Volvo EC330B Service Training Download Page 338 | Manualshive

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Boom Hose Rupture Valve Operation

P3 port is connected to overload pressure switch(A).
With Pi signal,boom lowering is possible.
The spool movement makes the tank connection of pilot check valve.

Picture text: 1 : Neutral condition
2 : Raising operation
3 : Lowering operation

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Summary of Contents for EC330B

Page 1: ...D12D Engine application EC330B EC460B 03 4_EC700B 04_Power Transmission 04 1_Swing motor EC330B EC360B 04 2_Swing motor EC460B 04 3_Swing motor EC700B 04 4_Travel motor_Old EC330B EC360B 04 5_Travel motor_New EC330B EC460B 04 6_Travel motor EC460B 04 7_Travel motor EC700B 05_Brake System 06_Steering System 07_Frame Undercarriage 08_Aircon 09_Hydraulic 09 1_Hydraulic_D10B D12C EC330B EC360B 09 2_Hy...

Page 2: ...1 Tier 2 Instrument panel and MDU Old alternator 2 I ECU application D12C Engine EMS1 Tier 2 IECU Programmable New alternator 3 D12D application D12D Engine EMS2 Tier 3 EU NA only Machine serial number starts from 80001 D12D Engine EMS1 Tier 3 based Tier 2 International region IECU Programmable New alternator Picture text ...

Page 3: ...d MDU Old alternator 2 I ECU application D12C Engine EMS1 Tier 2 IECU Programmable New alternator 3 D12D Engine application D12D Engine EMS2 Tier 3 EU NA only Machine serial number starts from 80001 D12D Engine EMS1 Tier 3 based Tier 2 International region IECU Programmable New alternator Picture text ...

Page 4: ...Design Change Overview EC700B D16E Engine EMS2 Tier 3 IECU Programmable New alternator Picture text ...

Page 5: ...Engine D10B Picture text ...

Page 6: ...fication Model D10B EAE2 Power kW 198 at 1700 rpm Power hp 269 hp at 1700 rpm Torque 1345 Nm at 1400 rpm Bore x Stroke 120 65mm x 140mm DISPLACEMENT 9600 cc Type 4 cycle diesel turbo charge air cooled Picture text ...

Page 7: ...l view 1 1 EMS E ECU 2 Fuel inlet 3 Water outlet 4 Engine PTO 5 Fan drive Pulley 6 Engine oil cooler 7 Engine oil filter full 8 Breather 9 Engine oil filter bypass 10 Fuel filter 11 Fuel feed pump Picture text ...

Page 8: ...l pump 2 Turbochargher 3 Cooler block heater 4 Cab heater supply 5 Coolant filter heater 6 Starter 7 Fuel shut off solenoid 8 Dipstick 9 Oil drain valve 10 Oil pan 11 Coolant filter return 12 Cab heater return Picture text ...

Page 9: ...E ECU Sensors 1 E ECU 2 3 Speed sensor 4 Coolant temp 5 Needle movement 6 Coolant level 7 Inlet air press temp 8 Boost air press temp 9 Oil press temp 10 Fuel press temp Picture text ...

Page 10: ...E ECU circuit Communication line is at the Red color connector Connector B Picture text ...

Page 11: ...s also placed on the bracket 3 From the feeder pump fuel is forced through the filter and into the injection pump feed side via the fuel shut off valve Return fuel from the injection pump goes via the fuel shut off valve and overflow valve 8 to the tank The leak off line from the injectors is connected to the injection pump via the suction line connection 1 Injector 2 Fuel filter 3 Bleeder nipple ...

Page 12: ...Fuel system Injector 1 Needle movement sensor 2 Feed pump 3 Manual feed pump 4 Overflow valve 5 Fuel cut off valve Off condition 6 Fuel cut off valve On condition Picture text ...

Page 13: ...stem Injection pump 1 Fuel rack control solenoid 2 Fuel rack injection quantity control 3 Injection timing control solenoid 4 Lever 5 Delivery valve 6 Timing sleeve 7 Speed sensor 8 Toothed wheel Picture text ...

Page 14: ...Fuel system Injection control Injection timing is adjusted by timing sleeve location Injection quantity is adjusted by fuel rack operation Picture text ...

Page 15: ...Engine D12C Picture text ...

Page 16: ...rial number of the engine is to be found stamped in the cylinder block on the rear left side The cylinder head is of cast iron and manufactured in one piece which is necessary in order to provide stable bearings for the overhead camshaft The cylinder liner is sealed against the coolant casing with rubber rings The D12C has a four valve system and overhead camshaft The engine timing gear transmissi...

Page 17: ...External view 1 External view component location 1 E ECU 2 Dip stick 3 Fuel filter 4 Start motor 5 Breather 6 Oil drain valve 7 Alternator Picture text ...

Page 18: ...ternal view 2 External view component location 1 Turbocharger 2 Air inlet 3 Water outlet 4 Coolant filter connection 5 Water inlet 6 Oil filter by pass 7 Oil filter full flow 8 Exhaust outlet Picture text ...

Page 19: ...er housing and the turbocharger inlet 8 Oil pressure temperature The other sensors are 1 Fuel pressure sensor Senses the pressure after the fuel filter 3 Camshaft position sensor Located in the upper timing mechanism cover 4 Engine coolant level Located in the expansion tank 6 Engine coolant temperature Located in the rear end of the cylinder head 7 Engine speed sensor Located in the fly wheel cov...

Page 20: ...unctions as a back up for the other databus if this for any reason does not function The Engine Management System EMS consists of a control unit EECU mounted to the engine sensors and a wiring harness The EECU Engine Electronic Control Unit is connects to both the data bus SAE J1939 and SAE J1708 The unit receives signals from the Vehicle Control Unit VECU It sends signals to control various funct...

Page 21: ...E ECU Electric circuit New New sensor 1 Oil temp oil pressure sensor 2 Boost temp boost pressure sensor Picture text ...

Page 22: ...r head and block Oil pressure reducing The regulator valve regulates the engine oil pressure and excess oil is led back to the sump Piston cooling The valve for piston cooling is pressure sensitive and opens just above the normal idling pressure The oil is led in to the lengthways channel in the block and sprayed via nozzle one for each piston onto the inside of the piston By pass filter Overflow ...

Page 23: ...overflow valve to the feeder pump suction side The feeder pump 1 forces the fuel to the filter housing past both of the non return valves 10 for the hand pump 2 and at the same time valve 12 opens for the return fuel to the tank If there is some air in the system it will automatically be bleeded After through the filter 3 to the cylinder head lengthways channel to feed the injectors 9 The overflow...

Page 24: ...age to the solenoid valve the fuel valve is open and the fuel flows back in return to the feeder channel 3 Injection phase The pump piston is still on the way down Now the solenoid valve has received voltage from the control unit The valve cone is lifted and the valve closes Since fuel cannot pass through the valve a pressure is quickly built up which lifts the nozzle needle and injection occurs I...

Page 25: ...Engine D12D Picture text ...

Page 26: ...e totally different Machine with D12DEBE3 has new serial number started with 80001 and will cover EU NA region EC460B Excavator uses the D12DEAE3 D12DEAE2 For those 2 engines external layout fuel line cooling inlet exhaust mounting is almost same but internal components ECU Unit injector Piston etc are totally different Machine with D12DEAE3 has new serial number started with 80001 and will cover ...

Page 27: ...evel of electronic features and to enhance reliability 3 The proven new high pressure dual solenoid diesel fuel injector Delphi E3 introduced with the Volvo U S EPA 2002 highway engine is an integral part of the V ACT Volvo Advanced Combustion Technology system When replacing the injector we need parameter programing for trim code with VCADS Pro Picture text 1 Switch Able Internal EGR Double Rocke...

Page 28: ...ure sensor 2 Cam speed sensor 3 Coolant level sensor 4 Boost press temp sensor 5 Fuel feed pressure sensor 6 Water in fuel sensor 7 Coolant temp sensor 8 Crank speed sensor 9 Engine oil press sensor 10 Crankcase pressure sensor 11 PTO Picture text ...

Page 29: ...External view 2 Tier 3 1 IEGR solenoid 2 Coolant pump 3 Fuel feed pump 4 Fuel lift pump 5 Fuel filter 6 Water seperator 7 Engine oil level temp sensor Picture text ...

Page 30: ...E ECU circuit D12D Tier 3 Picture text ...

Page 31: ...Main components D12D Tier 3 based Tier 2 EMS1 Delphi E1 injector Picture text ...

Page 32: ...sensor before a combined pressure and temperature sensor water in fuel sensor new and oil level and temperature sensor before only a level sensor Picture text 1 Crankcase pressure sensor 2 Coolant level sensor 3 Camshaft speed sensor 4 Oil pressure sensor 5 Charge air pressure and temperature sensor 6 Air pressure and temperature sensor 7 Fuel pressure sensor 8 Water in fuel sensor 9 Coolant tempe...

Page 33: ...E ECU circuit D12D Tier 3 based Tier 2 Picture text ...

Page 34: ...ow back to suction side when the fuel pressure become too high e g when the fuel filter is clogged Check valve 12 opens when the hand pump in the filter housing 13 is used Automatic deaeration If air has entered the system automatic deaeration occurs when the engine is started The air is pushed through the deaeration valve 14 down to the tank via the fuel return hose 15 from cylinder head Deaerati...

Page 35: ...IEGR V ACT NOx reduction solution is provided by Internal Exhaust Gas Recirculation IEGR which is altering engine valve lift Picture text ...

Page 36: ...e high pressure fuel line The fuel pressure increases acting on the injection needle lift area The NCV is still not activated still closed connecting the needle backing chamber with the high pressure fuel line why the needle can not be lifted 3 The SV is still closed and the fuel pressure is still increasing When the desired pressure is achieved the NCV is activated opened closing the high pressur...

Page 37: ...uated allowing the needle to lift E The injection needle is lifted F The fuel amount required is now injected and the NCV is deactivated closed The needle backing chamber is now again connected to the high pressure fuel line and the needle is forced to close G The needle closes and injection ends H As the SV is still closed the pressure continues to increase as long as the pump piston is moving do...

Page 38: ... being adjusted The marking on the camshaft shall be placed between the two marks on the front camshaft bearing cap Before checking the double rocker arm clearance adjust the exhaust valve lash also inlet valve lash and preload the injector according to normal procedure Loosen the oil drain nipple 3 Loosen the lock nut 1 and counter hold the piston 2 with an internal 4 mm Allen head key Picture te...

Page 39: ...ection Insert a special go no go gauge tool D P N 88820003 2 between the follower arm contact surface and the cam base circle The go gauge side F must pass through between the follower arm surface and the cam base circle if not the IEGR lift will be too big Insert the opposite no go side E between the follower arm contact surface and the cam base circle The no go gauge side must not pass through i...

Page 40: ...Engine protection function Excavator are using only basic protection function Picture text ...

Page 41: ...Engine D16E Model D16EEAE3 Rated output 346kW 1800rpm Picture text ...

Page 42: ...Diesel Turbo charged Air to Air After cooled No of cylinder 6 vertical in line type Bore X Stroke 144mm X 165mm Max Power fan not in operation 346kW 1800rpm Max Torque fan not in operation 2500Nm 1080rpm Governor type EMS2 Displacement 16100cc Emission Tier3 Picture text ...

Page 43: ...evel of electronic features and to enhance reliability 3 The proven new high pressure dual solenoid diesel fuel injector Delphi E3 introduced with the Volvo U S EPA 2002 highway engine is an integral part of the V ACT Volvo Advanced Combustion Technology system When replacing the injector we need parameter programing for trim code with VCADS Pro Picture text 1 Switch Able Internal EGR Double Rocke...

Page 44: ...nal view 1 1 Crankcase pressure sensor 2 Engine oil temp Level 3 Engine oil press sensor 4 Water in fuel sensor 5 Fuel feed pressure sensor 6 Boost press temp sensor 7 Fuel feed pump 8 Breather Picture text ...

Page 45: ...External view 2 1 Crank speed sensor 2 Cam speed sensor 3 Coolant temp sensor 4 Coolant level sensor 5 Inlet air temp Pressure Picture text ...

Page 46: ...Electric circuit D16E Picture text ...

Page 47: ...ety valve 13 which allows fuel to flow back to suction side when the fuel pressure become too high e g when the fuel filter is clogged Check valve 14 opens when the hand pump in the filter housing 15 is used Automatic deaeration If air has entered the system automatic deaeration occurs when the engine is started The air is pushed through the air bleed valve 11 down to the tank via the fuel return ...

Page 48: ...I EGR Valve operation Picture text ...

Page 49: ... the nut 38 Nm A Inlet B Injector C Exhaust 3 Eliminate the clearance between the adjusting screw and the injector by turning the adjusting screw Turn the adjusting screw another 240º 4 hexagons 180 60 Torque to tighten the nut 52 Nm 4 The valve caliper must be balanced before adjusting the exhaust rocker arm clearance Adjust the clearance between the exhaust rocker arm ball socket and the valve c...

Page 50: ...Air intake system 1 Rain cover Filter 2 Pre cleaner with scavanger Filter 3 Oil bath type pre cleaner Filter A check valve Picture text ...

Page 51: ...Electric system Before I ECU EC330B EC460B Picture text ...

Page 52: ...e charge warning lamp and goes to alternator terminal D and magnetizes the field coil When the start switch is START position R2 signal goes to V ECU to inform the key position and C signal activate safety start relay so power from battery can drive the starter From this alternator can produce electric power W signal from alternator indicates engine status to the instrument panel IC Start inter Lo...

Page 53: ...eries for protection of electrical components when welding servicing of circuits and as a safety precaution when parking the machine Mounted on the battery cover If battery disconnect switch is turned to the ON position the automatic greasing option fuel filler pump and room lamp are available even when the start switch is in the OFF position Picture text ...

Page 54: ...switch to control the power of the batteries with a small capacity wire When you replace this component pay attention to the signs on the relay Wrong connection can cause early failure of relay 2 Safety start relay When trying to restart the engine while the engine is running or if the start switch is in the START position after the engine is activated the relay cuts off the current to the starter...

Page 55: ...charges the battery The current from D flows to the safety start relay to cut off the operation of starter motor and prevent accidentally re engaging the starter After the engine starting the battery charge warning lamp is turned off because the signal from D remove voltage difference at lamp Picture text ...

Page 56: ... Fuse failure is often caused by a fine crack in the fuse and this kind of crack is very hard to detect by visual inspection Checking fuse continuity with a tester is far superior to eye inspection Picture text ...

Page 57: ...lectric Box 1 Resistance box for emergency pump control 2 Slow blow fuse 80A 3 Slow blow fuse 140A 4 Preheater relay 5 Safety start relay 6 Battery relay 7 Slow blow fuse 40A 8 Relay R1 R12 Picture text ...

Page 58: ...ol system First of all think about operating power and ground of each ECU Then move on to each function After understanding each function and input output of VECU Compare those functions with this circuit diagram When you pushed line in the circuit the color of line will be changed Picture text ...

Page 59: ...ver is in the up position the hydraulic system will work When the safety lever is in the down position the servo pressure is cut off to functions which are operated with control levers and pedals 2 Emergency switch 3 Auto Manual switch Picture text ...

Page 60: ...low control switch Two switches are almost same components Only different thing is that the flow control switch needs screw driver to adjust the step Input voltage is 24v and output voltage is 0 5 4 5V They have a shield ground to prevent noise at signal line Picture text ...

Page 61: ...lic pressure varies in proportion to the current value at the proportional solenoid valve The proportional solenoid valve spool vibrates continuously to maintain the secondary servo hydraulic pressure and is very sensitive to contamination due to the close tolerances of the spool valve body In the event of a malfunction always inspect the valve for contamination before replacing it Picture text ...

Page 62: ... Attachment Pilot pressure switch Travel Pilot pressure switch Travel alarm Option On 20 Kgf cm 2 Off 14 Kgf cm 2 2 Hammer Pilot pressure switch Boom float Pilot pressure switch On 7 Kgf cm 2 Off 5 Kgf cm 2 Picture text ...

Page 63: ... is very fast Information bus SAE J1708 This bus is connected to all control units and the service socket and have back up function for the control bus of E ECU The system status is continuously updated By using this bus we can use MATRIS and VCADS Pro and can program the ECU MID Message Identification Description Unique number for each control unit PID Parameter Identification Description Unique ...

Page 64: ... people have to know about the function first and input output signal to diagnose and fix the problem Function of VECU Self diagnose Machine status indication Mode selection Engine Speed Sensing Power Control ESSPC Automatic return to idle Automatic and one touch power boost Safe start and stop Automatic travel speed control Emergency control Limp home mode Pump flow control for optional equipment...

Page 65: ...nnectors for VECU JA connector has 70 pins and JB has 16 pins When you replace the VECU you have to check the part number of VECU because you need to run the conversion kit of VCADS Pro if failed VECU is old one Picture text ...

Page 66: ... receives the current engine speed from the E ECU It balances engine horsepower and pump consuming power by changing output current to power shift valve Power shift valve is kind of proportional valve using PWM signal By controlling power shift valve we can change the swash plate angle and finally change pump flow rate So system can keep pump torque maintain lower than engine torque at the selecte...

Page 67: ...Engine and pump control specification USA market do not have P mode Picture text ...

Page 68: ...trol switch is in F mode VECU turns off power to travel speed solenoid That means travel speed is fixed to low speed regardless of travel speed select switch position VECU energize power boost solenoid to increase main relief set pressure by 10 VECU turns on power to boom arm conflux cut off solenoid Then boom arm use only 1 pump flow for slow speed Picture text ...

Page 69: ...es this condition and automatically goes to the emergency mode If emergency switch is up position engine speed will be emergency high speed and power shift valve current is set to the value that corresponds to 85 of the maximum pump input torque from V ECU 3 When malfunction of V ECU Emergency switch control the engine speed and Auto Manual switch decide power shift current with resistor box Machi...

Page 70: ...s down to I1 mode This increase fuel economy and decrease noise After engine has decelerated if the operator changes one of input signals then engine speed return to the previous speed Default time delay is 5 second This can be adjusted form 3 to 10 seconds by VCADS Pro Picture text ...

Page 71: ...boost is not needed for travel only mode in EC460B 2 In F mode machine has power boost function 3 When selection switch is boost or shear position by pushing RH joystick button we can use power boost function for 9 seconds We call this one touch power boost This is useful function when machine confront the heavy load Picture text ...

Page 72: ...n driving Fan speed has two steps low and high according to the temperature of hydraulic oil If temperature goes up to 70 degree V ECU turns on solenoid then fan motor speed become high If temperature goes down to 50 degree V ECU turns off solenoid then fan motor speed become low Picture text ...

Page 73: ...ing to prevent machine drifting toward because of reaction force from bucket V ECU realize the stop condition from travel pilot pressure switch then V ECU cut off the power to the travel speed solenoid regardless of the position of travel speed selection switch 2 High speed 3 F mode control Picture text ...

Page 74: ... sudden rpm increase in cold period or other situation 2 During starting if safety lever is up this signal disengage starter to prevent from sudden movement of hydraulic function 3 After starting any attachment operation or speed control switch operation makes engine return to the speed set by rpm control switch 4 When start switch is turned off Start switch signal is transferred to E ECU Importan...

Page 75: ... operator adjust flow control switch display automatically shows the flow value at the present engine rpm 2 When operator uses the option attachment the pilot pressure switch will be activated V ECU receives this signal and then start to controls the flow control valve according to flow control switch position If the pilot switch is off position there is no output current from V ECU That means flo...

Page 76: ...Flow setting video Picture text ...

Page 77: ...utton display contents are changed from engine speed to battery voltage hammer operating hour key number pump flow rate and error code When pump flow rate is selected if you push the arrow button for 5 second the unit of flow will be changed between lpm and gpm When error code is selected active error codes are displayed consecutively If pump flow rate option is changed set value is displayed on m...

Page 78: ... Unit The service display unit can be connected to service socket above the radio The display unit is used for the service troubleshooting This can give additional information which cannot be seen on the MDU Picture text ...

Page 79: ...hould be checked daily and replaced if burnt out because the indicators alert the operator of a failure in the machine The panel contains a coolant temperature gauge fuel gauge hour meter and alert indicators to show machine conditions The instrument panel utilizes a plug in printed circuit board PCB to facilitate replacement and troubleshooting If a failure is suspected always check the plug in c...

Page 80: ...connectors connector A B of the printed circuit board 2 Central warning and buzzer sound W signal indicates engine status whether engine is running or not IC in the instrument panel receives warning signal and this W signal and then decides that this situation is warning case or not For example when we turn the key switch from OFF to ON we can see only charge warning lamp and engine oil low pressu...

Page 81: ...ument panel circuit Inside of instrument panel there is an IC chip to control the lamp and warning case In this page think about how to operate this circuit to make the function of previous page Picture text ...

Page 82: ...Engine oil pressure switch Check the location of this sensor Picture text ...

Page 83: ...f this sensor is very small between ON OFF This can cause frequent on off of warning lamp To prevent this we have some special program at ECU To turn on the lamp coolant switch should maintain off position for some period Picture text ...

Page 84: ...Coolant temperature sensor This sensor is used for needle gage of instrument panel Picture text ...

Page 85: ...Fuel level sensor This unit sends variable resistance value according to the level of the fuel in the fuel tank to the fuel level gauge on the instrument panel Picture text ...

Page 86: ...Switch circuit By using this circuit you can do continuity test for switches Picture text ...

Page 87: ...Fuel filler pump This shows the 50LPM pump with level sensor This has automatic stop function when fuel level reach to maximum Picture text ...

Page 88: ... B Washer switch C Lower wiper switch D Wiper controller E F Upper and lower limit switch G Upper motor H Washer pump During wiping Y and G are connected So even though switch A or C is OFF motor G or I will work to its stroke end Picture text ...

Page 89: ... by joystick button and pedal In this case RH joystick 3 can be used for hammer or power boost according to the position of hammer shear select switch But double acting shear is operated by only the pedal And RH joystick 1 can be used for boom floating function Boom floating is to make both chamber of cylinder connected to tank Picture text ...

Page 90: ...e solenoid valve for double acting without the pedal Single acting hammer is operated by joystick button In this case RH joystick 3 can be used for hammer But double acting shear is operated by RH joystick 3 2 And RH joystick 1 can be used for one touch power boost Picture text ...

Page 91: ... rotator circuit These two systems can be activated after lifting up the safety lever Lifting safety lever activate pressure switch then turn on the R12 This is safety function for this option hydraulic Picture text ...

Page 92: ...d DC DC converter From DC DC converter 2 lines are used for operating power and 1 line is used for frequency memory function If the cassette mute switch is installed and turned to ON the speaker is cut off even when the cassette power is ON Picture text ...

Page 93: ...stem I ECU application New I ECU is introduced for commonality With the New I ECU changes electric circuit changes took place at the same time Applied Serial no EC330B 10417 EC360B 11226 EC460B 10922 Picture text ...

Page 94: ...Machine information system change Picture text ...

Page 95: ... A C switch moves to RH control box 2 Emergency Auto Manual and 1 2 pump select switch move to LH control box 3 Hour meter is located at LH control box 4 No flow control switch Flow setting will be done at I ECU Picture text ...

Page 96: ...Electronic control system overview Programmable I ECU added Picture text ...

Page 97: ...V ECU input and output Many input signal was directly connected to instrument panel for old system Now those signals go to V ECU which sends information to I ECU Picture text ...

Page 98: ...Control circuit Picture text ...

Page 99: ...olant temp fuel Gauge C Warning indicator D MCD Message Center Display E Key button 2 Key OFF condition 3 Key ON Booting operation Central warning lamp 2 times gauge all segment ON all indicator lamp ON 4 Key OFF Shutdown operation Picture text ...

Page 100: ...New I ECU circuit New I ECU uses only 10 pin connector because I ECU use the communication line for various signal Picture text ...

Page 101: ...MCD Operation 1 Normal condition 2 Anti theft Code lock condition 3 X1 menu 4 Error display Picture text ...

Page 102: ... will be saved in the IECU b Enter the PIN code through IECU arrow confirm buttons c Push the confirm button more than 2 sec d If the correct code is entered Indicator Operation menu is displayed e Alarm sound can be off by pushing confirm button Picture text 0 ...

Page 103: ...Pop up indicator This is not a warning but just indication of activation Picture text ...

Page 104: ...Indicator operation Picture text ...

Page 105: ...r from 30 to 500 at flow setting screen But if you select number that is larger than actual maximum flow the set value will not be changed as you select For example if you select 240 at EC210B the set value will be changed to 200 Picture text ...

Page 106: ...Start circuit New alternator New alternator and old instrument panel Picture text ...

Page 107: ...Start circuit New alternator and New I ECU New alternator with new I ECU Picture text ...

Page 108: ...Alternator change Picture text ...

Page 109: ...om fuel line we need more cranking time to start engine But new alternator produces a little bit higher voltage at the terminal L This deactivate safety relay and interrupt start motor To prevent this we add the time delay function at the safety relay Picture text ...

Page 110: ...D12D Engine Applicatin EC330B EC460B Applied Serial no Tier 3 EC330B 80001 EC360B 80001 EC460B 80001 Applied Serial no Tier 3 based Tier 2 EC330B 10713 EC360B 12152 EC460B 11515 Picture text ...

Page 111: ...VECU input output 1 Fan speed select solenoid 2 speed Fan speed select PWM Variable speed 2 Start lock function 3 Travel speed circuit 4 Travel alarm controlled by V ECU Picture text ...

Page 112: ...Control system circuit Tier3 Old Serial No 80001 E ECU EMS2 Picture text ...

Page 113: ...Control system circuit Tier 3 New Changed items 1 Power supply to Emergency sw Old F24 F15 New F15 2 WECU New option Picture text ...

Page 114: ...Control system circuit Tier3 based Tier2 Old EC330B 10713 EC360B 12152 EC460B 11515 Picture text ...

Page 115: ...Control system circuit Tier3 based Tier2 New Changed items 1 Power supply to Emergency sw Old F24 F15 New F15 2 WECU New option Picture text ...

Page 116: ...Start circuit Start lock system change Picture text ...

Page 117: ...Start circuit New 1 Master switch removed 2 Slow blow fuse change 40A 30A Tier3 EC330B 80426 EC360B 80993 EC460B 80661 Tier3 based Tier2 EC330B 10780 EC360B 13096 EC460B 12543 Picture text ...

Page 118: ...Electric box The number of relay is reduced Only 1 relay box Picture text ...

Page 119: ...Engine Pump control spec 1 EC330B EC360B Engine control spec is same with D12C engine 2 EC460B Because of pump change power shift current value is changed Picture text ...

Page 120: ...Travel speed control Electric circuit change Picture text ...

Page 121: ... lock relay will be off when wrong password Safety lever up engine running for 6 second after engine start for 2 second after engine off If Auto Maunal switch is at Manual the power for start lock relay will be supplied by Auto Manual switch Picture text ...

Page 122: ...Power supply to E ECU Picture text ...

Page 123: ... controls fan speed according to the input from hydraulic oil temperature sensor In previous machine there was only 2 speed step but now is variable speed EC360B EC330B 60oCrpm1000 1000 mA 575520 90oCrpm2000 2000 mA 130100 Picture text ...

Page 124: ...Proportional relief valve This valve is inverse proportional valve As the current goes up 2ndary pressure drops down Picture text ...

Page 125: ...Wiper circuit New wiper controller Picture text ...

Page 126: ...can be planned and followed up Different alarms and error codes will be handled under service management Service Machine position Instantaneous Machine data Geographical fence Location report Sanil Trail Machine Utilization Report Event Report Performance Productivity Report Immobilizer Alarms Warnings Error Codes Service Report Logged Machine Data Complete Download Logged Machine Data Partial Dow...

Page 127: ... Antenna and cable installation by Dealer Base machine production by Volvo China GPS Parameter MXD must be turned on by VCAD pro Anti thieft protection ABP must be turned off by VCAD pro Shut down request from V ECU Power line cut 60 Duty ratio output by GPS ECU GSM cable cut or GPS cable cut 70 Open ECU cover 80 Stop request from web 90 GPS ECU failure 100 GPS ECU thift 0 Engine running condition...

Page 128: ...Connector naming method change The way of naming connector is changed Picture text ...

Page 129: ...Electric system EC700B Picture text ...

Page 130: ...ator 15 pre magnetization ACC VECU Air conditioner EMS power relay 2 Key Start R2 VECU C safety start relay 3 Engine running Alternator L hour meter safety start relay VECU charge lamp off Resistor between alternator and BR termainal for quick charge lamp off Alternator B alternator BS voltage sensing for regulation Alternator 15 battery relay 4 Key Off VECU JA61 battery relay Picture text ...

Page 131: ...elays for EMS power and EMS data R3 R4 relay were removed 1 Circuit animation if you click the line the color will be changed 2 Component location if you clikc the symbol on the circuit you can see the location of component Picture text ...

Page 132: ...Electric Box Picture text ...

Page 133: ...ng 2 Boom float switch on the RH side of the RCV 3 Hammer and shear selection switch 4 Engine speed control switch 5 Power max selection switch 6 Auto idle selection switch 7 Start switch 8 Boom float position pressure switch 9 Travel pilot pressure switch 10 Attachment pilot pressure switch 11 Hammer pilot pressure switch 12 Fuel level sensor 13 Alternator L signal Lamp 15 Safety lever 16 Hydraul...

Page 134: ...lve power line inside V ECU 4 V ECU status line to IECU 5 Boom floating button solenoid function 6 Travel speed switch relay solenoid function 7 Hammer shear selection switch and solenoid 8 Fuse and its related components 9 Hydraulic oil cooling valve Proportional relief valve 10 Travel alarm relay connection Picture text ...

Page 135: ...Control System Circuit New 1 R3 R4 Relay removal Direct power supply from the emergency switch Serial No break 10076 2 WECU Option Picture text ...

Page 136: ...Engine and Pump Control specification Picture text ...

Page 137: ... X connector view P Pressurized port Max 100 bar VBAT Battery Voltage Hydraulic pressure sensor strain gauge sensor Electric switch Transistor type and Normally open Switching hystereses are On 4 5 bar and Off 3 5 bar The location of this is behind CAB and below electric box Picture text ...

Page 138: ...Fuel Filler Pump A Pump 100 lpm location B Location of fuel level sensor for auto stop D Fuel level sensor for auto stop E Circuit Picture text ...

Page 139: ...Power transmission Picture text ...

Page 140: ...Swing System EC330B EC360B Swing motor Gear box Pinion Turning joint Swing Ring gear Picture text ...

Page 141: ...r ratio 24 37 Oil SAE NO 90 6 liter Compare the circuit port on the motor A B Main Mu Anti cavitation Dr Case drain PG Brake releasing SH Brake pilot GA GB Pressure checking SGo Oil filling Au Air vent port for oil filling Dr RG Gear oil drain SGr Grease filling port AGr Air vent port for grease filling Picture text ...

Page 142: ...Sectional view A swing drive unit B reduction gear box C swing motor D Mechanical brake E Anti cavitation check valve F Relief valve G Rebound damping valve H Time delay valve Picture text ...

Page 143: ...ost of brake force comes from this relief valve when we stop slewing Therefore we need smooth build up of pressure for smooth braking 1 Low pressure relief 2 Pressure increasing with time 3 Final stage of relief Picture text 1 ...

Page 144: ...the valve 2 Swing B port in A port out valve is pushed to A port and closed 3 Hydraulic braking rebound begin A port is pressurized by discharged oil But valve is moving slowly A B ports are connected 4 Rebound damping high press A is gone to B port through the valve Picture text 1 ...

Page 145: ...he brake chamber and oil in side of that chamber shoud be drained But there is only small hole for drain near to time delay valve In the beginning oil pass through the orifice and go to tank but pressure will be built up in front of the orifice and push the valve Now the valve blocks tank line There is no flow to tank That means there is no pressure difference between front and rear side of valve ...

Page 146: ...Swing System EC460B Swing motor 2EA Gear box Pinion Turning joint Swing Ring gear Picture text ...

Page 147: ...Gearbox Gear ratio 20 01 Oil SAE NO 90 6 liter Compare the circuit port on the motor A B Main M Anti cavitation Dr Case drain PG Brake releasing SH Brake pilot PA PB Pressure checking GI L Gear oil filling Oil level checking GO Gear oil outlet E Air vent port for gear oil filling Picture text ...

Page 148: ...moothly on the swash plate Valve plate is pressed against the cylinder block surface by the mechanical pressure of spring and hydraulic pressure working on the bushing Between the outer diameter of the cylinder block and housing a mechanical brake for parking is mounted The cover section has a relief valve for cushioning and an anti cavitation valve to prevent cavitation and rebound damping valve ...

Page 149: ...Sectional view 2 Gear box reduce the speed and increase torque using planetary gear Picture text ...

Page 150: ...ce comes from this relief valve when we stop slewing Therefore we need smooth build up of pressure for smooth braking 1 Closing position 2 Low pressure relief 3 Relief pressure increase by moving of piston 4 Final stage of relief Picture text ...

Page 151: ... starts rebound PA pressure drops down If PA is lower than the spring force of damping valve those two valves starts to return to original position But return speed is different because of small hole of front valve This speed difference make gap between two valves This gap connects A B ports As result PA PB will be same for short time That means there is no force to rotate motor again Finally this...

Page 152: ...go to the brake chamber and oil in side of that chamber shoud be drained But there is only small hole for drain near to time delay valve In the beginning oil pass through the orifice and go to tank but pressure will be built up in front of the orifice and push the valve Now the valve blocks tank line There is no flow to tank That means there is no pressure difference between front and rear side of...

Page 153: ...Swing System EC700B Swing motor 2EA Gear box Pinion Turning joint Swing Ring gear Picture text ...

Page 154: ... piston motor Relief valve pressure 250 kgf cm2 Max drain pressure 3 kgf cm2 Brake release pressure Min 33 Max 50 kgf cm2 Brake delay time 5 8 sec SH Pilot signal for brake release PG Brake releasing pressure signal Dr Drain GA GB Gauge port Mu Anti cavitation port A B In out port Picture text ...

Page 155: ...Sectional View A Swing drive unit B Swing reduction gear C Swing motor D Mechanical brake E Anti canvitation check valve F Relief valve G Rebounding damping valve H Time delay valve Picture text ...

Page 156: ...Relief Valve 1 Pressure increase 2 Gradual pressure increase The inner cylinder push the spring seat and during the movement the pressure increases gradualy 3 Setting pressure Picture text ...

Page 157: ...Travel motor Old Picture text ...

Page 158: ...External view Circuit animation for travel motor Picture text ...

Page 159: ...Sectional view 1 Set screw for large displacement 2 Set screw for small displacement Picture text ...

Page 160: ... can go to tank 2 Overrun When machine travels at the down slope this can cause overrun That means the amount oil of supply line is less than expected In this case we need brake function to control the machine from over speed The pressure of supply line becomes low and the brake valve return to the neutral position So we can block the return line and slow down the machine speed Picture text ...

Page 161: ...Relief valve operation 1 1 The pressure is lower than the set value 2 The pressure is reached to the set value Picture text ...

Page 162: ... Pilot pressure at pi port Speed change spool is moved downward Supply pressure H is supplied to L port 3 Automatic downshift Pilot pressure at pi port Supply pressure reaches to 265bar B Speed change spool is pushed upward against pi pressure Supply pressure H is connected to S port Picture text ...

Page 163: ...Parking brake 1 Time delay valve Picture text ...

Page 164: ...Travel system New EC330B EC360B Travel motor Gear box Picture text ...

Page 165: ...except the displacement gear ratio Travel motors Displacement 129 178 cc rev Relief pressure 370 kgf cm 2 36 3 MPa Speed changeover pressure 265Kgf cm 2 26 0 MPa Brake release pressure 8 kgf cm 2 0 83MPa Gear box Gear ratio 65 436 Oil SAE 90 Gear oil 6 2 liter Picture text ...

Page 166: ...ctional view 1 1 Pressure reducing valve for parking brake 2 Counter balance valve or Brake valve 3 Relief valve 4 High speed set screw 5 Speed changeover valve 6 Swash piston 7 Parking brake Picture text ...

Page 167: ...s valve 1 Supply pressure goes to brake chamber to release the brake 2 If the pressure of brake chamber exceed the specified value spring tension main pressure push the valve to the right becasue of area difference of valve and disconnect passage between main pressure and brake chamber Therefore the parking pressure cannot exceed the setting pressure Picture text 1 ...

Page 168: ...machine travels at the down slope this can cause overrun That means the amount oil of supply line is less than expected In this case we need brake function to control the machine from over speed The pressure of supply line becomes low and the brake valve return to the neutral position So we can block the return line and slow down the machine speed During this period the orifice on the brake valve ...

Page 169: ...essure at Pi The supply oil through check ball folws to the swash piston Swash pisto pushs the swash plate and decrease swash angle so the motor rotates at high speed 3 In this picture the force by Pi port pressure acts against the force by supply pressure which is applied on the differential area and spring When the supply pressure reach to specified value the force by supply pressure and spring ...

Page 170: ...Travel System EC460B travel motor Gear box Picture text ...

Page 171: ...vel motor Travel motors Bent axis type Displacement 99 160 cc rev Relief pressure 330bar 33 MPa Speed changeover pressure 240 bar 24 0 MPa Brake release valve set pressure 21 4bar Gear box Gear ratio 108 1 Oil SAE80W 90 5 liter Picture text ...

Page 172: ...Sectional view 1 When you click the component on the circuit diagram you can see the location of correspondent component Picture text ...

Page 173: ...Sectional view 2 Gear box Picture text ...

Page 174: ... high 3 This high pressure release the parking brake through the reducing valve 4 This high pressure applies to the backside of brake valve and then pushes the brake valve against spring So return side oil can go to tank Machine starts to move 5 When machine over running supply side pressure will be low This moves the brake valve to the neutral side Picture text 1 ...

Page 175: ... machine travels at high speed condition 3 While the machine travels at high speed condition according to the travel load increment pressure at the speed change valve is increased Due to the sectional area A is larger than sectional area B the suply pressure is applied to the ring area A B When the supply pressure reaches to the setting pressure of spring the speed change valve moves to the left a...

Page 176: ...Travel System EC700B travel motor Gear box Picture text ...

Page 177: ...c rev Relief valve pressure 350 kgf cm2 Speed changeover pressure High low 263 kgf cm2 at Pi 40 kgf cm2 Brake release pressure 18 4 kgf cm2 Drain pressure Continuous Lower than 2 kgf cm2 Intermittent Lower than 5 kgf cm2 G1 G2 Gauge port Dr R Dr L Drain Pi Pilot signal for travel speed changeover P1 P2 In Out port Picture text ...

Page 178: ...Sectional View Picture text ...

Page 179: ...ce valve to the right direction and open its return passage 3 Downhill travelling During downhill operation the motor is driven by machine s weight The supply port pressure drop and the counter balance valve return to its neutral position Blocked return passage And travel speed decrease Picture text ...

Page 180: ...alve Operation 1 Pressure increase 2 During the free piston movement the pressure is maintained stable as low 3 If the free piston pushed to its stroke end the pressure increase to its set pressure Picture text ...

Page 181: ...d 2 High speed If there is Pi travel speed valve is pushed to the right And high pressure is supplied to tilting piston chamber Min angle high speed 3 Automatic down shift If the main pressure red color is increased travel speed valve is pushed to the left And the tilting piston chamber is connected to tank Picture text ...

Page 182: ...Parking Brake Operation 1 The brake chamber is connected to tank and springs push brake piston to the friction plates 2 The brake chamber is pressurized and pushed against spring tension Picture text ...

Page 183: ...Brake system Picture text ...

Page 184: ...Steering system Picture text ...

Page 185: ...Frame Track Unit Picture text ...

Page 186: ...pper frame D12D engine 1 Center frame 2 Cabin mouting position 3 Engine mounting position 4 Swing motor mounting position 5 Turning joint mounting position 6 Counterweight mounting position Picture text ...

Page 187: ...Upper frame EC700B 1 Upper frame EC700B 2 Low noise kit Picture text ...

Page 188: ...djuster cylinder through grease nipple A using a grease gun with a maximum capacity 690 bar 10000 psi To increase track sag loosen valve assembly B one turn so that grease in the track adjuster cylinder can be drained through rod hole C Tighten the valve assembly when track sag is correct 3 Lower roller ISO VG 220 EP Oil 4 Roller guard Standard 5 Roller guard Heavy duty 6 Swing supporter area 7 Tr...

Page 189: ...Track Link 1 Link LH 2 Link RH 3 PIN Regular 4 PIN Master 5 Bushing Regular 6 Bushing Master 7 Seal 8 Spacer 9 Greasing area 10 Greasing area 11 Do not apply grease here EP2 Grease Picture text ...

Page 190: ...oom Rear Bearing 2 Boom Center Bearing 3 Arm Cylinder Lug Boom side 4 Boom Front Lug 5 Stiffener 6 Arm Cylinder Lug Arm side 7 Boom Arm Bearing 8 Bucket Cylinder Lug 9 Yoke Bearing 10 Arm front Bearing Picture text ...

Page 191: ...Air conditioning system Picture text ...

Page 192: ...g system overview Heating and cooling system is installed in a single unit Can select indoor or outdoor air Mix door controls target temperature of system by mixing cold and hot air There are two filters Picture text ...

Page 193: ...uto mode or manual mode By pushing AUTO switch system can be operated automatically The only thing what operator has to do is setting the target temperature In auto mode when other switches except temperature setting and trouble checking switch is operated the control system is changed to the manual mode Picture text ...

Page 194: ...Aircon system electric circuit Old By clicking the line you can change the color of the line Picture text ...

Page 195: ...Aircon system electric circuit New An additional 5A FU24 fuse has been installed in the air conditioning compressor circuit to protect it from excessive current Picture text ...

Page 196: ...dication The status display has two modes Operator mode and Service mode In operator mode you can check only target temperature ambient temperature and error code In service mode you can check all of items Picture text ...

Page 197: ...Error code Picture text ...

Page 198: ...Manual mode control Picture text ...

Page 199: ...Air conditioning switch animation Press button step by step Picture text ...

Page 200: ...controller Manual type controller is an option for tropical area It has only cooling unit There is no heating unit so there is also no mix door actuator and coolant temperature sensor And for this option there is no in car ambient temperature sensor Picture text ...

Page 201: ...2 Connection point Refrigerant 3 Actuator LH foot 4 Connection point Coolant 5 Actuator Mix door 6 Actuator Face door 7 Filter Main 8 Blower fan 9 Heater core 10 Evaporator 11 Duct temp sensor 12 Expansion valve 13 Filter Ambient Picture text ...

Page 202: ... sensor is installed at the core of evaporator If sensor is failed compressor clutch will be disabled 1 Duct temperature sensor 2 In car temperature sensor 3 Ambient temperature sensor 4 Coolant temperature sensor Picture text ...

Page 203: ...or actuator there is a position sensor This informs the real position to controller for precise positioning Feedback control 2 Foot Face door acutator MO8704 6 Opeating angle 90 degree 3 Intake door acutator MO8703 Operating angle 120 degree Picture text ...

Page 204: ...elays are used for controlling blower speed And 1 relay is used for compressor clutch control Inside of resistor there is two lead fuses If there is problem with this resistor we can use only maximum fan speed 1 Relay 2 Resistor Picture text ...

Page 205: ...Compressor S Suction port bigger port D Delivery port high pressure side smaller port New compressor has 2 pin connector GND Old type has one pin connector body GND Picture text ...

Page 206: ...Expansion valve This is a kind of feedback system From output temperature from evaporator System decides the amount of refrigerant Output temp high More flow Output temp low Less flow Picture text ...

Page 207: ...articles from the system Has desiccant to absorb moisture from the refrigerant Has a built in pressure switch to protect system from excessive high or low pressure 1 Desiccant 2 Filter 3 Baffle plate 4 Inner tube 5 Outlet port 6 Inlet port 7 Pressure switch Low pressure OFF 2 0 0 2 kgf cm 2 High pressure OFF 32 2 kgf cm 2 Picture text ...

Page 208: ... plug the thermostats the flame sensor the controller the electric motor and the fuse The case of the unit has the fuel supplying port the coolant inlet outlet port the air inlet port and the exhaust port 3 Fuel pump The fuel pump supplies the diesel heater with the fuel from the tank 4 Water pump The water pump is located between the diesel heater and the engine block and supplies the diesel heat...

Page 209: ...Hydraulic System EC330B EC360B Picture text ...

Page 210: ...it has 3 fixed gear pumps P3 is for servo system P4 is for hydraulic oil cooler fan motor P1 is for X3 Travel straight travel function Boom up 2 pump flow Boom down Regeneration Boom Holding function Arm in out 2 pump flow Arm Holding function Arm in Regeneration Option 2 pump flow selectable Swing priority against arm during simultaneous operation Picture text ...

Page 211: ...the way how to read our circuit diagram 1 Main pump 2 Rotator pump 3 MCV 4 Boom cylinder 5 Arm cylinder 6 Bucket cylinder 7 Pump for Hyd oil cooling 8 Flow control valve 9 Swing Drive unit 10 Track motor 11 Track gear box 12 Slewing ring gear 13 Turning joint 14 Fan motor 15 Shunt valve 16 Pilot filter 17 Accumulator block 18 Quick coupler 19 Accumulator 20 Solenoid valve 1 21 Solenoid valve 2 22 ...

Page 212: ...Brief circuit 1 D10B Brief circuit for main line Picture text ...

Page 213: ...Brief circuit 2 D10B Brief circuit for pilot servo line Picture text ...

Page 214: ... animation D10B This animation can be used when you explain or study the hydraulic circuit By pressing the lines character or spool with mouse you can change the colour of lines and spool location Picture text ...

Page 215: ...Full Option Circuit D12C Due to D12C application there was some changes at the hydraulic system Major change is pump Picture text ...

Page 216: ...Brief circuit 1 D12C Picture text ...

Page 217: ...Brief Circuit 2 D12C Picture text ...

Page 218: ...Circuit Animation D12C Picture text ...

Page 219: ...Hydraulic pump Picture text ...

Page 220: ...External veiw D10B Check the port location and compare with the circuit diagram Picture text ...

Page 221: ...Sectional view D10B Picture text ...

Page 222: ...Pump circuit D10B Picture text ...

Page 223: ...External veiw D12C Picture text ...

Page 224: ...ssed against the shoe plate by the action of the cylinder spring through the set plate and spherical bushing Similarly the cylinder block is pressed against valve plate by the action of the cylinder spring The swash plate group consists of swash plate shoe plate swash plate support tilting bushing tilting pin and servo piston The servo piston moves to the right and the left as hydraulic oil contro...

Page 225: ...New gear pump D12C Picture text ...

Page 226: ...P Q curve Hp T X rpm P X Q Picture text ...

Page 227: ...nal solenoid valve is provided However secondary pressure Pf power shift pressure flows into the horsepower control portion of each pump regulator through an inner passage and shifts it to same horsepower setting respectively Delivery flow rate of the pump can be changed so the proper power level suitable for the work conditions can be acquired Negative flow control Varying the servo hydraulic pre...

Page 228: ...Regulator animation By pressing the arrow button you can increase or decrease control pressure Pay attention to the movement of feedback lever Picture text ...

Page 229: ...Main Control Valve Picture text ...

Page 230: ...Main Control Valve Push the component in the circuit diagram with mouse then you can see the location of that components or disassembled components and section view Picture text ...

Page 231: ... the amount of flow from pump according to the joystick stroke 1 Neutral condition Central passage fully open High Pi Minimum flow 2 Half stroke Central passage partially open Medium Pi Medium flow 3 Full stroke Central passage fully close the lowest Pi Maximum flow Picture text ...

Page 232: ... is lower than the set pressure close 2 Pump pressure is reached to the set pressure pilot poppet open 3 Main poppet open and pump line has tank connection 4 Pressure drop down pilot poppet close 5 Main poppet close PL1 ON 1 Boost signal comes from port PL1 and push the piston to increase the tension of spring Picture text ...

Page 233: ...n set pressure close 2 Cylinder pressure is reached to set pressure pilot poppet open 3 Small piston which is inside of main poppet moves to right and sit on the pilot poppet Main poppet open and makes tank passage Make up anti cavitation 4 Cylinder pressure drop down to the vacuum pressure Main poppet will be opened by tank pressure and fill up the cylinder chamber Picture text ...

Page 234: ...hen x1 selection switch is ON and X1 uses 1way releif valve goes to low pressure setting without pilot pressure 2 2 way Shear When x1 selection switch is ON and X1 uses 2way releif valve goes to high pressure setting due to pilot pressure ON Picture text ...

Page 235: ...age open Holding valve closed 2 Joystick signal on BU Boom1 Boom2 Spool move to LH side Center passge close pressurize 3 Open load check Oil from parallel passage open load check 4 Holding valve open and supply oil to cylinder Picture text 1 ...

Page 236: ...spool 3 Oil supplied to the small chamber and return oil try to return to tank 4 Holding valve open Return oil go through the hole of spool and open back pressure check valve then return to tank valve Build up return pressure When supply pressure is low internal check valve can be open and make passage to the supply side Picture text 1 ...

Page 237: ... 1 Neutral 2 Bucket IN BI signal ON Spool move Center passage block 3 Supply oil to the cylinder 4 When using Boom Up at the same time PAcs signal limit the stroke of the bucket spool Boom priority Picture text 1 ...

Page 238: ... valve 4 Holding valve open Return line is restricted by arm regeneration valve when supplying pressure is low Internal check open and return line is connecting to supply line 5 When supplying pressure is high arm regeneration valve make wide hole for return line to reduce back pressure 6 When using Boom up at the same time Center passge is blocked by boom1 spool Arm2 logic valve is closed by boom...

Page 239: ...movement block the line from orifice and bulid up pressure Travel pilot pressure switch ON P2 oil goes to TL side directly and Boom1 side parallel passage 3 Travel LH Spool movement block the line from orifice and bulid up pressure P1 oil goes to TL side directly and Boom1 side parallel passage 4 Swing operation Swing spool movement block the line from the other orifice and build up pressure Attac...

Page 240: ...lic oil temperature reaches 50 celsius Shunt valve operation 2 When the hydraulic oil temperature is lower than 70 celsius the solenoid valve relay is at ON position due to hydraulic oil temperature sensor P1 pump flow to solenoid valve then through shunt valve Pi port moves shunt valve spool to the right Some amount of oil supplied from P2 pump to shunt valve A port flows to B port through shunt ...

Page 241: ...Fan motor Picture text ...

Page 242: ...mount of backpressure which is used for make up function 4 5bar check valve is used for bypass function when hydraulic oil cooler is clogged 27 3 0k Return check valve 28 4 5k Return check valve 29 Hydraulic oil cooler 34 Hydraulic tank Picture text ...

Page 243: ...Option hydraulics Picture text ...

Page 244: ...ammer return line directly goes to tank But shear uses double action So we need 3 way valve 2 step port relief valve 2 step port relief valve always maintains high pressure except hammer use X1 option pedal Flow control function Option 2 pump flow 2 switch control without pedal Picture text ...

Page 245: ...X1 Components 41 Hammer Shear select solenoid valve 46 X1 Flow control valve 48 Hammer Shear select valve 42 Option pedal Picture text ...

Page 246: ...Rotator circuit This is X3 option X3 option is composed of gear pump at PTO rotator valve and additional case drain line for motor This is operated using LH joystick button Picture text ...

Page 247: ...X3 line piping Picture text ...

Page 248: ... signal goes to VECU VECU energize the solenoid When joystick is in boom down position this signal operate hose rupture valve and boom floating valve This makes boom cylinder piston side and rod side go to tank So boom can drop down by its weight Picture text ...

Page 249: ...Boom floating components Picture text ...

Page 250: ... lock cylinder locking the bucket in place against the rear hook This means that the lock wedge adjusts itself and provides gap free locking When lock wedge is released the servo pressure is transferred to the piston rod side If necessary the release pressure can be increased by loading the bucket cylinder in its end position There is a red marker on the left side of the quick fit attachment which...

Page 251: ...S Quick fit Components Picture text ...

Page 252: ...U Quick fit X Quick fit valve 26 Pilot block Picture text ...

Page 253: ...Removal counterweight P2 pump oil can be supplied by blocking center bypass valve For safety large chamber oil is restricted to out Picture text ...

Page 254: ...Hydraulic System EC330B EC360B D12D engine application Picture text ...

Page 255: ...Full option circuit Straight travel function is added Picture text ...

Page 256: ...Fan motor There is a check valve to prevent motor from cavitation Picture text ...

Page 257: ...Straight travel pedal Without operating two travel pedals C for straight travel we can use only option pedal B Picture text ...

Page 258: ...Hydraulic System EC460B D12C engine application Picture text ...

Page 259: ...gear pumps P3 is for servo system P2 is for hydraulic oil cooler fan motor P1 is for X3 Travel straight travel function Boom up 2 pump flow Boom down Regeneration Boom Holding function Arm in out 2 pump flow Arm Holding function Arm in Regeneration Option 2 pump flow selectable Bucket 2 pump flow selectable Swing priority against arm during simultaneous operation Picture text ...

Page 260: ... is the way how to read our circuit diagram 1 Main pump 2 Servo pump 3 Main control valve 4 Boom cylinder 5 Arm cylinder 6 Bucket cylinder 7 Swing motor 8 Swing gear box 9 Swing drive unit 10 Travel motor 11 Travel gear box 12 Swing ring gear 13 Turning joint 14 Fan motor 15 Shunt valve 16 Pilot filter 17 Accumulator block 18 Quick coupler 19 Accumulator 20 Solenoid valve 1 21 Solenoid valve 2 22 ...

Page 261: ...Brief circuit 1 Old Brief circuit for main line Picture text ...

Page 262: ...Brief circuit 2 Old Brief circuit for pilot servo line Picture text ...

Page 263: ... animation Old This animation can be used when you explain or study the hydraulic circuit By pressing the lines character or spool with mouse you can change the colour of lines and spool location Picture text ...

Page 264: ...nit 10 Travel motor 11 Travel gear box 12 Swing ring gear 13 Turning joint 14 Fan motor 15 Shunt valve 16 Pilot filter 17 Accumulator block 18 Quick coupler 19 Accumulator 20 Solenoid valve 1 21 Solenoid valve 2 22 RCV LH 23 RCV RH 24 RCV pedal 25 Shuttle block 27 Check valve 28 Check valve 29 Hyd oil cooler 30 Return filter 31 Bypass valve 32 Bypass strainer 33 Air breather ...

Page 265: ...Brief circuit 1 New Picture text ...

Page 266: ...Brief circuit 2 New Picture text ...

Page 267: ...Circuit animation New Picture text ...

Page 268: ...Hydraulic pump Picture text ...

Page 269: ...External veiw Compare the circuit diagram with the external view Picture text ...

Page 270: ...s pressed against the shoe plate by the action of the cylinder spring through the set plate and spherical bushing Similarly the cylinder block is pressed against valve plate by the action of the cylinder spring The swash plate group consists of swash plate shoe plate swash plate support tilting bushing tilting pin and servo piston The servo piston moves to the right and the left as hydraulic oil c...

Page 271: ...P Q curve Picture text ...

Page 272: ...Gear pump Picture text ...

Page 273: ...Main Control Valve Picture text ...

Page 274: ...Main Control Valve Animation Push the component in the circuit diagram with mouse then you can see the location of that components Picture text A click at finger pointer gives you more informations ...

Page 275: ... the amount of flow from pump according to the joystick stroke 1 Neutral condition Central passage fully open High Pi Minimum flow 2 Half stroke Central passage partially open Medium Pi Medium flow 3 Full stroke Central passage fully close the lowest Pi Maximum flow Picture text ...

Page 276: ...r than the set pressure 2 Pump pressure is reached to the set pressure Main relief valve operation 2 Old 3 Main poppet open and pump line has tank connection 4 Boost signal comes from port pc and push the piston to increase the tension of spring Picture text ...

Page 277: ...m pressure pc OFF 1 Pump pressure is lower than the set pressure close 2 Pump pressure is reached to the set pressure pilot poppet open Main poppet open and pump line has tank connection pc ON 1 Boost signal comes from port pc and push the piston to increase the tension of spring Picture text ...

Page 278: ...alve operation Old 1 Cylinder pressure is lower than the set pressure 2 Cylinder pressure is reached to the set pressure 3 Piston inside of main poppet will move 4 Main poppet open and make tank passage Picture text ...

Page 279: ... piston which is inside of main poppet move to right and sit on the pilot poppet 3 Main poppet open and makes tank passage Anti cavitation Make up 1 Cylinder pressure drop down to the vacuum pressure Main poppet will be opened by tank pressure and fill up the cylinder chamber 2 statge port relief valve operation 1 Hammer Relief valve goes to low pressure setting without pilot pressure 2 Shear Reli...

Page 280: ...Makeup valve operation Picture text ...

Page 281: ...Boom 2 Spool Change 1 Remove the stroke limiter from Boom2 spool 2 Remove the make up valve from Boom2 head side Picture text ...

Page 282: ...Center bypass Valve Change 1 Simplification of the center bypass valve 2 Remove the make up valve from Arm2 rod side Picture text ...

Page 283: ...ve closed 2 Joystick signal on BU Boom1 Boom2 Spool move Center passge close pressurize 3 Open load check Oil from parallel passage open load check 4 Holding valve open and supply oil to cylinder 5 AI signal ON Boom2 spool returns to the neutral Picture text 1 ...

Page 284: ...alve open 7 Regeneration Return oil go through the spool and open back pressure check valve then return to tank Build up return pressure When supply pressure is low internal check valve can be open and make passage to the supply side A small amount of oil go to the center passage through the boom regeneration pilot check valve to reduce the amount of pump flow 8 Boom down Travel The boom regenrati...

Page 285: ...ricted by arm regeneration valve when supplying pressure is low Internal check open and return line is connecting to supply line 8 When supplying pressure is high arm regeneration valve make wide hole for return line to reduce back pressure 9 When using Boom up at the same time Center passge is blocked by boom1 spool Arm parallel conflux changeover valve reduce the passage for the summation of flo...

Page 286: ... side 2 Travel LH Spool movement block the line from orifice and bulid up pressure Travel pilot pressure switch ON P2 oil goes to TL side directly and Boom1 side parallel passage 3 Travel RH Spool movement block the line from orifice and bulid up pressure P1 oil goes to TR side directly and Boom1 side parallel passage 4 Boom Up operation Boom spool movement block the line from the other orifice an...

Page 287: ...Option hydraulics Picture text ...

Page 288: ...er return line directly goes to tank But shear uses double action So we need 3 way valve 2 step port relief valve 2 step port relief valve always maintains high pressure except hammer use X1 option pedal Flow control function Option 2 pump flow 2 switch control without pedal Picture text ...

Page 289: ...ion you have to open the option conflux check valve fully Flow control starts the function after hammer pressure switch is on 46 X1 flow control valve 47 X1 2 Pump select solenoid valve 61 X1 pressure switch 73 Option conflux check valve Picture text ...

Page 290: ...Rotator circuit X3 This is X3 option X3 option is composed of gear pump at PTO rotator valve and additional case drain line for motor This is operated using LH joystick button Picture text ...

Page 291: ...X3 components Picture text ...

Page 292: ... signal goes to VECU VECU energize the solenoid When joystick is in boom down position this signal operate hose rupture valve and boom floating valve This makes boom cylinder piston side and rod side go to tank So boom can drop down by its weight Picture text ...

Page 293: ...Boom floating components Picture text ...

Page 294: ...e lock cylinder locking the bucket in place against the rear hook This means that the lock wedge adjusts itself and provides gap free locking When lock wedge is released the servo pressure is transferred to the piston rod side If necessary the release pressure can be increased by loading the bucket cylinder in its end position There is a red marker on the left side of the quick fit attachment whic...

Page 295: ...S Quick fit Components Picture text ...

Page 296: ...U Quick fit X Quick fit solenoid valve 26 Pilot block Picture text ...

Page 297: ... counterweight The counterweight removal equipment consists of control valve check valve solenoid valve and stop valve This equipment makes it easier to remove install a counterweight to the machine Picture text ...

Page 298: ...Removable counterweight components Picture text ...

Page 299: ...Hydraulic System D12D Picture text ...

Page 300: ...Full option circuit EC460B D12D Picture text ...

Page 301: ...Hydraulic circuit animation D12D Picture text ...

Page 302: ...Hyd pump change Main pump Displacement change from 182cc to 192 5cc due to engine max rpm reduction Gear pump Displacement increases due to engine max rpm reduction No tropical option at P2 Picture text ...

Page 303: ...Pump P Q curve Picture text ...

Page 304: ...X1 circuit D12D Picture text ...

Page 305: ...ect sol 42 X1 pedal 43 45 X1 shuttle block 47 2 pump select sol 48 X1 3 way valve 52 Rotator solenoid 55 Quick fit sol 87 X1 pilot select valve for 2 step relief valve 88 Thumb sol 89 Pattern change valve 90 Boom floating sol 92 Straight travel pedal 93 Straight travel shuttle valve Picture text ...

Page 306: ...Hydraulic System EC700B Picture text ...

Page 307: ... power from engine converted to hydraulic power Machine has two main pumps that are variable displacement piston pump And it has 2 fixed gear pumps it is for servo system and cooling fan Two Pump flow Boom Up Arm IN Out X1 Option Picture text ...

Page 308: ...avel gear box 12 Swing gear box 13 Turning joint 14 Fan motor 15 Proportional relief valve 16 Pilot filter 17 Accumulator block 18 Strainer in breather 19 Accumulator 20 Solenoid valve 1 21 Solenoid valve 2 22 RCV LH 23 RCV RH 24 RCV pedal 25 Shuttle block 26 Pilot block 27 Check valve_3 0 bar 28 Check valve_4 5 bar 29 Hyd Oil cooler 30 Return filter 31 Bypass valve 32 Bypass strainer ...

Page 309: ...valve 4Boom cylinder 5Arm cylinder 6Bucket cylinder 7Swing motor 8Shockless valve 9Pressure switch 10 Travel motor 11 Travel gear box 12 Swing gear box 13 Turning joint 14 Fan motor 15 Proportional relief valve 16 Pilot filter 17 Accumulator block 18 Strainer in breather 19 Accumulator 20 Solenoid valve 1 21 Solenoid valve 2 22 RCV LH 23 RCV RH 24 RCV pedal 25 Shuttle block ...

Page 310: ...Brief Hydraulic Circuit 1 New Picture text ...

Page 311: ...Brief Hydraulic Circuit 2 New Picture text ...

Page 312: ...ation Servo circuit is displayed at a click servo Main page is displayed at a click main Line click change the color of the line Hyd component symbol click may move the circuit symbol Port name local port name Port name connected to Port name destination Picture text ...

Page 313: ...Hydraulic Pump Picture text ...

Page 314: ...2 lpm Max input torque 171 1 kgf m Mean casing pressure 1 kgf cm2 Picture text A location of main pump A1 A2 outlet B1 suction Dr1 Dr3 Drain pi1 pilot line for flow control P1 pump pi2 pilot line for flow control P2 pump a1 pluged a2 connected to removable counterweight a3 check port of power shift 2nd pressure Psv1 Psv2 pilot servo pressure supply line ...

Page 315: ...lock 2 via the splined bore If the swash plate is tilted the pistons arranged in the cylinder block make another 180 degree motion towards the valve plate oil discharging stroke as the cylinder block rotates When the swash plate tilting angle is closer to zero the piston does stroke very few angle nor discharge oil There are two sets of adjustable screws locking nuts on the top side of each pump T...

Page 316: ...low Q quantity 4 Flow control curve Q 3 vs Pi 2 5 Max flow rate area No pump control regulator internal components don t move 6 Constant engine power curve 7 1st flow reduction area outer spring compressed 8 2nd flow reduction area outer and inner springs compressed 9 Min flow rate curve pi 40 kgf cm2 and variant delivery pressure Picture text ...

Page 317: ...Gear pump 1 Gear pump on PTO without X3 G200 20 3 17 8 cc rev 2 Gear pump on PTO with X3 Model G200 35 6 20 3 17 8 Picture text ...

Page 318: ...Main Control Valve Picture text ...

Page 319: ...MCV animation Picture text A click at finger pointer gives you more informations ...

Page 320: ...l valve 14 Cooling fan motor 15 Proportional relief valve 16 Pilot filter 17 Accumulator block 19 Accumulator 20 Solenoid valve 21 Boom Arm conflux cut off solenoid valve 25 Shuttle block 26 Pilot block 41 X1 Flow control valve Picture text ...

Page 321: ...Hydraulic oil cooling system 2 Gear pump 14 Cooling fan motor 15 Proportional relief valve 27 Return check valve 3 0 k 28 Return check valve 4 5 k Picture text ...

Page 322: ...Option hydraulics Picture text ...

Page 323: ...r hammer operation pilot signal have to be supplied to the 3 way valve Tank connection and pilot selector valve 2 step port relief low pressure setting Sol b is a hammer position Even though 2 pump flow is set if option spool doesn t move No pilot pressure on the option spool option conflux doesn t happen Picture text ...

Page 324: ...lock A2 Hammer solenoid valve 26 Pilot block 39 Hammer Shear select solenoid valve 40 X1 Pedal 41 X1 Flow control valve 43 3 way selector valve 44 X1 return filter 46 Pilot selector valve 47 Solenoid valve 2 switch control Picture text ...

Page 325: ...X3 Circuit 2 Gear pump 74 Check valve 75 Rotator valve 76 Rotator solenoid valve Picture text ...

Page 326: ...U Quick fit 70 Quick fit valve 71 Block 72 Quick fit cylinder Picture text ...

Page 327: ... The button on the joystick can make VECU energize floating solenoid Floating pressure switch is activated and rupture valve and floating valve is proportionally pressurized according to the joystick operation Picture text ...

Page 328: ...g Components The large and small chamber pipes are connected to floating valve B The 2nd pressure of joystick is connected to rupture valve and floating valve A Floating solenoid valve B Floating valve Picture text ...

Page 329: ...locked by pilot signal from selector solenoid valve 3 The flow from B to FB is fast But its opposite flow is slow from orifice restriction There is a pressurized flow at port P on the valve 1 all the time Picture text 1 Removable counterweight valve 2 Slow return valve 3 Pilot selector solenoid valve 4 Stop valve ...

Page 330: ...d center bypass valve must be blocked by pilot signal from pilot selector solenoid valve 3 by toggle switch S operation O Open Stop valve 4 X Closed Stop valve 4 Y Pilot selector solenoid valve 3 Z Removable counterweight valve 1 S Switch for pilot selector solenoid valve 3 Picture text ...

Page 331: ...Hydraulic System COMMON Picture text ...

Page 332: ...Cylinder 1 Piston 2 Tube 3 Rod 4 Gland 5 Cushion ring 6 Cushion plunger a Dust wiper b Rod packing c Buffer ring d Dry bearing e Contamination seal f Wear ring g Piston packing Picture text ...

Page 333: ...Cushion operation Picture text ...

Page 334: ...lve and has four reducing valves controlling the secondary pressure in one valve casing Its secondary pressure is controlled by adjusting the tilting angle of the handle And the electric switches are equipped inside of joystick for various option Picture text 1 1 ...

Page 335: ...Travel pedal Basic function is almost same with joystick and this pedal has damping function to prevent oscilation when releasing the lever Picture text 1 ...

Page 336: ...Option pedal The component itself is almost same between X1 X2 pedal but the characteristic curve is a little bit different Picture text 1 ...

Page 337: ...Pattern change Picture text ...

Page 338: ...n P3 port is connected to overload pressure switch A With Pi signal boom lowering is possible The spool movement makes the tank connection of pilot check valve Picture text 1 Neutral condition 2 Raising operation 3 Lowering operation ...

Page 339: ...se Rupture Valve Operation With Pi signal arm in operation is possible The spool movement makes the tank connection of pilot check valve Picture text 1 Neutral condition 2 Arm out operation 3 Arm in operation ...

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