Section E - Hydraulics

Technical Data
General Data

Main Hydraulic Pump

Table 1.
Type Twin variable displacement piston pump
Displacement Volume 145 cm3/rev (8.8 in3/rev) (2 x 290 l/min)
Operating Pressure RATED 348 bar (5047 lb/in2)
Maximum Output @ 2000 rev/min 290 l/min x 2 (64 UK gal/min x2)
Inlet pressure 1.47 bar (21.3 lb/in2) @ 2050 rpm
Dry weight 275 kg (606 lb)

Servo Pump
Table 2.
Type Fixed displacement gear pump
Rated flow 30 l/min (6.60 UK gal/min)
Displacement Volume 15 cm3/rev (0.92 in3/rev)
Working Pressure 44.1 bar (639.6 lb/in2)

Proportional Pressure Reducing Valve

Table 3.
Max. primary pressure 44 bar (638 Ib/in2)
Max, back pressure (allowable pressure) 1 bar (14.5 Ib/in2)
Secondary pressure setting range 0-44 bar (0-638 Ib/in2)
Electrical specifications
Rated current 700 mA
Coil resistance (at 20°C) 17.5 +/-0.7 W
Recommended fluctuation of proportional 80 Hz, 22 mA
solenoid current

E-1 9803/6540-4 E-1

 Section E - Hydraulics
Technical Data
General Data

Slew Motor
Table 4.
Type Fixed displacement piston motor
Suction Capacity 210.1 cm3/rev (12.8 in3/rev)
Working Pressure Max. 279 bar (4052 lb/in2)
Work Flow 276.1 l/min (60.7 UK gal/min)
Set Pressure Relief 279 bar (4046 Ibf/in2)
Reduction Gears Planetary gears with 2 gear reduction
Reduction Gear Ratio 23.25
Brake Torque 965 Nm (712 lb/ft)
Brake Pressure Release 34.5 bar (500 lb/in2)
Dry Weight 410 kg (904 lb)

Main Control Valve

Table 5.
Type Hydraulic Pilot System
Operating System Set pressure relief
Main Relief Pressure
Standard 319 bar (4627 lb/in2) @ 217 l/min (47.7 UK gal/min)
Pressure Raising 348 bar (5047 lb/in2) @ 274 l/min (60.3 UK gal/min)
Overload Relief Pressure
Boom Raising, Arm, Bucket 363 bar (5265 lb/in2) @ 20l/min (4.40 UK gal/min)
Boom Lowering Pressure 245 bar (4206 lb/in2) @ 20l/min (4.40 UK gal/min)
Function Travel priority, slew priority, boom and dipper holding valves, boom and dipper
2-speed internal confluence
Dry weight 375 kg (826 lb)

E-2 9803/6540-4 E-2

 Section E - Hydraulics
Hydraulic Pump/Regulator
Hydraulic Pump Operation

Hydraulic Pump/Regulator
Hydraulic Pump Operation

Introduction Pump Hydraulic Circuit Diagram

The pump/regulator consists of two variable displacement For schematic K Fig 1. ( T E-68).
type axial piston pumps (P1 and P2) supplying pressurised
oil to operate machine functions, plus a gear type pilot Table 1. Port Identification
pump (Pp) to provide pilot circuit pressure for operator Port Function
control of machine functions.
A1 Delivery port
The axial piston pumps each incorporate a regulator which A2 Delivery port
adjusts the output flow rate according to system demand. A3 Gear pump delivery port
a1 Gauge port
a2 Gauge port
a3 Gauge port
Psv Servo assist port
B3 Gear pump suction port
Dr1 Drain port
Dr2 Drain port
Dr3 Gear pump drain port
Pb1 Tank
Pb2 Tank
Pi1 Negative control port
Pi2 Negative control port
Pm1 Q Max cut port
Pm2 Q Max cut port
B1 Suction port
D0 Oil filling port
Dr3 Gear pump drain port
a4 Gauge port

E-67 9803/6540-4 E-67

 Section E - Hydraulics
Hydraulic Pump/Regulator
Hydraulic Pump Operation

Hydraulic Pump Regulation

G F D
Pm2

E 37 Dr 3
Pi2

Pb2
H Dr2
44 bar
at 29 L/ min a4
a2 B
A

A2 A3
15 CC/ rev
a3 B3

B1
Psv
B4
20 CC/ rev
A1 A4

a1
M
D0
Pb1

Pi1
38
Pm1
Fig 1.

On start up, the swash plate piston F is held in the spool to close off the oil to the servo control piston. The
maximum flow position by the spring A. Servo pressure pump will now move to max flow.
from port Psv will also pass the check valves H and act
against the servo control piston. This will assist the spring When P mode is selected a 40 bar (580 Ib/in2)signal from
A in holding the pump on maximum flow. the Max flow cut solenoid on the 8 spool solenoid valve is
sent to port Pm2 of the pump. This prevents the pump from
As pump pressure builds it will get a 35-40 bar (508 lb/in2 - selecting 100% flow and limits it to 60% flow.
580 lb/in2) signal back from the valve block into the
negative control port Pi2. This signal is now available to In A mode the secondary pressure drops to approximately
push piston D and force the piston against spring A. Servo 6 bar (87 Ib/in2). This reduction in secondary pressure at
pressure is then available across the spool and into the piston G has to be made up for by higher pump pressure
larger side of the servo control piston B. The pump is now at pistons D and E before the sumater spool starts to
held on minimum flow. select, hence more hydraulic horsepower.

When a service is selected the negative control signal, The regulator on pump A1 works the same as above.
Port Pi2, will drop off. Spring pressure A will now force the

E-68 9803/6540-4 E-68

 Section E - Hydraulics
Hydraulic Pump/Regulator
Regulator

Regulator

Specifications

Displacement 97.2 (96.5) cm3

Revolving Speed Range Rated 2070 (2200) rev/min
Pressure Rated 318 bar (4608 lb/in2) Max. 343 bar (4978 lb/in2)
Maximum Flow Rate 201 (211) l/min (44.2 (46.4) UK gal/min) Rated revolution load pressure 78.5 bar (1138 lb/in2)
Minimum Flow Rate 50 (50) l/min (11 (11) UK gal/min) Rated revolution load pressure 78.5 bar (1138 lb/in2)
Input Horsepower 91.9 (113) kW (125 (154) PS)
Maximum Input Torque 426 (482) Nm (314 (356) lb/ft)
Control Function Full horsepower control
Power shift control
Negative flow control
Q max. cut control
Other KHI 10 cm3/rev (0.61 in3/rev) with gear pump
Proportional pressure reducing valve (KDRDE5PR-10/40C04)

Proportional Pressure Reducing Valve

Max. primary pressure 39.2 bar (569 lb/in2)
Max, back pressure (allowable pressure) 9.79 bar (142 lb/in2)
Secondary pressure setting range 39.2 bar (0-569 lb/in2) at primary press.= 39.2 bar (569 lb/in2)
Max. flow rate 6 l/min (1.32 UK gal/min)
Electrical specifications:
Rated current 800 mA
Coil resistance (at 20°C) 13.5 +/-0.7 û
Recommended fluctuation of proportional 70 ~ 75 Hz, 400 ~ 600 mA
solenoid current

E-81 9803/6540-4 E-81

 Section E - Hydraulics
Hydraulic Pump/Regulator
Regulator

Operation
KR3D-9S04 A
The regulator consists of the following control
mechanisms: P2

Pf
1 Horsepower control.

Automatically reduces the pump swash angle

(delivery flow) according to the increase in P1 pump Pm
delivery pressure and P2 pump delivery pressure and
limits the input torque to below a preset value. The
system operates by the summation of load pressure
of the two pumps so that engine overload is
prevented. Pi Pb

2 Power shift control (Power modes H, S, L). B

JS03590
The pump output horsepower set value is shifted by
Fig 24.
changing the electric current supplied to the
proportional pressure reducing valve attached to the
4 Q max cut control.
regulator. There is one proportional pressure
reducing valve but the secondary pressure Pf (power
Maximum delivery flow is controlled by pilot pressure
shift pressure) goes through the pump's inner
Pm. This control is a two-position control so by
passages to the horsepower control part of the
switching ON-OFF pilot pressure Pm, the maximum
regulator for each pump, shifting each pump to the
delivery flow rate can be reduced by 35%. Either of
same horsepower set value. With this mechanism, it
the two steps only can be selected, not intermediate
is possible to change the output power of the pump to
sections.
the most suitable power for the machine application.
The regulator possesses the above four control
3 Flow rate control (Negative control).
mechanisms but when each control works in combination
with another, the low swash (low flow rate) instructions
The pump swash angle and therefore the delivery
have priority as explained below.
flow rate is controlled by changing the pilot pressure
Pi. The regulator has the flow rate control (negative
control) system in which the delivery flow rate Q
reduces in relation to valve block negative pressure.
The pump delivers only the required flow so that
power is not wasted.

E-82 9803/6540-4 E-82

 Section E - Hydraulics
Hydraulic Pump/Regulator
Regulator
Proportional Pressure Reducing Valve – Primary press. 38.6 bar (568.8 lb/in2)
– Flow in port A. 0 l/min Fluctuation of proportional
Allowable range of current pressure profile solenoid current. 70 - 75 Hz, 400 ~ 600 mA

40

Upper Limit

30 Pressure setting
condition
25 +- 1kgf/cm 2
at 350mA
Pressure in port A (kgf/cm 2)

Lower Limit

20

10

0 100 200 300 400 500 600 700 800

Input current (mA)

JS03740

Fig 25.

E-83 9803/6540-4 E-83

 Section E - Hydraulics
Hydraulic Pump/Regulator
Regulator

Regulator Trouble Shooting Note: Depending on which wire is disconnected will

determine the polarity of the current reading.
Engine Overloads
3 Insert an multimeter in series between the bullet
Put a load on each pump to determine if the front or rear connector and the wire that has been disconnected.
pump is malfunctioning. If both pumps are abnormal,
check 1 and 2. If only one pump is abnormal, begin with 3. 4 Ensure that the multimeter is scaled to mAmps not
Amps.
1 Check to see if the power shift command current
value I is normal or not. 5 Switch engine on to maximum revs.

2 Power shift pressure is low. 6 Measure the current at the Proportional Solenoid.

a Check fluctuation of solenoid current.

b Renew the proportional pressure reducing valve.

3 Disassemble and clean the compensatory piston,

compensatory rod.

4 Disassemble and clean the pin (898).

Maximum Flow Rate Is Not Achieved

1 Confirm that the pilot pressure Pi is normal or not.

2 Disassemble and clean the pilot piston.

3 Disassemble and clean the piston (648).

4 Disassemble and clean the spool.

Note: If any of the parts shows wear or scratches, replace

it.

Checking the Proportional Solenoid Current

Service Procedure

Method 1

Refer to Self Test, Self Test Function, Pump Input

Amperage.

Method 2

1 Switch engine off.

2 2 Pull apart bullet connector on any of the two wires

leading from the Proportional Solenoid on the
Hydraulic Pump.

E-84 9803/6540-4 E-84

 Section E - Hydraulics
Hydraulic Pump/Regulator
Regulator

Regulator Dismantling and Assembly these components as this could alter the pre-set flow
settings.
the working environment must be clean and the
workbench covered with a cloth or rubber sheet to prevent
damage to the components. 5
6
The item numbers called up in the following procedures
correspond with those in the exploded view,
K Fig 35. ( T E-88).

Dismantling

Before dismantling, remove dust, rust, etc. using clean

hydraulic oil.

Retain all washers, snap rings etc. for later re-use. O-rings
should be renewed.

1 If not already done, separate the regulator 1 from the Fig 27.
pump casing by removing socket head screws 2 and
3 (2 off each). Do not lose the large O-ring. 3 From regulator body 1, withdraw outer spring 13,
inner spring 14 and spring seat 15. Also withdraw
adjusting ring 16, pilot spring 17 and spring seat 18.
3
Note: Use an M4 screw Z attached to the end of adjusting
ring 16 to facilitate its easy removal.
2
13
14
15
1 16

17
18 Z

Fig 28.

Fig 26. 4 Remove socket head screws 19 and 20 and lift off
pilot cover 21. Take out set spring 22.
2 Remove the four socket head screws 5 and lift off
cover 6 complete with adjusters 7/8, adjusting screw
9, two locking nuts 10, mounting nut 11 and adjusting
ring 12. Do not interfere with the settings of any of

E-85 9803/6540-4 E-85

 Section E - Hydraulics
Hydraulic Pump/Regulator
Regulator

33
22
29
28

20
31
21 Y
30
19
Fig 31.
Fig 29.
7 Remove lever 32 leaving pin 33A in position on the
5 Remove snap ring 23 taking care not to allow the lever.
components behind it to spring out. Take out spring
seat 24 return spring 25 and sleeve 26 (complete with
snap ring 27). 1

25
23

26 1

32
24
Fig 30. 33A
Fig 32.
6 Remove snap ring 28 and take out fulcrum plug 29,
complete with pin 33. Remove snap ring 31-30 and 8 Knock out pin 34 (4 mm dia.) using a suitable metal
take out adjusting plug 31. rod X and a plastic hammer.

Note: 2 Use an M6 screw Y attached to the ends of

fulcrum plug 29 and adjusting plug 31 to facilitate their
easy removal.

E-86 9803/6540-4 E-86

 Section E - Hydraulics
Hydraulic Pump/Regulator
Regulator
Note: Piston case 40 can be removed by pressing
compensating rod 42 from the opposite side of regulator
body 1.

Fig 33.

9 Withdraw feedback lever 35.

35

Fig 34.

10 Remove lever 36 from pin 37 (in the regulator body)

leaving pin 37A in position on the lever.

11 Draw out pilot piston 38 and spool 39.

12 Withdraw piston case 40, compensating piston 41

and compensating rod 42.

E-87 9803/6540-4 E-87

E-88

14
13

15

12

42
D
41 B 36
40
35
F
34 16
32 17 5
37A 18
39 11
A
26 G
10
22 E
6
24 C
25 33A
23 10
7
8
9803/6540-4

38 3 2
9

Hydraulic Pump/Regulator
Section E - Hydraulics
37

3
F 29
G 28A
20 A
B 28
C

31
19
4 30A

Regulator
21 30

Fig 35.
E-88
 Section E - Hydraulics
Hydraulic Pump/Regulator
Regulator
Assembly

Before assembling:

a Thoroughly clean all components with clean

hydraulic oil and dry with compressed air. 36 32
b Apply clean hydraulic oil to all sliding surfaces,
bearings, etc.
c Renew any damaged components.
d Renew all O-rings and other seals.

1 Insert compensating rod 42 into hole B of regulator

body 1. 35
2 Locate pin 37A in lever 36 in the groove of
compensating rod 42. Locate lever 36 on pin 37 in
regulator body 1. Fig 37.

3 Fit spool 39 and sleeve 26 into hole A of regulator 5 Insert pilot piston 38 into hole C of regulator body 1.
body 1. Check that the spool and the sleeve slide Check that the piston slides freely without binding.
smoothly in the body without binding. Check the
orientation of the spool with respect to feedback lever 6 Locate pin 33A in lever 32 in the groove of pilot piston
35, K Fig 36. ( T E-89). 38. Position lever 32 in regulator body 1.

7 Fit fulcrum plug 29 so that integral pin 33 locates with

lever 32. Fit a new seal 28A and install snap ring 28.

39 35

Fig 36.
29
4 Install feedback lever 35, orientating it as shown
below and aligning its pin hole with that of spool 39.
Insert pin 34.
1

Fig 38.

E-89 9803/6540-4 E-89

 Section E - Hydraulics
Hydraulic Pump/Regulator
Regulator
8 Insert adjusting plug 31. Fit a new seal 30A and install
snap ring 30. 1
Check that feedback lever 35 moves freely but does
not have excessive play. 22
9 Insert return spring 25 and spring seat 24 into hole A
of regulator body 1. Compress the spring and secure
with snap ring 23.

41
40

Fig 40.
23
11 Insert spring seat 18 (flat face first), pilot spring 17
and adjusting ring 16 into hole E of regulator body 1.
24
Insert spring seat 15 (flat face first) inner spring 14
25 and outer spring 13 into hole D of regulator body 1.

1 13
14
1 15

Fig 39. 16
10 Insert set spring 22 into hole A of regulator body. 17
18
Insert compensating piston 41 and piston case 40
into hole B of regulator body 1.

Fit pilot cover 21 and secure with socket head screws

Fig 41.
19 and 20 tightened to a torque of 11.8 Nm (10.3 lb/ft).

E-90 9803/6540-4 E-90

 Section E - Hydraulics
Hydraulic Pump/Regulator
Regulator
12 Install the cover 06 assembly comprising adjusting
screws 7, 8, adjusting ring 12, mounting nut 11, two
locking nuts 10 and adjusting screw 9.

Secure the cover using socket head screws 5

tightened to a torque of 11.8 Nm (10.3 lb/ft).

7
Fig 42.

E-91 9803/6540-4 E-91

 Section E - Hydraulics

Basic System Operation

Hydraulic Component Location

Table 1.
A Slew motor
B Boom up speed restriction and boom priority
over slew solenoid valve
C Tank manifold
D Hydraulic pump
E Plexus filter
F 8 spool solenoid valve
G Servo filter
H Main control valve
J Cushion valve
K Shuttle valve
L Remote control valve
M Travel pedals
N Hammer/auxiliary pedal
P Cab manifold
R Merge 2 solenoid valve
S Hammer solenoid valve
T Merge solenoid valve

E-5 9803/6540-4 E-5

 Section E - Hydraulics
Basic System Operation
Hydraulic Component Location
S
P

M
N
L

T
K
J
R
H

Fig 1.
A
B
C
D
G

E
F
E-6 9803/6540-4 E-6
 Section E - Hydraulics

Circuit Descriptions
Hydraulic Schematic

JS330 Tier III Note: * denotes option.

The item numbers in the following table are identified on

the Hydraulic Schematic diagram K Fig 1. ( T E-15)

Table 1.
Item Part number Description Location
1 701/80372 Pressure switch (Auto Mode) On shuttle block.
3 KSC0196U-A Slew motor Centre of machine.
4 05/200100 Reduction gears In slew gearbox.
5 331/42428 Cylinder arm On top of boom.
6 JSA0073 Motor travel and gearbox In between the tracks.
7 JSA0155 Joint, centre Centre of machine.
8 331/42429 Cylinder bucket On dipper.
9 331/42426 Cylinder boom From boom to main frame.
10 25/222384 Arm HBCV On arm cylinder (optional).
11 25/222492 Control valve In centre of machine.
12 25/222531 Check valve In cooler return line from main control valve.
13 25/221094 LH hand control valve In cab.
14 25/221009 Solenoid valve In centre of machine.
15 701/80373 Pressure switch (slew/boom up) On shuttle block.
16 331/51156 Cab manifold Under cab.
17 KSJ2465X-A Track control valve In cab.
18 CNA0584Y-A Filtered adaptor -
19 CNA0584Y-A Filtered adaptor -
20 928/60339 Hammer/auxiliary control valve In centre of machine.
21 25/222709 Dual solenoid valve Under cab.
22 25/221095 LH hand control valve In cab.
23 JHJ0168 Filtered adaptor In hand control.
24 JSJ0083 Low flow DCV In centre of machine.
25 JRV0434 Low flow manifold In centre of machine.
26 25/222638 Multi shuttle valve Under cab.
27 25/220042 Cushion valve Behind cab.
28 25/222885 8 spool solenoid valve In hydraulic pump bay.
30 JHJ0050 Accumulator In hydraulic pump bay.

E-13 9803/6540-4 E-13

 Section E - Hydraulics
Circuit Descriptions
Hydraulic Schematic

Item Part number Description Location

32 3292514 Line filter In cooler return line.
33 701/80462 Auto pressure switch (Boost) On main control valve.
34 KHJ0568U-A Line filter In hydraulic pump bay.
35 701/80375 Travel pressure switch On main control valve.
36 701/80374 Attachment/hammer pressure switch Control valve/under cab.
37 20/925652 Hydraulic pump In pump bay.
38 01/145273 T3 diesel engine In engine bay.
39 JSV0352 Stop valve on end of dipper (optional).
40 25/222595 LH hammer/auxiliary valve On top of "A" frame by the boom.
41 25/222594 RH hammer/auxiliary valve On top of "A" frame by the boom.
42 JBJ00066 Line filter Hammer return filter.
44 JSJ0075 Return filter Hydraulic tank.
45 JSJ0084 Relief valve -
46 32/925670 Strainer In hydraulic tank.
47 BRJ1286 Plug Bottom of hydraulic tank.
48 335/07786 Sump tank On engine.
50 32/925692 Breather Top of hydraulic tank.
51 KNJ0287 Servo return filter Hydraulic pump bay.
52 25/222508 4 Bar check valve Cooler return line.
55 30/926356 Radiator Cooler bay.
56 KHJ0897Y-A Drain cock Bottom of radiator.
57 JRJ0238 Filter Plexus filter.
58 KTJ1660 Tank return manifold In hydraulic pump bay.
60 20/925311 Low flow pump On hydraulic pump (option).
61 JRJ0132 Manifold Centre of machine by boom.
62 JSV0329 Merged valve Centre of machine.
63 701/80199 Pressure switch HBCV manifold.
64 25/222383 Boom HBCV On boom ram (optional).

E-14 9803/6540-4 E-14

E-15

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
ARM CYLINDER BOOM CYLINDERS
160? 110?1733
RIGHT LEFT MIN.L2425
? 140? 100?1480
10 BUCKET CYLINDER MIN.L2095
?
B A 64 9 9
Pm2 PS PS Pm1 140? 95?1275 64
5
M V2 BL MIN.L1890
A C2 228.9/130.7 228.9/130.7 A
CC/rev CC/rev
i=60.774 i=60.774 6 8
636
V2 BL BL V2

PB PA
T 2 T 1
V2 T P E C2 C2
27.9 MPa
285 }kgf /cm 2
at 260 / min 14
BACKWARD BACKWARD
L-1
P 2 LEFT RIGHT P 1

R/G

R/G
V2 T P E E P T V2
P 1
FORWARD FORWARD P 2
15
B I-14
LEFT RIGHT B

32.4 at40 MPa / min 7 32.4 at40 MPa / min T P L L P T

330 kgf} /cm 2 330 kgf} /cm 2
Pm1 Pm2 T 13
3 12 P l-14
B A l-2
D C
PSW
Ps Dr
? 222bar
5
H-13
DB 1
C H-13 C
210.1 63 ?
CC/rev
PR

i=23.247

4
? 15
Z=86
2 bar
ON 5 Bar 12 ?
Z=15 OFF 3 Bar 25

HAM/AUX ? MERGED ? P5 PSL T1 DR1 T2 PSR 11

D LH CAB FLOOR
14 SOL X 14 D
RH CAB FLOOR n
J-2 2.7MPa 28kgf/cm 2 } 2.7MPa 28kgf/cm 2 }
Pi3
at55 /min at55 /min
6 DR3 X X X X
a H-13
b
3 3 G-11 G-11
2 2 p Pi2 XX
J-3
1 1 36.3MPa 370kgf/cm 2 }
AL4

BACKWARD

BACKWARD
1 2 at20 /min(IN,OUT) X X

FORWARD

FORWARD
4 10 BL4

RIGHT

RIGHT
LEFT

LEFT
L-16
H-13
IN OUT OUT IN
HAM/AUX q PLb4 PRb5 i
L-1 I-3

T4 P4 ARM(1) ARM(2)
E T5 T3
r PLa4 36.3MPa 370kgf/cm 2 }
? E
P5 P3 PRa5
L-2
Pi1 at20 /min h 24
T6 T2 I-3
BL3 36.3MPa 370kgf/cm 2 } BR4
P6 P2 at20 /min AR4
T P AL3
T7 T1
P T BUCKET
P7 P1 1 2 3 4 RIGHT LEFT OUT IN

B
m
T8 T j PLb3 PRb4 J-2
J-1 P4
20 c e
11
P8 P ? 19 G-6 18 d
G-6 H-11
17 f
G-11 MERGED SWING o
SOL X g PRa4 J-2

200 bar
J-3 3 1 u
H-4 Pi5 L-3
Pi7 36.3MPa 370kgf/cm 2 } DR4 7
H-13

200 bar
k PLa3 at20 /min(UP) Pi6 l
16 J-1 24.5MPa 250kgf/cm
P6 2 } AR3 J-2
at20 /min(DOWN)
2 ? BR3
F 14 UP UP
F
DOWN DOWN
PLb2 PRb3 s
L-2

BOOM(1)
BOOM(2) PRa3 t
L-2
v
PLa2 Pi4 H-4 T
BL1 BR2 175 bar
AL1 AR2

P
9803/6540-4

BACKWARD
FORWARD
13 d PLb1 PRb2 b
23 22 23 F-3 D-3
P3
G T P T P 21 TRAVEL(L) OPTION G
PRa2 a
D-3
c PLa1 BR1
F-3 AR1 58
T1 T2 BACKWARD
CONNECTION FOR FORWARD
PRb1 f T10
STANDARD BUILD
P1 P2 F-4
15 T8 T9 8
B-3 J-10
PTS TRAVEL(R)
SWING ARM BUCKET BOOM PRa1 e 10 T6 T7 6
3 1 4 2 3 1 4 2 F-4
E-2 D-5
RIGHT LEFT IN OUT CLOSE OPEN DOWN UP T4 T5 7
F-11
C2 C1 319 bar
T2 T3 5
at 240 l/min C-8
g v
H F-6 F-12 348 bar 62
9 T1
H
BOOM DOWN SPEED at 220 l/min
BOOM PRIORITY D-5
1 2
OVER SWING RESTRICTION C-3 J-10
T
P1
P1 PT PP Pi8 Pm PF P2
T12 T11
15 15 1 ON 26 Bar
ON 22 bar ON 298 Bar ON 12 Bar Pilot
OFF 20 bar
OFF 22 Bar
OFF 282 Bar OFF 9 Bar
Dr
52 10?
ON 5 bar ON 5 bar p
OFF 3 bar OFF 3 bar D-6
P2
A1 S1 A2 A3 S2 S3 A4 A5 C9 C10 C5 A6 A7 A8 55
RIGHT DOWN OUT IN OPEN 3 4 bar 51
LEFT UP L-15
CLOSE 35 34 xx 36
I C8 BOOM ARM BUCKET 28 10um
I
C7 SWING
15 50
C6 A T1 3 B-3

MAX FLOW CONT 2 STAGE TRAVEL 13 0.05MPm

C-13 0.005MPa
B1 B2 B3 C1 C2 B4 B5 C3 C4 B6 B7 C10 B8 0.5 kgf /cm 2 0.05 kgf /cm 2
C4 C5 8
H-13
10? 1.5
j k l h i m n o 0.15 MPa
E-6 F-6 F-11 E-11 E-11 E-11 D-6 F-11 1.5 } kgf /cm 2
26 Pm2 9
10?
H-13 150MESH
SWING LOCK SWING SHUT OFF
37 Dr3 56 57 56
B Pi2
27 C6
J 1 bar 2 J
H-14 48

Section E - Hydraulics
Pb2 43
A Dr2 ?
B E F 44 bar
at 29 / min a4 44 45 46
T 11
LEVER LOCK
2 STAGE RELIEF a2
F-1 32
C7 47
A3
A2

A
15

B
CC/rev
x
a3 140 CC/rev B3 ? x-x
?

P
CUSHION i=1.032 39 42
SWING PARK BRAKE SOFT/HARD C8
B1
C1 Psv 145

T
S CC/rev
K i=1.0 B 4
HAMMER RETURN K

Circuit Descriptions
20 CC/rev
A1 A 4 38 10?

R P C10 60 *

T
a1 HAMMER FEED
A1 C D G H
E1 C11
M 0.34 MPa

D
4

P
0.5 BAR C12 D0 E-1 3.5 } kgf /cm 2

A
Pb1

B
14 q r 12 s t u ? 3
39

Hydraulic Schematic
B-3 E-6 E-6 C-12 F-11 F-11 F-12 H-12
C13 T2 B2 C9
ISUZU 202 KW (270.7 PS) 2000rpm
?
BOOM UP Pi1 40
PRIORITY
L OVER BUCKET IN
Pm1

xx
H-12
CAPACITY GAS
29 300 cm 3 PRESS.
15 Bar

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Fig 1. 331/47239 - Issue 1

E-15
 Section E - Hydraulics
Circuit Descriptions
Pilot Line

Pilot Line

Components Hose Colour

BL Blue
For schematic K Fig 2. ( T E-17)
BR Brown
1 Cab manifold CL Colourless

2 Left hand control G Green

GR Grey
3 Right hand control LB Light Blue
4 Travel pedal O Orange
P Pink
5 Solenoid valve (8 Spool)
R Red
6 Shuttle valve V Violet
W White
7 Dual solenoid valve
Y Yellow
8 Cushion valve LG Light Green
DG Dark Green
9 Main control valve
CL Colourless
a Dipper 2

b Boom

c Bucket

d Travel right hand

e Dipper 1

f Boom

g Slew

h Option

i Travel left hand

E-16 9803/6540-4 E-16

E-17

7
P C1 B A C4 C13

T1 T2

C9 C5 C6 C7 C8 C10 C11 C12 B2 HOSE ENDS

STD
P A1 E1
W NC A C

P/G LG
6 R
B D
90

C5 E G
P T G C11 C10
Y/G BL/V
BUCKET OPEN 1 B F
H
BOOM UP 2
C8
O/G R S T
BUCKET CLOSE 3
BOOM DOWN 4
R S3 C7
O/O 8
P/V
3 S2 C4

LG/V
S1 C3

R/G
C9 C2
P
C6 C1

B7
Y
A8

2 Y A7 B8
G
R

ARM IN 4
LG A6
B6
SWING RIGHT 3
ARM OUT 2 A5 PRb5 PRb3 PRb4 PRb1 PLb4 PLa2 PLb3 Pb2 PLb1 Pi2 Pi3 Pi5
1 B5

9
SWING LEFT
P T O a b c d e f g h i
9803/6540-4

A4 B4

PRa5 PRa3 PRa4 PRa1 PLa4 PLb2 PLa3 Pa2 PLa1 Pi1 Pi4 Pi6 Pi7
BL
A3 B3

A2 B2
O
CL BL
LG
A1 B1
V
P

LB/R LB/LB
LB
P7

P8

Y/G
T8
T7

V
CL
P6
P5

P
T6
T5

1 2
P
P4

T1 C1
P3

W W
T
T4
T3

P1
CL

Section E - Hydraulics
3 4

4 P2
P1
P2

CL
7
T1

T2
T2

C2

BR
1 GR

Circuit Descriptions
Fig 2. Pilot Line Schematic 215/12626 - Issue 5

Pilot Line
E-17
 Section E - Hydraulics
Circuit Descriptions
Pilot Pressure and Return Line

Pilot Pressure and Return Line

Components
For schematic K Fig 3. ( T E-19)

1 Cab manifold

2 Slew motor

3 Rotary coupling

4 Solenoid valve (8 Spool)

5 Servo filter

6 Cushion valve

7 Main pump

8 Tank manifold

9 Main control valve

10 Shuttle block

Hose Colour
BL Blue
BR Brown
CL Colourless
G Green
GR Grey
LB Light Blue
O Orange
P Pink
R Red
V Violet
W White
Y Yellow
LG Light Green
DG Dark Green

E-18 9803/6540-4 E-18

E-19

4
4

1 5
8 3

5
2

1 1 DR3
1 2
OIL COOLER
PM1 PM2 RETURN PIPE
A1 E1
A C PI1 DR2 PI2
T8 T6 T4 T2 T1 T
PB1 PB2
B D T11
P C1 A B C4 C13
T10
T12
E G
T1 T2 T5
T9 T7 T3
H PSV
F
C9 C5 C6 C7 C8 C10 C11 C12 B2 R S T 5
1

1 3 3 3
6 4 3 1
1 3
5 2
1 1 1 2 4
3 4 7 2 1
4
3
1 1
9 9
1
7
1
9803/6540-4

4
4
2
1
10
C5
C10
HOSE ENDS
C8
PS
STD
S3 C7

S2 C4
90
S1 C3
PR PRB5 PRB3 PRB4 PRB1 PLB4 Pb4 PLB3 PSL DR1 PI8 PP
C9 C2

C6 C1
PRA5 PRA3 Pa7 PRA1 PLA4 Pa4 PLA3 PSR DR3 DR4 PI6
A8 B7
2

Section E - Hydraulics
1 A7 B8
P

Pilot Pressure and Return Line

A6
P7

P8

B6
T8
T7

A5
B5

Circuit Descriptions
P6

DENOTES KIT NUMBER

P5

1
A4 B4
T6
T5

2
DENOTES ITEM NO. IN KIT
P4
P3

A3 B3 REFERENCE INFO:-
T4
T3

2
P1

A2 B2
P2

2
2
ITEM 1 HOSE KIT - 8 STN.SOLENOID VALVE 340/00537
ITEM 2 HOSE KIT - CAB MANIFOLD 340/00538
T1
T2

3
A1 B1 ITEM 3 HOSE KIT - TANK MANIFOLD 340/00540
ITEM 4 HOSE KIT - MISCELLANEOUS 340/00539
ITEM 5 HOSE KIT - PUMP 340/00428

Fig 3. Pilot Pressure and Return Line Schematic 215/12625 - Issue 5

E-19