC (9). Therefore, MC (9) recognizes that the pilot shut-off lever is in the UNLOCK position. M

5 1 4 3

L 3 L

3 W

L R11 1 3 ACC̲CUT

3 R

8f 2f 2f

W AV WB AEX B

38+ 5

22+

27+ 2 YR 36+ 2 RW

W 32+ 5

22- 10A

5 W

28+ 24+

34+ 3 R 25+ 2 YB

WR G L 7+ 1.25 14+ 3 18+ 3

FUSE̲BOX2

DCDC 12̲OUT IGNI 2 GND3 GND6

12V(SW) 24V̲IN

2 B 2 B 2 B

4+ 5 W 8+ 3 R

16+ 2 YB

1+ 5 W

19+ 3 R 13+ 2 G

15+ 3 W

11+ 5 W

R R

Y 2 12V̲UNIT

39- 5A 26- 5A 27- 10A 36- 5A 23- 20A

37- 10A

USB

38- 10A

31- 5A

4 9 10 17 6 20 5 7 14 18

33- 10A

16 12 11 3 15 8 2 1 19 13

282435342529-

10A 10A 20A 20A 5A 10A

R1 2 5 4 LOAD DUMP

R4 STARTER CUT

20A 10A 5A 5A 20A 5A 5A 5A 5A 5A

2 5 4

SOCKET(12V) 1.25 YR

2 1.25

12V̲SOCKET YR

5 YR

1 24V̲IN USB

5 BY AEX 1 ENG̲4

GLOW̲PLUG

5 RB

Br 2

6 B

7 V

3 4

PILOT̲SHUT-OFF̲SW

1 2 PILOT̲SHUT-OFF VALVE

AVS R AVS B CAB

0.85

RL RL

0.85

SF-3 AEX AEX

B19

1 2

4 1

L B

LINK

ENG̲STOP̲SW 3 NORMAL G STOP Y 5 NORMAL R 6 STOP W 2

G L

A17 A18

3 GyR

W W LY

B 8 R 2 0.85 L 3 0.85

B21

CASE̲EARTH

ACG

G BR G

WL 2

GLOW̲PLUG RELAY

4 2

3 GND

R RL L RB

FUEL̲PUMP

STARTER̲RELAY

4 5

W W

C B S E

3 1

AEX AEX

2 4

1 3

2 5 4

DIODE5 2 B AVSS A K

R AVX

A23

24 4 G SF-3 5

6 B SF-3

1 3

W AV

R AV

FORK̲10

B S

W SF-3 2 B

STARTER

1 3 R12 LOCK

VR 58

A E

1 3

5A 10A 5A 20A 10A 30A 15A 20A 10A 5A

5 R 2 W BATTERY̲RELAY

2 YB

B S 1

2 B

AVSS

60 -

BATTERY

W W W LY

5 5 0.85 0.85

60 R -

AVXS AVXS AEX AEX

DIODE3 A AVSS

R5 KEY̲ON̲CUT

2 5 4

2 G

AVSS AVXS

2 2

AVXS

3 R 2 W 5 W

5 W

1 59 2

L WR

AVXS

R W W 3 RW

AVXS

AEX

0.85 2

3 R

R R

DISCONNECT̲SW

2 RW

DIODE1 A K 2 W AVSS

1 3

2 5 4

61 13

RW LY

32- 10A 21- 10A

3f W 3f W 3f L 2f WR

START

KEY̲SW

H OFF ACC ON START

W5 1 4 3

B G1 G2 ACC M ST

RL 1 R3 SEC̲HORN 1 3 PG 2

REGULATOR

G L

SEC̲HORN

ALTERNATOR

A4 A3 D1 D9

GB B32

3 G

2 5 4

1 3

2 5 4

R2 ECU

D26 RB

V RW G L G L E30 E28 E23 E31

F18 D26

0.85 0.85 1.25 1.25 1.25

G L 52 53

E1 E2 D5 D6 D7 F25 C32

RB 14

GyR 26

L L R R R RB VR

F18

CAB/H̲4

4 AVS L

9 MC

G L V64 V81

AVSSCS AVSSCS

G L V60 V77

AVSS AVSS

RB AVSS V76

YW YW V40 V57

L AVSS L AVSS L AVSS

GyR AVSS V50

A B

15 16 13 14

123-

Battery Pilot Shut-Off Relay Pilot Shut-Off Solenoid Valve

45-

Starter Cut Relay Pilot Shut-Off Switch (Pilot Shut-Off Lever)

678-

Key Switch Fuse Box 2 Monitor Controller

0.75

V1 V3 V5

V91

1.25 1.25 1.25

BrY V74

G AVSSCS L AVSSCS

27 CAB/H̲2

VG 16

G AVSSCS L AVSSCS

910-

TDFY-02-05-006-1 ja MC Starter Relay

Auto Shut-Down Circuit/Automatic Engine Stop Circuit at Low Temperature 1. Current from the terminal M excites battery relay (2) through key switch ON cut relay (6) with key switch (3) set in the ON position. 2. Current from terminal M (4) flows to the coils of ACC cut relay (5), key switch ON cut relay (6), and starter cut relay (10) through fuse #18. 3. When all following conditions exist, monitor controller (7) connects terminal #B5 to the ground inside. (Refer to SYSTEM/Control System.) TODFY50-EN-00(10/01/2020)

T2-5-11

SECTION2 SYSTEM Group5 Electrical System Condition for Auto Shut-Down: •

Pilot shut-off lever: LOCK position

•

Auto shut-down: ON

•

Overheat alarm: OFF

•

Coolant temperature: 60 to 100 °C

•

Manual regeneration switch: OFF

•

Abnormal communication of ECM or monitor controller: None

• Overload alarm switch: OFF Condition for Automatic Engine Stop at Low Temperature: •

Pilot shut-off lever: LOCK position (60 minutes)

• Ambient temperature or intake-air temperature: -20 °C or less 4. Therefore, ACC cut relay (5) and key switch ON cut relay (6) are turned ON. 5. The current which indicates key switch (3) is in the ON position, stops flowing from fuse #17 to terminal #V76 of ECM (8). 6. At the same time, battery relay (2) is turned OFF at the same time. 7. Therefore, this is the same situation when key switch (3) is set to the OFF position. ECM (8) stops the fuel injection of the injector and stops the engine. 8. When the engine stops, ECM (8) turns OFF ECM main relay (9).

IMPORTANT After stopping the engine, the DEF pump continues to be operated for a specified time in order to return DEF from the hose to the DEF tank. Do not set the , battery disconnect switch to the OFF position while battery disconnect switch indicator is lighting.

NOTE When restarting the engine, return the key switch to the OFF or ACC position and then reset it to the START position.

TODFY50-EN-00(10/01/2020)

T2-5-12

SECTION2 SYSTEM Group5 Electrical System M

L 3 L

3 W

L R11 1 3 ACC̲CUT

3 R

8f 2f 2f

W AV WB AEX B

38+ 5

27+ 2 YR 36+ 2 RW

W 32+ 5

22+

32- 10A 21- 10A

28+ 24+

5 W

WR G L

DCDC 12̲OUT IGNI 2 GND3 GND6

12V(SW) 24V̲IN

2 B 2 B 2 B

4+ 5 W 8+ 3 R

1+ 5 W

19+ 3 R 13+ 2 G

11+ 5 W

R R

Y 2

12V̲UNIT

37- 10A

39- 5A 26- 5A 27- 10A 36- 5A 23- 20A USB

38- 10A

4 9 10 17 6 20 5 7 14 18

31- 5A

20A 10A 5A 5A 20A 5A 5A 5A 5A 5A

16 12 11 3 15 8 2 1 19 13

33- 10A

5A 10A 5A 20A 10A 30A 15A 20A 10A 5A

10A 10A 20A 20A 5A 10A

R1 2 5 4 LOAD DUMP

R4 STARTER CUT

SOCKET(12V) 1.25 YR

2 1.25

12V̲SOCKET

5 YR

1 24V̲IN

R RL L RB

USB

3 GND

GLOW̲PLUG

5 RB

Br 2

6 B

7 V

3 4

1 2 PILOT̲SHUT-OFF VALVE

STARTER̲RELAY

AVS R AVS B CAB

0.85

B19

G L

A17 A18

1 2

4 1

L B

LINK

ENG̲STOP̲SW 3 NORMAL G STOP Y 5 NORMAL R 6 STOP W 2

SF-3 AEX AEX

W W LY

GyR

B 8 R 2 0.85 L 3 0.85

B21

CASE̲EARTH

ACG E

PILOT̲SHUT-OFF̲SW

G BR G

WL 2

B SF-3 5 BY AEX 1 ENG̲4

FUSE̲BOX2

2 2 L WR 0.85 2 2 5 4

FUEL̲PUMP

GLOW̲PLUG RELAY

4 2

A23

4 5

W W

C B S E

3 1

2 5 4

24 4 G SF-3 5

AEX AEX

2 4

1 3

2 5 4

DIODE5 2 B AVSS A K

R AVX

1 3

W AV

R AV

FORK̲10

B S

W SF-3 2 B

STARTER M

1 3 R12 LOCK

VR 58

A E

R5 KEY̲ON̲CUT

1 3

5 R 2 W B S 1

BATTERY̲RELAY

2 B

AVSS

60 -

BATTERY

W W W LY

5 5 0.85 0.85

60 R -

AVXS AVXS AEX AEX

2 YB

15+ 3 W

AVSS AVXS

3 RW

2 5 4 2 G DIODE3 K A AVSS

R R

DISCONNECT̲SW

AVXS

34+ 3 R 25+ 2 YB

AVXS

3 R 2 W 5 W

282435342529-

5 W

1 59 2

2 RW

7+ 1.25 14+ 3 18+ 3

61 13

AVXS

16+ 2 YB

AEX

RW LY

R W W

3 R

2 4

DIODE1 A K 2 W AVSS

1 3

22- 10A

R 3f 6

5 1 4 3

3f W 3f W 3f L 2f WR

KEY̲SW

H OFF ACC ON START

W5 1 4 3

B G1 G2 ACC M ST

RL 1 R3 SEC̲HORN 1 3 PG 2

REGULATOR

G L

SEC̲HORN

ALTERNATOR 2 5 4

A4 A3 D1 D9

GB B32

3 G

9 1 3

2 5 4

R2 ECU

V RW G L G L E30 E28 E23 E31

F18 D26

0.85 0.85 1.25 1.25 1.25 E1 E2 D5 D6 D7 F25 C32

G L

G AVSSCS L AVSSCS

52 53

RB AVSS

AVSS AVSS

AVSSCS AVSSCS

G L

V76

V60 V77

V64 V81

CAB/H̲4

YW YW V40 V57

AVS

GyR AVSS V50

BrY V74

2 A B

15 16 13 14

8 ECM 123-

Battery Battery Relay Key Switch

456-

Fuse Box 1 ACC Cut Relay Key Switch ON Cut Relay

789-

0.75

V1 V3 V5

1.25 1.25 1.25

L AVSS L AVSS L AVSS

G AVSSCS L AVSSCS

16 YL V91

27 CAB/H̲2

GyR

L L R R R RB VR

V76

Monitor Controller ECM ECM Main Relay

10-

TDFY-02-05-007-1 ja Starter Cut Relay

Engine Stop Circuit 1. When key switch (1) is set from the ON position to OFF position, current from the terminal M in key switch (1) stops flowing to terminal #V76 of ECM (4). 2. ECM (4) stops the fuel injection of the injector and stops the engine. 3. When the engine stops, ECM (4) turns OFF ECM main relay (3). Then, ECM (4) is turned OFF.

TODFY50-EN-00(10/01/2020)

T2-5-13

SECTION2 SYSTEM Group5 Electrical System M

B G1 G2 ACC M ST

OFF

KEY̲SW

H OFF ACC ON START

L 3 L L

3 W

R11 1 3 ACC̲CUT

3 R

A E

R AVX W AV WB AEX B

38+ 5

22+

27+ 2 YR 36+ 2 RW

W 32+ 5

22- 10A

5 W

34+ 3 R 25+ 2 YB

28+ 24+

24V̲IN

Y 2

12V̲UNIT

39- 5A 26- 5A 27- 10A 36- 5A 23- 20A

37- 10A

USB

38- 10A

31- 5A

4 9 10 17 6 20 5 7 14 18

33- 10A

10A 10A 20A 20A 5A 10A 16 12 11 3 15 8 2 1 19 13

282435342529-

20A 10A 5A 5A 20A 5A 5A 5A 5A 5A

SOCKET(12V) 1.25 YR

2 1.25 B

5 YR

1 24V̲IN

5 RB

Br 2

6 B

3 4

7 V

3 GND

R PILOT̲SHUT-OFF̲SW

1 2

12V̲SOCKET YR

FUEL̲PUMP

IGNI 2 GND3 GND6

12V(SW)

2 B 2 B 2 B

WR G L 7+ 1.25 14+ 3 18+ 3

4+ 5 W 8+ 3 R

16+ 2 YB

1+ 5 W

FUSE̲BOX2

A23

DCDC 12̲OUT

1 2 PILOT̲SHUT-OFF VALVE

STARTER̲RELAY

AVS R AVS B CAB

1 2

4 1

0.85

B19

L B

LINK

ENG̲STOP̲SW NORMAL G 3 STOP Y 5 NORMAL R 6 STOP W 2

G L

A17 A18

SF-3 AEX AEX

GyR

W W LY

B 8 R 2 0.85 L 3 0.85

B21

ACG E

CASE̲EARTH

W W

8f 2f 2f

R4 STARTER CUT

AEX AEX

8f B S E

4 G SF-3 5

2 4

2 5 4

1 3

2 5 4

DIODE5 2 B AVSS A K

R AV

B SF-3

FORK̲10

B S

4 5

USB

W SF-3 2 B

STARTER M

1 3 R12 LOCK

BATTERY̲RELAY

5 R 2 W B S 1

G BR G

19+ 3 R 13+ 2 G

DIODE1 K 2 W AVSS A

2 B

AVSS

60 -

BATTERY

W W W LY

5 5 0.85 0.85

60 R -

AVXS AVXS AEX AEX

2 YB

2 G DIODE3 A AVSS

15+ 3 W

AVSS AVXS

11+ 5 W

AVXS

3 R 2 W 5 W

5A 10A 5A 20A 10A 30A 15A 20A 10A 5A

5 W

1 59 2

L WR

AVXS

R5 KEY̲ON̲CUT

2 5 4

0.85 2

AVXS

R W W

AEX

3 R

R R

DISCONNECT̲SW

3 RW

2 RW

61 13

1 3

2 5 4

RW LY

32- 10A 21- 10A

5 1 4 3

3f W 3f W 3f L 2f WR

W5 1 4 3

G L

REGULATOR

ALTERNATOR

A4 A3 D1 D9

3 G

3 1 3 R2 ECU

2 5 4

V RW G L G L E30 E28 E23 E31

F18 D26

1.25 1.25 1.25 D5 D6 D7 F25 C32

G L

G AVSSCS L AVSSCS

52 53 AVSS AVSS

AVSSCS AVSSCS

G L

V60 V77

V64 V81

G AVSSCS L AVSSCS

14 RB AVSS V76

4 AVS

CAB/H̲4

YW YW V40 V57

26 GyR AVSS V50

2 A B

15 16 13 14

0.75

V1 V3 V5

1.25 1.25 1.25

L AVSS L AVSS L AVSS

16 BrY V74

27 CAB/H̲2

GyR

R R R RB VR

V76

4 ECM

TDFY-02-05-008-1 ja 1-

Key Switch

Fuse Box 1

ECM Main Relay

ECM

Emergency Stop Circuit CAUTION Do not use engine stop switch (3) unless absolutely necessary. When the engine stops due to the machine failure, do not start the machine until the repair is completed. When the engine does not stop because of problems where the machine has failed or is damaged with key switch (1) set in the OFF position, set engine stop switch (3) to the ON position (lower position). Then, the engine stops. After that, return engine stop switch (3) to the OFF position (up). 1. If the engine does not stop after key switch (1) is set to the OFF position, the terminal B continues to be connected to the terminal M in key switch (1). 2. When engine stop switch (3) is set to the ON position at this time, current from fuse #17 flows to terminal #V50 of ECM (4).

TODFY50-EN-00(10/01/2020)

T2-5-14

SECTION2 SYSTEM Group5 Electrical System 3. ECM (4) recognizes that engine stop switch (3) is in the ON position. ECM (4) stops the fuel injection of the injector and stops the engine.

NOTE Even if the starter rotates with engine stop switch (3) set in the ON position, the engine does not start.

3 TDFY-02-05-023-1 ja 3-

Engine Stop Switch

TODFY50-EN-00(10/01/2020)

T2-5-15

SECTION2 SYSTEM Group5 Electrical System M

B G1 G2 ACC M ST

KEY̲SW

H OFF ACC ON START

L 3 L

3 W

R11 1 3 ACC̲CUT

3 R

A E

R AVX W AV WB AEX B

38+ 5

27+ 2 YR 36+ 2 RW

W 32+ 5

22+

32- 10A 21- 10A

5 W

28+ 24+

34+ 3 R 25+ 2 YB

FUSE̲BOX2

IGNI 2 GND3 GND6

12V(SW) 24V̲IN

Y 2

12V̲UNIT

37- 10A

39- 5A 26- 5A 27- 10A 36- 5A 23- 20A USB

38- 10A

31- 5A

4 9 10 17 6 20 5 7 14 18

33- 10A

10A 10A 20A 20A 5A 10A 16 12 11 3 15 8 2 1 19 13

282435342529-

20A 10A 5A 5A 20A 5A 5A 5A 5A 5A

SOCKET(12V) 1.25 YR

2 1.25

5 YR

1 24V̲IN

5 RB

Br 2

6 B

7 V

3 4

3 GND

R PILOT̲SHUT-OFF̲SW

12V̲SOCKET YR

FUEL̲PUMP

A23

DCDC 12̲OUT

2 B 2 B 2 B

WR G L 7+ 1.25 14+ 3 18+ 3

4+ 5 W 8+ 3 R

16+ 2 YB

19+ 3 R 13+ 2 G

4 5

1 2 PILOT̲SHUT-OFF VALVE

STARTER̲RELAY

AVS R AVS B CAB

1 2

4 1

L B

LINK

0.85

B19

ENG̲STOP̲SW NORMAL G 3 Y 5 STOP NORMAL R 6 W 2 STOP

G L

A17 A18

SF-3 AEX AEX

W W LY

GyR

B 8 R 2 0.85 L 3 0.85

B21

ACG E

CASE̲EARTH

W W

8f 2f 2f

R4 STARTER CUT

AEX AEX

8f B S E

4 G SF-3 5

2 4

2 5 4

1 3

2 5 4

DIODE5 2 B AVSS A K

R AV

B SF-3

FORK̲10

B S

USB

W SF-3 2 B

STARTER M

1 3 R12 LOCK

BATTERY̲RELAY

5 R 2 W B S 1

2 YB

G BR G

11+ 5 W

DIODE1 K 2 W AVSS A

2 B

AVSS

60 -

BATTERY

W W W LY

5 5 0.85 0.85

60 R -

AVXS AVXS AEX AEX

2 G DIODE3 A AVSS

15+ 3 W

AVSS AVXS

1+ 5 W

AVXS

3 R 2 W 5 W

5A 10A 5A 20A 10A 30A 15A 20A 10A 5A

5 W

1 59 2

L WR

AVXS

R5 KEY̲ON̲CUT

2 5 4

0.85 2

AVXS

R W W

AEX

3 R

R R

DISCONNECT̲SW

3 RW

2 RW

61 13

1 3

2 5 4

RW LY

22- 10A

5 1 4 3

3f W 3f W 3f L 2f WR

W5 1 4 3

G L

REGULATOR

A4 A3 D1 D9

3 G

ALTERNATOR

1 3 R2 ECU

2 5 4

V RW G L G L E30 E28 E23 E31

F18 D26

1.25 1.25 1.25 D5 D6 D7 F25 C32

G L

G AVSSCS L AVSSCS

52 53 AVSS AVSS G L

G L

V60 V77

V64 V81

G AVSSCS L AVSSCS

14 RB AVSS V76

4 AVS

CAB/H̲4

YW YW V40 V57

26 GyR AVSS V50

AVSSCS AVSSCS

A B

15 16 13 14

V50

0.75

V1 V3 V5

1.25 1.25 1.25

L AVSS L AVSS L AVSS

16 BrY V74

27 CAB/H̲2

GyR

R R R RB VR

4 ECM TDFY-02-05-009-1 ja

Key Switch

Fuse Box 1

Engine Stop Switch

ECM

Monitor Circuit of Electrical System The major functions and components in the monitor circuit are as follows. ● The security circuit disconnects current for engine starting from the key switch according to the signals from the external alarm system or monitor controller. At the same time, the security circuit turns OFF the pilot shut-off solenoid valve and disconnects the pilot circuit. The security circuit sounds the security horn at this time. (Monitor Controller, Security Horn Relay) ● The aerial angle circuit controls the camera image displayed on the monitor. ● The control lever auto pilot shut-off function turns OFF the pilot shut-off solenoid valve when performing front attachment, swing, or travel operation with the pilot shut-off lever set to the UNLOCK position. ● The seat belt reminder function activates the monitor indicator and buzzer depending on the state of the seat belt switch, engine operation, and pilot shut-off lever. ● The radio circuit operates the radio. (Monitor Controller, Switch Panel, Radio) TODFY50-EN-00(10/01/2020)

T2-5-16

SECTION2 SYSTEM Group5 Electrical System ● The air conditioner circuit operates the air conditioner. (Monitor Controller, Switch Panel, Air Conditioner Unit)

Security Circuit 1. When any one of the following conditions exists, monitor controller (4) connects terminals #B31 and #B32 to the ground inside. External alarm signal from e-Service: Yes

•

• Numerical keypad password input error signal: Yes 2. Therefore, security horn relay (6) and starter cut relay (1) are excited. 3. When security horn relay (6) is excited, current from fuse #9 activates security horn (5). 4. When starter cut relay (1) is excited, the circuit between terminal ST in key switch (3) and terminal S of starter relay (7) is disconnected. 5. Therefore, even if key switch (3) is set to the START position, the engine does not start. ST B G1 G2 ACC M ST

L 3 L L

3 W

R11 1 3 ACC̲CUT

3 R

A E

8f 2f 2f

W AV WB AEX B

38+ 5

22+

27+ 2 YR 36+ 2 RW

W 32+ 5

22- 10A

5 W

28+ 24+

34+ 3 R 25+ 2 YB

WR G L 7+ 1.25 14+ 3 18+ 3

2 B 2 B 2 B

4+ 5 W 8+ 3 R

16+ 2 YB

1+ 5 W

19+ 3 R 13+ 2 G

15+ 3 W

11+ 5 W

Y 2

12V̲UNIT

39- 5A 26- 5A 27- 10A 36- 5A 23- 20A

37- 10A

38- 10A

31- 5A

4 9 10 17 6 20 5 7 14 18

USB

16 12 11 3 15 8 2 1 19 13

33- 10A

20A 10A 5A 5A 20A 5A 5A 5A 5A 5A

282435342529-

10A 10A 20A 20A 5A 10A

R1 2 5 4 LOAD DUMP

R4 STARTER CUT

SOCKET(12V) 1.25 YR

15 WL

FUEL̲PUMP

GLOW̲PLUG RELAY

4 2

5 BY AEX 1 ENG̲4

GLOW̲PLUG

PILOT̲SHUT-OFF̲SW

5 RB

Br 2

6 B

7 V

3 4

Br GY

2 1.25

12V̲SOCKET YR

B SF-3

5 YR

1 24V̲IN

3 GND

4 L

0.85

RL RL

1 2

AVS R AVS B CAB

1 2

4 1

L B

LINK

ENG̲STOP̲SW 3 NORMAL G Y 5 STOP NORMAL R 6 W 2 STOP

0.85

B19

B31

G L

A17 A18

B31

SF-3 AEX AEX

5 GyR

W W LY

B21

CASE̲EARTH

B 8 R 2 0.85 L 3 0.85

ALTERNATOR

R R 2 5 4

ACG

REGULATOR

24V̲IN

4 G SF-3 5

PILOT̲SHUT-OFF VALVE

STARTER̲RELAY

3 1

IGNI 2 GND3 GND6

12V(SW)

W W

B S E

FUSE̲BOX2

A23

DCDC 12̲OUT

USB

AEX AEX

2 4

1 3

2 5 4

DIODE5 2 B AVSS A K

R AVX

1 3

W AV

R AV

FORK̲10

B S

4 5

W SF-3 2 B

STARTER M

1 3 R12 LOCK

VR 58

1 3

5 R 2 W B S 1

BATTERY̲RELAY

G BR G

2 YB

5A 10A 5A 20A 10A 30A 15A 20A 10A 5A

2 B

AVSS

60 -

BATTERY

W W W LY

5 5 0.85 0.85

60 R -

AVXS AVXS AEX AEX

DIODE3 A AVSS

R5 KEY̲ON̲CUT

2 5 4

2 G

AVSS AVXS

2 2

AVXS

3 R 2 W 5 W

5 W

1 59 2

L WR

AVXS

0.85 2

AVXS

R W W

DIODE1 A K 2 W AVSS

AEX

3 R

R R

2 RW

DISCONNECT̲SW

1 3

2 5 4

61 13

3 RW

RW LY

32- 10A 21- 10A

5 1 4 3

3f W 3f W 3f L 2f WR

W5 1 4 3

START 1 2

KEY̲SW

H OFF ACC ON START

RL 1 R3 SEC̲HORN 1 3 PG 2

G L

SEC̲HORN 2 5 4

A4 A3 D1 D9

GB B32

B32

3 G

1 3

2 5 4

R2 ECU

V RW F18 D26

G L G L E30 E28 E23 E31

F25 C32

G L

G AVSSCS L AVSSCS

52 53

RB AVSS

AVSS AVSS G L

G L

V76

V60 V77

V64 V81

CAB/H̲4

YW YW V40 V57

AVS

GyR AVSS V50

BrY V74

AVSSCS AVSSCS

15 16 13 14

A B

0.75

V1 V3 V5

1.25 1.25 1.25

L AVSS L AVSS L AVSS

G AVSSCS L AVSSCS

16 YL V91

27 CAB/H̲2

GyR

RB VR

TDFY-02-05-010-1 ja

TODFY50-EN-00(10/01/2020)

T2-5-17

SECTION2 SYSTEM Group5 Electrical System 12-

Starter Cut Relay Fuse Box 1

34-

Key Switch Monitor Controller

56-

Security Horn Security Horn Relay

Starter Relay

Aerial Angle Circuit 1. The images of rear view camera (4), camera left (5), and camera right (6) are sent to aerial angle controller (3). 2. The images combined in aerial angle controller (3) are displayed on monitor (2) through monitor controller (1). 3. The view of the combined image is switched between Machine Environment, Machine Environment + Rear, Rear + Right + Left, Machine Environment + Rear + Right, and Rear + Right by using aerial angle switch (7). 2 G3 G2 G5 G6 G1 G4

O G R B Br L

D10 D12 D16 D14 D15

R BY W Gy

D11 D13 D8 D6 D7

W Gy

1 4 5 6 3 2 1 2 3 4

CAMERA̲POW CAMERA̲GND

W Gy W Gy

5 6 2 3 1

AERIAL̲ANGLE̲SW 8 9 6

B WG WL

1 2 3

Monitor Controller Monitor

34-

W Gy RW LW B

26 6 7

B WG WL

21 29 28

1 2 3 4

R B W Gy

1 2 3 4

VCC GND SIGNAL S̲GND

RL BL W GyB

5 6 7 8

RL BL W GyB

1 2 3 4

VCC GND SIGNAL S̲GND

RY BY W GyR

RY 9 10 BY 11 W 12 GyR

1 2 3 4

VCC GND SIGNAL S̲GND

12 32 11 31

R BY W Gy

16 36 15 35

14 34 13 33

1 2 3 4

R BY W Gy

REAR̲CAMERA

LEFT̲CAMERA

RIGHT̲CAMERA

12-

19 39 20 40 5

Aerial Angle Controller Rear View Camera

56-

Camera Left Camera Right

TDFY-02-05-011-1 ja Aerial Angle Switch

Control Lever Automatic Pilot Shut-Off Circuit 1. When the pilot shut-off lever is set to the UNLOCK position and one of the following conditions exists, MC (6) connects terminal #C32 to the ground for approx. 3 seconds. •

Front pilot pressure sensor (7): Outputting signal

• Travel pilot pressure sensor (8): Outputting signal 2. Therefore, pilot shut-off relay (1) is excited. 3. When pilot shut-off relay (1) is excited, current flowing from terminal M of the key switch to the pilot shut-off solenoid valve (9) is shut off so that the pilot shut-off solenoid valve (9) is turned OFF. 4. Pressure oil supplied from the pilot pump to the pilot valve is blocked by the pilot shut-off solenoid valve (9). 5. At the same time, MC (6) sends the signal to monitor controller (4) by using the CAN communication. 6. Monitor controller (4) displays an alarm on monitor (5) and sounds buzzer (3).

TODFY50-EN-00(10/01/2020)

T2-5-18

SECTION2 SYSTEM Group5 Electrical System 5 G3 G2 G5 G6 G1 G4

1 2

SEATBELT̲WARN̲SW

1 3

YB B

4 YB 5 B

O G R B Br L

1 4 5 6 3 2

B14

R12 LOCK 2 5 4

2 1 2

1 2

PILOT̲SHUT-OFF VALVE

PILOT̲SHUT-OFF̲SW

Br 2

3 4

Br GY

5 RB

6 B

7 V

4 B34

CASE̲EARTH

AVSSCS AVSSCS

G L

1 2

A4 A3 D1 D9

G L GB

B̲CAN̲H B̲CAN̲L

G AVSSCS L AVSSCS E23 E31

CAN F18

VR C32

4 BODY-CAN H 10 BODY-CAN L

C32

TRAVEL

FRT

D16

6 MC

8 7 TDFY-02-05-012-1 ja

a- From Key Switch Terminal M 123-

Pilot Shut-Off Relay Pilot Shut-Off Switch Buzzer

456-

Monitor Controller Monitor MC

789-

Front Pilot Pressure Sensor Travel Pilot Pressure Sensor Pilot Shut-Off Solenoid Valve

Seat Belt Reminder Circuit 1. If you do not wear your seat belt, seat belt switch (2) is turned OFF. 2. When seat belt switch (2) is turned OFF, monitor controller (4) displays an icon on monitor (5). 3. Under this condition, when the pilot shut-off lever is set to the UNLOCK position, monitor controller (4) sounds buzzer (3) in approx. 5 seconds.

TODFY50-EN-00(10/01/2020)

T2-5-19

SECTION2 SYSTEM Group5 Electrical System 5 G3 G2 G5 G6 G1 G4

2 1 2

SEATBELT̲WARN̲SW

1 3

YB B

4 YB 5 B

O G R B Br L

1 4 5 6 3 2

B14

R12 LOCK 2 5 4

1 1 2

1 2

PILOT̲SHUT-OFF VALVE

PILOT̲SHUT-OFF̲SW

Br 2

3 4

Br GY

5 RB

6 B

7 V

B34

CASE̲EARTH

AVSSCS AVSSCS

G L

1 2

A4 A3 D1 D9

G L GB

B̲CAN̲H B̲CAN̲L

G AVSSCS L AVSSCS E23 E31

CAN F18

VR C32

4 BODY-CAN H 10 BODY-CAN L

6 MC TDFY-02-05-013-1 ja

a- From Key Switch Terminal M 12-

Pilot Shut-Off Switch Seat Belt Switch

34-

Buzzer Monitor Controller

56-

Monitor MC

Radio Circuit 1. The operation on switch panel (2) is displayed on monitor (1) through monitor controller (3). 2. When radio (5) is operated on switch panel (2), the signal is sent to monitor controller (3) by using the CAN communication. 3. Monitor controller (3) sends the signal to radio (5) by using the CAN communication and radio (5) is operated.

TODFY50-EN-00(10/01/2020)

T2-5-20

SECTION2 SYSTEM Group5 Electrical System 1

4 2

3 ฀

฀

5 CAN TDFY-02-05-014-1 ja 12-

Monitor Switch Panel

34-

Monitor Controller Fuse Box 1

Radio

Air Conditioner Circuit 1. The operation on switch panel (2) is displayed on monitor (1) through monitor controller (3). 2. When the air conditioner is operated on switch panel (2), the signal is sent to monitor controller (3) by using the CAN communication. 3. Monitor controller (3) sends the signal to air conditioner unit (5) by using the CAN communication and air conditioner unit (5) is operated.

TODFY50-EN-00(10/01/2020)

T2-5-21

SECTION2 SYSTEM Group5 Electrical System 1

4 2

3 ฀

5 ฀

฀

CAN TDFY-02-05-015-1 ja 12-

Monitor Switch Panel

34-

Monitor Controller Fuse Box 1

Air Conditioner Unit

Accessory Circuit The major functions and components in the accessory circuit are as follows. ● The work light circuit turns on the work light and boom light. (Monitor Controller, Switch Panel, Work Light Relay) ● The wiper circuit operates the wiper including intermittent operation and the washer. (Monitor Controller, Switch Panel, Wiper Relay, Washer Relay) ● The cab light circuit turns on/off the cab light by shifting the switch or by opening/closing the door.

Work Light Circuit (Work Light: ON) 1. When work light switch (4) is set to the 1 position, current from fuse #1 flows to terminal #B24 of monitor controller (5) and switch panel (3), and connects to the ground in switch panel (3). 2. Therefore, work light relay 1 (9) is turned ON and current from fuse #1 turns on work light (8). 3. Switch box controller (11) sends the signal equivalent to the operating condition of work light switch (4) to monitor controller (5) by using the CAN communication.

TODFY50-EN-00(10/01/2020)

T2-5-22

SECTION2 SYSTEM Group5 Electrical System

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ůİŮŪůġ

˩˫ˠˡ

őŖŔŉ

䰙

信

˩˫ˠˡ

䩩

ŕŖŏņ

a b c

őŖŔŉ

ŔŐŖœńņ łŎİŇŎ őŖŔŉ

őŖŔŉ

ŗŐōİőŘœȁ

łŖŕŐ İŐŇŇ łŖŕŐ

ůİŮŪůġ ůİŮŪůġ

2 ŐŇŇ

3 Ŋŏŕ ŐŇŇ

Őŏ őŖŔŉġ

ＯＦＦ

łń

ń Őŏ

Ŕŕł œŕ

0 Ŋŏŕ

Őŏ

ŐŇŇ őŖŔŉ

TDFY-02-05-018-1 ja

a- OFF Position b- 1 position 4-

c- 2 position

Work Light Switch

TODFY50-EN-00(10/01/2020)

T2-5-23

SECTION2 SYSTEM Group5 Electrical System 2

6 1 5 ฀

10 ฀

฀

B24 B23

฀

8 7 11 CAN

234-

Monitor Switch Panel Work Light Switch

567-

Monitor Controller Fuse Box 1 Boom Light

8910-

Work Light Work Light Relay 1 Work Light Relay 2

11-

TDFY-02-05-016-1 ja Switch Box Controller

Work Light Circuit (Work Light and Boom Light: ON) 1. When work light switch (4) is set to the 2 position, current from fuse #1 flows to terminals # B23 and #B24 of monitor controller (5) and switch panel (3), and connects to the ground in switch panel (3). 2. Therefore, work light relay 1 (9) and work light relay 2 (10) are turned ON and current from fuse #1 turns on work light (8) and boom light (7). 3. Switch box controller (11) sends the signal equivalent to the operating condition of work light switch (4) to monitor controller (5) by using the CAN communication.

TODFY50-EN-00(10/01/2020)

T2-5-24

SECTION2 SYSTEM Group5 Electrical System

őŖŔŉ

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ůİŮŪůġ

˩˫ˠˡ

őŖŔŉ

䰙

信

˩˫ˠˡ

䩩

ŕŖŏņ

a b c

őŖŔŉ

ŔŐŖœńņ łŎİŇŎ őŖŔŉ

őŖŔŉ

ŗŐōİőŘœȁ

łŖŕŐ İŐŇŇ łŖŕŐ

ůİŮŪůġ ůİŮŪůġ

2 ŐŇŇ

3 Ŋŏŕ ŐŇŇ

Őŏ őŖŔŉġ

ＯＦＦ

łń

ń Őŏ

Ŕŕł œŕ

0 Ŋŏŕ

Őŏ

ŐŇŇ őŖŔŉ

TDFY-02-05-018-1 ja

a- OFF Position b- 1 position 4-

c- 2 position

Work Light Switch

TODFY50-EN-00(10/01/2020)

T2-5-25

SECTION2 SYSTEM Group5 Electrical System 2

6 1 5 ฀

10 ฀

฀

B24 B23

฀

8 7 11 CAN

234-

Monitor Switch Panel Work Light Switch

567-

Monitor Controller Fuse Box 1 Boom Light

8910-

Work Light Work Light Relay 1 Work Light Relay 2

11-

TDFY-02-05-016-1 ja Switch Box Controller

Wiper Circuit 1. When wiper/washer switch (4) is set to the INT. position, switch box controller (5) sends the signal to monitor controller (6) according to the set interval by using the CAN communication. 2. Monitor controller (6) connects terminal #B29 to the ground inside according to the input interval. 3. Therefore, wiper relay (8) is turned ON and OFF repeatedly. 4. When wiper relay (8) is ON, current from fuse #2 flows to wiper motor (9) and the wiper is operated.

TODFY50-EN-00(10/01/2020)

T2-5-26

SECTION2 SYSTEM Group5 Electrical System

őŖŔŉ

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ůİŮŪůġ

˩˫ˠˡ

őŖŔŉ

䰙

信

˩˫ˠˡ

䩩

ŕŖŏņ

őŖŔŉ

ŔŐŖœńņ łŎİŇŎ őŖŔŉ

őŖŔŉ

ŗŐōİőŘœȁ

łŖŕŐ İŐŇŇ łŖŕŐ

ůİŮŪůġ ůİŮŪůġ

2 3

ŐŇŇ

Ŋŏŕ

ŐŇŇ

Őŏ őŖŔŉġ

ＯＦＦ

łń

ń Őŏ

Ŕŕł œŕ

4 1

0 Ŋŏŕ

Őŏ

ŐŇŇ őŖŔŉ

TDFY-02-05-018-2 ja 4-

Wiper/Washer Switch

No.

INT. Position

Set Time

Slow

8 seconds

Middle

6 seconds

Fast

3 seconds

TODFY50-EN-00(10/01/2020)

T2-5-27

SECTION2 SYSTEM Group5 Electrical System 1

7 3 2

17 6 ฀

11 ฀

B29 B26

฀

CAN

10 9 TDFY-02-05-017-1 ja 145-

Monitor Wiper/Washer Switch Switch Box Controller

678-

Monitor Controller Fuse Box 1 Wiper Relay

91011-

Wiper Motor Washer Motor Washer Relay

Washer Circuit 1. While wiper/washer switch (4) is held down, switch box controller (5) sends the signal to monitor controller (6) by using the CAN communication. 2. Monitor controller (6) connects terminal #B26 to the ground inside and washer relay (11) is excited. 3. Current from fuse #2 flows to washer motor (10) and washer liquid is jetted. 4. When pushing wiper/washer switch (4) for 1.4 seconds or more, monitor controller (6) turns ON washer relay (11) and wiper relay (8). 5. Therefore, the washer and wiper are operated at the same time.

TODFY50-EN-00(10/01/2020)

T2-5-28

SECTION2 SYSTEM Group5 Electrical System

őŖŔŉ

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ůİŮŪůġ

˩˫ˠˡ

őŖŔŉ

䰙

信

˩˫ˠˡ

䩩

ŕŖŏņ

őŖŔŉ

ŔŐŖœńņ łŎİŇŎ őŖŔŉ

őŖŔŉ

ŗŐōİőŘœȁ

łŖŕŐ İŐŇŇ łŖŕŐ

ůİŮŪůġ ůİŮŪůġ

2 3

ŐŇŇ

Ŋŏŕ ŐŇŇ

Őŏ őŖŔŉġ

ＯＦＦ

łń

ń Őŏ

Ŕŕł œŕ

4 1

0 Ŋŏŕ

Őŏ

ŐŇŇ őŖŔŉ

TDFY-02-05-018-3 ja 4-

Wiper/Washer Switch

7 3 2

17 6 ฀

11 ฀

B29 B26

฀

CAN

10 9 TDFY-02-05-017-1 ja

TODFY50-EN-00(10/01/2020)

T2-5-29

SECTION2 SYSTEM Group5 Electrical System 145-

Monitor Wiper/Washer Switch Switch Box Controller

678-

Monitor Controller Fuse Box 1 Wiper Relay

91011-

Wiper Motor Washer Motor Washer Relay

Cab Light Circuit (Cab Light Switch: Door Interlocking Position (Key Switch: ON)) 1. When cab light switch (7) is set to door interlocking position (5), current from fuse #9 flows to terminal #B3 of monitor controller (4). 2. When the cab door is closed, door open/close switch (3) is turned ON and terminal #B10 of monitor controller (4) is connected to the ground. 3. Monitor controller (4) recognizes that the cab door is closed and disconnects terminal #B3 inside from the ground. Consequently, cab light (8) is not turned on. 4. When the cab door is opened, door open/close switch (3) is turned OFF and terminal #B10 of monitor controller (4) is disconnected from the ground. 5. Monitor controller (4) recognizes that the cab door is open and connects terminal #B3 to the ground inside for 30 seconds. 6. Therefore, current from fuse #9 flows to terminal #B3 of monitor controller (4) and turns on cab light (8). 7. After cab light (8) is turned on for 30 seconds or when the cab door is closed, wiper/light controller (4) disconnects terminal #B3 inside from the ground. 8. Therefore, cab light (8) is tuned off. 9. Consequently, when cab light switch (7) is in door interlocking position (5), cab light (8) is turned on/off by opening/ closing the cab door.

NOTE In case the cab door is open and key switch (1) is set to the ON position, cab light (8) is not turned on with cab light switch (7) set in door interlocking position (5). When closing the cab door once and opening it again, cab light (8) can be turned on.

TODFY50-EN-00(10/01/2020)

T2-5-30

SECTION2 SYSTEM Group5 Electrical System 1 ON

B10 2 9 ฀

฀

B3 B4

฀

8 7

12-

Key Switch Fuse Box 1

34-

Door Open/Close Switch Monitor Controller

56-

Door Interlocking Position ON Position

78-

TDFY-02-05-022-1 ja Cab Light Switch Cab Light

Cab Light Circuit (Cab Light Switch: ON Position) 1. Monitor controller (4) connects terminal #B4 to the ground inside. 2. When cab light switch (7) is set to ON position (6), current from fuse #9 flows to terminal #B4 of monitor controller (4). 3. Consequently, when cab light switch (7) is in ON position (6), cab light (8) is always turned on.

TODFY50-EN-00(10/01/2020)

T2-5-31

SECTION2 SYSTEM Group5 Electrical System 1 ON

B10 2 9 ฀

฀

B3 B4

฀

8 7

12-

Key Switch Fuse Box 1

TODFY50-EN-00(10/01/2020)

34-

Door Open/Close Switch Monitor Controller

56-

T2-5-32

Door Interlocking Position ON Position

78-

TDFY-02-05-022-1 ja Cab Light Switch Cab Light

Output Curve of Swing Dampener Valve: Operation of Combination Valve B between D and E (During Aftershock).........................................T3-2-28

TODFY50-EN-00(10/01/2020)

Others (Undercarriage) ............................T3-8-1 Outline of Swing Bearing .................................................. T3-8-1 TODFY50-EN-00(10/01/2020)

MEMO

TODFY50-EN-00(10/01/2020)

SECTION3 COMPONENT OPERATION Group1 Pump Device Outline of Pump Device The pump device consists of transmission (14), main pump (pump 1 (2), pump 2 (4), pump 3 (3)), pilot pump (1), control solenoid valves, and sensors. The engine output power is transmitted to transmission (14) via coupling (15).After being distributed by the gear, the engine output power drives pump 1 (2), pump 2 (4), pump 3 (3), and pilot pump (1). The main pump is a bent-axis type variable displacement axial plunger pump.Pump 1 (2), pump 2 (4), and pump 3 (3) are contained in one housing. Pilot pump (1) is a gear pump. Pump 1 and 2 torque control solenoid valve (8), maximum pump 1 flow rate limit control solenoid valve (16), maximum pump 2 flow rate limit control solenoid valve (9), maximum pump 3 flow rate limit control solenoid valve (17), and pump 3 torque control solenoid valve (10) are installed in order to control the pumps. Pump delivery pressure sensors (5, 6, 7) and pump control pressure sensors (11, 12, 13) are installed in order to control the pump and valve. (Refer to SYSTEM/Control System.)

10 17

9 13

15 7 123456-

Pilot Pump Pump 1 Pump 3 Pump 2 Pump 2 Delivery Pressure Sensor Pump 3 Delivery Pressure Sensor

TODFY50-EN-00(10/01/2020)

6 78910-

5 Pump 1 Delivery Pressure Sensor Pump 1 and 2 Torque Control Solenoid Valve Maximum Pump 2 Flow Rate Limit Control Solenoid Valve Pump 3 Torque Control Sole noid Valve

1112131415-

T3-1-1

Pump 1 Control Pressure Sen sor Pump 3 Control Pressure Sen sor Pump 2 Control Pressure Sen sor Pump Transmission Coupling

1617-

TDFY-03-01-001-1 ja Maximum Pump 1 Flow Rate Limit Control Solenoid Valve Maximum Pump 3 Flow Rate Limit Control Solenoid Valve

SECTION3 COMPONENT OPERATION Group1 Pump Device Outline of Main Pump The main pump supplies pressure oil to actuate the hydraulic components such as motors or cylinders. The main pump consists of pump 1, pump 2, and pump 3. Shaft (3) is connected to pump cylinder block (5) via seven plungers (4). When shaft (3) is rotated with cylinder block (5) together, plunger (4) oscillate in cylinder block (5) and hydraulic oil is drawn and delivered. Each pump is equipped with regulator (1) which controls the pump delivery flow rate. 1 2

3 6

4 TDDQ-03-01-002-1 ja

12-

Regulator Housing

34-

Shaft Plunger

56-

Cylinder Block Valve Plate

Operational Principle of Main Pump Engine torque is transferred to shaft (3) and seven plungers (4) and turns cylinder block (5). Plungers (4) reciprocate in the cylinder block (5) bore and alternately hydraulic oil is drawn and delivered through valve plate (6).

TODFY50-EN-00(10/01/2020)

T3-1-2

SECTION3 COMPONENT OPERATION Group1 Pump Device 4

Shaft

Plunger

Cylinder Block

T105-02-03-002-1 ja Valve Plate

Increasing and Decreasing of Main Pump Delivery Flow Rate Changing inclination of cylinder block (5) causes the plungers (4) stroke to increase or decrease depending on the slant angle in order to control the main pump delivery flow rate. Up-down movement of servo piston (8) changes inclination of cylinder block (5). Servo piston (8) is connected to valve plate (6) via pin (7). The one end of cylinder block (5) is kept in contact with the surface of valve plate (6) and slides along it. 4

5 7

Maximum Displacement Angle TDDQ-03-01-102-1 ja

a- Maximum Displacement Angle 45-

Plunger Cylinder Block

TODFY50-EN-00(10/01/2020)

67-

Valve Plate Pin

T3-1-3

Servo Piston

SECTION3 COMPONENT OPERATION Group1 Pump Device

8 b

Minimum Displacement Angle TDDQ-03-01-101-1 ja

b- Minimum Displacement Angle 45-

Plunger Cylinder Block

67-

Valve Plate Pin

Servo Piston

Outline of Regulator Regulator (17) controls the main pump flow rate in response to the various command signal pressures so that the pump driving power does not exceed the engine output power. Pump 1, pump 2, and pump 3 are equipped with regulator (17) for each. The major parts of regulator (17) are as follows. Spring (1), Sleeve A (2), Sleeve B (8), Spool A (3), Spool B (7), Piston (4), Load Piston 1 (5), Load Piston 2 (6), Inner Spring (9), Outer Spring (10), Control Solenoid Valves (14, 15, 16, 19, 20) According to the various command signal pressures regulator (17) opens or closes the circuit to servo piston (11) and the inclination of cylinder block (12) is changed. Thus, the pump delivery flow rate is controlled.

NOTE Primary pilot pressure Pg constantly acts on the small chamber side of servo piston (11).

16 20

15 14

TDDQ-01-02-008-2 ja 1415-

Pump 1 and 2 Torque Control Solenoid Valve Maximum Pump 2 Flow Rate Limit Control Solenoid Valve

TODFY50-EN-00(10/01/2020)

1619-

Pump 3 Torque Control Sole noid Valve Maximum Pump 1 Flow Rate Limit Control Solenoid Valve

20-

T3-1-4

Maximum Pump 3 Flow Rate Limit Control Solenoid Valve

SECTION3 COMPONENT OPERATION Group1 Pump Device 17

12 11

11-

Servo Piston

12-

Cylinder Block

13-

Link

17-

TDDQ-03-01-003-1 ja Regulator

3 1 5

Pd2 Pps Pd1

Dr 9,10 13

Dr Pg

Pump 1 Regulator TDC1-03-01-007-1 ja

Pd1- Pump 1 Delivery Pressure Pd2- Pump 2 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure 1234-

Spring Sleeve A Spool A Piston

5678-

Pps- Torque Control Pressure Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease Load Piston 1 Load Piston 2 Spool B Sleeve B

9101113-

Inner Spring Outer Spring Servo Piston Link

1819-

Bleed air from the circuit. Maximum Pump 1 Flow Rate Limit Control Solenoid Valve

3 1 5

Pi 18

Dr Pd2 Pps Pd1 6

Dr Dr

8 11

Pg b

9,10 13 5

Pump 2 Regulator TDC1-03-01-008-1 ja

TODFY50-EN-00(10/01/2020)

T3-1-5

SECTION3 COMPONENT OPERATION Group1 Pump Device Pd1- Pump 1 Delivery Pressure Pd2- Pump 2 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure 12345-

Spring Sleeve A Spool A Piston Load Piston 1

678910-

Pps- Torque Control Pressure Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease Load Piston 2 Spool B Sleeve B Inner Spring Outer Spring

111314-

Servo Piston Link Pump 1 and 2 Torque Control Solenoid Valve

1518-

Maximum Pump 2 Flow Rate Limit Control Solenoid Valve Bleed air from the circuit.

3 1 Pi

5 Dr

Pd3 Pps 6

Dr 8

Dr 7

9,10 13

Pump 3 Regulator TDC1-03-01-004-2 ja

Pd3- Pump 3 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure Pps- Torque Control Pressure 12345-

Spring Sleeve A Spool A Piston Load Piston 1

678910-

Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease Load Piston 2 Spool B Sleeve B Inner Spring Outer Spring

11131618-

Servo Piston Link Pump 3 Torque Control Sole noid Valve Bleed air from the circuit.

20-

Regulator Control Function Each regulator performs the following controls. ● Regulators for Pump 1 and Pump 2: •

Control by Pump Control Pressure

•

Control by Own and Partner Pump Delivery Pressure

•

Control by Pilot Pressure from Torque Control Solenoid Valve

•

Control by Pilot Pressure from Maximum Pump Flow Rate Limit Control Solenoid Valve

● Pump 3 Regulator: •

Control by Pump Control Pressure

•

Control by Own Pump Delivery Pressure

•

Control by Pilot Pressure from Torque Control Solenoid Valve

• Control by Pilot Pressure from Maximum Pump Flow Rate Limit Control Solenoid Valve As for each regulator, functions are different, but the operational principles are the same.

TODFY50-EN-00(10/01/2020)

T3-1-6

Maximum Pump 3 Flow Rate Limit Control Solenoid Valve

SECTION3 COMPONENT OPERATION Group1 Pump Device Control by Pump Control Pressure When a control lever is operated, the pump flow rate control valve in the signal control valve regulates pump control pressure Pi in response to the control lever stroke. The regulators increase or decrease the pump delivery flow rate according to pump control pressure Pi. When the control lever is operated, pump control pressure Pi increases and the regulator increases the pump delivery flow rate. When the control lever is returned to neutral, pump control pressure Pi decreases and the regulator decreases the pump delivery flow rate. Q

Pi MDC1-00-165 ja

Q- Flow Rate

Pi- Pump Control Pressure Dr

Pi Pd2

Pps

Pd1 Dr Pg a

b TDAA-03-01-003-1 ja

Pd1- Pump 1 Delivery Pressure Pd2- Pump 2 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure 18-

Pps- Torque Control Pressure Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease

Air Bleeding

Control by Own and Partner Pump Delivery Pressure (Regulators for Pump 1 and Pump 2) The regulators for pump 1 and pump 2 receive own pump delivery pressure Pd1 (or Pd2) and parter pump delivery pressure Pd2 (or Pd1) as control signal pressure. If the two-pump average pressures increase over the set P-Q line, the regulator reduces both pump delivery flow rates and the total pump output is returned to the set P-Q line. Therefore, the engine is protected from being overloaded. Since the P-Q line is set using the average pressure of two main pump pressures, delivery rates of both pumps are approximately equal to each other.

TODFY50-EN-00(10/01/2020)

T3-1-7

SECTION3 COMPONENT OPERATION Group1 Pump Device Q c d

P MDC1-00-166 ja

Q- Flow Rate P- Pressure

c- Pressure Increase d- Flow Rate Decrease Dr

Pi Pd2

Pps

Pd1 Dr Pg a

b TDAA-03-01-003-1 ja

Pd1- Pump 1 Delivery Pressure Pd2- Pump 2 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure 18-

Pps- Torque Control Pressure Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease

Air Bleeding

Control by Own Pump Delivery Pressure (Pump 3 Regulator) The pump 3 regulator receives own pump delivery pressure Pd3 as control signal pressure. If the pump pressure increases over the set P-Q line, the regulator reduces pump delivery flow rate and the pump output is returned to the set P-Q line. Therefore, the engine is protected from being overloaded. Q c d

P MDC1-00-166 ja

TODFY50-EN-00(10/01/2020)

T3-1-8

SECTION3 COMPONENT OPERATION Group1 Pump Device Q- Flow Rate P- Pressure

c- Pressure Increase d- Flow Rate Decrease

Pi 18

Dr Pd3 Pps

Dr Dr Pg a

b TPPP-03-01-005-8 ja

Pd3- Pump 3 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure Pps- Torque Control Pressure 18-

Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease

Air Bleeding

Control by Pilot Pressure from Torque Control Solenoid Valves MC (main controller) sends the signals to torque control solenoid valves (14, 16) according to the engine speed and the signals from sensors. Torque control solenoid valves (14, 16) deliver torque control pilot pressure Pps to the regulator in response to the these signals. When receiving torque control pilot pressure Pps, the regulator decreases the pump delivery flow rate. (Refer to SYSTEM/Control System.) Q

Q- Flow Rate

TODFY50-EN-00(10/01/2020)

P- Pressure

T3-1-9

MDC1-00-167 ja

SECTION3 COMPONENT OPERATION Group1 Pump Device 14

Pi 18

Dr Pd2 Pps

Pd1 Dr Pg a

Pump 2 Regulator TPPP-03-01-005-1 ja

Pd1- Pump 1 Delivery Pressure Pd2- Pump 2 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure 14-

Pump 1 and 2 Torque Control Solenoid Valve

18-

Pps- Torque Control Pressure Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease Bleed air from the circuit.

Pi 18

Dr Pd3 Pps

Dr Dr Pg a

Pump 3 Regulator TPPP-03-01-005-2 ja

Pd3- Pump 3 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure Pps- Torque Control Pressure 16-

Pump 3 Torque Control Sole noid Valve

TODFY50-EN-00(10/01/2020)

18-

Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease Bleed air from the circuit.

T3-1-10

SECTION3 COMPONENT OPERATION Group1 Pump Device Control by Pilot Pressure from Maximum Pump Flow Rate Limit Control Solenoid Valves (Pump Flow Rate Limit Control) When the work mode is set to attachment, MC (main controller) sends the signals to the maximum pump flow rate limit control solenoid valves (15, 19, 20) according to the settings. Maximum pump flow rate limit control solenoid valves (15, 19, 20) decreases pump control pressure Pi in response to these signals. Therefore, the upper limit of pump flow rate is limited. (Refer to SYSTEM/Control System.) Q

Pi MDC1-00-168 ja

Q- Flow Rate

Pi- Pump Control Pressure c Q

P MDC1-00-169 ja

Q- Flow Rate P- Pressure

c- Maximum Flow Rate d- Upper Limit Flow Rate 15, 19, 20

Pi 18

Dr Pd2 Pps

Pd1 Dr Pg a

b TPPP-03-01-005-3 ja

Pd1- Pump 1 Delivery Pressure Pd2- Pump 2 Delivery Pressure TODFY50-EN-00(10/01/2020)

Pps- Torque Control Pressure Pg- Primary Pilot Pressure (From Pilot Pump)

T3-1-11

SECTION3 COMPONENT OPERATION Group1 Pump Device Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure 15-

Maximum Pump 1 Flow Rate Limit Control Solenoid Valve

18-

a- Displacement Angle Increase b- Displacement Angle Decrease Bleed air from the circuit.

19-

Maximum Pump 2 Flow Rate Limit Control Solenoid Valve

20-

Maximum Pump 3 Flow Rate Limit Control Solenoid Valve

Control by Pilot Pressure from Maximum Pump Flow Rate Limit Control Solenoid Valves (Pump Flow Rate Control) MC (main controller) sends the signal to maximum pump flow rate limit control solenoid valves (15, 19, 20) in response to each control lever stroke. Maximum pump flow rate limit control solenoid valves (15, 19, 20) decreases pump control pressure Pi in response to these signals. Therefore, the pump delivery flow rate is controlled. (Refer to SYSTEM/Control System.) Q

Pi MDC1-00-170 ja

Q- Flow Rate

Pi- Pump Control Pressure 15, 19, 20

Pi 18

Dr Pd Pps

Dr Dr Pg a

b TPPP-03-01-005-4 ja

Pd- Own Pump Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure Pps- Torque Control Pressure 15-

Maximum Pump 1 Flow Rate Limit Control Solenoid Valve

TODFY50-EN-00(10/01/2020)

18-

Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease Bleed air from the circuit.

19-

T3-1-12

Maximum Pump 2 Flow Rate Limit Control Solenoid Valve

20-

Maximum Pump 3 Flow Rate Limit Control Solenoid Valve

SECTION3 COMPONENT OPERATION Group1 Pump Device Flow Rate Increase Control by Pump Control Pressure NOTE As an example, the pump 1 regulator is explained here. 1. When a control lever is operated, the flow rate control valve in the signal control valve is shifted and pump control pressure Pi increases. 2. Piston (4) pushes spool A (3) and spring (1). Spool A (3) is moved toward the direction of the arrow. 3. The circuit from the large chamber of servo piston (11) is connected to the hydraulic oil tank. 4. As primary pilot pressure Pg acts on the small chamber of servo piston (11) at all times, servo piston (11) is moved toward the direction of the arrow. Therefore, the cylinder block is rotated in the maximum inclination direction and the pump delivery flow rate increases. 5. The movement of cylinder block is transmitted to sleeve A (2) via link (13). Sleeve A (2) is moved in the same direction as spool A (3). 6. When sleeve A (2) is moved with the same stroke as spool A (3), the open part between sleeve A (2) and spool A (3) is closed. The circuit from the large chamber of servo piston (11) to the hydraulic oil tank is closed. 7. Servo piston (11) is stopped and the pump delivery flow rate increasing operation is completed. Q

Pi MDC1-00-171 ja

Q- Flow Rate

Pi- Pump Control Pressure 1

Pi Pd2

Pps

Pd1 Dr Pg 11

13 TDAA-03-01-003-2 ja

Pd1- Pump 1 Delivery Pressure Pd2- Pump 2 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure

TODFY50-EN-00(10/01/2020)

Pps- Torque Control Pressure Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease

T3-1-13

SECTION3 COMPONENT OPERATION Group1 Pump Device 12-

Spring Sleeve A

TODFY50-EN-00(10/01/2020)

34-

Spool A Piston

1113-

T3-1-14

Servo Piston Link

18-

Air Bleeding

SECTION3 COMPONENT OPERATION Group1 Pump Device NOTE The illustration shows the pump1 regulator. 1

4 Pi

Pps

Pd2 13

Pd1

11 a

b TPPP-03-01-016-1 ja

Pd1- Pump 1 Delivery Pressure Pd2- Pump 2 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure 12-

Spring Sleeve A

TODFY50-EN-00(10/01/2020)

34-

Pps- Torque Control Pressure Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease Spool A Piston

1113-

T3-1-15

Servo Piston Link

SECTION3 COMPONENT OPERATION Group1 Pump Device 1

4 Pi

Pps

Pd2 13

Pd1

11 b

TPPP-03-01-017-1 ja

Pd1- Pump 1 Delivery Pressure Pd2- Pump 2 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure 12-

Spring Sleeve A

34-

Pps- Torque Control Pressure Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease Spool A Piston

1113-

Servo Piston Link

Flow Rate Decrease Control by Pump Control Pressure NOTE As an example, the pump 1 regulator is explained here. 1. When a control lever is returned, the flow rate control valve in the signal control valve is returned and pump control pressure Pi decreases. 2. Piston (4) and spool A (3) are pushed by spring (1). Spool A (3) is moved toward the direction of the arrow. 3. Primary pilot pressure Pg is routed to the large chamber of servo piston (11). 4. Due to the difference in the pressure receiving areas between the large and small chambers, servo piston (11) is moved toward the direction of the arrow. The cylinder block is rotated in the minimum inclination direction and the pump delivery flow rate decreases. 5. The movement of cylinder block is transmitted to sleeve A (2) via link (13). Sleeve A (2) is moved in the same direction as spool A (3). 6. When sleeve A (2) is moved with the same stroke as spool A (3), the open part between sleeve A (2) and spool A (3) is closed. Primary pilot pressure Pg routed to servo piston (11) is blocked. 7. Servo piston (11) is stopped and the pump delivery flow rate decreasing operation is completed.

TODFY50-EN-00(10/01/2020)

T3-1-16

SECTION3 COMPONENT OPERATION Group1 Pump Device Q

Pi MDC1-00-172 ja

Q- Flow Rate

Pi- Pump Control Pressure 1

Pi Pd2

Pps

Pd1 Dr Pg 11

13 TDAA-03-01-003-3 ja

Pd1- Pump 1 Delivery Pressure Pd2- Pump 2 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure 12-

Spring Sleeve A

TODFY50-EN-00(10/01/2020)

34-

Pps- Torque Control Pressure Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease Spool A Piston

1113-

T3-1-17

Servo Piston Link

18-

Air Bleeding

SECTION3 COMPONENT OPERATION Group1 Pump Device NOTE The illustration shows the pump1 regulator. 1

4 Pi

Pps

Pd2 13

Pd1

11 TPPP-03-01-018-1 ja

Pd1- Pump 1 Delivery Pressure Pd2- Pump 2 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure 12-

Spring Sleeve A

TODFY50-EN-00(10/01/2020)

34-

Pps- Torque Control Pressure Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease Spool A Piston

1113-

T3-1-18

Servo Piston Link

SECTION3 COMPONENT OPERATION Group1 Pump Device 1

4 Pi

Pps

Pd2 13

Pd1

11 b TPPP-03-01-019-1 ja

Pd1- Pump 1 Delivery Pressure Pd2- Pump 2 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure 12-

Spring Sleeve A

34-

Pps- Torque Control Pressure Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease Spool A Piston

1113-

Servo Piston Link

Flow Rate Decrease Control by Own and Partner Pump Delivery Pressure (Regulators for Pump 1 and Pump 2) NOTE As an example, the pump 1 regulator is explained here. 1. When pump 1 (own pump) is loaded, pump 1 delivery pressure Pd1 (own pump pressure) increases. (During operation, pump control pressure Pi is kept high.) 2. Load piston 2 (6) pushes spool B (7), inner spring (9), and outer spring (10). Spool B (7) is moved toward the direction of the arrow. 3. Primary pilot pressure Pg is routed to the large chamber of servo piston (11). 4. Due to the difference in the pressure receiving areas between the large and small chambers, servo piston (11) is moved toward the direction of the arrow. The cylinder block is rotated in the minimum inclination direction and the pump delivery flow rate decreases. 5. The movement of cylinder block is transmitted to sleeve B (8) via link (13). Sleeve B (8) is moved in the same direction as spool B (7). 6. When sleeve B (8) is moved by the same stroke as spool B (7), the open part between sleeve B (8) and spool B (7) is closed. Primary pilot pressure Pg routed to servo piston (11) is blocked. 7. Servo piston (11) is stopped and the pump delivery flow rate decreasing operation is completed. 8. When pump 2 (partner pump) is also loaded at this time, pump 2 delivery pressure (Pd2) acts on load piston 2 (6) and moves spool B (7) further. TODFY50-EN-00(10/01/2020)

T3-1-19

SECTION3 COMPONENT OPERATION Group1 Pump Device 9. Consequently, as the movement of spool B (7) increases, the pump delivery flow rate decreases further. Q

Q- Flow Rate

MDC1-00-173 ja

P- Pressure Dr

5 Pi Pd2

Pps

Pd1 Dr 6

9,10

Pg 11

13 TDAA-03-01-003-4 ja

Pd1- Pump 1 Delivery Pressure Pd2- Pump 2 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure 567-

Load Piston 1 Load Piston 2 Spool B

8910-

Pps- Torque Control Pressure Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease Sleeve B Inner Spring Outer Spring

111318-

NOTE The illustration shows the pump1 regulator.

TODFY50-EN-00(10/01/2020)

T3-1-20

Servo Piston Link Air Bleeding

SECTION3 COMPONENT OPERATION Group1 Pump Device 5

8 Pi

Pps

Pd2

Pd1

11 TPPP-03-01-013-1 ja

Pd1- Pump 1 Delivery Pressure Pd2- Pump 2 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure 56-

Load Piston 1 Load Piston 2

78-

Pps- Torque Control Pressure Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease Spool B Sleeve B

910-

Inner Spring Outer Spring

1113-

Servo Piston Link

8 Pi

Pps

Pd2

Pd1

11 a

b TPPP-03-01-014-1 ja

TODFY50-EN-00(10/01/2020)

T3-1-21

SECTION3 COMPONENT OPERATION Group1 Pump Device Pd1- Pump 1 Delivery Pressure Pd2- Pump 2 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure 56-

Load Piston 1 Load Piston 2

78-

Pps- Torque Control Pressure Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease Spool B Sleeve B

910-

Inner Spring Outer Spring

1113-

Servo Piston Link

Flow Rate Increase Control by Own and Partner Pump Delivery Pressure (Regulators for Pump 1 and Pump 2) NOTE As an example, the pump 1 regulator is explained here. 1. When the load of pump 1 (own pump) is reduced, pump 1 delivery pressure Pd1 (own pump pressure) decreases. (During operation, pump control pressure Pi is kept high.) 2. Load piston 1 (5), load piston 2 (6), and spool B (7) are pushed by inner spring (9) and outer spring (10). Spool B (7) is moved toward the direction of the arrow. 3. The circuit from the large chamber of servo piston (11) is connected to the hydraulic oil tank. 4. As primary pilot pressure Pg acts on the small chamber of servo piston (11) at all times, servo piston (11) is moved toward the direction of the arrow. Therefore, the cylinder block is rotated in the maximum inclination direction and the pump delivery flow rate increases. 5. The movement of cylinder block is transmitted to sleeve B (8) via link (13). Sleeve B (8) is moved in the same direction as spool B (7). 6. When sleeve B (8) is moved by the same stroke as spool B (7), the open part between sleeve B (8) and spool B (7) is closed. The circuit from the large chamber of servo piston (11) to the hydraulic oil tank is closed. 7. Servo piston (11) is stopped and the pump delivery flow rate increasing operation is completed. 8. When the load of pump 2 (partner pump) is also reduced at this time, load piston 1 (5), load piston 2 (6), and spool B (7) are further. pushed by inner spring (9) and outer spring (10). 9. Consequently, as the movement of spool B (7) increases, the pump delivery flow rate increases further. Q

Q- Flow Rate

TODFY50-EN-00(10/01/2020)

P- Pressure

T3-1-22

MDC1-00-174 ja

SECTION3 COMPONENT OPERATION Group1 Pump Device 3

5 Pi Pd2

Pps

Pd1 Dr 6

9,10

Pg 11

13 TDAA-03-01-003-5 ja

Pd1- Pump 1 Delivery Pressure Pd2- Pump 2 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure 235-

Sleeve A Spool A Load Piston 1

TODFY50-EN-00(10/01/2020)

678-

Pps- Torque Control Pressure Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease Load Piston 2 Spool B Sleeve B

91011-

T3-1-23

Inner Spring Outer Spring Servo Piston

1318-

Link Air Bleeding

SECTION3 COMPONENT OPERATION Group1 Pump Device NOTE The illustration shows the pump1 regulator. 5

7 Pi

Pps

Pd2

Pd1

11 TPPP-03-01-020-1 ja

Pd1- Pump 1 Delivery Pressure Pd2- Pump 2 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure 235-

Sleeve A Spool A Load Piston 1

TODFY50-EN-00(10/01/2020)

678-

Pps- Torque Control Pressure Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease Load Piston 2 Spool B Sleeve B

91011-

T3-1-24

Inner Spring Outer Spring Servo Piston

13-

Link

SECTION3 COMPONENT OPERATION Group1 Pump Device 5

8 Pi

Pps

Pd2

Pd1

11 a

b TDAA-03-01-008-1 ja

Pd1- Pump 1 Delivery Pressure Pd2- Pump 2 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure 235-

Sleeve A Spool A Load Piston 1

678-

Pps- Torque Control Pressure Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease Load Piston 2 Spool B Sleeve B

91011-

Inner Spring Outer Spring Servo Piston

13-

Link

Flow Rate Decrease Control by Own Pump Delivery Pressure (Pump 3 Regulator) NOTE As an example, the pump 3 regulator is explained here. 1. When pump 3 (own pump) is loaded, pump 3 delivery pressure Pd3 (own pump pressure) increases. (During operation, pump control pressure Pi is kept high.) 2. Load piston 2 (6) pushes spool B (7), inner spring (9), and outer spring (10). Spool B (7) is moved toward the direction of the arrow. 3. Primary pilot pressure Pg is routed to the large chamber of servo piston (11). 4. Due to the difference in the pressure receiving areas between the large and small chambers, servo piston (11) is moved toward the direction of the arrow. The cylinder block is rotated in the minimum inclination direction and the pump delivery flow rate decreases. 5. The movement of cylinder block is transmitted to sleeve B (8) via link (13). Sleeve B (8) is moved in the same direction as spool B (7). 6. When sleeve B (8) is moved by the same stroke as spool B (7), the open part between sleeve B (8) and spool B (7) is closed. Primary pilot pressure Pg routed to servo piston (11) is blocked. 7. Servo piston (11) is stopped and the pump delivery flow rate decreasing operation is completed.

TODFY50-EN-00(10/01/2020)

T3-1-25

SECTION3 COMPONENT OPERATION Group1 Pump Device Q

Q- Flow Rate

MDC1-00-173 ja

P- Pressure

Dr Pd3 Pps

Dr 6

9,10

Dr 7

11 a

b TPPP-03-01-005-5 ja

Pd3- Pump 3 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure Pps- Torque Control Pressure 567-

Load Piston 1 Load Piston 2 Spool B

TODFY50-EN-00(10/01/2020)

8910-

Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease Sleeve B Inner Spring Outer Spring

111318-

T3-1-26

Servo Piston Link Air Bleeding

SECTION3 COMPONENT OPERATION Group1 Pump Device 6

Pd3 5

Pps

Pi Dr 13

TDAA-03-01-004-1 ja

Pd3- Pump 3 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure Pps- Torque Control Pressure 56-

Load Piston 1 Load Piston 2

78-

Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease Spool B Sleeve B

910-

Inner Spring Outer Spring

1113-

Servo Piston Link

Pd3 5

Pps

Pi Dr 13

11 a

b TDAA-03-01-005-1 ja

Pd3- Pump 3 Delivery Pressure TODFY50-EN-00(10/01/2020)

Pg- Primary Pilot Pressure (From Pilot Pump)

T3-1-27

SECTION3 COMPONENT OPERATION Group1 Pump Device Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure Pps- Torque Control Pressure 56-

Load Piston 1 Load Piston 2

78-

a- Displacement Angle Increase b- Displacement Angle Decrease Spool B Sleeve B

910-

Inner Spring Outer Spring

1113-

Servo Piston Link

Flow Rate Increase Control by Own Pump Delivery Pressure (Pump 3 Regulator) NOTE As an example, the pump 3 regulator is explained here. 1. When the load of pump 3 (own pump) is reduced, pump 3 delivery pressure Pd3 (own pump pressure) decreases. (During operation, pump control pressure Pi is kept high.) 2. Load piston 1 (5), load piston 2 (6), and spool B (7) are pushed by inner spring (9) and outer spring (10). Spool B (7) is moved toward the direction of the arrow. 3. The circuit from the large chamber of servo piston (11) is connected to the hydraulic oil tank. 4. As primary pilot pressure Pg acts on the small chamber of servo piston (11) at all times, servo piston (11) is moved toward the direction of the arrow. Therefore, the cylinder block is rotated in the maximum inclination direction and the pump delivery flow rate increases. 5. The movement of cylinder block is transmitted to sleeve B (8) via link (13). Sleeve B (8) is moved in the same direction as spool B (7). 6. When sleeve B (8) is moved by the same stroke as spool B (7), the open part between sleeve B (8) and spool B (7) is closed. The circuit from the large chamber of servo piston (11) to the hydraulic oil tank is closed. 7. Servo piston (11) is stopped and the pump delivery flow rate increasing operation is completed. Q

Q- Flow Rate

TODFY50-EN-00(10/01/2020)

P- Pressure

T3-1-28

MDC1-00-174 ja

SECTION3 COMPONENT OPERATION Group1 Pump Device 2

3 Pi

Dr Pd3 Pps

Dr 6

9,10

Dr 7

11 a

b TPPP-03-01-005-6 ja

Pd3- Pump 3 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure Pps- Torque Control Pressure 235-

Sleeve A Spool A Load Piston 1

678-

Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease Load Piston 2 Spool B Sleeve B

91011-

Inner Spring Outer Spring Servo Piston

1318-

Link Air Bleeding

Pd3 5

Pps

Pi Dr

11 TDAA-03-01-006-1 ja

Pd3- Pump 3 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure Pps- Torque Control Pressure

TODFY50-EN-00(10/01/2020)

Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease

T3-1-29

SECTION3 COMPONENT OPERATION Group1 Pump Device 235-

Sleeve A Spool A Load Piston 1

678-

Load Piston 2 Spool B Sleeve B

91011-

Inner Spring Outer Spring Servo Piston

13-

Link

Pd3 5

Pps

Pi Dr

11 TDAA-03-01-007-1 ja

Pd3- Pump 3 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure Pps- Torque Control Pressure 235-

Sleeve A Spool A Load Piston 1

678-

Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease Load Piston 2 Spool B Sleeve B

91011-

Inner Spring Outer Spring Servo Piston

13-

Link

Flow Rate Decrease Control by Pilot Pressure from Torque Control Solenoid Valve NOTE As an example, the pump 2 regulator is explained here. 1. The torque control solenoid valve (14) is activated by the signals from MC (main controller), and torque control pressure Pps increases. 2. Torque control pressure Pps adding to pump delivery pressure acts on load piston 1 (5). 3. Load piston 1 (5) pushes load piston 2 (6), spool B (7), inner spring (9), and outer spring (10). Spool B (7) is moved toward the direction of the arrow. 4. Primary pilot pressure Pg is routed to the large chamber of servo piston (11). 5. Due to the difference in the pressure receiving areas between the large and small chambers, servo piston (11) is moved toward the direction of the arrow. The cylinder block is rotated in the minimum inclination direction and the pump delivery flow rate decreases. 6. The movement of cylinder block is transmitted to sleeve B (8) via link (13). Sleeve B (8) is moved in the same direction as spool B (7). 7. When sleeve B (8) is moved with the same stroke as spool B (7), the open part between sleeve B (8) and spool B (7) is closed. Primary pilot pressure Pg routed to servo piston (11) is blocked.

TODFY50-EN-00(10/01/2020)

T3-1-30

SECTION3 COMPONENT OPERATION Group1 Pump Device 8. Servo piston (11) is stopped and the pump delivery flow rate decreasing operation is completed. Q

Q- Flow Rate

MDC1-00-167 ja

P- Pressure 14

Dr Pd2 Pps

Pd1 6

9,10

Dr 7

8 11

Pg a

b TPPP-03-01-005-7 ja

Pd1- Pump 1 Delivery Pressure Pd2- Pump 2 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure 567-

Load Piston 1 Load Piston 2 Spool B

8910-

Pps- Torque Control Pressure Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease Sleeve B Inner Spring Outer Spring

1113-

1418-

NOTE The illustration shows the pump2 regulator.

TODFY50-EN-00(10/01/2020)

Servo Piston Link

T3-1-31

Pump 1 and 2 Torque Control Solenoid Valve Bleed air from the circuit.

SECTION3 COMPONENT OPERATION Group1 Pump Device 5

8 Pi

Pps

Pd2

Pd1

11 a

b TPPP-03-01-022-1 ja

Pd1- Pump 1 Delivery Pressure Pd2- Pump 2 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure 56-

Load Piston 1 Load Piston 2

78-

Pps- Torque Control Pressure Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease Spool B Sleeve B

910-

Inner Spring Outer Spring

1113-

Servo Piston Link

8 Pi

Pps

Pd2

Pd1

b 11 TPPP-03-01-023-1 ja

TODFY50-EN-00(10/01/2020)

T3-1-32

SECTION3 COMPONENT OPERATION Group1 Pump Device Pd1- Pump 1 Delivery Pressure Pd2- Pump 2 Delivery Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure 56-

Load Piston 1 Load Piston 2

78-

Pps- Torque Control Pressure Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease Spool B Sleeve B

910-

Inner Spring Outer Spring

1113-

Servo Piston Link

Flow Rate Control by Pilot Pressure from Maximum Pump Flow Rate Limit Control Solenoid Valves (Pumps 1, Pump 2, and Pump 3) 1. Maximum pump flow rate limit control solenoid valves (15, 19, 20) in the pump control pressure Pi circuit is activated by the signals from MC (main controller). 2. Maximum pump flow rate limit control solenoid valves (15, 19, 20) decreases pump control pressure Pi in response to these signals. 3. The pump control is performed by decreased pump control pressure Pi. Therefore, the pump delivery flow rate is limited less than normal regardless of the same control lever stroke.

NOTE The pump regulator is operated in the same way as the pump control pressure. 15, 19, 20

Pi 18

Dr Pd Pps

Dr Dr Pg a

b TPPP-03-01-005-4 ja

Pd- Own Pump Pressure Dr- Returning to Hydraulic Oil Tank Pi- Pump Control Pressure Pps- Torque Control Pressure 15-

Maximum Pump 1 Flow Rate Limit Control Solenoid Valve

TODFY50-EN-00(10/01/2020)

18-

Pg- Primary Pilot Pressure (From Pilot Pump) a- Displacement Angle Increase b- Displacement Angle Decrease Bleed air from the circuit.

19-

T3-1-33

Maximum Pump 2 Flow Rate Limit Control Solenoid Valve

20-

Maximum Pump 3 Flow Rate Limit Control Solenoid Valve

SECTION3 COMPONENT OPERATION Group1 Pump Device Outline of Maximum Flow Rate Limit Control Solenoid Valve and Torque Control Solenoid Valve The maximum pump 1 flow rate limit control solenoid valve is installed in the pump 1 regulator. Pump 1 and 2 torque control solenoid valve and the maximum pump 2 flow rate limit control solenoid valve are installed in the pump 2 regulator. Pump 3 torque control solenoid valve and the maximum pump 3 flow rate limit control solenoid valve are installed in the pump 3 regulator. Pump 1 and 2 torque control solenoid valve supply torque control pressure Pps to both the pump 1 and pump 2 regulators and the pump delivery flow rate is reduced. Pump 3 torque control solenoid valve supplies torque control pressure Pps to the pump 3 regulator and the pump delivery flow rate is reduced. The maximum pump 1, 2, 3 flow rate limit control solenoid valves decrease pump control pressure Pi to the pump 1, 2, 3 regulators, and the pump delivery flow rate is controlled.

Operation of Maximum Flow Rate Limit Control Solenoid Valve and Torque Control Solenoid Valve 1. When in neutral, port P (5) is connected to output port (4) through the notch on spool (3). 2. When current flows to solenoid (7) from MC (main controller), solenoid (7) is excited and pushes piston (6). 3. As piston (6) pushes spool (3), output port (4) is connected to port T (8) through the notch on spool (3). 4. Pressure at output port (4) begins to decrease. 5. Diameter B is larger than diameter A as for the notch of spool (3). 6. When pressure at output port (4) begins to decrease, spool (3) is move to the right due to the force as Fsol (9)+S1>P1× (A-B)+S2. 7. When pressure at output port (4) decreases and the following formula exists, Fsol (9)+S1=P1×(A-B)+S2, spool (3) is stopped. P1: Pressure at Output Port (4) A, B: Pressure Receiving Area on Spool (3) S1: Spring 1 (1) Force (Force pushing spool (3) to the right) S2: Spring 2 (2) Force (Force returning spool (3) to the left) Fsol: Solenoid (7) Force

TODFY50-EN-00(10/01/2020)

T3-1-34

SECTION3 COMPONENT OPERATION Group1 Pump Device 1

6 7

Neutral State TDAA-03-01-001-1 ja 123-

Spring 1 Spring 2 Spool

456-

Output Port Port P Piston

789-

Solenoid Port T Fsol

6 9 7

Operating State TDAA-03-01-002-1 ja 123-

Spring 1 Spring 2 Spool

TODFY50-EN-00(10/01/2020)

456-

Output Port Port P Piston

789-

T3-1-35

Solenoid Port T Fsol

SECTION3 COMPONENT OPERATION Group1 Pump Device Outline of Pilot Pump The pilot pump is a gear pump. Drive gear (1) is driven by the engine via the transmission, which rotates driven gear (2) as they are meshed together. 2

1 a

b T137-02-03-005-1 ja

a- Suction Port 1-

Drive Gear

b- Delivery Port 2-

Driven Gear

Outline of 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.

3 34-

Ground Output Signal

Power Source (5 V)

6 6-

T157-02-03-010-1 ja

Pressure Receiving Area (Dia phragm)

Outline of Pump Control Pressure Sensor The pump control pressure sensor detects the pump control 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 (6) is detected as electrical signals.

TODFY50-EN-00(10/01/2020)

T3-1-36

T176-03-01-023-1 ja

SECTION3 COMPONENT OPERATION Group1 Pump Device 7-

Pressure Receiving Area (Dia phragm)

TODFY50-EN-00(10/01/2020)

89-

Ground Output Signal

10-

T3-1-37

Power Source (5 V)

SECTION3 COMPONENT OPERATION Group1 Pump Device MEMO

TODFY50-EN-00(10/01/2020)

T3-1-38

SECTION3 COMPONENT OPERATION Group2 Swing Device Outline of Swing Device The swing device consists of valve unit (1), swing motor (2), and swing reduction gear (3). Valve unit (1) prevents the cavitation and the overload in the swing circuit. Swing motor (2) is a swash plate type axial plunger motor (with built-in swing parking brake), which is driven by pressure oil from the pump, and the rotation is transmitted to swing reduction gear (3). Swing reduction gear (3) converts swing motor (2) output into slow large torque to rotate the shaft. Therefore, the upperstructure is swing. The swing dampener valve is built in valve unit (1). The swing dampener valve reduces shock when the swing brake is applied and prevents aftershock.

TDAA-03-02-001-1 ja 1-

Valve Unit (built in swing dampener valve)

TODFY50-EN-00(10/01/2020)

23-

Swing Motor Swing Reduction Gear

T3-2-1

SECTION3 COMPONENT OPERATION Group2 Swing Device Outline of Swing Reduction Gear The swing reduction gear is a two-stage planetary reduction gear. Ring gear (4) is installed to housing (11) and is fixed to the upperstructure. Shaft (2) in swing motor (1) rotates first stage sun gear (10), whose rotating torque is transmitted to second stage sun gear (8) through first stage planetary gears (3) and first stage carrier (9). Second stage sun gear (8) rotates shaft (6) through second stage planetary gear (5) and second stage carrier (7). Shaft (6) is engaged with the internal gear of the swing bearing which is fixed to the undercarriage and swings the upperstructure. 1

10 9

123-

Swing Motor Shaft (Swing Motor) First Stage Planetary Gear

TODFY50-EN-00(10/01/2020)

456-

Ring Gear Second Stage Planetary Gear Shaft

789-

T3-2-2

Second Stage Carrier Second Stage Sun Gear First Stage Carrier

1011-

TDAA-03-02-002-1 ja First Stage Sun Gear Housing

SECTION3 COMPONENT OPERATION Group2 Swing Device Outline of Swing Motor The swing motor consists of swash plate (9), rotor (12), plungers (6), valve plate (13), housing (11), and swing parking brake (14) (springs (1), brake piston (2), plates (3), friction plates (5), and swing parking brake selection valve (4)). Shaft (8) is connected to rotor (12) by a spline joint. Plungers (6) are inserted into rotor (12). When pressure oil is supplied from the pump, plungers (6) are pushed. As swash plate (9) is inclined, shoes (10) on the end of plungers (6) slide along swash plate (9) and rotor (12) rotates. The end of shaft (8) is splined to the first stage sun gear of swing reduction gear. Therefore, the rotation of shaft (8) is transmitted to the swing reduction gear.

1 13 2 4 3

11 5 10

9 1234-

Spring Brake Piston Plate Swing Parking Brake Selection Valve

TODFY50-EN-00(10/01/2020)

56789-

8 Friction Plate Plunger Retainer Shaft Swash Plate

1011121314-

T3-2-3

Shoe Housing Rotor Valve Plate Swing Parking Brake

TDAA-03-02-003-1 ja

SECTION3 COMPONENT OPERATION Group2 Swing Device Outline of Swing Parking Brake The parking brake is a wet-type spring set hydraulic released multi-disc brake. When the brake release pressure moves the piston and pressure oil is routed to brake piston chamber, the brake is released. The brake release pressure flows from the pilot pump only when both swing and front attachments are operated. In other cases (including engine stopping), brake piston chamber is connected to the hydraulic oil tank, and the brake is automatically applied by springs.

When Brake is Released of Swing Parking Brake 1. When the swing and front attachment control levers are operated, the swing parking brake release spool in the signal control valve is shifted. Therefore, pilot pressure from the pilot pump flows to port SH (5). 2. Pilot pressure supplied to port SH (5) opens check valve (4) and acts on brake piston chamber (6). 3. Consequently, as brake piston (2) moves upward, plates (8) and friction plates (7) become free each other so that the brake is released. 1 9 2 3 10 4 8 5

7 123-

Spring Brake Piston Orifice

45-

Check Valve Port SH (Brake Release Pres sure)

678-

Brake Piston Chamber Friction Plate Plate

910-

TDAA-03-02-008-1 ja Rotor Swing Parking Brake Selection Valve

When Brake is Applied of Swing Parking Brake 1. When the swing and front attachment control levers are returned to the neutral position, the swing parking brake release spool in the signal control valve returns to the neutral. The supply of the pilot pressure to port SH (5) stops. 2. Therefore, check valve (4) is closed and the brake release pressure is released to the swing motor housing through orifice (3). 3. Consequently, the force of springs (1) act on friction plates (7) engaging on the outer circumference of rotor (9) and plates (8) engaging on the inner circumference of the motor housing via brake piston (2). Consequently, the friction force occurs and the rotor (9) outer circumference is secured. When the engine stops, the brake is automatically applied as pressure is not supplied to port SH (5).

TODFY50-EN-00(10/01/2020)

T3-2-4

SECTION3 COMPONENT OPERATION Group2 Swing Device 1 9 2 3 10 4 8 5

7 123-

Spring Brake Piston Orifice

TODFY50-EN-00(10/01/2020)

45-

Check Valve Port SH (Brake Release Pres sure)

678-

T3-2-5

Brake Piston Chamber Friction Plate Plate

910-

TDAA-03-02-008-1 ja Rotor Swing Parking Brake Selection Valve

SECTION3 COMPONENT OPERATION Group2 Swing Device Outline of Valve Unit The valve unit consists of the make-up valves, the swing relief valves, and the swing dampener valves (the combination valve). The make-up valve prevents cavitation in the circuit from occurring. The swing relief valve prevents surge pressure in the circuit from occurring and protects the circuit from being overloaded.

Operation of Make-Up Valve During swing stopping operation, the swing motor is driven by inertial force of the upperstructure. As the swing motor is turned forcibly in excess of oil flow rate from the pump, cavitation occurs in the motor. In order to avoid this cavitation, when the swing circuit pressure becomes lower than pressure in the tank circuit (port M (1)), poppet (8) is opened, hydraulic oil is drawn, and the lack of oil feed is compensated. 2 1

6 3

4 TDDQ-03-02-001-1 ja 12-

Port M Make-Up Valve

TODFY50-EN-00(10/01/2020)

34-

Swing Relief Valve Control Valve

56-

T3-2-6

Combination Valve Swing Dampener Valve

SECTION3 COMPONENT OPERATION Group2 Swing Device 7

3 12-

Port M Make-Up Valve

TODFY50-EN-00(10/01/2020)

34-

Swing Relief Valve Control Valve

56-

T3-2-7

Combination Valve Swing Dampener Valve

TDAA-03-02-006-1 ja Valve Unit

SECTION3 COMPONENT OPERATION Group2 Swing Device

4 2

3 12-

Port M Make-Up Valve

34-

Swing Relief Valve Control Valve

TDAA-03-02-007-1 ja 78-

Valve Unit Poppet

Outline of Swing Relief Valve When starting or stopping swing operation, the swing circuit pressure becomes high. The swing relief valve prevents the circuit pressure from rising higher than the set pressure.

Low-Pressure Relief Operation (Shockless Function) of Swing Relief Valve 1. Pressure at port HP (swing circuit) is routed to oil chamber C (9) through orifice (2) in poppet (1). 2. Pressure oil in chamber C (9) flows to oil chamber A (8) through passage A (4) and flows to oil chamber B (7) through passage B (5). 3. As the pressure receiving area in oil chamber B (7) is larger than the pressure receiving area in oil chamber A (8), piston (6) moves to the left. 4. As long as piston (6) keeps moving, a pressure difference is developed between the front and rear of orifice (2) due to orifice (2). When this pressure difference is increased beyond the spring (3) force, poppet (1) is opened and pressure oil flows to port LP. 5. When piston (6) reaches the stroke end, the pressure difference between the front and rear of orifice (2) disappears and poppet (1) is closed.

TODFY50-EN-00(10/01/2020)

T3-2-8

SECTION3 COMPONENT OPERATION Group2 Swing Device 1

HP- Port HP (Swing Circuit) 123-

Poppet Orifice Spring

T178-03-02-005-1 ja

LP- Port LP (Returning Circuit) 456-

Passage A Passage B Piston

789-

Oil Chamber B Oil Chamber A Oil Chamber C

High-Pressure Relief Operation (Overload Prevention) of Swing Relief Valve 1. After piston (6) reaches the stroke end, the circuit pressure becomes the normal relief set pressure. 2. When pressure at port HP increases further and is beyond the spring (3) set pressure, poppet (1) is opened and pressure oil flows to port LP. 3. When pressure at port HP is decreased to the specified level, poppet (1) is closed by the spring (3) force. 1

HP- Port HP (Swing Circuit) 123-

Poppet Orifice Spring

LP- Port LP (Returning Circuit) 456-

Passage A Passage B Piston

789-

Outline of Swing Dampener Valve Swing dampener valve (2) is built in valve unit (1).

TODFY50-EN-00(10/01/2020)

T3-2-9

Oil Chamber B Oil Chamber A Oil Chamber C

T178-03-02-005-1 ja

SECTION3 COMPONENT OPERATION Group2 Swing Device Swing dampener valve (2) consists of two combination valves (3). When returning the control lever, swing dampener valve (2) relieves swing brake pressure (aftershock pressure) to the circuit in opposite side (low-pressure side). Swing dampener valve (2) reduces shock of swing brake operation and prevents aftershock. 2

TDAA-03-02-001-2 ja 1-

Valve Unit

Swing Dampener Valve

Combination Valve

Operation of Swing Dampener Valve NOTE Swing (right) operation is explained here.

Output Curve of Swing Dampener Valve: Between A and B (When Relieving) 1. When returning the control lever, the spool in control valve (16) moves to the neutral position. As swing motor (8) rotates due to the inertia force of machine, pressure in the circuit at port BM (returning side) increases momentarily and operates the swing relief valve. 2. Pressure oil from port BM acts on combination valve (A) (12) and combination valve B (13) respectively. P

BCD

Pressure at Port AM T1V1-03-02-001-1 ja

P- Pressure

TODFY50-EN-00(10/01/2020)

T- Time

T3-2-10

SECTION3 COMPONENT OPERATION Group2 Swing Device P

B C D

a E

Pressure at Port BM T1V1-03-02-002-1 ja

P- Pressure T- Time

TODFY50-EN-00(10/01/2020)

a- With Combination Valve b- Without Combination Valve

T3-2-11

SECTION3 COMPONENT OPERATION Group2 Swing Device 8 AM

12 1

5 14

4 2

3 3

15 7

6 17

16 123456-

Poppet Ball Plunger Spring Piston Orifice

78910-

Spring Swing Motor Plug Chamber N (Combination Valve A)

11121314-

Chamber M (Combination Valve A) Combination Valve A Combination Valve B Chamber M (Combination Valve B)

151617-

T1V1-03-02-013-1 ja Chamber N (Combination Valve B) Control Valve Spring Chamber

Output Curve of Swing Dampener Valve: Operation of Combination Valve A between A and B (During Relief) 1. Pressure oil acts on combination valve A (12) opens ball (2) through poppet (1) and flows to chamber N (10).

TODFY50-EN-00(10/01/2020)

T3-2-12

SECTION3 COMPONENT OPERATION Group2 Swing Device 2. When pressure in chamber N (10) is larger than spring (4) force and spring (7) force, piston (5) tries to move to the left. However, piston (5) is blocked by plug (9) and cannot move. 3. Plunger (3) and poppet (1) compress springs (4, 7) and move to the right as a unit. This state continues until pressure at port BM begins to decrease (output curve: B). P

BCD

Pressure at Port AM T1V1-03-02-001-1 ja

P- Pressure

T- Time P

B C D

a E

Pressure at Port BM T1V1-03-02-002-1 ja

P- Pressure T- Time

TODFY50-EN-00(10/01/2020)

a- With Combination Valve b- Without Combination Valve

T3-2-13

SECTION3 COMPONENT OPERATION Group2 Swing Device 8 AM

12 1

5 14

4 2

3 3

15 7

6 17

16 123456-

Poppet Ball Plunger Spring Piston Orifice

78910-

Spring Swing Motor Plug Chamber N (Combination Valve A)

11121314-

Chamber M (Combination Valve A) Combination Valve A Combination Valve B Chamber M (Combination Valve B)

151617-

T1V1-03-02-013-1 ja Chamber N (Combination Valve B) Control Valve Spring Chamber

Output Curve of Swing Dampener Valve: Operation of Combination Valve B between A and B (During Relief) 1. Pressure oil routed to combination valve B (13) flows to spring chamber (17) through the inner passage.

TODFY50-EN-00(10/01/2020)

T3-2-14

SECTION3 COMPONENT OPERATION Group2 Swing Device 2. When pressure in spring chamber (17) is larger than spring (4) force and spring (7) force, plunger (3), piston (5), and poppet (1) compress springs (4, 7) and move to the left as a unit. This state continues until pressure at port BM decreases (output curve: C ). P

BCD

Pressure at Port AM T1V1-03-02-001-1 ja

P- Pressure

T- Time P

B C D

a E

Pressure at Port BM T1V1-03-02-002-1 ja

P- Pressure T- Time

TODFY50-EN-00(10/01/2020)

a- With Combination Valve b- Without Combination Valve

T3-2-15

SECTION3 COMPONENT OPERATION Group2 Swing Device 8 AM

12 1

5 14

4 2

3 3

15 7

6 17

16 123456-

Poppet Ball Plunger Spring Piston Orifice

78910-

Spring Swing Motor Plug Chamber N (Combination Valve A)

11121314-

Chamber M (Combination Valve A) Combination Valve A Combination Valve B Chamber M (Combination Valve B)

151617-

T1V1-03-02-013-1 ja Chamber N (Combination Valve B) Control Valve Spring Chamber

Output Curve of Swing Dampener Valve: Between B and C (Pressure Begins to Decrease) When the swing motor (8) rotation due to the inertia force of machine is decreased, pressure at port BM decreases. At this time, combination valve A (12) is operated as follows.

TODFY50-EN-00(10/01/2020)

T3-2-16

SECTION3 COMPONENT OPERATION Group2 Swing Device P

BCD

Pressure at Port AM T1V1-03-02-001-1 ja

P- Pressure

T- Time P

B C D

a E

Pressure at Port BM T1V1-03-02-002-1 ja

P- Pressure T- Time

TODFY50-EN-00(10/01/2020)

a- With Combination Valve b- Without Combination Valve

T3-2-17

SECTION3 COMPONENT OPERATION Group2 Swing Device 8 AM

12 1

5 14

4 2

3 3

15 7

16 12345-

Poppet Ball Plunger Spring Piston

6789-

Orifice Spring Swing Motor Plug

10111213-

Chamber N (Combination Valve A) Chamber M (Combination Valve A) Combination Valve A Combination Valve B

141516-

T1V1-03-02-014-1 ja Chamber M (Combination Valve B) Chamber N (Combination Valve B) Control Valve

Output Curve of Swing Dampener Valve: Operation of Combination Valve A between B and C (Pressure Begins to Decrease) 1. When pressure at port BM decreases, pressure routed to chamber N (10) also decreases. 2. When pressure in chamber N (10) is smaller than the spring (4) force, the spring (4) force moves plunger (3) to the left. TODFY50-EN-00(10/01/2020)

T3-2-18

SECTION3 COMPONENT OPERATION Group2 Swing Device 3. Poppet (1) is also pushed to the left by the spring (7) force at the same time. 4. As the pressure difference is caused due to orifice (6) at this time, pressure in chamber M (11) increases. 5. Poppet (1) moves to the left more slowly. 6. Consequently, a clearance between poppet (1) and plunger (3) appears.Pressure oil from port BM flows to port AM through the clearance between poppet (1) and plunger (3). 7. As combination valve A (12) allows pressure oil in port BM (high pressure) to flow to port AM (low pressure), pressure increase at the high-pressure side is controlled and aftershock pressure is reduced. This state continues until aftershock pressure at port AM appears (output curve:D).

NOTE Combination valve B (13) on the output curve between B and C is kept operated as the output curve between A and B. (Refer to "Output Curve of Swing Dampener Valve: Between A and B (When Relieving)"T3-2-10) This state continues until pressure at port BM decreases (output curve: C). P

BCD

Pressure at Port AM T1V1-03-02-001-1 ja

P- Pressure

T- Time P

B C D

a E

Pressure at Port BM T1V1-03-02-002-1 ja

P- Pressure T- Time

TODFY50-EN-00(10/01/2020)

a- With Combination Valve b- Without Combination Valve

T3-2-19

SECTION3 COMPONENT OPERATION Group2 Swing Device 8 AM

12 1

5 14

4 2

3 3

15 7

16 12345-

Poppet Ball Plunger Spring Piston

6789-

Orifice Spring SWING MOTOR Plug

10111213-

Chamber N (Combination Valve A) Chamber M (Combination Valve A) Combination Valve A Combination Valve B

141516-

T1V1-03-02-014-1 ja Chamber M (Combination Valve B) Chamber N (Combination Valve B) Control Valve

Output Curve of Swing Dampener Valve: Between C and D (Port BM Pressure Decreases) When the swing motor (8) rotation is decreased further, pressure at port BM decreases further. At this time, combination valve B (13) is operated as follows.

TODFY50-EN-00(10/01/2020)

T3-2-20

SECTION3 COMPONENT OPERATION Group2 Swing Device P

BCD

Pressure at Port AM T1V1-03-02-001-1 ja

P- Pressure

T- Time P

B C D

a E

Pressure at Port BM T1V1-03-02-002-1 ja

P- Pressure T- Time

TODFY50-EN-00(10/01/2020)

a- With Combination Valve b- Without Combination Valve

T3-2-21

SECTION3 COMPONENT OPERATION Group2 Swing Device 8 AM

12 1

5 14

4 2

3 3

15 7

6 17

16 123456-

Poppet Ball Plunger Spring Piston Orifice

78910-

Spring Swing Motor Plug Chamber N (Combination Valve A)

11121314-

Chamber M (Combination Valve A) Combination Valve A Combination Valve B Chamber M (Combination Valve B)

151617-

T1V1-03-02-015-1 ja Chamber N (Combination Valve B) Control Valve Spring Chamber

Output Curve of Swing Dampener Valve: Operation of Combination Valve B between C and D (Port BM Pressure Decreases) 1. When pressure at port BM decreases further, pressure routed to the spring (17) chamber in combination valve B (13) also decreases. TODFY50-EN-00(10/01/2020)

T3-2-22

SECTION3 COMPONENT OPERATION Group2 Swing Device 2. When pressure in the spring chamber (17) is smaller than the spring (4) force, the spring (4) force moves plunger (3) to the right. 3. Poppet (1) is also pushed to the right by the spring (7) force at the same time. 4. As the pressure difference is caused due to orifice (6) at this time, pressure in chamber M (14) increases. 5. Poppet (1) moves to the right more slowly. 6. Consequently, a clearance between poppet (1) and plunger (3) appears.Pressure oil from port BM acts on poppet (1) and ball (2). 7. Ball (2) is pushed by poppet (1).Poppet (1) and ball (2) compress spring (7) and move to the left as a unit. 8. This state continues until aftershock pressure at port AM appears (output curve:D).

NOTE Combination valve A (12) on the output curve between C and D is kept operated as the output curve between B and C. (Refer to "Output Curve of Swing Dampener Valve: Between B and C (Pressure Begins to Decrease)"T3-2-16) This state continues until aftershock pressure at port AM appears (output curve: D). P

BCD

Pressure at Port AM T1V1-03-02-001-1 ja

P- Pressure

T- Time P

B C D

a E

Pressure at Port BM T1V1-03-02-002-1 ja

P- Pressure T- Time

TODFY50-EN-00(10/01/2020)

a- With Combination Valve b- Without Combination Valve

T3-2-23

SECTION3 COMPONENT OPERATION Group2 Swing Device 8 AM

12 1

5 14

4 2

3 3

15 7

6 17

16 123456-

Poppet Ball Plunger Spring Piston Orifice

78910-

Spring SWING MOTOR Plug Chamber N (Combination Valve A)

11121314-

Chamber M (Combination Valve A) Combination Valve A Combination Valve B Chamber M (Combination Valve B)

151617-

T1V1-03-02-015-1 ja Chamber N (Combination Valve B) Control Valve Spring Chamber

Output Curve of Swing Dampener Valve: Between D and E (During Aftershock) When swing motor (8) stops rotating, aftershock pressure appears at port AM and pressure at port AM increases. (Port AM: High Pressure, Port BM: Low pressure) At this time, combination valve A (12) and combination valve B (13) are operated as follows.

TODFY50-EN-00(10/01/2020)

T3-2-24

SECTION3 COMPONENT OPERATION Group2 Swing Device P

BCD

Pressure at Port AM TDC1-03-02-001-1 ja

P- Pressure

T- Time P

B C D

a E

Pressure at Port BM T1V1-03-02-002-1 ja

P- Pressure T- Time

TODFY50-EN-00(10/01/2020)

a- With Combination Valve b- Without Combination Valve

T3-2-25

SECTION3 COMPONENT OPERATION Group2 Swing Device 8 AM

12 1

2 2

1 13

16 T1V1-03-02-016-1 ja 12-

Poppet Ball

812-

Swing Motor Combination Valve A

1316-

Combination Valve B Control Valve

Output Curve of Swing Dampener Valve: Operation of Combination Valve A between D and E (During Aftershock) 1. Pressure oil from port AM acts on ball (2) and poppet (1) through the inner passage. 2. Ball (2) and poppet (1) move to the right.

TODFY50-EN-00(10/01/2020)

T3-2-26

SECTION3 COMPONENT OPERATION Group2 Swing Device P

BCD

Pressure at Port AM TDC1-03-02-001-1 ja

P- Pressure

T- Time P

B C D

a E

Pressure at Port BM T1V1-03-02-002-1 ja

P- Pressure T- Time

TODFY50-EN-00(10/01/2020)

a- With Combination Valve b- Without Combination Valve

T3-2-27

SECTION3 COMPONENT OPERATION Group2 Swing Device 8 AM

12 1

2 2

1 13

16 T1V1-03-02-016-1 ja 12-

Poppet Ball

812-

Swing Motor Combination Valve A

1316-

Combination Valve B Control Valve

Output Curve of Swing Dampener Valve: Operation of Combination Valve B between D and E (During Aftershock) 1. Pressure oil from port AM opens ball (2) through poppet (1) and flows to port BM. 2. As combination valve B (13) is operated as the output curve between B and E and allows pressure oil in port AM (high pressure) to flow to port BM (low pressure), pressure increase at high-pressure side is controlled and aftershock pressure is reduced.

TODFY50-EN-00(10/01/2020)

T3-2-28

SECTION3 COMPONENT OPERATION Group2 Swing Device Combination valve A (12) and combination valve B (13) repeat these procedures on the output curve between B and E, and prevent aftershock of machine. When pressures at ports AM and BM decrease completely, the combination valve stops operating. P

BCD

Pressure at Port AM TDC1-03-02-001-1 ja

P- Pressure

T- Time P

B C D

a E

Pressure at Port BM T1V1-03-02-002-1 ja

P- Pressure T- Time

TODFY50-EN-00(10/01/2020)

a- With Combination Valve b- Without Combination Valve

T3-2-29

SECTION3 COMPONENT OPERATION Group2 Swing Device 8 AM

12 1

2 2

1 13

16 T1V1-03-02-016-1 ja 12-

Poppet Ball

TODFY50-EN-00(10/01/2020)

812-

Swing Motor Combination Valve A

1316-

T3-2-30

Combination Valve B Control Valve

SECTION3 COMPONENT OPERATION Group3 Control Valve Outline of Control Valve The control valve controls the pressure, flow rate, and flow direction in the hydraulic circuit. The control valve consists of the main relief valve, overload relief valve, flow combiner valve, anti-drift valve, flow rate control valve, regenerative valve, digging regenerative valve, boom lower meter-in cut valve, auxiliary flow combiner valve, bypass shut-out valve, and spools. The spools are operated by pilot oil pressure. Viewed from the machine front side in the A side block, the spools are arranged as follows:travel (right) (9), bucket (10), arm 2 (11), boom 1 (12), boom 3 (13) and swing (14). Viewed from the machine front side in the B side block, the spools are arranged as follows: travel (left) (7), auxiliary 1 (6), arm 1 (5), boom 2 (4), and positioning/auxiliary 2 (2) 2

5 6 7

13 B 12 11 10 9

a A b

Control Valve TDFY-03-03-001-1 ja

a- Machine Upper Side 1245-

Main Relief Valve (P1, P2) Positioning/Auxiliary 2 Boom 2 Arm 1

TODFY50-EN-00(10/01/2020)

b- Machine Front Side 6789-

Auxiliary 1 Travel (Left) Main Relief Valve (P3) Travel (Right)

10111213-

T3-3-1

Bucket Cylinder Arm 2 Boom 1 Boom 3

14-

Swing

SECTION3 COMPONENT OPERATION Group3 Control Valve Components in Control Valve 1

10 11

50 12 49

15 16

47 46

41 22 40 39 23 24

25 37 26 36 27 17 35 34

51 TDFY-03-03-002-1 ja

TODFY50-EN-00(10/01/2020)

T3-3-2

SECTION3 COMPONENT OPERATION Group3 Control Valve 1234567891011121314-

Check Valve (Main Relief Cir cuit) Main Relief Valve (P1, P2) Check Valve (Main Relief Cir cuit) Load Check Valve (Travel (Left) Parallel Circuit) Auxiliary Flow Combiner Valve Check Valve (Auxiliary Flow Combiner Circuit) Load Check Valve (Orifice) (Bucket) Check Valve (Bucket Tandem Circuit) Check Valve (Flow Combiner Circuit) Flow Combiner Valve Bucket Regeneration Cut Valve Bucket Regenerative Valve Check Valve (Arm 2 Parallel Circuit) Arm Roll-In Meter-Out Open Control Spool

15161718192021222324252627-

Overload Relief Valve (Bucket: Rod Side) Overload Relief Valve (Bucket: Bottom Side) Auxiliary 2 Hydraulic Pressure Source Selector Spool Load Check Valve (Boom 1 Parallel Circuit) Boom Lower Meter-In Cut Valve Boom Anti-Drift Valve (Check Valve) Overload Relief Valve (Boom: Bottom Side) Overload Relief Valve (Boom: Rod Side) Boom Anti-Drift Valve (Selec tor Valve) Pump 1 Bypass Shut-Out Valve Boom Regenerative Valve Load Check Valve (Boom 3 Tandem Circuit) Main Relief Valve (P3)

28293031323334353637383940-

Load Check Valve (Swing Tan dem Circuit) Load Check Valve (Boom 3 Parallel Circuit) Digging Regenerative Valve Load Check Valve (Auxiliary 2 Parallel Circuit) Load Check Valve (Auxiliary 2 Tandem Circuit) Pump 3 Bypass Shut-Out Valve Overload Relief Valve (Posi tioning/Auxiliary 2) Overload Relief Valve (Posi tioning/Auxiliary 2) Load Check Valve (Boom 2 Parallel Circuit) Arm 1 Flow Rate Control Valve (Poppet Valve) Arm 1 Flow Rate Control Valve (Selector Valve) Load Check Valve (Digging Regenerative Circuit) Arm Regenerative Valve

41424344454647484950515253-

Load Check Valve (Arm Re generative Circuit) Arm Bottom Anti-Drift Valve (Check Valve) Overload Relief Valve (Arm: Bottom Side) Arm Rod Anti-Drift Valve (Se lector Valve) Arm Bottom Anti-Drift Valve (Selector Valve) Arm Rod Anti-Drift Valve (Check Valve) Overload Relief Valve (Arm: Rod Side) Auxiliary Flow Rate Control Valve (Selector Valve) Auxiliary Flow Rate Control Valve (Poppet Valve) Load Check Valve (Travel (Left) Tandem Circuit) Pump 2 Pump 3 Pump 1

A Side 27 20,23

X e 16 11

28 a 29

18 14 f

13 8

b X 7

9 TDFY-03-03-003-1 ja

a- Machine Upper Side b- Machine Front Side c- Arm 2 Roll-In Pilot Pressure Sensor

d- Bucket Roll-In Pilot Pressure Sensor e- Bucket Roll-Out Pilot Pressure Sensor f- Arm Roll-Out Pilot Pressure Sensor

19-

7891011-

Check Valve (Main Relief Cir cuit) Load Check Valve (Orifice) (Bucket) Check Valve (Bucket Tandem Circuit) Check Valve (Flow Combiner Circuit) Flow Combiner Valve Bucket Regeneration Cut Valve

TODFY50-EN-00(10/01/2020)

1314151618-

Check Valve (Arm 2 Parallel Circuit) Arm Roll-In Meter-Out Open Control Spool Overload Relief Valve (Bucket: Rod Side) Overload Relief Valve (Bucket: Bottom Side) Load Check Valve (Boom 1 Parallel Circuit)

20212223-

T3-3-3

Boom Lower Meter-In Cut Valve Boom Anti-Drift Valve (Check Valve) Overload Relief Valve (Boom: Bottom Side) Overload Relief Valve (Boom: Rod Side) Boom Anti-Drift Valve (Selec tor Valve)

24272829-

Pump 1 Bypass Shut-Out Valve Main Relief Valve (P3) Load Check Valve (Swing Tan dem Circuit) Load Check Valve (Boom 3 Parallel Circuit)

SECTION3 COMPONENT OPERATION Group3 Control Valve 1

10 11

50 12 49

15 16

47 46

41 22 40 39 23 24

25 37 26 36 27 17 35 34

51 TDFY-03-03-002-1 ja

TODFY50-EN-00(10/01/2020)

T3-3-4

SECTION3 COMPONENT OPERATION Group3 Control Valve 1234567891011121314-

15161718192021222324252627-

28293031323334353637383940-

41424344454647484950515253-

B Side 44,46 2

47 33

37,38

48,49

a 36

b 50 1

6 4

Y 42,45

30 g

17 43 39 TDFY-03-03-004-1 ja

a- Machine Upper Side b- Machine Front Side 1245617-

Check Valve (Main Relief Cir cuit) Main Relief Valve (P1, P2) Load Check Valve (Travel (Left) Parallel Circuit) Auxiliary Flow Combiner Valve Check Valve (Auxiliary Flow Combiner Circuit) Auxiliary 2 Hydraulic Pressure Source Selector Spool

TODFY50-EN-00(10/01/2020)

g- Boom Raise Pilot Pressure Sensor h- Travel Pilot Pressure Sensor 303233363738-

Digging Regenerative Valve Load Check Valve (Auxiliary 2 Tandem Circuit) Pump 3 Bypass Shut-Out Valve Load Check Valve (Boom 2 Parallel Circuit) Arm 1 Flow Rate Control Valve (Poppet Valve) Arm 1 Flow Rate Control Valve (Selector Valve)

3942434445-

T3-3-5

Load Check Valve (Digging Regenerative Circuit) Arm Bottom Anti-Drift Valve (Check Valve) Overload Relief Valve (Arm: Bottom Side) Arm Rod Anti-Drift Valve (Se lector Valve) Arm Bottom Anti-Drift Valve (Selector Valve)

4647484950-

Arm Rod Anti-Drift Valve (Check Valve) Overload Relief Valve (Arm: Rod Side) Auxiliary Flow Rate Control Valve (Selector Valve) Auxiliary Flow Rate Control Valve (Poppet Valve) Load Check Valve (Travel (Left) Tandem Circuit)

SECTION3 COMPONENT OPERATION Group3 Control Valve 1

10 11

50 12 49

15 16

47 46

41 22 40 39 23 24

25 37 26 36 27 17 35 34

51 TDFY-03-03-002-1 ja

TODFY50-EN-00(10/01/2020)

T3-3-6

SECTION3 COMPONENT OPERATION Group3 Control Valve 1234567891011121314-

TODFY50-EN-00(10/01/2020)

15161718192021222324252627-

28293031323334353637383940-

T3-3-7

41424344454647484950515253-

SECTION3 COMPONENT OPERATION Group3 Control Valve b

A-A

G H R

L B

B-B

Q-Q

a 50

40 30 6 17

33 TDFY-03-03-005-1 ja

a- Machine Upper Side 235-

Main Relief Valve (P1, P2) Check Valve (Main Relief Cir cuit) Auxiliary Flow Combiner Valve

TODFY50-EN-00(10/01/2020)

b- Machine Front Side 61710-

Check Valve (Auxiliary Flow Combiner Circuit) Auxiliary 2 Hydraulic Pressure Source Selector Spool Flow Combiner Valve

303340-

T3-3-8

Digging Regenerative Valve Pump 3 Bypass Shut-Out Valve Arm Regenerative Valve

50-

Load Check Valve (Travel (Left) Tandem Circuit)

SECTION3 COMPONENT OPERATION Group3 Control Valve 1

10 11

50 12 49

15 16

47 46

41 22 40 39 23 24

25 37 26 36 27 17 35 34

51 TDFY-03-03-002-1 ja

TODFY50-EN-00(10/01/2020)

T3-3-9

SECTION3 COMPONENT OPERATION Group3 Control Valve 1234567891011121314-

TODFY50-EN-00(10/01/2020)

15161718192021222324252627-

28293031323334353637383940-

T3-3-10

41424344454647484950515253-

SECTION3 COMPONENT OPERATION Group3 Control Valve D-D

G H R

L B

E-E

F-F

l m

44 11 15 46 8

16 TDFY-03-03-006-1 ja

a- Machine Upper Side i- Travel (Left) j- Travel (Right) k- Auxiliary 1 8111213-

Check Valve (Bucket Tandem Circuit) Bucket Regeneration Cut Valve Bucket Regenerative Valve Check Valve (Arm 2 Parallel Circuit)

TODFY50-EN-00(10/01/2020)

l- Bucket m- Arm 1 n- Arm 2 151637-

Overload Relief Valve (Bucket: Rod Side) Overload Relief Valve (Bucket: Bottom Side) Arm 1 Flow Rate Control Valve (Poppet Valve)

384446-

T3-3-11

Arm 1 Flow Rate Control Valve (Selector Valve) Arm Rod Anti-Drift Valve (Se lector Valve) Arm Rod Anti-Drift Valve (Check Valve)

4849-

Auxiliary Flow Rate Control Valve (Selector Valve) Auxiliary Flow Rate Control Valve (Poppet Valve)

SECTION3 COMPONENT OPERATION Group3 Control Valve 1

10 11

50 12 49

15 16

47 46

41 22 40 39 23 24

25 37 26 36 27 17 35 34

51 TDFY-03-03-002-1 ja

TODFY50-EN-00(10/01/2020)

T3-3-12

SECTION3 COMPONENT OPERATION Group3 Control Valve 1234567891011121314-

TODFY50-EN-00(10/01/2020)

15161718192021222324252627-

28293031323334353637383940-

T3-3-13

41424344454647484950515253-

SECTION3 COMPONENT OPERATION Group3 Control Valve G-G

G H R

30 B

A a

H-H

R-R o

47 21

42, 45 43 22

TDFY-03-03-007-1 ja

a- Machine Upper Side o- Boom 2 14181921-

Arm Roll-In Meter-Out Open Control Spool Load Check Valve (Boom 1 Parallel Circuit) Boom Lower Meter-In Cut Valve Overload Relief Valve (Boom: Bottom Side)

TODFY50-EN-00(10/01/2020)

p- Boom 1 22243036-

Overload Relief Valve (Boom: Rod Side) Pump 1 Bypass Shut-Out Valve Digging Regenerative Valve Load Check Valve (Boom 2 Parallel Circuit)

39404142-

T3-3-14

Load Check Valve (Digging Regenerative Circuit) Arm Regenerative Valve Load Check Valve (Arm Re generative Circuit) Arm Bottom Anti-Drift Valve (Check Valve)

434547-

Overload Relief Valve (Arm: Bottom Side) Arm Bottom Anti-Drift Valve (Selector Valve) Overload Relief Valve (Arm: Rod Side)

SECTION3 COMPONENT OPERATION Group3 Control Valve 1

10 11

50 12 49

15 16

47 46

41 22 40 39 23 24

25 37 26 36 27 17 35 34

51 TDFY-03-03-002-1 ja

TODFY50-EN-00(10/01/2020)

T3-3-15

SECTION3 COMPONENT OPERATION Group3 Control Valve 1234567891011121314-

TODFY50-EN-00(10/01/2020)

15161718192021222324252627-

28293031323334353637383940-

T3-3-16

41424344454647484950515253-

SECTION3 COMPONENT OPERATION Group3 Control Valve J-J

a r

G H R

33 20

L 25 17 B

T-T

A a

L-L a

32 28

TDFY-03-03-008-1 ja

a- Machine Upper Side r- Boom 3 172023-

Auxiliary 2 Hydraulic Pressure Source Selector Spool Boom Anti-Drift Valve (Check Valve) Boom Anti-Drift Valve (Selec tor Valve)

TODFY50-EN-00(10/01/2020)

s- Positioning/Auxiliary t- Swing 25262728-

Boom Regenerative Valve Load Check Valve (Boom 3 Tandem Circuit) Main Relief Valve (P3) Load Check Valve (Swing Tan dem Circuit)

293233-

T3-3-17

Load Check Valve (Boom 3 Parallel Circuit) Load Check Valve (Auxiliary 2 Tandem Circuit) Pump 3 Bypass Shut-Out Valve

SECTION3 COMPONENT OPERATION Group3 Control Valve 1

10 11

50 12 49

15 16

47 46

41 22 40 39 23 24

25 37 26 36 27 17 35 34

51 TDFY-03-03-002-1 ja

TODFY50-EN-00(10/01/2020)

T3-3-18

SECTION3 COMPONENT OPERATION Group3 Control Valve 1234567891011121314-

15161718192021222324252627-

28-

293031323334353637383940-

41424344454647484950515253-

a M-M

7 N-N

N O-O

1 O

TDFY-03-03-009-1 ja

a- Machine Upper Side 1-

Check Valve (Main Relief Cir cuit)

TODFY50-EN-00(10/01/2020)

Load Check Valve (Orifice) (Bucket)

T3-3-19

Check Valve (Flow Combiner Circuit)

SECTION3 COMPONENT OPERATION Group3 Control Valve 1

10 11

50 12 49

15 16

47 46

41 22 40 39 23 24

25 37 26 36 27 17 35 34

51 TDFY-03-03-002-1 ja

TODFY50-EN-00(10/01/2020)

T3-3-20

SECTION3 COMPONENT OPERATION Group3 Control Valve 1234567891011121314-

15161718192021222324252627-

28293031323334353637383940-

P-P

41424344454647484950515253-

TDFY-03-03-010-1 ja

a- Machine Upper Side 4-

b- Machine Front Side

Load Check Valve (Travel (Left) Parallel Circuit)

Main Circuit of Control Valve Pressure oil from pump 1 (21) flows to each spool of travel (right) (4), bucket (5), arm 2 (9), and boom 1 (10) at the A side of control valve. Pressure oil from pump 2 (19) flows to each spool of boom 2 (27), arm 1 (28), auxiliary 1 (30), and travel (left) (32) at the B side of control valve. Pressure oil from pump 3 (20) flows to each spool of swing (15), boom 3 (13), and positioning/auxiliary 2 (23) at the A and B sides of control valve. The parallel circuits (8, 25, 18) are provided in each main circuit of pump 1 (21), pump 2 (19), and pump 3 (20), and makes the combined operation possible. TODFY50-EN-00(10/01/2020)

T3-3-21

SECTION3 COMPONENT OPERATION Group3 Control Valve Flow combiner circuit (2) is provided in the arm circuit. Flow combiner circuit (2) combines pressure oil from both pump 1 (21) and pump 2 (19) when performing arm single operation. Flow combiner circuit (17) is provided in the boom raise circuit. Flow combiner circuit (17) combines pressure oil from pump 1 (21), pump 2 (19), and pump 3 (20) when performing boom raise single operation. In case of boom lower (with the track raised off the ground), pressure oil from pump 3 (20) is not combined and pressure oil from only pump 1 (21) and pump 2 (19) are combined. The main relief valves (1, 16) are provided in the main circuit (between the pump and the actuator). Main relief valves (1, 16) prevent the pressure in main circuit from exceeding the set pressure when the spool is operated (when the control lever is operated). The overload relief valves (7, 12, 22, 29) are provided in the actuator circuits (between the control valve and the actuator) of boom, arm, bucket, auxiliary. The overload relief valves (7, 12, 22, 29) prevent surge pressure caused by external force in the actuator circuit from exceeding the set pressure when the spool is in neutral (with the control lever set in neutral).

TODFY50-EN-00(10/01/2020)

T3-3-22

SECTION3 COMPONENT OPERATION Group3 Control Valve 3

33 1

5 30 29

7 8 11

10 27 25

24 13

23 15

21 123456789-

Main Relief Valve (P1, P2) Flow Combiner Circuit (Arm) Travel Motor (Right) Travel (Right) Spool Bucket Spool Bucket Cylinder Overload Relief Valve Parallel Circuit (Pump 1) Arm 2 Spool

TODFY50-EN-00(10/01/2020)

101112131415161718-

Boom 1 Spool Boom Cylinder Overload Relief Valve Boom 3 Spool Swing Motor Swing Spool Main Relief Valve (P3) Flow Combiner Circuit (Boom) Parallel Circuit (Pump 3)

192021222324252627-

T3-3-23

Pump 2 Pump 3 Pump 1 Overload Relief Valve Positioning/Auxiliary 2 Spool Positioning Cylinder Parallel Circuit (Pump 2) Arm Cylinder Boom 2 Spool

282930313233-

TDFY-03-03-011-1 ja Arm 1 Spool Overload Relief Valve Auxiliary 1 Spool Attachment Travel (Left) Spool Travel Motor (Left)

SECTION3 COMPONENT OPERATION Group3 Control Valve Pilot Operation Control Circuit of Control Valve Pressure oil (1 to 16) from the pilot valve are routed to the spools in the control valve and move the spools. Pressure oil acts on the following selector valves when performing the following operations. •

When performing arm roll-in (4) operation, pressure oil moves the arm spool and shifts the selector valve spool of the arm rod anti-drift valve (e).

•

When performing arm roll-out (3) operation, pressure oil shifts the selector valve spool of the arm bottom anti-drift valve (d).

•

When performing boom lower (2) operation, pressure oil shifts the selector valve spool of the boom anti-drift valve (c). The divided pressure oil shifts the boom 1 spool and the boom 2 spool through the boom lower meter-in cut valve (b).

•

Air bleed circuit (a) is located in the upper of control valve and bleeds air automatically. a

11 9

10 12

14 7

b d 3

1 4 2 15 16

Pilot Operation Control Circuit TDFY-03-03-012-1 ja

TODFY50-EN-00(10/01/2020)

T3-3-24

SECTION3 COMPONENT OPERATION Group3 Control Valve a- Air Bleed Circuit b- Boom Lower Meter-In Cut Valve c- Boom Anti-Drift Valve 12345-

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

678910-

d- Arm Bottom Anti-Drift Valve e- Arm Rod Anti-Drift Valve Swing Right Bucket Roll-In Bucket Roll-Out Travel Left Forward Travel Left Reverse

11121314-

Travel Right Forward Travel Right Reverse Auxiliary 1 (Open) Auxiliary 1 (Close)

1516-

Positioning Raise/Auxiliary 2 (Open) Positioning Lower/Auxiliary 2 (Close)

External Pilot Pressure Circuit of Control Valve ● Relief pressure of main relief valves (1, 6) is increased by pilot pressure (a) from 5-spool solenoid valve unit (SI). ● Arm regenerative valve (8) is shifted by pilot pressure (g) from 5-spool solenoid valve unit (SC). ● Arm roll-in meter-out open control spool (3) is shifted by pilot pressure (d) from 5-spool solenoid valve unit (SD). ● Digging regenerative valve (4) is shifted by pilot pressure (e) from 5-spool solenoid valve unit (SF). ● Arm 1 flow rate control valve (7) is shifted by pilot pressure (f ) from 5-spool solenoid valve unit (SE). ● Flow combiner valve (2) is shifted by pilot pressure (c) from the flow combiner valve control spool in the signal control valve. ● Pump 1 Bypass shut-out valve (5) is shifted by pilot pressure (i) from 2-spool solenoid valve unit (SJ). ● Arm 2 spool (11) is controlled by pilot pressure (j) from 3-spool solenoid valve unit (SK1). ● Arm 3 spool (12) is controlled by pilot pressure (k) from 3-spool solenoid valve unit (SK2). ● Pupm 3 Bypass shut-out valve (13) is shifted by pilot pressure (i) from 3-spool solenoid valve unit (SK3). ● Auxiliary flow rate control valve (9) is shifted by pilot pressure (h) from the auxiliary flow rate control solenoid valve (Option). ● Auxiliary flow combiner valve (10) and pump 1 bypass shut-out valve (5) are shifted by pilot pressure (b) from auxiliary flow combiner control solenoid valve (Option).

NOTE In general, auxiliary flow combiner valve (10) and auxiliary flow rate control valve (9) are connected to the drain circuit. The auxiliary flow rate control solenoid valve and auxiliary flow combiner control solenoid valve are equipped for only the machine equipped with the optional parts.

TODFY50-EN-00(10/01/2020)

T3-3-25

SECTION3 COMPONENT OPERATION Group3 Control Valve 1

a 10 9 11 3 h

4 8 5 b, i k

12 7 13

m 6

External Pilot Pressure Circuit TDFY-03-03-013-1 ja

a- Pilot Pressure from 5-Spool Solenoid Valve Unit (SI) g- Pilot Pressure from 5-Spool Solenoid Valve Unit (SC) b- Pilot Pressure from Auxiliary Flow Combiner Control Sole h- Pilot Pressure from Auxiliary Flow Rate Control Solenoid noid Valve (Option) Valve (Optional) c- Pilot Pressure from Flow Combiner Valve Control Spool in i- Pilot Pressure from 2-Spool Solenoid Valve Unit (SJ) Signal Control Valve d- Pilot Pressure from 5-Spool Solenoid Valve Unit (SD) j- Pilot Pressure from 3-Spool Solenoid Valve Unit (SK1) e- Pilot Pressure from 5-Spool Solenoid Valve Unit (SF) k- Pilot Pressure from 3-Spool Solenoid Valve Unit (SK2) f- Pilot Pressure from 5-Spool Solenoid Valve Unit (SE) m- Pilot Pressure from 3-Spool Solenoid Valve Unit (SK3) 1234-

Main Relief Valve (P1, P2) Flow Combiner Valve Arm Roll-In Meter-Out Open Control Spool Digging Regenerative Valve

TODFY50-EN-00(10/01/2020)

5678-

Pump 1 Bypass Shut-Out Valve Main Relief Valve (P3) Arm 1 Flow Rate Control Valve Arm Regenerative Valve

91011-

T3-3-26

Auxiliary Flow Rate Control Valve Auxiliary Flow Combiner Valve Arm 2 Spool

1213-

Boom 3 Spool Pump 3 Bypass Shut-Out Valve

SECTION3 COMPONENT OPERATION Group3 Control Valve Operation of Flow Combiner Valve NOTE As an example, the combined operation of travel and boom raise is explained here. 1. When performing the combined operation boom raise and travel, pilot pressure shifts travel (right) spool (5), travel (left) spool (4), boom 1 spool (7), boom 2 spool (13), and boom 3 spool (9). 2. At the same time, the travel (right) pilot pressure shifts the flow combiner valve control spool in the signal control valve. 3. Pressure oil from the pilot pump flows to port SL in the flow combiner valve through the flow combiner valve control spool and acts on spool (1). 4. When pressure at port SL increases beyond the spring (2) force, spool (1) compresses spring (2) and moves to the left. 5. Pressure oil from pump 1 (12) flows to travel (right) spool (5). In addition, pressure oil from pump 1 (12) flows to travel (left) spool (4) through spool (1). 6. Pressure oil from pump 2 (10) flows to boom cylinder (8) through boom 2 spool (13) and moves the boom at this time. 7. Pressure oil from pump 3 (11) flows through boom 3 spool (9), is combined with pressure oil from pump 2 (10), and moves the boom. 8. Consequently, pressure oil from pump 1 (12) is equally supplied to both left and right travel motors, and the machine can travel straight. a

TDAA-03-03-057-2 ja

a- Pressure Oil from Pump 1 (12) b- Pilot Pressure from Flow Combiner Valve Control Spool 1-

Spool (Flow Combiner Valve)

TODFY50-EN-00(10/01/2020)

c- To Travel (Left) Spool (4) d- To Hydraulic Oil Tank

Spring

T3-3-27

SECTION3 COMPONENT OPERATION Group3 Control Valve 6

3 4

10 TDFY-02-04-009-2 ja

b- Pilot Pressure from Flow Combiner Valve Control Spool 1234-

Spool (Flow Combiner Valve) Spring Travel Motor (Left) Travel (Left) Spool

TODFY50-EN-00(10/01/2020)

5678-

Travel (Right) Spool Travel Motor (Right) Boom 1 Spool Boom Cylinder

9101112-

T3-3-28

Boom 3 Spool Pump 2 Pump 3 Pump 1

13-

Boom 2 Spool

SECTION3 COMPONENT OPERATION Group3 Control Valve Outline of Main Relief Valve The main relief valve prevents the pressure in the main circuit from exceeding the set pressure when the actuator such as the motor or the cylinder is operated. Therefore, oil leak from hose and pipe joints and breakage of the actuator are prevented.

Relief Operation of Main Relief Valve 1. Pressure in port HP (main circuit) is routed to pilot poppet (8) through orifice A (2) in main poppet (1) and orifice B (3) in seat (4). 2. When pressure in port HP reaches the set pressure of spring B (6), pilot poppet (8) is opened. Pressure oil from passage A (5) flows along the external circumference of sleeve (11) and flows to port LP (hydraulic oil tank). 3. At this time, a pressure difference is caused between port HP and the spring chamber (10) due to orifice A (2). 4. When the force generated by this pressure difference reaches the set pressure of spring A (9), main poppet (1) is opened and pressure oil from port HP flows to port LP. 5. Consequently, the main circuit pressure decreases. 6. When the main circuit pressure decreases to the specified level, main poppet (1) is closed by the force of spring A (9). Pilot poppet (8) is also closed by the force of spring B (6). 2

LP 11

When Performing Normal Operation TDAB-03-03-020-1 ja

HP- Main Circuit 123-

LP- Hydraulic Oil Tank

Main Poppet Orifice A Orifice B

456-

Seat Passage A Spring B

789-

Piston Pilot Poppet Spring A

1011-

Spring Chamber Sleeve

LP 11

When Performing Relief Operation TDAB-03-03-021-1 ja

HP- Main Circuit TODFY50-EN-00(10/01/2020)

LP- Hydraulic Oil Tank

T3-3-29

SECTION3 COMPONENT OPERATION Group3 Control Valve 123-

Main Poppet Orifice A Orifice B

456-

Seat Passage A Spring B

789-

Piston Pilot Poppet Spring A

1011-

Spring Chamber Sleeve

Pressure Increasing Operation of Main Relief Valve 1. When performing pressure increasing operation, pilot pressure (SG) from 5-spool solenoid valve unit (SI) acts on piston (7) and spring B (6) is compressed. 2. The force of spring B (6) becomes strong. 3. Consequently, as pressure required in order to open pilot poppet (8) is increased, the relief set pressure is increased. 6

LP 8

When Performing Pressure Increase Operation T157-02-05-004-1 ja

HP- Main Circuit LP- Hydraulic Oil Tank 6-

Spring B

TODFY50-EN-00(10/01/2020)

SG- Pilot Pressure from 5-Spool Solenoid Valve Unit (SI) 7-

Piston

T3-3-30

Pilot Poppet

SECTION3 COMPONENT OPERATION Group3 Control Valve Outline of Overload Relief Valve (With Make-Up Function) The overload relief valves are provided in the boom, arm, bucket, and auxiliary circuits. The overload relief valve prevents the pressure in each actuator circuit from exceeding the set pressure when the actuators are moved by external force. In addition, when the actuator circuit pressure decreases, the overload relief valve draws hydraulic oil from the hydraulic oil tank and prevents the occurrence of cavitation (make-up function).

Relief Operation of Overload Relief Valve 1. Pressure in port HP (actuator circuit) acts on pilot poppet (8) through orifice (11) of piston (10). 2. When pressure in port HP reaches the set pressure of spring B (6), pilot poppet (8) is opened, pressure oil from passage A (5) flows along the outer circumference of sleeve (3), and flows to port LP (hydraulic oil tank). 3. At this time, a pressure difference occurs between port HP and spring chamber (9) due to orifice (11). 4. When the force generated by this pressure difference reaches the set pressure of spring A (4), piston (10) and main poppet (2) are opened and pressure oil from port HP flows to port LP. 5. Consequently, the actuator circuit pressure decreases. 6. When the actuator circuit pressure decreases to the specified level, piston (10) and main poppet (2) are closed by the force of spring A (4). Pilot poppet (8) is also closed by the force of spring B (6). 2

LP 11

When Performing Normal Operation T107-02-05-019-1 ja

HP- Actuator Circuit 234-

Main Poppet Sleeve Spring A

TODFY50-EN-00(10/01/2020)

LP- Hydraulic Oil Tank 567-

Passage A Spring B Spring C

8910-

T3-3-31

Pilot Poppet Spring Chamber Piston

11-

Orifice

SECTION3 COMPONENT OPERATION Group3 Control Valve 2

LP 11

When Performing Relief Operation T178-03-03-049-1 ja

HP- Actuator Circuit 234-

LP- Hydraulic Oil Tank

Main Poppet Sleeve Spring A

567-

Passage A Spring B Spring C

8910-

Pilot Poppet Spring Chamber Piston

11-

Orifice

Make-Up Operation of Overload Relief Valve 1. When pressure in port HP (actuator circuit) decreases lower than pressure in port LP (hydraulic oil tank), sleeve (3) is moved to the right. 2. Hydraulic oil in port LP flows to port HP and cavitation is prevented. 3. When pressure in port HP increases to the specified pressure, sleeve (3) is closed by the force of spring C (7). 3

LP 7

When Performing Make-Up Operation T178-03-03-050-1 ja

HP- Actuator Circuit 3-

Sleeve

TODFY50-EN-00(10/01/2020)

LP- Hydraulic Oil Tank 7-

Spring C

T3-3-32

SECTION3 COMPONENT OPERATION Group3 Control Valve Outline of Regenerative Valve The regenerative valves are provided in the boom lower, arm roll-in, and bucket roll-in circuits. The regenerative valves increase cylinder speed, improve machine controllability, and prevent cylinder hesitation.

Operation of Boom Regenerative Valve 1. When performing boom lower operation with the front attachment above the ground, returning oil from the boom cylinder (2) bottom side shifts boom lower meter-in cut valve (1). Boom 1 spool and boom 2 spool are returned to neutral. (Refer to "Outline of Boom Lower Meter-In Cut Valve"T3-3-51) 2. Pressure oil flowing to boom 3 spool (3) acts on check valve (4) through hole (5) of boom 3 spool (3). 3. At this time, when pressure in the boom cylinder (2) rod side is lower than the bottom side, check valve (4) is opened. 4. Consequently, returning oil from the boom cylinder (2) bottom side is supplied to the rod side and the regenerative operation is done. 5. When boom cylinder (2) reaches the stroke end or digging loads increase, pressure in the boom cylinder (2) rod side circuit is higher than the bottom side. 6. Therefore, check valve (4) of the boom regenerative valve is closed and regenerative operation is stopped. 1

3 a

4 TDFY-03-03-028-1 ja

a- Boom Lower Pilot Pressure 1-

Boom Lower Meter-In Cut Valve

TODFY50-EN-00(10/01/2020)

b- Pilot Pressure from Boom 2 Spool 23-

Boom Cylinder Boom 3 Spool

T3-3-33

Check Valve

SECTION3 COMPONENT OPERATION Group3 Control Valve a

When Performing Boom Regenerative Operation TDAA-03-03-029-1 ja

a- Boom Lower Pilot Pressure c- Returning Oil from Boom Cylinder (2) Bottom Side

d- Pressure Oil to Boom Cylinder (2) Rod Side

Boom 3 Spool

Check Valve

Hole

Outline of Bucket Regenerative Valve The bucket regenerative valve supplys returning oil of the bucket cylinder rod side to the bottom side, prevent cylinder hesitation, and increase bucket roll-in operating speed when performing bucket roll-in operation.

TODFY50-EN-00(10/01/2020)

T3-3-34

SECTION3 COMPONENT OPERATION Group3 Control Valve Operation When Performing Bucket Regenerative Operation 1. Returning oil from the bucket cylinder (1) rod side is routed to check valve (2) through hole (4) of bucket spool (3) when performing bucket roll-in operation. 2. At this time, when pressure in the bucket cylinder (1) bottom side is lower than the rod side, check valve (2) is opened. 3. Consequently, returning oil from the bucket cylinder (1) rod side flows to the bottom side and is combined with pressure oil from pump 1. The combined pressure oil is delivered to the bucket cylinder (1) bottom side and regenerative operation is done. 4. Therefore, cylinder hesitation is prevented and bucket roll-in operating speed increases during bucket roll-in operation. a 1

2 TDAA-03-03-030-1 ja

a- Pressure Oil from Pump 1 1-

Bucket Cylinder

TODFY50-EN-00(10/01/2020)

Check Valve

T3-3-35

Bucket Spool

SECTION3 COMPONENT OPERATION Group3 Control Valve

b 4

c 2

When Performing Bucket Regenerative Operation TDAA-03-03-031-1 ja

b- Returning Oil from Bucket Cylinder (1) Rod Side

c- Pressure Oil to Bucket Cylinder (1) Bottom Side

Check Valve

Bucket Spool

Hole

Operation When Performing Bucket Regenerative Cut Operation 1. When bucket cylinder (3) reaches the stroke end or digging loads increase when performing bucket roll-in operation, pressure in the bucket cylinder (3) bottom side increases. At this time, pressure oil from pump 1 acts on spool (1) of the bucket regeneration cut valve. 2. Spool (1) compresses spring (2) and moves upward (to the right in the circuit diagram). 3. Pressure in the cylinder (3) rod side is lower than the bucket cylinder (3) bottom side. As check valve (4) of the bucket regenerative valve is kept closed and pressure oil from the bucket cylinder (3) rod side does not flow to the bucket cylinder (3) bottom side, regenerative operation is not done. 4. Pressure oil from the cylinder (3) rod side flows to the hydraulic oil tank through bucket spool (5) and spool (1). 5. Therefore, the pressure at bucket cylinder (3) rod side decreases and the digging force is improved. TODFY50-EN-00(10/01/2020)

T3-3-36

SECTION3 COMPONENT OPERATION Group3 Control Valve a

b 2 3

4 TDAA-03-03-032-1 ja

a- Pressure Oil from Pump 1 1-

Spool (Bucket Regeneration Cut Valve)

TODFY50-EN-00(10/01/2020)

b- To Hydraulic Oil Tank 23-

Spring Bucket Cylinder

45-

T3-3-37

Check Valve Bucket Spool

SECTION3 COMPONENT OPERATION Group3 Control Valve

2 1

c 6 7 5 a

d 4

When Performing Bucket Regeneration Cut Operation TDAA-03-03-033-1 ja

a- Pressure Oil from Pump 1 b- To Hydraulic Oil Tank 1-

Spool (Bucket Regeneration Cut Valve)

c- Returning Oil from Bucket Cylinder (3) Rod Side d- Pressure Oil to Bucket Cylinder (3) Bottom Side 24-

Spring Check Valve

56-

Bucket Spool Hole

Orifice

Operation When Performing Arm Regenerative Operation The arm regenerative valves supply returning oil of the arm cylinder (5) rod side to the bottom side, prevent cylinder hesitation, and increase arm roll-in operating speed when performing arm roll-in operation. 1. Returning oil from the arm cylinder (5) rod side flows to chamber A (6) through notch part (9) of arm 1 spool (1) when performing normal arm roll-in operation. 2. Pressure oil which flows to chamber A (6) is divided into two directions.One flows to the hydraulic oil tank through notch (7) of arm 1 spool (1). The other is blocked by spool (4) of the arm regenerative valve.

TODFY50-EN-00(10/01/2020)

T3-3-38

SECTION3 COMPONENT OPERATION Group3 Control Valve 3. Only the circuit through notch (7) of arm 1 spool (1) is the circuit which flows from chamber A (6) to the hydraulic oil tank, and pressure in chamber A (6) increases. 4. As pressure in chamber A (6) increases, pressure in the rod side is higher than the arm cylinder (5) bottom side. 5. Pressure oil from pump 2 (2) and pressure in chamber A (6) act on to check valve (3). When these pressure become larger than the spring (8) force, check valve (3) is opened. 6. Consequently, returning oil from the arm cylinder (5) rod side is combined with pressure oil from pump 2 (2). The combined pressure oil is delivered to the arm cylinder (5) bottom side. 7. Therefore, regenerative operation is done.When performing arm roll-in operation, arm hesitation is prevented, and the arm roll-in speed increases. 1

4 3

12-

Arm 1 Spool Pump 2

TODFY50-EN-00(10/01/2020)

Check Valve

T3-3-39

Spool (Arm Regenerative Valve)

TDFY-03-03-014-1 ja Arm Cylinder

SECTION3 COMPONENT OPERATION Group3 Control Valve 1

3 a

6 4 b c

b 9

Before Regeneration Operation TDFY-03-03-015-1 ja

a- Pressure in Chamber A (6) b- Pressure Oil from Pump 2 (2) 13-

Arm 1 Spool Check Valve

c- Returning Oil from Arm Cylinder (5) Rod Side d- Pressure Oil to Arm Cylinder (5) Bottom Side Spool (Arm Regenerative Valve)

67-

Chamber A Notch

89-

Spring Notch Part

8 7

3 a

6 4 d c

d 9

After Regeneration Operation TDFY-03-03-016-1 ja

a- Pressure in Chamber A (6) b- Pressure Oil from Pump 2 (2) 13-

Arm 1 Spool Check Valve

TODFY50-EN-00(10/01/2020)

c- Returning Oil from Arm Cylinder (5) Rod Side d- Pressure Oil to Arm Cylinder (5) Bottom Side Spool (Arm Regenerative Valve)

67-

T3-3-40

Chamber A Notch

89-

Spring Notch Part

SECTION3 COMPONENT OPERATION Group3 Control Valve Operation When Releasing Arm Regenerative Operation When performing arm roll-in operation, spool (4) in arm regenerative valve is shifted according to other operating conditions and working conditions, and controls the correct operation according to the pump load. 1. When 5-spool solenoid valve unit (SC) is activated by the signal from MC (main controller), spool (4) of the arm regenerative valve is shifted by pilot pressure. (Refer to SYSTEM/Control System.) 2. Pressure oil which flows to chamber A (6) from the arm cylinder (5) rod side flows to the hydraulic oil tank through hole (12) of spool (4). 3. Pressure in the arm cylinder (5) rod side is lower than the arm cylinder (5) bottom side. 4. Pressure oil from pump 2 (2) flows to chamber B (11) through orifice (10) of check valve (3) at this time. As check valve (3) is pushed downward by pressure in chamber B (11) and the spring (8) force, check valve (3) is not opened. 5. Consequently, pressure oil from the arm cylinder (5) rod side does not flow to the bottom side and regenerative operation is not done. 6. Therefore, the pressure at arm cylinder (5) rod side decreases and the digging force is improved. 1

2 4 3 TDFY-03-03-017-1 ja

e- Pilot Pressure from Solenoid Valve Unit (SC) 12-

Arm 1 Spool Pump 2

Check Valve

Spool (Arm Regenerative Valve)

Arm Cylinder

10 a 6

b c

12 4

e b TDFY-03-03-018-1 ja

TODFY50-EN-00(10/01/2020)

T3-3-41

SECTION3 COMPONENT OPERATION Group3 Control Valve a- Pressure in Chamber A (6) b- Pressure Oil from Pump 2 (2) 13-

Arm 1 Spool Check Valve

TODFY50-EN-00(10/01/2020)

c- Returning Oil from Arm Cylinder (5) Rod Side e- Pilot Pressure from Solenoid Valve Unit (SC) Spool (Arm Regenerative Valve)

6810-

T3-3-42

Chamber A Spring Orifice

1112-

Chamber B Hole

SECTION3 COMPONENT OPERATION Group3 Control Valve Outline of Anti-Drift Valve The anti-drift valves are provided in the circuits of the boom cylinder bottom side, arm cylinder rod side, and arm cylinder bottom side, and reduces the cylinder drift.

NOTE Both boom and arm anti-drift valves are identical in structure.

Holding Operation of Anti-Drift Valve 1. As pressure oil from the pilot valve does not flow with the control lever set in neutral (the spool in neutral), the selector valve (3) in anti-drift valve is not shifted. 2. Pressure in the boom cylinder (1) bottom side (arm cylinder rod or bottom side) acts on check valve (2) (the spring (4) side) in the anti-drift valve through selector valve (3). 3. Consequently, as check valve (2) is pushed and the return circuit from boom cylinder (1) is blocked, the boom cylinder (1) drift is reduced. 1

2 TDAA-03-03-039-1 ja

Boom Cylinder

Check Valve (Anti-Drift Valve)

Selector Valve (Anti-Drift Valve)

3 4 2

d e TDAA-03-03-041-1 ja

TODFY50-EN-00(10/01/2020)

T3-3-43

SECTION3 COMPONENT OPERATION Group3 Control Valve d- Returning Oil from Cylinder (1) (Boom Cylinder: Bottom Side, Arm Cylinder: Rod or Bottom Side)

e- To Main Spool

Check Valve (Anti-Drift Valve)

Selector Valve (Anti-Drift Valve)

Spring

Releasing Operation of Anti-Drift Valve 1. Pressure oil from the pilot valve pushes piston (5) of the anti-drift valve and shifts selector valve (3) when performing arm roll-in, arm roll-out, or boom lower operation. 2. Pressure oil in the spring (4) chamber of check valve (2) is returned to the hydraulic oil tank through the passage of selector valve (3). 3. When pressure in the spring (4) chamber decreases, and pressure in the spring (4) chamber and the spring (4) force are lower than pressure in the boom cylinder (1) bottom side, check valve (2) moves upward (to the right in the circuit diagram). 4. Consequently, returning oil from the boom cylinder (1) bottom side (arm cylinder rod side or bottom side) flows to the spool. 5. Orifice (6) of selector valve (3) decreases pressure in the spring (4) chamber slowly.Therefore, check valve (2) is prevented from moving quickly and shock when performing arm roll-in or boom lower operation is reduced. 1

2 TDAA-03-03-040-1 ja

a- Pressure Oil from Pump 1 b- To Hydraulic Oil Tank 1-

Boom Cylinder

TODFY50-EN-00(10/01/2020)

c- Pressure Oil from Pilot Valve 2-

Check Valve (Anti-Drift Valve)

T3-3-44

Selector Valve (Anti-Drift Valve)

SECTION3 COMPONENT OPERATION Group3 Control Valve

3 4 2

e TDAA-03-03-058-1 ja

c- Pressure Oil from Pilot Valve d- Returning Oil from Cylinder (1) (Boom Cylinder: Bottom Side, Arm Cylinder: Rod or Bottom Side)

e- To Main Spool

23-

Check Valve Selector Valve

45-

Spring Piston

Orifice

Outline of Flow Rate Control Valve The flow rate control valves are provided in the arm 1 and auxiliary 1 circuits, restricts oil flow rate in the circuit when performing combined operation, and gives priority to other actuators. Each flow rate control valve is operated when performing combined operation as shown in the table. Flow Rate Control Valve Arm 1

Combined Operation Attachment, Arm Boom Raise, Arm

Auxiliary 1

Swing, Arm Roll-In, Boom Raise Travel Attachment, Arm Roll-In (when adjusting priority (arm roll-in)) Attachment, Arm Roll-Out (when adjusting priority (arm roll-out))

Normal Operation of Flow Rate Control Valve NOTE As an example, the arm 1 flow rate control valve is explained here. 1. Pressure oil from pump 2 (a) acts on check valve (4) of poppet valve (3). 2. Normally, as selector valve (2) is kept open, pressure oil (a) from pump 2 opens check valve (4) and flows to the arm 1 spool through selector valve (2). 3. When load in the actuator side is high, poppet valve (3) is opened and pressure oil (a) from pump 2 flows to the arm 1 spool. TODFY50-EN-00(10/01/2020)

T3-3-45

SECTION3 COMPONENT OPERATION Group3 Control Valve 4. Flow rate flowing to the arm 1 spool increases and arm operating speed becomes fast. 2 3 1

a TDFY-03-03-019-1 ja

a- Pressure Oil from Pump 2 1-

Arm Cylinder

Selector Valve

Poppet Valve

Check Valve

3 b

c a

2 c

When Performing Normal Operation TDFY-03-03-021-1 ja

a- Pressure Oil from Pump 2 b- To Arm 1 Spool 2-

Selector Valve

c- To Hydraulic Oil Tank 3-

Poppet Valve

Check Valve

Flow Rate Control Operation of Flow Rate Control Valve NOTE As an example, the arm 1 flow rate control valve is explained here. 1. The signal from MC activates the 5-spool solenoid valve unit (SE). Selector valve (2) of the arm 1 flow rate control valve is shifted by pilot pressure (d) from the 5-spool solenoid valve unit (SE). 2. Back pressure in poppet valve (3) increases and the force to close poppet valve (3) appears. 3. The opening clearance of poppet valve (3) is reduced and pressure oil flow rate flowing to the arm 1 spool is restricted. 4. Pressure oil from pump 2 flows to the auxiliary 1 spool by priority.

TODFY50-EN-00(10/01/2020)

T3-3-46

SECTION3 COMPONENT OPERATION Group3 Control Valve 2 3 1

d a TDFY-03-03-020-1 ja

a- Pressure Oil from Pump 2 1-

Arm Cylinder

d- Pilot Pressure from 5-Spool Solenoid Valve Unit (SE) 2-

Selector Valve

Poppet Valve

3 b

d a 2 c

When Performing Flow Rate Control Operation TDFY-03-03-022-1 ja

a- Pressure Oil from Pump 2 b- To Arm 1 Spool 2-

Selector Valve

c- To Hydraulic Oil Tank d- Pilot Pressure from 5-Spool Solenoid Valve Unit (SE) 3-

Poppet Valve

Outline of Arm Roll-In Meter-Out Open Control Spool The arm roll-in meter-out open control spool is provided in the return circuit of arm roll-in. The arm roll-in meter-out open control spool is operated when digging operation is performed or arm roll-in operation above the ground is performed. When arm roll-in meter-out open control spool is shifted, the arm-roll in meter-out opening increases. Therefore, pressure loss of the arm roll-in meter-out side is reduced in order to reduce fuel consumption. (Refer to SYSTEM/Control System.)

Operation of Arm Roll-In Meter-Out Open Control Spool 1. When 5-spool solenoid valve unit (SD) is activated by the signal from MC (main controller), pressure oil from the pilot pump flows to port SD through 5-spool solenoid valve unit (SD). 2. Pressure oil from port SD acts on the end surface of spool (2) through inner passage (3). 3. Spool (2) compresses spring (1) and moves to the left. 4. The arm roll-in meter-out opening increases so that pressure oil from the arm cylinder (11) rod side (return side) flows through spool (2) to the arm cylinder (11) bottom side.

TODFY50-EN-00(10/01/2020)

T3-3-47

SECTION3 COMPONENT OPERATION Group3 Control Valve 5. Therefore, pressure loss of the arm roll-in meter-out side is reduced in order to reduce fuel consumption. SD b

c TDFY-03-03-023-1 ja

a- To Arm Cylinder (11) Bottom Side b- Pilot Pressure from 5-Spool Solenoid Valve Unit (SD)

c- Returning Oil from Arm Cylinder (11) Rod Side

Spring

TODFY50-EN-00(10/01/2020)

Spool (Arm Roll-In Meter-Out Open Control Spool)

T3-3-48

Inner Passage

SECTION3 COMPONENT OPERATION Group3 Control Valve

5 4

6 b 11

10 2

7 TDFY-02-04-024-2 ja

b- Pilot Pressure from 5-Spool Solenoid Valve Unit (SD) 24-

Spool (Arm Roll-In Meter-Out Open Control Spool) Bucket Spool

TODFY50-EN-00(10/01/2020)

567-

Bucket Cylinder Arm 2 Spool Pump 2

8910-

T3-3-49

Pump 3 Pump 1 Arm 1 Spool

11-

Arm Cylinder

SECTION3 COMPONENT OPERATION Group3 Control Valve Outline of Digging Regenerative Valve The digging regenerative valve is provided in the return circuit of boom raise. The digging regenerative valve is activated when performing combined operation of boom raise and arm roll-in. When the digging regenerative valve is shifted, pressure oil from the boom cylinder rod side (return side) flows through the digging regenerative valve, is combined with pressure oil from pump 2, and flows to arm 1 spool. Therefore, speed of arm roll-in increases. (Refer to SYSTEM/Control System.)

Operation of Digging Regenerative Valve 1. When 5-spool solenoid valve unit (SF) is activated by the signal from MC (main controller), pressure oil from the pilot pump flows to port SF through 5-spool solenoid valve unit (SF). 2. Pressure oil from port SF acts on the end of spool (4) through inner passage (2). 3. Spool (4) compresses spring (3) and moves downward. 4. Pressure oil from the boom cylinder (6) rod side (return side) opens check valve (1), is combined with pressure oil from pump 2 (8), and flows to arm 1 spool (12). 5. Consequently, as flow rate flowing to arm cylinder (13) increases, speed of arm roll-in increases. a

b c

3 TDAA-03-03-047-1 ja

a- To Arm 1 Spool (12) b- Pilot Pressure from 5-Spool Solenoid Valve Unit (SF)

c- Returning Oil from Boom Cylinder (6) Rod Side

12-

Check Valve Inner Passage

TODFY50-EN-00(10/01/2020)

Spring

T3-3-50

Spool (Digging Regenerative Valve)

SECTION3 COMPONENT OPERATION Group3 Control Valve 2

5 12 b 6

11 7

8 TDFY-02-04-010-2 ja

b- Pilot Pressure from 5-Spool Solenoid Valve Unit (SF) 14-

Check Valve Spool (Digging Regenerative Valve)

567-

Arm 2 Spool Boom Cylinder Boom 1 Spool

8910-

Pump 2 Pump 3 Pump 1

Outline of Boom Lower Meter-In Cut Valve The boom lower meter-in cut valve is provided in the boom lower circuit.

TODFY50-EN-00(10/01/2020)

T3-3-51

111213-

Boom 2 Spool Arm 1 Spool Arm Cylinder

SECTION3 COMPONENT OPERATION Group3 Control Valve Boom lower meter-in cut control is deactivated when the track raised off the ground, and the boom is given priority to operate and jack-up force increases. When performing boom lower operation with the front attachment above the ground, pilot pressure which acts on boom 1 spool is blocked. The boom lowers due to own weight by the regenerative circuit of boom 3 spool and allows pressure oil from the pump to other actuator. Consequently, operating speed of other actuator increases. (Refer to SYSTEM/ Hydraulic System.)

Operation of Boom Lower Meter-In Cut Valve (With the Track off the Ground) 1. As pressure at the boom cylinder (3) bottom side decreases with the track raised off the ground, pressure which acts on spool (2) decreases. 2. When pressure from the boom cylinder (3) bottom side is smaller than the spring (16) force, boom lower meter-in cut valve (2) moves to the right due to the spring (16) force. 3. As pilot pressure from port PI7 flows to boom 1 spool (6) and boom 2 spool (12) through spool (2) and port PI 9. 4. Consequently, pressure oil from the pump flows to boom cylinder (3) through boom 1 spool (6) and boom 2 spool (12). Then, jack-up force increases. 5. Therefore, boom lower meter-in cut control is not operated with the track raised off the ground. (Refer to SYSTEM/ Hydraulic System.) a

b PI7

PI9

15 d

c TDAA-03-03-049-2 ja

PI7- Port PI7 PI9- Port PI9 a- To Boom 1 Spool (6) and Boom 2 Spool (12) 2-

Spool (Boom Lower Meter-In Cut Valve)

TODFY50-EN-00(10/01/2020)

1516-

b- Boom Lower Pilot Pressure c- Pressure Oil from Boom Cylinder (3) Bottom Side d- To Hydraulic Oil Tank

Orifice Spring

T3-3-52

SECTION3 COMPONENT OPERATION Group3 Control Valve

2 3 PI7 PI9 6 12 7

8 TDFY-02-04-016-2 ja

PI7- Port PI7 PI9- Port PI9 23-

Spool (Boom Lower Meter-In Cut Valve) Boom Cylinder

TODFY50-EN-00(10/01/2020)

b- Boom Lower Pilot Pressure 678-

Boom 1 Spool Boom 3 Spool Pump 2

91012-

T3-3-53

Pump 3 Pump 1 Boom 2 Spool

SECTION3 COMPONENT OPERATION Group3 Control Valve Operation of Boom Lower Meter-In Cut Valve (With the Front Attachment above the Ground) 1. Pilot pressure acts on spool (2) through port PI7), when lowering the boom. 2. Returning oil from the boom cylinder (3) bottom side is divided into two directions. 3. One acts on spool (2) through orifice (15). When pressure from the boom cylinder (3) bottom side exceeds the spring (16) force, spool (2) compresses spring (16) and moves to the left. 4. As port PI9 is connected to the hydraulic oil tank through spool (2), boom 1 spool (6) does not move. 5. Other acts on boom 3 spool (7). Pressure oil flows to the boom cylinder (3) rod side through the boom regenerative valve in boom 3 spool (7). In addition, pressure oil flowing to boom 2 spool (12) returns to the hydraulic oil tank. 6. The boom lowers due to own weight. 7. Consequently, when performing combined operation of boom lower and other actuator, more pressure oil is supplied to other actuator and speed of actuator increases.

TODFY50-EN-00(10/01/2020)

T3-3-54

SECTION3 COMPONENT OPERATION Group3 Control Valve a

b PI9

PI7

15 d

c TDAA-03-03-049-1 ja

PI7- Port PI7 PI9- Port PI9 a- To Boom 1 Spool (6) and Boom 2 Spool (12) 2-

Spool (Boom Lower Meter-In Cut Valve)

TODFY50-EN-00(10/01/2020)

1516-

b- Boom Lower Pilot Pressure c- Pressure Oil from Boom Cylinder (3) Bottom Side d- To Hydraulic Oil Tank

Orifice Spring

T3-3-55

SECTION3 COMPONENT OPERATION Group3 Control Valve NOTE The illustration shows when performing combined operation of boom lower with front attachment above the ground and arm roll-out.

1 2

14 13

3 PI7 PI9

6 12

8 TDFY-02-04-015-2 ja

PI7- Port PI7 PI9- Port PI9

TODFY50-EN-00(10/01/2020)

b- Boom Lower Pilot Pressure

T3-3-56

SECTION3 COMPONENT OPERATION Group3 Control Valve 12-

Arm 2 Spool Spool (Boom Lower Meter-In Cut Valve)

367-

Boom Cylinder Boom 1 Spool Boom 3 Spool

8910-

Pump 2 Pump 3 Pump 1

121314-

Boom 2 Spool Arm Cylinder Arm 1 Spool

Outline of Auxiliary Flow Combiner Valve and Pump 1 Bypass Shut-Out Valve The auxiliary flow combiner valve is provided in the pump 2 side circuit, and pump 1 bypass shut-out valve is provided in the downstream of pump 1 side neutral circuit. These valve functions differ depending on whether only the front attachment is single-operated or combined- operated.

Operation of Auxiliary Flow Combiner Valve and Pump 1 Bypass Shut-Out Valve (During Single Operation) The auxiliary flow combiner valve (1) combines pressure oil from both pump 1 (6) and pump 2 (5) when performing attachment (8) single operation. Therefore, operating speed of attachment (8) increases. 1. When attachment (8) is single operated, attachment pilot pressure acts on port SM and port SJ, and spools (1, 3) in the auxiliary flow combiner valve and pump 1 bypass shut-out valve are shifted. 2. When spool (3) in the pump 1 bypass shut-out valve is shifted, the neutral circuit in pump 1 (6) side is blocked. 3. At this time, as spool (1) in the auxiliary flow combiner valve is also shifted, pressure oil in pump 1 (6) flows to auxiliary 1 spool (7) through the auxiliary flow combiner valve. 4. Consequently, pressure oil in both pump 1 (6) and pump 2 (5) are combined and operating speed of attachment (8) increases.

NOTE When attachment (8) is operated, attachment pilot pressure shifts the pump 1 flow rate control valve in signal control valve through auxiliary flow combiner control solenoid valve (4). Therefore, the displacement angle of pump 1 (6) increases and the pump delivery flow rate increases. (Refer to COMPONENT OPERATION/ Pump Device, Signal Control Valve.) a

c 2 1

Auxiliary Flow Combiner Valve TDAA-03-03-054-1 ja

a- To Auxiliary 1 Spool (7) b- Attachment Pilot Pressure TODFY50-EN-00(10/01/2020)

c- Pressure Oil from Pump 1 (6) d- To Hydraulic Oil Tank

T3-3-57

SECTION3 COMPONENT OPERATION Group3 Control Valve 1-

Spool (Auxiliary Flow Combin er Valve)

Check Valve

d SJ

Pump 1 Bypass Shut-Out Valve TDAA-03-03-051-1 ja

b- Attachment Pilot Pressure c- Pump 1 (6) Neutral Circuit 3-

d- To Hydraulic Oil Tank

Spool (Pump 1 Bypass ShutOut Valve)

NOTE The illustration shows when attachment is operated.

TODFY50-EN-00(10/01/2020)

T3-3-58

SECTION3 COMPONENT OPERATION Group3 Control Valve 4

SM SN

2 7

5 TDFY-03-03-024-1 ja

a- Attachment Pilot Pressure 12-

Spool (Auxiliary Flow Combin er Valve) Check Valve

c- Pressure Oil from Pump 1 (6) 3-

Spool (Pump 1 Bypass ShutOut Valve)

45-

Auxiliary Flow Combiner Con trol Solenoid Valve Pump 2

678-

Pump 1 Auxiliary 1 Spool Attachment

Operation of Auxiliary Flow Combiner Valve and Pump 1 Bypass Shut-Out Valve (During Combined Operation) When performing combined operation of attachment (8) and travel, the auxiliary flow combiner valve is not shifted. Therefore, the machine travel operating speed can be kept at the same speed during normal combined operation. 1. When attachment (8) is operated, attachment pilot pressure acts on port SM in the auxiliary flow combiner valve. 2. When travel is operated at the same time, pilot pressure from the signal control valve acts on port SN. TODFY50-EN-00(10/01/2020)

T3-3-59

SECTION3 COMPONENT OPERATION Group3 Control Valve 3. Pressure oil from port SM acts on spool (1) of the auxiliary flow combiner valve to the open direction, and pressure oil from port SN and the spring (9) force acts on spool (1) of the auxiliary flow combiner valve to the close direction. 4. As the force to the close direction is stronger, spool (1) is kept closed. 5. Consequently, as pressure oil from pump 1 (6) is not combined with pressure oil from pump 2 (5), the machine travel operating speed can be kept at the same speed when performing normal combined operation. a

2 1 9

Auxiliary Flow Combiner Valve TDAA-03-03-056-1 ja

a- To Auxiliary 1 Spool (7) b- Attachment Pilot Pressure 1-

Spool (Auxiliary Flow Combin er Valve)

TODFY50-EN-00(10/01/2020)

c- Pressure Oil from Pump 1 (6) e- Travel Pilot Pressure 29-

Check Valve Spring

T3-3-60

SECTION3 COMPONENT OPERATION Group3 Control Valve NOTE The illustration shows when performing auxiliary 1 (open)/travel (reverse) operation. 12

SN 8

5 TDFY-03-03-025-1 ja

a- Attachment Pilot Pressure 13-

Spool (Auxiliary Flow Combin er Valve) Spool (Pump 1 Bypass ShutOut Valve)

TODFY50-EN-00(10/01/2020)

e- Pilot Pressure from Signal Control Valve 456-

Auxiliary Flow Combiner Con trol Solenoid Valve Pump 2 Pump 1

781011-

T3-3-61

Auxiliary 1 Spool Attachment Travel Motor (Left) Travel (Left) Spool

1213-

Travel (Right) Spool Travel Motor (Right)

SECTION3 COMPONENT OPERATION Group3 Control Valve Outline of Pump 3 Bypass Shut-Out Valve Pump 3 bypass shut-out valve is provided in the pump 3 side neutral circuit. The pump 3 bypass shut-out valve is operated when performing boom raise operation. When the pump 3 bypass shut-out valve is shifted, the amount of pressure oil returning from the pump 3 neutral circuit into the hydraulic oil tank is reduced. Therefore, fuel consumption is reduced and the boom operating speed is maintained. (Refer to SYSTEM/Control System.)

Operation of Pump 3 Bypass Shut-Out Valve NOTE As an example, combined operation of arm roll-in and boom raise (at high load) is explained here. 1. When 3-spool solenoid valve unit (SK3) is activated by the signal from MC (main controller), pressure oil from the pilot pump flows to port SK3 through 3-spool solenoid valve unit (SK3). 2. Pressure oil from port SK3 acts on the end surface of spool (9). 3. Spool (9) compresses spring (13) and moves to the left. 4. The pump 3 neutral circuit (c) is blocked by spool (9). 5. Consequently, the amount of pressure oil returning from the pump 3 neutral circuit (c) into the hydraulic oil tank is reduced so that fuel consumption is reduced and the boom operating speed is maintained.

a SK3

9 TDFY-03-03-027-1 ja

SK3- Port SK3 a- Pilot Pressure from 3-Spool Solenoid Valve Unit (SK3) 9-

Spool (Pump 3 Bypass ShutOut Valve)

TODFY50-EN-00(10/01/2020)

13-

c- Pump 3 Neutral Circuit d- To Hydraulic Oil Tank

Spring

T3-3-62

SECTION3 COMPONENT OPERATION Group3 Control Valve 1

2 11 b 3

10 4 9

SK3 a

6 TDFY-03-03-026-1 ja

SK3- Port SK3 a- Pilot Pressure from 3-Spool Solenoid Valve Unit (SK3)

b- Pilot Pressure from 5-Spool Solenoid Valve Unit (SF)

89-

23-

Spool (Digging Regenerative Valve) Arm 2 Spool Boom Cylinder

TODFY50-EN-00(10/01/2020)

4567-

Boom 1 Spool Boom 3 Spool Pump 2 Pump 3

10-

T3-3-63

Pump 1 Spool (Pump 3 Bypass ShutOut Valve) Boom 2 Spool

1112-

Arm 1 Spool Arm Cylinder

SECTION3 COMPONENT OPERATION Group3 Control Valve MEMO

TODFY50-EN-00(10/01/2020)

T3-3-64

SECTION3 COMPONENT OPERATION Group4 Pilot Valve Outline of Pilot Valve The pilot valve controls pilot pressure oil in order to move the spool in the control valve. The pilot valve outputs pressure according to the control lever stroke by PPC (Pressure Proportional Control) function. The 4-port pilot valves for front attachment/swing and for travel are standard. The 2-port pilot valve is for auxiliary (option) and for positioning (only 2-piece boom spec. machine).

Outline of Front Attachment/Swing Pilot Valve Port No. Right

Left

Hitachi Pattern

Bucket Roll-Out

←

Boom Lower

←

Bucket Roll-In

←

Boom Raise

←

Swing (Right)

Arm Roll-In

Arm Roll-Out

Swing (Right)

Swing (Left)

Arm Roll-Out

Arm Roll-In

Swing (Left)

ISO Control Pattern

3 2

3 1

TDFY-03-04-001-1 ja

P- Port P (Pressure Oil from Pilot Pump)

T- Port T (To Hydraulic Oil Tank)

Port 1

TODFY50-EN-00(10/01/2020)

Port 2

T3-4-1

Port 3

Port 4

SECTION3 COMPONENT OPERATION Group4 Pilot Valve Outline of Travel Pilot Valve Port No. 1

Travel (Right Reverse)

Travel (Right Forward)

Travel (Left Forward)

Travel (Left Reverse) P

T 1

2 3

1 TDC1-03-04-008-1 ja

P- Port P (Pressure Oil from Pilot Pump) 1-

Port 1

T- Port T (To Hydraulic Oil Tank) 2-

Port 2

Port 3

Outline of Auxiliary 1 and Positioning/Auxiliary 2 Pilot Valves Port No. Auxiliary 1 Positioning/Auxiliary 2

TODFY50-EN-00(10/01/2020)

Open

Lower/Close

Raise/Open

T3-4-2

Port 4

SECTION3 COMPONENT OPERATION Group4 Pilot Valve P

P 1

2 TDC1-03-04-009-1 ja

P- Port P (Pressure Oil from Pilot Pump) 1-

Port 1

T- Port T (To Hydraulic Oil Tank) 2-

Port 2

Operation of Front Attachment/Swing and Travel Pilot Valves The spool (7) head is hanged from the upper surface of spring guide (4). Spring guide (4) is kept raised by return spring (6).

NOTE Total lever strokes for front attachment/swing controls are determined by stroke dimension (E) of pusher (2). Total lever stroke for travel control is determined by stroke dimension (E) of cam (1).

TODFY50-EN-00(10/01/2020)

T3-4-3

SECTION3 COMPONENT OPERATION Group4 Pilot Valve X

1 E

2 3 4

3 4

5 5 6 6

8 7 8

TDFY-03-04-002-1 ja

X- Front Attachment/Swing Pilot Valve

Y- Travel Pilot Valve

12-

56-

Cam Pusher

34-

Casing Spring Guide

Balance Spring Return Spring

78-

Spool Hole

When Front Attachment/Swing and Travel Pilot Valves are in Neutral (Output Curve: A to B) 1. When in neutral, spool (7) completely blocks pressure oil from port P (pilot pump). The output port is connected to port T (hydraulic oil tank) through the inner passage in spool (7). 2. Therefore, pressure in the output port is equal to pressure in port T. 3. When the control lever is slightly tilted, cam (1) is tilted and pusher (2) is pushed downward. Pusher (2) integral with spring guide (4) compresses return spring (6) and moves downward. 4. At this time, as pressure in the output port is equal to pressure in port T, spool (7) moves downward due to the balance spring (5) force while keeping the lower surface of the spool (7) head in contact with spring guide (4). 5. This status continues until hole (8) on spool (7) is connected to port P. E

T523-02-05-001 ja

a- Pilot Pressure TODFY50-EN-00(10/01/2020)

b- Lever Stroke

T3-4-4

SECTION3 COMPONENT OPERATION Group4 Pilot Valve X

X 1

7 T

8 P d

Y 1

2 T

3 3

d T

7 P

TDFY-03-04-003-1 ja

X- Front Attachment/Swing Pilot Valve Y- Travel Pilot Valve P- Port P

T- Port T d- Output Port

12-

56-

Cam Pusher

TODFY50-EN-00(10/01/2020)

34-

Casing Spring Guide

T3-4-5

Balance Spring Return Spring

78-

Spool Hole

SECTION3 COMPONENT OPERATION Group4 Pilot Valve During Metering or Decompressing of Front Attachment/Swing and Travel Pilot Valves (Output Curve: C to D) 1. When the control lever is further tilted and pusher (2) is moved downward further, hole (8) on spool (7) is connected to port P and pressure oil in port P flows to the output port. 2. Pressure in the output port acts on the bottom surface of spool (7) and spool (7) is pushed upward. 3. When the force to move spool (7) upward is smaller than the balance spring (5) force, balance spring (5) is not compressed and spool (7) is not raised and pressure in the output port increases. 4. Pressure in the output port increases further, the force to move spool (7) upward increases. When this force overcomes the balance spring (5) force, spool (7) compresses balance spring (5) and moves upward. 5. When spool (7) is moved upward, hole (8) is closed and pressure oil does not flow from port P to the output port. Therefore, pressure in the output port stops increasing. 6. When spool (7) is moved downward, balance spring (5) is compressed same as spool (7) movement. The spring force balances with the force which pressure acts on the spool, and its pressure is the output port pressure. E

T523-02-05-001 ja

a- Pilot Pressure

TODFY50-EN-00(10/01/2020)

b- Lever Stroke

T3-4-6

SECTION3 COMPONENT OPERATION Group4 Pilot Valve X

X 1

4 8

5 6

6 P

2 T

7 3 P

4 8

6 a

7 P

8 d

d TDFY-03-04-004-1 ja

X- Front Attachment/Swing Pilot Valve Y- Travel Pilot Valve P- Port P

T- Port T d- Output Port

12-

56-

Cam Pusher

TODFY50-EN-00(10/01/2020)

34-

Casing Spring Guide

T3-4-7

Balance Spring Return Spring

78-

Spool Hole

SECTION3 COMPONENT OPERATION Group4 Pilot Valve Full Stroke of Front Attachment/Swing and Travel Pilot Valves (Output Curve: E to F) 1. (Front Attachment/Swing Pilot Valve) When control lever is set to the full stroke, pusher (2) moves downward until it comes in contact with the stepped part of casing (3). (Travel Pilot Valve) When control lever is set to the full stroke, cam (1) moves downward until it comes in contact with casing (3). 2. At this time, the bottom surface of pusher (2) directly pushes spool (7). Therefore, even if pressure in the output port increases further, hole (8) on spool (7) is kept open. 3. Consequently, pressure in the output port is equal to pressure in port P. E

T523-02-05-001 ja

a- Pilot Pressure

b- Lever Stroke

Y 1 1 2

2 3 3 4

T P T

8 d

d TDFY-03-04-005-1 ja

X- Front Attachment/Swing Pilot Valve Y- Travel Pilot Valve P- Port P TODFY50-EN-00(10/01/2020)

T- Port T d- Output Port

T3-4-8

SECTION3 COMPONENT OPERATION Group4 Pilot Valve 12-

Cam Pusher

TODFY50-EN-00(10/01/2020)

34-

Casing Spring Guide

56-

T3-4-9

Balance Spring Return Spring

78-

Spool Hole

SECTION3 COMPONENT OPERATION Group4 Pilot Valve Operation of Auxiliary 1 and Positioning/Auxiliary 2 Pilot Valves The spool (7) head is hanged from the upper surface of spring guide (4). Spring guide (4) is kept raised by return spring (6).

NOTE The total stroke of the auxiliary 1 and positioning/auxiliary 2 levers is determined by stroke dimension (E) of cam (1). 1

2 3 4 5 6 7 8

TDAA-03-04-001-1 ja 12-

Cam Pusher

34-

Plate Spring Guide

56-

Balance Spring Return Spring

78-

Spool Hole

When Auxiliary 1 and Positioning/Auxiliary 2 Pilot Valves are in Neutral (Output Curve: A to B) 1. When the control pedal is in neutral, spool (7) completely blocks pressure oil from port P. The output port is connected to port T (hydraulic oil tank) through the inner passage in spool (7). 2. Therefore, pressure in the output port is equal to pressure in port T. 3. When the control pedal is slightly depressed, cam (1) is moved and pusher (2) is pushed downward. Pusher (2) compresses return spring (6) along with spring guide (4) together and moves downward. 4. At this time, as pressure in the output port is equal to pressure in port T, spool (7) moves downward due to the balance spring (5) force while keeping the lower surface of the spool (7) head in contact with spring guide (4). 5. This status continues until hole (8) on spool (7) is connected to port P.

NOTE The pusher stroke provided until hole (8) in spool (7) is connected to port P is play of the control pedal.

TODFY50-EN-00(10/01/2020)

T3-4-10

SECTION3 COMPONENT OPERATION Group4 Pilot Valve

a D

b T1F3-03-09-004 ja

a- Pilot Pressure

b- Pusher Stroke

1 7

8 P 3

4 5

6 7

8 8 d

TDC1-03-04-014-2 ja

P- Port P T- Port T 12-

Cam Pusher

d- Output Port 34-

Plate Spring Guide

56-

Balance Spring Return Spring

78-

Spool Hole

During Metering or Decompressing of Auxiliary 1 and Positioning/Auxiliary 2 Pilot Valves (Output Curve: C to D) 1. When the control pedal is further depressed and pusher (2) is moved downward further, hole (8) on spool (7) is connected to port P and pressure oil in port P flows to the output port. 2. Pressure in the output port is routed to the bottom surface of spool (7) and spool (7) is pushed upward. 3. When the force to move spool (7) upward is smaller than the balance spring (5) force, balance spring (5) is not compressed and spool (7) is not raised and pressure in the output port increases. 4. As pressure in the output port increases further, the force to move spool (7) upward increases. When this force overcomes the balance spring (5) force, spool (7) compresses balance spring (5) and moves upward. 5. When spool (7) is moved upward, hole (8) is closed and pressure oil does not flow from port P to the output port. Therefore, pressure in the output port stops increasing.

TODFY50-EN-00(10/01/2020)

T3-4-11

SECTION3 COMPONENT OPERATION Group4 Pilot Valve 6. When spool (7) is moved downward, balance spring (5) is compressed same as spool (7) movement. The spring force balances with the force which pressure acts on spool (7), and its pressure is the output port pressure. a D

b T1F3-03-09-004 ja

a- Pilot Pressure

b- Pusher Stroke

1 T

8 P

4 T

6 7

4 T

6 7

8 d

d TDC1-03-04-015-2 ja

P- Port P T- Port T 12-

Cam Pusher

TODFY50-EN-00(10/01/2020)

d- Output Port 34-

Plate Spring Guide

56-

T3-4-12

Balance Spring Return Spring

78-

Spool Hole

SECTION3 COMPONENT OPERATION Group4 Pilot Valve Outline of Shockless Function (Only Travel Pilot Valve) The travel pilot valve has damper (1) enabling damping of the speed change shock by travel control lever (4). Damper (1) is consist of support (5), gear 1 (9), gear 2 (8), and others. Gear 1 (9) is connected to support (5). Support (5) is secure to bracket (6) by spring pin (2). Travel control lever (4) and travel pedal (3) are secure to bracket (6). Therefore, support (5) rotates to the left and right around pin (7) according to movement of travel control lever (4). 1

A-A

4 5 1 5 6 7 8 9 A

TDC1-03-04-016-1 ja 123-

Damper Spring Pin Travel Pedal

456-

Travel Control Lever Support Bracket

789-

Pin Gear 2 Gear 1

Operation of Shockless Function 1. If travel control lever (4) is released while traveling, spring force of the return spring returns travel control lever (4) to the neutral position. 2. At this time, gear 1 (9) and gear 2 (8) inside damper (1) receive resistance force due to friction. 3. Consequently, as travel control lever (4) gradually returns to the neutral position, the extent of sudden stop at the time of abrupt release of travel control lever (4) is reduced.

TODFY50-EN-00(10/01/2020)

T3-4-13

SECTION3 COMPONENT OPERATION Group4 Pilot Valve 1

A-A

4 5 1 5 6 7 8 9 A

TDC1-03-04-016-1 ja 123-

Damper Spring Pin Travel Pedal

TODFY50-EN-00(10/01/2020)

456-

Travel Control Lever Support Bracket

789-

T3-4-14

Pin Gear 2 Gear 1

SECTION3 COMPONENT OPERATION Group5 Travel Device Outline of Travel Device The travel device consists of travel motor (4), travel reduction gear (2), and travel brake valve (1). Travel motor (4) is a swash plate type variable displacement axial plunger motor and equipped with a parking brake (a wet-type spring set hydraulic released multi-disc brake). Travel motor (4) is driven by pressure oil from the pump and transmits the rotation power to travel reduction gear (2). Travel reduction gear (2) is a three-stage planetary reduction gear, converts the travel motor (4) rotation power to a slowlarge torque, and rotates sprocket (3) and the track link. Travel brake valve (1) protects the travel circuit from being overloaded and prevents the occurrence of cavitation. 1

3 4 1-

Travel Brake Valve

Travel Reduction Gear

Sprocket

Outline of Travel Reduction Gear The travel reduction gear is a three-stage planetary reduction gear.

TODFY50-EN-00(10/01/2020)

T3-5-1

TDFY-03-05-001-2 ja Travel Motor

SECTION3 COMPONENT OPERATION Group5 Travel Device The travel motor rotates propeller shaft (7). This rotation is transmitted to ring gear (1) through first stage planetary gears (8), first stage carrier (6), second stage sun gear (5), second stage planetary gears (9), second stage carrier (4), third stage sun gear (3), third stage planetary gears (10), and third stage carrier (2). Housing (14) of the travel motor is secured to the track frame with bolts. In addition, housing (14) supports drum (13) via bearings (15) so that drum (13) can rotate. Third stage carrier (2) is connected to housing (14) by a spline joint. Ring gear (1), drum (13), and sprocket (12) are secured with bolts respectively. Therefore, when ring gear (1) rotates, drum (13) and sprocket (12) also rotate. 15

2 3

12 TDFY-03-05-001-1 ja 1234-

Ring Gear Third Stage Carrier Third Stage Sun Gear Second Stage Carrier

5678-

Second Stage Sun Gear First Stage Carrier Propeller Shaft First Stage Planetary Gear

9101112-

Second Stage Planetary Gear Third Stage Planetary Gear Bearing Nut Sprocket

131415-

Drum Housing Bearing

Outline of Travel Motor The travel motor is a swash plate type variable displacement axial plunger motor, and consists of valve plate (6), swash plate (4), rotor (2), plungers (5), and shaft (1). Shaft (1) is connected to rotor (2) by a spline joint. Plungers (5) are inserted into rotor (2). When pressure oil is supplied from the pump, plungers (5) are pushed. As swash plate (4) is inclined, shoes (3) on the ends of plungers (5) slide along swash plate (4) and the rotor (2) rotation power occurs.

TODFY50-EN-00(10/01/2020)

T3-5-2

SECTION3 COMPONENT OPERATION Group5 Travel Device 1

5 TDFY-03-05-002-1 ja

12-

Shaft Rotor

34-

Shoe Swash Plate

56-

Plunger Valve Plate

Operation of Travel Motor 1. Pressure oil flows to port B in valve plate (6), enters one side in rotor (2), and pushes plungers (5). 2. Shoes (3) at the ends of plungers (5) slide on swash plate (4) due to this force, and rotates rotor (2) and output shaft (1). 3. As rotor (2) rotates, plungers (5) rotates.When plungers (5) reach port A, plungers (5) are pushed back and pressure oil is returned to the hydraulic oil tank. 4. Whether forward travel or reverse travel depends on whether pressure oil is supplied to port A or port B.

TODFY50-EN-00(10/01/2020)

T3-5-3

SECTION3 COMPONENT OPERATION Group5 Travel Device A

A B

6 2 5

6 T183-03-05-009-2 ja

A- Port A (Pressure oil from main pump or returning oil to hydraulic oil tank)

B- Port B (Pressure oil from main pump or returning oil to hydraulic oil tank)

12-

56-

Shaft Rotor

34-

Shoe Swash Plate

Plunger Valve Plate

Outline of 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 is routed to brake piston chamber (a) to move brake piston (5). The parking brake is automatically applied at all times unless the travel function is operated. Friction plates (2) and plates (3) are connected to rotor (4) and housing (1) of the travel motor by a spline joint respectively.

TODFY50-EN-00(10/01/2020)

T3-5-4

SECTION3 COMPONENT OPERATION Group5 Travel Device 6

2 D

2 E

7 7

5 a

1 4

b BV

TDFY-03-05-003-1 ja

AV- Port AV (Pressure oil from main pump) BV- Port BV (Pressure oil from main pump) a- Brake Piston Chamber

b- To Brake Piston D- When Brake is Released E- When Brake is Applied

12-

56-

Housing Friction Plate

34-

Plate Rotor

Brake Piston Orifice

78-

Disc Spring Counterbalance Spool

Operation of Parking Brake (When Parking Brake is Released) 1. When the travel control lever is operated, pressure oil from the main pump flows to port AV or BV in the travel motor through the control valve. 2. This pressure oil shifts counterbalance valve spool (8) in the travel brake valve and acts on brake piston (5) through the notch on counterbalance valve spool (8).

TODFY50-EN-00(10/01/2020)

T3-5-5

SECTION3 COMPONENT OPERATION Group5 Travel Device 3. Consequently, as brake piston (5) is pushed, plates (3) and friction plates (2) become freed each other so that the brake is released. 2 3

7 a

1 4

b BV

TDFY-03-05-009-1 ja

AV- Port AV (Pressure oil from main pump) BV- Port BV (Pressure oil from main pump)

a- Brake Piston Chamber b- To Brake Piston

12-

57-

Housing Friction Plate

34-

Plate Rotor

Brake Piston Disc Spring

Counterbalance Spool

Operation of Parking Brake (When Parking Brake is Applied) 1. When the travel control lever is returned to neutral, counterbalance valve spool (8) in the travel brake valve is returned to neutral. 2. As pressure oil acted on brake piston (5) is returned to the drain circuit through orifice (6), brake piston (5) is returned by disc spring (7).

TODFY50-EN-00(10/01/2020)

T3-5-6

SECTION3 COMPONENT OPERATION Group5 Travel Device 3. Consequently, the spring force acts on friction plate (2), which is engaged with the external circumference of rotor (4), and on plate (3), which is engaged with the inside of housing (1) of the travel motor, through brake piston (5).Therefore, the external circumference of rotor (4) is secured with friction force. 6

1 2 3

7 5

1 4

b BV

TDFY-03-05-010-1 ja

AV- Port AV (Pressure oil from main pump) BV- Port BV (Pressure oil from main pump)

a- Brake Piston Chamber b- To Brake Piston

12-

56-

Housing Friction Plate

34-

Plate Rotor

Brake Piston Orifice

78-

Outline of Travel Brake Valve The travel brake valve is located on the travel motor head and consists of the following valves. •

Counterbalance Valve (2):

TODFY50-EN-00(10/01/2020)

T3-5-7

Disc Spring Counterbalance Spool

SECTION3 COMPONENT OPERATION Group5 Travel Device Counterbalance valve (2) ensures smooth start/stop travel operation and prevents the machine from rollaway when traveling on a down slope. In addition, counterbalance valve (2) routes the travel motor operating pressure oil in the high-pressure port (AV or BV) to the parking brake. •

Check Valve (3): Check valve (3) assists the counterbalance valve (2) operation and prevents cavitation in the motor circuit.

•

Travel Relief Valve (6): Travel relief valve (6) prevents the occurrence of overload and surge pressure in the motor circuit and reduces shock loads developed when stopping travel operation.

•

Shuttle Valve (1): Shuttle valve (1) supplies the travel motor operating pressure oil in high pressure port (AM or BM) to travel motor displacement angle control valve (5).

•

Travel Motor Displacement Angle Control Valve (5): This travel motor displacement angle control valve (5) is shifted by pilot pressure from 5-spool solenoid valve unit (SI). Travel motor displacement angle control valve (5) delivers pressure oil routed by shuttle valve (1) for piston operation to the piston through orifice (4) (for fast/slow speed).

•

Orifice (4) (for fast/slow speed): Orifice (4) makes the travel mode control (displacement angle control) smooth. A 1

A-A

A 5

6 12-

Shuttle Valve Counterbalance Valve

34-

Check Valve Orifice

Travel Motor Displacement Angle Control Valve

TDFY-03-05-008-1 ja Travel Relief Valve

Operation of Counterbalance Valve (During Travel) 1. When pressure oil from the control valve enters port AV (8), pressure oil flows around the outer circumference of spool (9), unseats check valve AC (7), and flows to motor port AM (6). 2. On the other hand, returning oil from the travel motor returns to motor port BM (4). However, its passage is blocked by check valve BC (3) and spool (9). 3. When pressure in port AV (8) increases further, pressure oil acts on chamber A (10) through orifice (f ) in spool (9) and moves spool (9) to the right. TODFY50-EN-00(10/01/2020)

T3-5-8

SECTION3 COMPONENT OPERATION Group5 Travel Device 4. Consequently, returning oil from the travel motor flows to port BV (1) through notch (h) on spool (9). As pressure oil starts flowing at this stage, the travel motor starts rotating. 5. When the travel control lever is returned to neutral, spool (9) is returned to the original position by the spring force and blocks the oil passage.Then, the travel motor rotation is stopped.

) %

( '

& #

(

& TDFY-03-05-004-1 ja

D- During Travel Operation E- When Travel Operation is Neutral

f- Orifice h- Notch

123-

789-

Port BV Chamber B Check Valve BC

TODFY50-EN-00(10/01/2020)

456-

Motor Port BM Travel Relief Valve Motor Port AM

T3-5-9

Check Valve AC Port AV Spool (Counterbalance Valve)

10-

Chamber A

SECTION3 COMPONENT OPERATION Group5 Travel Device Operation of Counterbalance Valve (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. When the travel motor draws oil, oil pressure in port AV (8) and chamber A (10) decreases. Spool (9) moves to the left and restricts the return circuit from the travel motor. 3. Therefore, oil pressure on the motor port BM (4) side increases and functions as the brake of travel motor. 4. Pressure in port AV (8) increases again and moves spool (9) to the right. 5. The machine descends the slope when spool (9) is in the position where pressure in port AV (8) balances with pressure at the motor port BM (4) side. 6. Therefore, the hydraulic brake is applied and prevents the machine from rollaway.

123-

Port BV Chamber B Check Valve BC

TODFY50-EN-00(10/01/2020)

456-

Motor Port BM Travel Relief Valve Motor Port AM

789-

T3-5-10

Check Valve AC Port AV Spool (Counterbalance Valve)

10-

TDFY-03-05-011-1 ja Chamber A

SECTION3 COMPONENT OPERATION Group5 Travel Device Outline of Travel Relief Valve When the travel motor circuit pressure increases beyond the set pressure, the travel relief valve is opened and high pressure oil is relieved to the low-pressure side. Therefore, the travel motor is protected from being overloaded. In addition, the overload relief valve relieves the shock loads developed due to inertia force when stopping the travel motor. When the travel motor draws pressure oil like a pump, check valve is unseated (make-up operation) and prevents the cavitation.

Operation of Travel Relief Valve (During Relief) 1. Pressure oil in the travel circuit acts on poppet (5) through motor port AM (9) (or motor port BM (3)). 2. Pressure oil flows to the spring (7) chamber through orifice (4) in poppet (5). 3. Pressure oil flowing to the spring (7) chamber acts on piston (6) through orifice (8) and moves piston (6) upward. 4. As long as piston (6) keeps moving, a pressure difference is developed between the front and rear of poppet (5). When this pressure difference is increased beyond the spring (7) force, poppet (5) is opened and the pressure oil flows to motor port BM (3) or motor port AM (9) on the low-pressure side. (Shockless Function) 5. When piston (6) reaches the stroke end, the pressure difference between the front and rear of poppet (5) disappears and poppet (5) is closed. 6. Under this condition, the pressure in the travel motor circuit increases to the set pressure. 7. When the pressure in the travel motor circuit increases beyond the spring (7) force, poppet (5) is opened and pressure oil at the relief set pressure flows to motor port BM (3) or motor port AM (9) on the low-pressure side. 8. As described above, relief operation in two-stages prevents the travel motor from being overloaded and reduces shocks developed in the circuit when stopping the travel motor.

TODFY50-EN-00(10/01/2020)

T3-5-11

SECTION3 COMPONENT OPERATION Group5 Travel Device 2

1 10

4 4 5 5 6 6 7 7

Port AV Side 123-

Port AV Port BV Motor Port BM

456-

Orifice Poppet Piston

789-

Spring Orifice Motor Port AM

1011-

TDFY-03-05-013-1 ja Check Valve AC Check Valve BC

Operation of Travel Relief Valve (During Make-Up) 1. When the machine descends a slope, the travel motors are forcibly rotated by the machine self weight like a pump. 2. When pressure in the port AV (1) (or port BV (2)) circuit becomes lower than pressure in the motor port AM (9) (or motor port BM (3)), check valve AC (10) (or check valve BC (11)) is opened, hydraulic oil is drawn, and the lack of oil feed is compensated.

TODFY50-EN-00(10/01/2020)

T3-5-12

SECTION3 COMPONENT OPERATION Group5 Travel Device 2

10 3

9 4

4 5 5 6 6 7 7

Port AV Side 123-

Port AV Port BV Motor Port BM

TODFY50-EN-00(10/01/2020)

456-

Orifice Poppet Piston

789-

T3-5-13

Spring Orifice Motor Port AM

1011-

TDFY-03-05-012-1 ja Check Valve AC Check Valve BC

SECTION3 COMPONENT OPERATION Group5 Travel Device Outline of Travel Mode Control The displacement angle of swash plate is changed by piston movement and shift the travel mode.

Operation of Selecting Travel Mode (Slow Speed) 1. When the travel mode switch is in the slow speed position, MC (main controller) does not send the signal to 5-spool solenoid valve unit (SI). Therefore, pilot port (4) of travel motor displacement angle control valve (3) is connected to the hydraulic oil tank. Then, spool (5) of the travel motor displacement angle control valve (3) is pushed upward by spring (6). 2. As pressure oil from motor port AM (1) or BM (2) at the high-pressure side does not act on piston (11), the displacement angle is held to the maximum. Therefore, the stroke of plungers (9) will be longer and the travel motor rotates at slow speed.

7 1, 2

6 a

8 9

TDFY-03-05-006-1 ja

a- To Drain

TODFY50-EN-00(10/01/2020)

T3-5-14

SECTION3 COMPONENT OPERATION Group5 Travel Device 123-

Motor Port AM Motor Port BM Travel Motor Displacement Angle Control Valve

4567-

Pilot Port Spool Spring Piston Control Shuttle Valve

891011-

Orifice (For Slow/Fast Speed) Plunger Swash Plate Piston

Operation of Selecting Travel Mode (Fast Speed) 1. When the travel mode switch is set to the fast speed position, MC (main controller) sends the signal to solenoid valve unit (SI) in response to travel loads. (Refer to "Travel Motor Displacement Angle Control"T2-2-66) 2. Pilot pressure is supplied from pilot port (4) of travel motor displacement angle control valve (3) and moves spool (5) downward. 3. Pressure oil (b) from high-pressure side of motor port (AM (1) or BM (2)) flows through the inner passage of travel motor, shuttle valve (7), spool (5), and orifice (8). Pressure oil flowing through orifice (8) gradually acts on piston (11). 4. Therefore, piston (11) pushes swash plate (10) and the displacement angle of swash plate (10) is reduced. As the stroke of plungers (9) will be shorter, the travel motor rotates at fast speed.

7 b 1, 2

3 5

TDFY-03-05-007-1 ja

b- Pressure Oil from Motor Port AM (1) or BM (2)

TODFY50-EN-00(10/01/2020)

T3-5-15

SECTION3 COMPONENT OPERATION Group5 Travel Device 123-

Motor Port AM Motor Port BM Travel Motor Displacement Angle Control Valve

TODFY50-EN-00(10/01/2020)

4567-

Pilot Port Spool Spring Piston Control Shuttle Valve

891011-

T3-5-16

Orifice (For Slow/Fast Speed) Plunger Swash Plate Piston

SECTION3 COMPONENT OPERATION Group6 Signal Control Valve Outline of Signal Control Valve The signal control valve is provided in the pilot circuit between the pilot valve and the control valve, and controls various signal pressure used to regulate the pumps and valves. The signal control valve consists of the shuttle valves, shockless valve (1), pump 1 flow rate control valve (6), pump 2 flow rate control valve (3), pump 3 flow rate control valve (2), flow combiner valve control spool (4), and swing parking brake release spool (5). A-A

TDC1-03-06-002-1 ja

a- Pilot Valve Side 12-

Shockless Valve Pump 3 Flow Rate Control Valve

Pump 2 Flow Rate Control Valve

Flow Combiner Valve Control Spool

56-

Swing Parking Brake Release Spool Pump 1 Flow Rate Control Valve

Pilot Valve Side of Pilot Port Port Name

Connection

Remarks

Port A

Pilot Valve (Right)

Boom Raise Pilot Pressure

Port B

Pilot Valve (Right)

Boom Lower Pilot Pressure

Port C

Pilot Valve (Left)

Arm Roll-Out Pilot Pressure

Port D

Pilot Valve (Left)

Arm Roll-In Pilot Pressure

Port E

Pilot Valve (Left)

Swing (Left) Pilot Pressure

Port F

Pilot Valve (Left)

Swing (Right) Pilot Pressure

Port G

Pilot Valve (Right)

Bucket Roll-In Pilot Pressure

Port H

Pilot Valve (Right)

Bucket Roll-Out Pilot Pressure

Port I

Travel Pilot Valve

Travel (Left Forward) Pilot Pressure

Port J

Travel Pilot Valve

Travel (Left Reverse) Pilot Pressure

Port K

Travel Pilot Valve

Travel (Right Forward) Pilot Pressure

Port L

Travel Pilot Valve

Travel (Right Reverse) Pilot Pressure

Port M

Auxiliary 1 Pilot Valve

Auxiliary 1 Open Pilot Pressure

Port N

Auxiliary 1 Pilot Valve

Auxiliary 1 Close Pilot Pressure

Port O

Positioning/Auxiliary 2 Pilot Valve

Positioning Raise/Auxiliary 2 Open Pilot Valve

Port P

Positioning/Auxiliary 2 Pilot Valve

Positioning Lower/Auxiliary 2 Close Pilot Valve

TODFY50-EN-00(10/01/2020)

T3-6-1

SECTION3 COMPONENT OPERATION Group6 Signal Control Valve Port Name

Connection

Remarks

Port SA

Pump 1 Regulator

Pump 1 Control Pressure

Port SB

Pump 2 Regulator

Pump 2 Control Pressure

Port PI

Pilot Shut-off Solenoid Valve

Primary Pilot Pressure

Port SH

Swing Parking Brake

Brake Release Pressure

Port DF

Hydraulic Oil Tank

Returning to Hydraulic Oil Tank

Port SR

Control Valve (Boom Lower Circuit)

Pump 1 Flow Rate Control Valve Control Pressure

Port SX

Pump 3 Regulator

Pump 3 Control Pressure

Port DR

5-Spool Solenoid Valve Unit

Returning to Hydraulic Oil Tank

Machine with Positioning, Auxiliary 2 Equipped Port Name Port DR

Connection

Remarks

Auxiliary 2 Pilot Pressure Sensor C

Remarks

D A

E SR

SA G P O H DR PI K

SH SB L

Pilot Valve Side TDAA-03-06-005-1 ja

Control Valve Side of Pilot Port Port Name

Connection

Remarks

Port 1

Control Valve

Boom Raise Pilot Pressure

Port 2

Control Valve

Boom Lower Pilot Pressure

Port 3

Control Valve

Arm Roll-Out Pilot Pressure

Port 4

3-Spool Solenoid Valve Unit

Arm Roll-In Pilot Pressure

Port 5

Control Valve

Swing (Left) Pilot Pressure

Port 6

Control Valve

Swing (Right) Pilot Pressure

TODFY50-EN-00(10/01/2020)

T3-6-2

SECTION3 COMPONENT OPERATION Group6 Signal Control Valve Port Name

Connection

Remarks

Port 7

Control Valve

Bucket Roll-In Pilot Pressure

Port 8

Control Valve

Bucket Roll-Out Pilot Pressure

Port 9

Control Valve

Travel (Left Forward) Pilot Pressure

Port 10

Control Valve

Travel (Left Reverse) Pilot Pressure

Port 11

Control Valve

Travel (Right Forward) Pilot Pressure

Port 12

Control Valve

Travel (Right Reverse) Pilot Pressure

Port 13

Control Valve

Auxiliary 1 Open Pilot Pressure

Port 14

Control Valve

Auxiliary 1 Close Pilot Pressure

Port 15

Control Valve

Positioning Raise/Auxiliary 2 Open Pilot Valve

Port 16

Control Valve

Positioning Lower/Auxiliary 2 Close Pilot Valve

Port SQ

Hydraulic Oil Tank

Returning to Hydraulic Oil Tank

Port SM

Hydraulic Oil Tank

Returning to Hydraulic Oil Tank

Port SN

Plug

Port SP

Hydraulic Oil Tank

Returning to Hydraulic Oil Tank

Port SL

Control Valve

Flow Combiner Valve Control Pressure

Port S3

Swing Pilot Pressure Sensor

Port TR

Control Valve

Auxiliary Flow Combiner Valve Control Pressure

Travel Pilot Pressure Sensor

Machine with Attachment (Pulverizers 1 to 5 and Crushers 1 to 5) Equipped Port Name Port SM

Connection

Remarks

Auxiliary Flow Combiner Control Solenoid Valve Auxiliary 1 Pilot Pressure Auxiliary 1 Pilot Pressure Sensor

Port SN

Plug

Port SP

Auxiliary Flow Combiner Control Solenoid Valve Pump 1 Control Pressure Auxiliary Flow Combiner Valve and Pump 1 Bypass Shut-Out Valve Control Pressure

TODFY50-EN-00(10/01/2020)

T3-6-3

SECTION3 COMPONENT OPERATION Group6 Signal Control Valve 1

4 3

6 SQ

8 15

S3 TR

9 10

Control Valve Side TDAA-03-06-010-1 ja

Outline of Shuttle Valve The shuttle valve selects pilot pressure used to perform each operation and routes pilot pressure to the corresponding control valves and/or control spools. The spools corresponding to each operation are shown in the table: Pump 1 Flow Rate Pump 2 Flow Rate Pump 3 Flow Rate Flow Combiner Control Valve Control Valve Control Valve Valve Control Spool

Swing Parking Brake Release Spool

Boom Raise

○

Boom Lower

*1○

○

Arm Roll-Out

○

Arm Roll-In

○

Bucket Roll-In

○

Bucket Roll-Out

○

Swing (Right)

○

Swing (Left)

○

Travel (Right)

○

Travel (Left)

○

Auxiliary 1

*2○

○

Positioning/Auxili ary 2

○

The boom lower pilot pressure is routed to the pump 1 flow rate control valve in the signal control valve through the control valve.

TODFY50-EN-00(10/01/2020)

T3-6-4

SECTION3 COMPONENT OPERATION Group6 Signal Control Valve *2

As for only the machine with attachment (pulverizers 1 to 5 and crushers 1 to 5) equipped, the pump 1 flow rate control valve is operated by pressure from the auxiliary 1 pilot valve. 3

5 a

6 b

8 c

11 e

g h

17 1

18 19 20

i n

22 k

j TDFY-03-06-001-1 ja

a- Travel (Left) b- Travel (Right) c- Swing d- Arm e- Boom f- Bucket g- Auxiliary 1 123456-

Boom, Arm, Bucket, Travel (Right), Auxiliary 1 Travel (Left) Travel (Left), Travel (Right) Travel (Right) Boom, Arm, Bucket, Travel (Right) Arm

TODFY50-EN-00(10/01/2020)

h- Positioning/Auxiliary 2 i- Auxiliary Flow Combiner Control Solenoid Valve j- Pump 3 Flow Rate Control Valve k- Swing Parking Brake Release Spool l- Flow Combiner Valve Control Spool m- Pump 2 Flow Rate Control Valve n- Pump 1 Flow Rate Control Valve 7891011-

Boom Raise, Arm, Bucket, Travel (Right) Boom Raise, Arm Boom Raise, Arm, Travel (Left), Auxiliary 1 Boom Raise, Arm, Bucket Boom, Arm, Bucket, Swing, Auxiliary 1

121314151617-

T3-6-5

Boom Raise, Arm, Bucket, Swing, Auxiliary 1 Boom Raise, Swing, Position ing/Auxiliary 2 Bucket Swing Auxiliary 1 Positioning/Auxiliary 2

18192021-

22-

Swing, Auxiliary 1 Swing, Positioning/Auxiliary 2 Boom Raise, Swing, Position ing/Auxiliary 2 Boom, Arm, Bucket, Swing, Auxiliary 1, Positioning/Auxili ary 2 Boom Raise, Arm, Auxiliary 1

SECTION3 COMPONENT OPERATION Group6 Signal Control Valve A-A

A A

15 12 20

19 a

10 4

B-B

B B

14 17

11 2 3

5 TDC1-03-06-003-1 ja

a- Pilot Valve Side 123456-

Boom, Arm, Bucket, Travel (Right), Auxiliary 1 Travel (Left) Travel (Left), Travel (Right) Travel (Right) Boom, Arm, Bucket, Travel (Right) Arm

TODFY50-EN-00(10/01/2020)

b- Control Valve Side 7891011-

Boom Raise, Arm, Bucket, Travel (Right) Boom Raise, Arm Boom Raise, Arm, Travel (Left), Auxiliary 1 Boom Raise, Arm, Bucket Boom, Arm, Bucket, Swing, Auxiliary 1

121314151617-

T3-6-6

Boom Raise, Arm, Bucket, Swing, Auxiliary 1 Boom Raise, Swing, Position ing/Auxiliary 2 Bucket Swing Auxiliary 1 Positioning/Auxiliary 2

18192021-

22-

Swing, Auxiliary 1 Swing, Positioning/Auxiliary 2 Boom Raise, Swing, Position ing/Auxiliary 2 Boom, Arm, Bucket, Swing, Auxiliary 1, Positioning/Auxili ary 2 Boom Raise, Arm, Auxiliary 1

SECTION3 COMPONENT OPERATION Group6 Signal Control Valve Outline of Shockless Valve The shockless valve is provided in the boom raise circuit and functions during boom lowering operation or when stopping boom raise operation.

Operation of Shockless Valve (During Boom Raise Operation) 1. Boom raise pilot pressure is routed to spool (1) through port A (2). 2. Immediately after operation is started, the pilot pressure is low. The low pilot pressure is routed to the spring B (3) chamber through clearance C between spool (1) and housing (7) and inner passage 3 (9). The pilot pressure is also routed to the port 1 (4) side through inner passage 2 (5) at the same time. 3. When pilot pressure increases, pressure in the spring B (3) chamber also increases. Spool (1) pushes spring A (6) and is moved to the left. 4. As spool (1) is moved, port A (2) is connected to port 1 (4) and pressure in the port 1 (4) side increases. Then, the control valve spool is moved. 1

5 4

4 TDC1-03-06-004-1 ja 12-

Spool Port A

TODFY50-EN-00(10/01/2020)

34-

Spring B Port 1

56-

T3-6-7

Inner Passage 2 Spring A

SECTION3 COMPONENT OPERATION Group6 Signal Control Valve 6

2 C

3 1

4 2

During Boom Raise Operation TDC1-03-06-005-1 ja 12-

Spool Port A

34-

Spring B Port 1

56-

Inner Passage 2 Spring A

Housing

Operation of Shockless Valve (During Boom Lower Operation or When Stopping Boom Raise Operation (Shock Reducing Operation)) 1. During boom lower operation or when stopping boom raise operation, returning oil from the boom raise spool in control valve is routed to port 1 (4). 2. As spool (1) blocks the oil passage between port 1 (4) and port A (2), returning oil cannot flow directly to port A (2). 3. Port 1 (4) is connected to the spring A (6) side in spool (1) through inner passage 1 (8) and to oil chamber (9) through inner passage 2 (5). 4. Pressure oil in oil chamber (9) flows from clearance C between spool (1) and housing (7) and pressure in oil chamber (9) decreases. Spool (1) is moved to the right by the pressure routed to the spring A (6) side. Therefore, clearance C between spool (1) and housing (7) is closed and pressure oil is blocked. 5. When clearance C is closed, pressure in oil chamber (9) increases and spool (1) is moved to the left. Then, clearance C is opened again and pressure oil flows to the port A (2) side. 6. As the operations in step 4 to step 5 are repeated and pressure oil is gradually returned to the port A (2) side, the control valve spool is returned slowly. 7. Consequently, the shockless valve reduces the shock during boom lower operation or when stopping boom raise operation.

TODFY50-EN-00(10/01/2020)

T3-6-8

SECTION3 COMPONENT OPERATION Group6 Signal Control Valve 2

8 5 4

4 12-

Spool Port A

TODFY50-EN-00(10/01/2020)

34-

Spring B Port 1

56-

T3-6-9

Inner Passage 2 Spring A

TDC1-03-06-006-1 ja Inner Passage 1

SECTION3 COMPONENT OPERATION Group6 Signal Control Valve 6

7 2

1 5

4 2

During Boom Lower Operation or When Stopping Boom Raise Operation (Shock Reducing Operation) TDC1-03-06-007-1 ja 123-

Spool Port A Spring B

TODFY50-EN-00(10/01/2020)

456-

Port 1 Inner Passage 2 Spring A

789-

T3-6-10

Housing Inner Passage 1 Oil Chamber

SECTION3 COMPONENT OPERATION Group6 Signal Control Valve Operation of Pump 1 Flow Rate Control Valve, Pump 2 Flow Rate Control Valve, and Pump 3 Flow Rate Control Valve The pump flow rate control valve delivers pump control pressure Pi to the pump regulator in response to the pilot pressure from the pilot valve. 1. Pilot pressure (5) from the pilot valve acts on the spring (1) chamber side in the pump 1, pump 2, or pump 3 flow rate control valve after being selected by shuttle valve (4) in the signal control valve. 2. Spool (2) is moved to the left and primary pilot pressure (6) is routed to port SA, port SB, or port SX. 3. Therefore, pressure in port SA, port SB, or port SX increases. 4. Pressure oil in the port SA, port SB, or port SX side is also routed to chamber A (3). Therefore, spool (2) is pushed back until the pressure force in the port SA, port SB, or port SX side balances with the pilot pressure acts on the spring (1) chamber side. Then, pressure in the port SA, port SB, or port SX side stops increasing.

NOTE The pump 1 flow rate control valve is operated when the boom (raise, lower), arm (roll-in, roll-out), bucket (roll-in, rollout), auxiliary 1 (machine with the attachment (pulverizers 1 to 5, crushers 1 to 5) equipped), and travel (right) functions are operated. The pump 2 flow rate control valve is operated when the boom (raise), arm (roll-in, roll-out), travel (left), and auxiliary 1 functions are operated. The pump 3 flow rate control valve is operated when the boom (raise), swing (left or right), and positioning/auxiliary 2 functions are operated. a, b, c

6 5 e

a- To Port SA b- To Port SB c- To Port SX 12-

Spring Spool

TODFY50-EN-00(10/01/2020)

d- To Hydraulic Oil Tank e- From Pilot Valve 34-

Chamber A Shuttle Valve

56-

T3-6-11

Pilot Pressure Primary Pilot Pressure

TDC1-03-06-001-1 ja

SECTION3 COMPONENT OPERATION Group6 Signal Control Valve Operation of Flow Combiner Valve Control Spool ● The flow combiner valve control spool is shifted by travel (right) pilot pressure and supplies primary pilot pressure to the flow combiner valve in control valve. a

Flow Combiner Valve Control Spool T178-03-06-014-1 ja

a- To Hydraulic Oil Tank b- Primary Pilot Pressure 1-

Spool

c- To Flow Combiner Valve d- Travel (Right) Pilot Pressure 2-

Spring

Operation of Swing Parking Brake Release Spool ● The swing parking brake release spool is shifted by the boom, arm, bucket, swing, auxiliary 1, and positioning/ auxiliary 2 pilot pressure and supplies primary pilot pressure to the swing motor. a

Swing Parking Brake Release Spool T178-03-06-014-2 ja

a- To Hydraulic Oil Tank b- Primary Pilot Pressure 1-

Spool

TODFY50-EN-00(10/01/2020)

e- To Swing Motor f- Boom, Arm, Bucket, Swing, Auxiliary 1, Positioning/Auxili ary 2 2-

Spring

T3-6-12

SECTION3 COMPONENT OPERATION Group7 Others (Upperstructure) Outline of Pilot Shut-Off Solenoid Valve The pilot shut-off solenoid valve is a switch valve of the solenoid valve type. Spool (1) in the pilot shut-off solenoid valve is shifted by the pilot shut-off lever and turns ON/OFF pilot pressure oil to the pilot valve and signal control valve. Z

A3 Z T2

Z-Z

T1᳸T4

P A1᳸A3

1 TDC1-03-07-001-1 ja

P- Pressure Oil from Pilot Pump A1- Pilot Pressure to Travel, Auxiliary 1 Pilot Valve A2- Pilot Pressure to Boom, Bucket, Positioning/Auxiliary 2 Pilot Valve

TODFY50-EN-00(10/01/2020)

T1- Returning Oil from Travel, Auxiliary 1 Pilot Valve T2- Returning Oil from Boom, Bucket, Positioning/Auxiliary 2 Pilot Valve T3- Returning Oil from Arm, Swing Pilot Valve

T3-7-1

SECTION3 COMPONENT OPERATION Group7 Others (Upperstructure) A3- Pilot Pressure to Arm, Swing Pilot Valve 1-

T4- Returning Oil to Hydraulic Oil Tank

Spool

Pilot Shut-Off Lever: LOCK Position 1. When the pilot shut-off lever is set to the LOCK position, the pilot shut-off relay is turned OFF, and the pilot shut-off solenoid valve is turned OFF. (Refer to SYSTEM/Electrical System.) 2. Pressure oil from the pilot pump is blocked by spool (1) in the pilot shut-off solenoid valve. 3. Each port in pilot valves (A1 to A3) is connected to the hydraulic oil tank. 4. Therefore, even if the control / travel control lever is operated, the pilot valve is not activated.

T1᳸T4

P A1᳸A3

Pilot Shut-Off Lever: LOCK Position TDEN-03-06-005-1 ja

P- Pressure Oil from Pilot Pump A1- Pilot Pressure to Travel, Auxiliary 1 Pilot Valve A2- Pilot Pressure to Boom, Bucket, Positioning/Auxiliary 2 Pilot Valve A3- Pilot Pressure to Arm, Swing Pilot Valve 1-

T1- Returning Oil from Travel, Auxiliary 1 Pilot Valve T2- Returning Oil from Boom, Bucket, Positioning/Auxiliary 2 Pilot Valve T3- Returning Oil from Arm, Swing Pilot Valve T4- Returning Oil to Hydraulic Oil Tank

Spool

Pilot Shut-Off Lever: UNLOCK Position 1. When the pilot shut-off lever is set to the UNLOCK position, the pilot shut-off relay is turned ON, and the pilot shut-off solenoid valve is excited. (Refer to SYSTEM/Electrical System.) 2. Spool (1) in the pilot shut-off solenoid valve is pushed down, and pressure oil from the pilot pump flows to the pilot valve. 3. Consequently, when the control / travel control lever is operated, the pilot valve is activated.

TODFY50-EN-00(10/01/2020)

T3-7-2

SECTION3 COMPONENT OPERATION Group7 Others (Upperstructure)

T1᳸T4

P A1᳸A3

Pilot Shut-Off Lever: UNLOCK Position TDEN-03-06-007-1 ja

Spool

Outline of Solenoid Valve The following solenoid valves are provided in this machine in order to control the functions. Solenoid Valve

Control

5-Spool Solenoid Valve Unit

The 5-spool solenoid valve unit is for the valve control.

3-Spool Solenoid Valve Unit

The 3-spool solenoid valve unit is for the pump and valve control.

2-Spool Solenoid Valve Unit

The 2-spool solenoid valve unit is for the aftertreatment device regener ation control.

Auxiliary Flow Rate Control Solenoid Valve Unit The auxiliary flow rate control solenoid valve unit is for the auxiliary flow (Option) rate control,

Outline of 5-Spool Solenoid Valve Unit The 5-spool solenoid valve unit controls the control valve and the valve in travel motor according to the signal from MC (main controller). (Refer to SYSTEM/Control System.) The 5-spool solenoid valve unit consists of proportional solenoid valves (SC, SF, SE, SD, and SI). SC: This valve controls the arm regenerative valve in control valve. SF: This valve controls the digging regenerative valve in control valve. SE: This valve controls the arm 1 flow rate control valve (selector valve) in control valve. SD: This valve controls the arm roll-in meter-out open control spool in control valve. SI: This valve increases pressure of the main relief valve in control valve and controls the travel motor displacement angle control valve.

TODFY50-EN-00(10/01/2020)

T3-7-3

SECTION3 COMPONENT OPERATION Group7 Others (Upperstructure) SC

TDAA-03-07-001-2 ja

Outline of 3-Spool Solenoid Valve Unit The 3-spool solenoid valve unit controls the pump and control valve according to the signal from MC (main controller). (Refer to SYSTEM/Control System.) The 3-spool solenoid valve unit consists of proportional solenoid valves (SK1, SK2, and SK3). SK1: Arm 2 Roll-In Pilot Pressure Control SK2: Boom 3 Raise Pilot Pressure Control SK3: This valve controls the pump 3 bypass shut-out valve in control valve. SK1

SK2

SK3

TDFY-03-07-001-1 ja

Outline of 2-Spool Solenoid Valve Unit (For Aftertreatment Device Manual Regeneration Control) The 2-spool solenoid valve unit controls the pump and control valve according to the signal from MC (main controller). (Refer to SYSTEM/Control System.) The 2-spool solenoid valve unit consists of proportional solenoid valves (SZ and SJ). SZ: This valve controls the pump 1 regulator (delivery flow rate increase). SJ: This valve controls the pump 1 bypass shut-out valve in control valve.

TODFY50-EN-00(10/01/2020)

T3-7-4

SECTION3 COMPONENT OPERATION Group7 Others (Upperstructure) SZ

TDAA-03-07-002-2 ja

Outline of Auxiliary Control Solenoid Valve Unit (Option) The auxiliary control solenoid valve unit consists of auxiliary flow combiner control solenoid valve (1) and auxiliary flow rate control solenoid valve (2). Auxiliary flow combiner control solenoid valve (1) is an ON/OFF solenoid valve. When the attachment is selected by using the monitor, the auxiliary flow combiner control solenoid valve (1) is turned ON and shifts the auxiliary flow combiner valve in control valve. (Refer to SYSTEM/Control System.) Auxiliary flow rate control solenoid valve (2) is a proportional solenoid valve. The auxiliary flow rate control valve (selector valve) in control valve is shifted by the signal from MC (main controller). 1

TDAA-03-07-012-1 ja 1-

Auxiliary Flow Combiner Con trol Solenoid Valve

TODFY50-EN-00(10/01/2020)

Auxiliary Flow Rate Control Solenoid Valve

T3-7-5

SECTION3 COMPONENT OPERATION Group7 Others (Upperstructure) Outline of Proportional Solenoid Valve The proportional solenoid valve is controlled by the electric current signal from MC (main controller) and outputs pressure in proportional to the electric current.

Operation of Proportional Solenoid Valve (When in Neutral) ● Spring (2) pushes spool (1) to the right and output port S is connected to tank port T. S

a TDAA-03-07-013-1 ja 1-

Spool

Spring

Solenoid

Operation of Proportional Solenoid Valve (When Excited) 1. Solenoid (3) pushes spool (1) to the left in proportion to the current value flowing to 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.

TODFY50-EN-00(10/01/2020)

T3-7-6

SECTION3 COMPONENT OPERATION Group7 Others (Upperstructure) S

a TDAA-03-07-013-1 ja 1-

Spool

TODFY50-EN-00(10/01/2020)

Spring

T3-7-7

Solenoid

SECTION3 COMPONENT OPERATION Group7 Others (Upperstructure) Outline of ON/OFF Solenoid Valve The ON/OFF solenoid valve is shifted by each control switch, and shifts pilot pressure.

Operation of ON/OFF Solenoid Valve (when in Neutral) Spool (1) is pushed to the right by spring (2). Output port S is connected to tank port T. 1

2 S

T TDAA-03-07-014-1 ja 1-

Spool

Spring

Solenoid

Operation of ON/OFF Solenoid Valve (When in Operation) As solenoid (3) is excited, spool (1) is pushed to the left. Pilot port P is connected to output port S and tank port T is blocked. 1

2 S

T TDAA-03-07-014-1 ja 1-

Spool

TODFY50-EN-00(10/01/2020)

Spring

T3-7-8

Solenoid

SECTION3 COMPONENT OPERATION Group7 Others (Upperstructure) Outline of Hose Rupture Valve The hose rupture valve is installed to boom cylinder (bottom side circuit), arm cylinder (rod side circuit), and positioning cylinder (2-piece boom) (rod side circuit). When the hose of front attachment is damaged, the hose rupture valve blocks returning oil from each cylinder and prevents the front attachment from falling.

NOTE The hose rupture valve in boom cylinder is explained here.

Operation of Hose Rupture Valve (When Control Lever is in Neutral) 1. As pilot pressure Pi dose not act on spool(2), spool (2) is pushed to the right by the spring (10) force. 2. One holding pressure of cylinder at port B acts on poppet (6) and the other acts on spool (2) through passage E (8). 3. Pressure oil which flows to the spring (5) chamber through poppet (6) also acts on spool (2) through passage C (4). Pressure oil is blocked by spool (2) and does not flow to passage D (9). Holding pressure of cylinder through passage E (8) is blocked by spool (2). 4. Poppet (6) is pushed down by the force (pressure of the spring (5) chamber + spring (5) force). 5. Consequently, as holding pressure of cylinder at port B is blocked completely, the front attachment is prevented from falling when the hose of front attachment is damaged. 5

6 Pi B

a TDAA-03-07-005-1 ja

A- Port A B- Port B 24-

Spool Passage C

TODFY50-EN-00(10/01/2020)

a- To Control Valve Spool (To Front Attachment Hose) b- External Load 56-

Spring Poppet

89-

T3-7-9

Passage E Passage D

10-

Spring

SECTION3 COMPONENT OPERATION Group7 Others (Upperstructure)

X Y

X-X

1 11

9 8 A 3 1

4 5

Y-Y

A TDC1-03-07-002-1 ja

A- Port A 123-

Relief Valve Spool Piston

B- Port B 456-

Passage C Spring Poppet

789-

Orifice Passage E Passage D

1011-

Spring Orifice

Operation of Hose Rupture Valve (During Boom Lower Operation (Control Lever Stroke: Less than Half-Stroke)) 1. When the boom is lowered, pilot pressure Pi is acts on piston (3). 2. When the boom control lever is less than half-stroke, piston (3) pushes spool (2) to the position where passage E (8) connects to pert A. 3. Pressure oil in the spring (5) chamber is blocked by spool (2) and poppet (6) is pushed down. 4. Pressure oil from port B flows to the spool in control valve through passage E (8), orifice (11), passage D (9), and port A, and lowers the boom.

TODFY50-EN-00(10/01/2020)

T3-7-10

SECTION3 COMPONENT OPERATION Group7 Others (Upperstructure) 5. As flow rate flowing to the spool in control valve is restricted by orifice (11), the boom can be lowered slowly even if the hose of front attachment is damaged. 5

11 Pi B

a TDAA-03-07-007-1 ja

A- Port A B- Port B 234-

Spool Piston Passage C

TODFY50-EN-00(10/01/2020)

a- To Control Valve Spool 568-

Spring Poppet Passage E

91011-

T3-7-11

Passage D Spring Orifice

SECTION3 COMPONENT OPERATION Group7 Others (Upperstructure)

X Y

X-X 11

9 8 A

1 4

Y-Y

A TDC1-03-07-003-1 ja

A- Port A B- Port B 123-

Relief Valve Spool Piston

a- To Control Valve Spool 456-

Passage C Spring Poppet

789-

Orifice Passage E Passage D

1011-

Spring Orifice

Operation of Hose Rupture Valve (During Boom Lower Operation (Control Lever Stroke: More than Half-Stroke)) 1. When the boom control lever is more than half-stroke, piston (3) pushes in spool (2) to the position where passage C (4) is connected to hole (12) on spool (2). 2. Pressure oil in the spring (5) chamber flows to passage D (9) through hole (12) on spool (2) and the passage of spool (2). 3. Pressure oil in passage E (8) flows to passage D (9) through orifice (11).

TODFY50-EN-00(10/01/2020)

T3-7-12

SECTION3 COMPONENT OPERATION Group7 Others (Upperstructure) 4. As pressure difference arises between port B and spring (5) chamber due to orifice (7) at this time, poppet (6) is moved up. 5. Consequently, returning oil from port B flows to the spool in control valve through poppet (6) and port A, and lowers the boom. 6. As pressure oil in port B flows to port A directly, flow rate which flowing to the spool in control valve increases and boom lowering speed becomes fast. 5

6 7

11 Pi B

a TDAA-03-07-009-1 ja

A- Port A B- Port B 234-

Spool Piston Passage C

TODFY50-EN-00(10/01/2020)

a- To Control Valve Spool 567-

Spring Poppet Orifice

8910-

T3-7-13

Passage E Passage D Spring

11-

Orifice

SECTION3 COMPONENT OPERATION Group7 Others (Upperstructure)

X Y

X-X 11

9 8 A

1 4

Y-Y

A TDC1-03-07-004-1 ja

A- Port A B- Port B 123-

Relief Valve Spool Piston

TODFY50-EN-00(10/01/2020)

a- To Control Valve Spool 456-

Passage C Spring Poppet

789-

T3-7-14

Orifice Passage E Passage D

101112-

Spring Orifice Hole

SECTION3 COMPONENT OPERATION Group7 Others (Upperstructure) Outline of Pilot Relief Valve Pilot relief valve (2) is built into pilot filter (3). Pilot relief valve (2) functions to regulate pilot pump pressure supplied to port P (1) to a constant pressure. 2 1

T178-03-07-001-1 ja 1-

Port P

TODFY50-EN-00(10/01/2020)

Pilot Relief Valve

T3-7-15

Pilot Filter

SECTION3 COMPONENT OPERATION Group7 Others (Upperstructure) Outline of Recirculation Valve Recirculation valve (1) is installed in fuel pre-filter (2). Recirculation valve (1) circulates a part of returning fuel which has been warmed in the engine without returning to the fuel tank when fuel temperature is low. Fuel temperature rises and clogging of the fuel filter is prevented. When fuel temperature rises beyond the specified value, it makes all fuel from the engine return to the fuel tank and keeps fuel appropriate temperature. A

A-A

A-A b

4 5

E TDC1-03-07-005-1 ja

a- From Engine b- To Fuel Tank c- To Fuel Pre-Filter 12-

Recirculation Valve Fuel Pre-Filter

TODFY50-EN-00(10/01/2020)

D- When Fuel Temperature is Low E- When Fuel Temperature is High 34-

Spring Piston

56-

T3-7-16

Spool Thermostat

SECTION3 COMPONENT OPERATION Group8 Others (Undercarriage) Outline of Swing Bearing The swing bearing supports the upperstructure on the undercarriage and allows the upperstructure to swing smoothly. This bearing is a single row type ball bearing and consists of outer race (1), inner race (3), balls (6), supports (5), and seals (2, 4). Outer race (1) is bolted to the upperstructure. Inner race (3) is bolted to the undercarriage. The internal gear of inner race (3) meshes with the output shaft of the swing reduction gear.

1 2

5 3

6 T135-03-02-001-1 ja 12-

Outer Race Seal

TODFY50-EN-00(10/01/2020)

34-

Inner Race Seal

56-

T3-8-1

Support Ball

SECTION3 COMPONENT OPERATION Group8 Others (Undercarriage) Outline of Center Joint The centerjoint is a joint which can turn freely. When the upper structure swings, the centerjoint eliminates twisting of the hoses and allows hydraulic oil to flow the travel motors. Spindle (1) is secured to the upperstructure and can not turn. Body (2) is secured to the swing center of the undercarriage. Pressure oil flows to the right and left travel motors through spindle (1) and each oil port of body (2). Seals (3) prevent oil leaks between spindle (1) and body (2). a

1 e

3 f :g :h :e

T157-03-02-004-1 ja

a- Travel (Left Reverse) b- Travel (Right Forward) c- Travel (Right Reverse) d- Travel (Left Forward) 1-

Spindle

TODFY50-EN-00(10/01/2020)

e- Pilot Pressure for Travel Mode Selector f- Drain g- Forward h- Reverse 2-

Body

T3-8-2

Seal

SECTION3 COMPONENT OPERATION Group8 Others (Undercarriage) Outline of Track Adjuster (Front Idler Integrated Type) The track adjuster consists of front idler (4), spring (3), and adjuster cylinder (1), and is held by the side frame. The track adjuster absorbs the load applied to the front idler (4) part at spring (3). Track sag is adjusted by adjuster cylinder (1). •

When grease is supplied through grease fitting (5), grease fills chamber (a) in adjuster cylinder (1), pushes piston rod (2), and reduces track sag. 1

TDC1-03-08-001-1 ja 12-

Adjuster Cylinder Piston Rod

TODFY50-EN-00(10/01/2020)

34-

Spring Front Idler

T3-8-3

Grease Fitting

SECTION3 COMPONENT OPERATION Group8 Others (Undercarriage) MEMO

TODFY50-EN-00(10/01/2020)

T3-8-4

Hitachi Construction Machinery Co., Ltd. Attn: Service Material Development Tel: 029-832-9673 Fax: 029-831-1162 E-mail: HCM-TIC-GES@hitachi-kenki.com

Hitachi ref. No.

SERVICE MANUAL REVISION REQUEST FORM COMPANY NAME: YOUR NAME: DATE: Fax: E-mail:

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