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Producto: NO SE HA ESCOGIDO NINGUN EQUIPO
Modelo: NO SE HA ESCOGIDO NINGUN EQUIPO
Configuracin: NO SE HA ESCOGIDO NINGUN EQUIPO
Operacin de Sistemas
330D Excavator Hydraulic System
Nmero de medio -RENR9584-01
Fecha de publicacin -01/09/2006
Fecha de actualizacin -11/09/2006

i02578588
General Information
SMCS - 4000; 4250; 4265; 4284; 4300; 4801; 5050
ReferenceFor testing and adjusting of the hydraulic system, refer to Testing and Adjusting,
"Excavator Hydraulic System" for your machine.
ReferenceFor systems operation of the electronic control unit and electronic system, refer to
Systems Operation/Testing and Adjusting, "Machine Electronic Control System" for your machine.
ReferenceFor more information on specifications with illustrations, refer to Specifications,
"Excavator Machine System Specifications" for your machine.
ReferenceFor more information on the hydraulic schematics, refer to Schematic, "Excavator
Hydraulic System" for your machine.
ReferenceFor more information on electrical schematics, refer to Schematic, "Excavator Electrical
System" for your machine.
Copyright 1993 - 2006 Caterpillar Inc.

Todos los derechos reservados.
Red privada para licenciados del SIS.
Tue Oct 17 17:22:45 EST 2006
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/s... 17/10/2006
MANUAL DEL ESTUDIANTE

INSTRUCCIN TCNICA
CURSO: Excavadora 330D

TEMA: Operacin de Sistemas, Pruebas y
Ajustes
DESARROLLO TECNICO
OCTUBRE, 2006
DSSE0060
Preparado por Jorge Gorritti Rey
Curso : Excavadora 330D

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Material del Estudiante
INDICE
Pgina
1
INDICE
DESCRIPCION DEL CURSO
Resumen................................................................................................................
Laboratorios durante el Curso.............................................................................
Objetivos Generales..............................................................................................
Requisitos..............................................................................................................
AGENDA DEL CURSO
MATERIAL NECESARIO
Literatura................................................................................................................
Literatura de Referencia.......................................................................................
Material de Entrenamiento....................................................................................
Herramientas Necesarias......................................................................................
MODULO 1: INTRODUCCION A LA EXCAVADORA

Leccin 1.1: Familiarizacin................................................................................
Hoja 1.1: Seguridad....................................................................................
Hoja 1.2: Especificaciones de la Mquina................................................
Hoja 1.3 Mantenimiento Diario...................................................................
Hoja 1.4 Puntos de Servicio.......................................................................
Hoja 1.5: Controles de Cabina...................................................................
Hoja 1.6: Operacin ...................................................................................
MODULO 2: SISTEMAS ELECTRICO, ELECTRNICO Y MONITOR

Leccin 2.1: Uso de Esquema Elctrico.............................................................
Texto de Ref: Localizacin de fallas en sensores...................................
Laboratorio 2.1: Esquema Elctrico.........................................................
Laboratorio 2.2: Esquema de Arranque y Carga.....................................
Laboratorio 2.3: Evaluacin de Sensores................................................
Laboratorio 2.4: Evaluacin de un Relay.................................................
Laboratorio 2.5: Evaluacin Sistema de arranque y carga....................
Leccin 2.2: Sistema Electrnico.......................................................................
Leccin 2.2.1: Generalidades.....................................................................
Leccin 2.2.2: Componentes Electrnicos...............................................
Leccin 2.2.3: Operacin del Sistema.......................................................
Ferreyros S.A.A.
Jorge Gorritti - Setiembre 06
11
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15
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24
25
28
28
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31
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Manual del Estudiante 330D Indice Descripcin Agenda

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Leccin 2.3: Sistema Monitor..............................................................................
42
Leccin 2.3.1: Funciones del Monitor.......................................................

Texto de Referencia: Sistema de Advertencia.........................................
Leccin 2.3.2: Mens del Monitor.............................................................
Laboratorio 2.6: Sistema Monitor..............................................................
Laboratorio 2.7: Barrido de la PRV...........................................................
Laboratorio 2.8: Diagnstico.....................................................................
Tablas ..........................................................................................................
43
44
47
49
51
52
53
57
MODULO 3: MOTOR
Leccin 3.1: Sistemas del Motor C9...................................................................
60
Texto de Referencia: Motores ACERT........................................................

Hoja de trabajo 3.1: Configuracin.............................................................
Hoja de trabajo 3.2: Sistemas Principales.................................................
Hoja 3.2A: Sistema de Admisin y Escape................................................
Hoja 3.2B: Sistema de Lubricacin............................................................
Hoja 3.2C: Sistema de Enfriamiento..........................................................
Hoja de trabajo 3.2: Ubicacin de Componentes......................................
61
61
62
62
64
66
67
Leccin 3.2: Sistema de Combustible con Control Electrnico HEUI...............
68
Texto de Referencia: Componentes del Circuito......................................

Hoja de Trabajo 3.3: Sistema HEUI.............................................................
69
70
Leccin 3.3: Sistema Electrnico de Control......................................................
73
Texto de Referencia: Circuito de Control..................................................

Hoja de Trabajo 3.4: Componentes Electrnicos Motor HEUI.................
Hoja de Trabajo 3.5: Evaluacin con el ET................................................
Texto de Referencia: Rendimiento del Motor............................................
Hoja de Trabajo 3.6: Prueba de Rendimiento en Excavadoras................
Hoja de Trabajo 3.7: Prueba de Refuerzo en Excavadoras......................
Hoja de Trabajo 3.8: Sensores Velocidad Tiempo....................................
Hoja de Trabajo 3.9: Grado de Aceite.........................................................
Texto de Referencia: Trim Code en motor ACERT...................................
74
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89
Ferreyros S.A.A.
Desarrollo Tcnico

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91
MODULO 4: SISTEMA HIDRULICO

Leccin 4.1: Informacin General........................................................................
94
Hoja de Trabajo 4.1: Sistema Hidrulico...................................................

Hoja de Trabajo 4.2: Control Electrnico..................................................
Hoja de Trabajo 4.3: Sistema Piloto...........................................................
Hoja de Trabajo 4.4: Circuitos del Sistema Piloto.....................................
95
98
99
100
Leccin 4.2: Bomba Hidrulica Principal............................................................
105
Leccin 4.2.1: Bomba Hidrulica Principal................................................

Hoja de Trabajo 4.4: Bomba Principal........................................................
Leccin 4.2.2: Principio de Operacin de la Bomba.................................
Leccin 4.2.3: Operacin de la Bomba......................................................
Hoja de Trabajo 4.5: Controles de la Bomba.............................................
Leccin 4.2.4: Etapas de Operacin ..........................................................
Hoja de Trabajo 4.6: Regulacin de la Bomba..........................................
106
107
109
110
112
114
118
Leccin 4.3: Sistema de Implementos.................................................................
119
Hoja de Trabajo 4.7: Vlvula de Control Principal....................................

Leccin 4.3.1: Circuitos de la Excavadora................................................
Circuito NFC.........................................................................................
Conexiones de la Unin Giratoria......................................................
Circuitos de la Pluma..........................................................................
Circuitos del Brazo..............................................................................
Circuitos del Cucharn.......................................................................
Circuitos de Giro.................................................................................
Circuitos de Traslacin.......................................................................
Hoja de Trabajo 4.8: Prueba de Velocidad del Motor...............................
Hoja de Trabajo 4.9: Pruebas de Trnsito.................................................
Hoja de Trabajo 4.10: Pruebas de Giro......................................................
Hoja de Trabajo 4.11: Prueba de Corrimiento de los Cilindros...............
Hoja de Trabajo 4.12: Prueba de Velocidad de los Cilindros...................
Hoja de Trabajo 4.13: Pruebas de Presin.................................................
Hoja de Trabajo 4.14: Pruebas de Flujo de Drenaje..................................
Texto de Referencia: Medidor de Flujo .....................................................
Hoja de Trabajo 4.15: Pruebas de Flujo.....................................................
120
123
123
124
125
129
132
134
136
137
138
139
140
141
142
148
149
150
ENCUESTA
Ferreyros S.A.A.
117
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DESCRIPCION DEL CURSO

CURSO: EXCAVADORA HIDRULICA 330D
Tiempo de duracin:
5 das
Numero de Participantes:
8 Estudiantes
(40 horas)
DIRIGIDO A
Este curso ha sido diseado para mecnicos, tcnicos de servicio,

instructores, comunicadores tcnicos, supervisores e ingenieros de servicio
que trabajan con maquinaria Caterpillar.
RESUMEN
El curso se desarrollar 50% en el aula y 50% en la mquina de acuerdo a la

disponibilidad de esta.
La clase de aula ser una presentacin de la Excavadora 330D.
En cada mdulo se revisar la ubicacin de componentes as como el
funcionamiento de los distintos sistemas de la mquina utilizando
presentaciones, el manual de servicio a travs del SIS Caterpillar, los
esquemas respectivos y una mquina, tambin se revisarn los puntos de
servicio y mantenimiento. Se har nfasis en el sistema de monitoreo y el
control electrnico de la 330D.
Realizaremos varios laboratorios para que los participantes refuercen los
conocimientos aprendidos en clase y practiquen sus habilidades en la
mquina.
Se incide en realizar las pruebas segn los procedimientos del manual de
servicio y se tendr una discusin en clase de los resultados obtenidos para
comprobar lo aprendido.
Durante el curso podran tocarse temas de Diagnstico de Mquina o
laboratorios similares a una Certificacin de Tcnicos en Maquinarias, segn
la disponibilidad de tiempo
Ferreyros S.A.A.
Desarrollo Tcnico

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EJERCICIOS
DURANTE EL
CURSO
MODULO 1: INTRODUCCION A LA MAQUINA

-
Normas de Seguridad
Especificaciones tcnicas
Localizacin de componentes mayores y puntos de servicio
Tareas de mantenimiento programado
Controles de cabina
Operacin de la Excavadora
MODULO 2: SISTEMA ELECTRICO Y MONITOR

-
Uso del esquema elctrico

Identificacin y localizacin de componentes
Evaluacin de sensores
Prueba de arranque y carga
Uso del Monitor
Diagnsticos y calibraciones con el ET o Monitor
Calibracin de la PRV y velocidades del motor
MODULO 3: MOTOR C9 ACERT

-
Localizacin de componentes de los sistemas del motor C9

Evaluacin del motor con el ET
Prueba de rendimiento del motor
Calibraciones del motor
MODULO 4: SISTEMA HIDRULICO

-
Ferreyros S.A.A.
Localizacin de componentes del sistema hidrulico en el

esquema y en la mquina
Recorrido del flujo de los circuitos en el esquema
Pruebas operacionales
Pruebas de presin
Pruebas de flujo
Ajustes
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OBJETIVOS
GENERALES
REQUISITOS
Al trmino de este curso, los estudiantes estarn en capacidad de realizar los

siguientes procesos:
Ubicar los componentes mayores y puntos de servicio de acuerdo al

Manual de Operacin y Mantenimiento.
Realizar el mantenimiento programado e inspeccin diaria de la

Excavadora 330D
Comprobar el sistema de arranque y carga.
Explicar el funcionamiento de los sistemas del motor C9 ACERT
Evaluar el motor con el ET.
Ubicar los componentes elctricos y electrnicos de la Excavadora
Diagnosticar el sistema electrnico de la excavadora usando el ET o

el Monitor
Explicar el funcionamiento del Sistema Hidrulico
Ubicar los componentes hidrulicos en el esquema y la mquina
Realizar las pruebas operacionales, pruebas de presin y pruebas de

flujo siguiendo los procedimientos del manual de servicio
Los estudiantes debern tener conocimientos bsicos de:
_
_
_
_
_
Ferreyros S.A.A.
Hidrulica.
Electricidad.
Uso de Herramientas.
Ingls (de preferencia)
Manejo de Herramientas Electrnicas: SIS, ET
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AGENDA DEL CURSO

PRIMER DA
SEGUNDO DA
TERCER DA
CUARTO DA
QUINTO DA
Maana
Presentacin Inicial, Expectativas

Pre-Test
Mdulo 1, Introduccin a la Mquina
Laboratorio Familiarizacin
Tarde
Mdulo 2: Elctrico
Laboratorio Sensores y Arranque
Maana
Mdulo 2, Electrnico y Monitor

Laboratorio Uso del Monitor
Tarde
Mdulo 3, Motor
Laboratorio Evaluacin del Motor
Maana
Mdulo 4, Sistema Hidrulico

Laboratorio: Pruebas de Operacin
Tarde
Mdulo 4, Bomba Principal

Laboratorio: Pruebas de Flujo
Maana
Mdulo 4, Circuitos Hidrulicos
Tarde
Laboratorio: Pruebas de Presin
Maana
Laboratorio: Pruebas Hidrulicas con el

ET y el Monitor
Tarde
Repaso General
Examen Final
Encuesta Final
Horario de Clase:
de 8:10am a 5:00 pm
Horarios de Intermedios recomendados:
10:15 am y 3:00 pm
Duracin: 15 minutos
Horario de Almuerzo recomendado:
12:00 m (1:00 pm)
Duracin: 60 minutos
Ferreyros S.A.A.
Desarrollo Tcnico

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MATERIAL NECESARIO
LITERATURA
_
RENR 7348 Manual de Servicio: 330D (B6H1-1Up)

_ SSBU 8046 Operation and Maintenance 330D
_ RENR 9587 Esquema Elctrico: 330D
_ RENR 9980 Esquema Hidrulico: 330D
LITERATURA DE REFERENCIA
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AEHQ 5667Folleto de Especificaciones: 330D

SEBD0518 Conozca su Sistema de Enfriamiento
SEBD0717 El Combustible y su Motor
SEBD0640 El Aceite y su Motor
SEBD0979 El Refrigerante y su Motor
PEHP6001 Cmo tomar una buena Muestra de Aceite
TEJB1015 Analizando un reporte S.O.S.
NENG2500 Caterpillar Service Technology Tools & Shop Products
Guide
PECP6026 Una Fuente Segura
SMHS7531 Instruccin Especial: Uso del Kit de Reparacin de
Conectores Sure Seal 6V-3000)
SEHS9615 Instruccin Especial: Mantenimiento de Conectores DT
SEHS9065 Instruccin Especial: Uso de la Herramienta para
conectores CE
SEHS8038 Instruccin Especial: Uso de la Herramienta para
conectores VE
NEHS0605 Manual de Operacin de Herramientas: 9U-7400 Multitach
NEHS0565 Manual de Operacin de Herramientas: 4C9910 Portable
Hydraulic Tester
NEHS0818 Manual de Operacin de Herramientas: 198-4240 Digital
Pressure Indicator Group
MATERIAL DE ENTRENAMIENTO
_
_
_
Ferreyros S.A.A.
CD presentacin Excavadora
Videos Operacin Excavadoras
Componentes para armar y desarmar
Desarrollo Tcnico

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HERRAMIENTAS NECESARIAS
PRUEBAS DE
OPERACIN
_
_
_
_
_
1_ Cronmetro (stop watch)

1_ 5P3277 Cinta metrica (tape measure)
1_ Regla de 150 mm (scale)
1_ 6V3121 9U7400 Tacmetro (multitach group)
1_ 1643310 8T0470 Termometro (thermometer)
PRUEBAS DE
PRESION
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_
_
_
_
1_ 8T0855 Manmetro 500 PSI (pressure gauge)

1_ 1U5481 Grupo de manmetros (pressure gauge group)
1_ 1U5482 Mangueras y adaptadores
(pressure hose and adapter)
1_ 1984240 Manmetro digital (digital pressure indicator)
1_ Caja de herramientas de mecnico (mechanics toll box)
1_ Laptop con ET (CAT Electronic Technician)
1_ 1714400 Grupo adaptador de comunicaciones
(Com Adapter II)
1_ 1464080 9U7400 6V3121 Multmetro (multimeter)
1_ 1888588 Probeta 2 bornes para pruebas elctricas
1_7X-6370 Probeta 3 bornes para pruebas elctricas
1_ FT2542 Pasador de bloqueo (track block assembly)
1_ 1755507 Grupo Cargador de Nitrgeno
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_
_
_
_
Ferreyros S.A.A.
Desarrollo Tcnico

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10
HERRAMIENTAS NECESARIAS
PRUEBAS DE
FLUJO
(una bomba)
Ferreyros S.A.A.
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1_ Recipiente medible de 40 litros de capacidad

1_ Manguera baja presin, 20mm dimetro interno y 2 metros largo
4_ 6V8398 O-ring seal
1_ 6V9830 Tapn
1_ 6V9509 Tapn con sello
1_ 4C9910 Medidor de flujo (Portable Flow Meter)
1_ 6V9840 Tee giratoria (swivel tee).
1_ 7I7133 Plato bloqueador (blocking cover).
1_ 9U7335 Plato bloqueador (blocking cover)
1_ 1U8303 Adaptador (fitting)
16_ 5K9090 Sellos tipo anillo (O Ring seal)
2_ 5P0201 Manguera de 10 metros (hose)
4_ 5P1010 Acople (sleeve).
4_ 4C8767 Acople (coupling)
8_ 7M8485 Sellos tipo anillo (O Ring seal)
4_ 3J1907 Sellos tipo anillo (O Ring seal)
4_ 7M8485 Sellos tipo anillo (O Ring seal)
2_ 6V3965 Acople (nipple ass)
4_ 4C6481 Acople (coupling).
4_ 4C6482 Acople (nipple).
1_ 4I6140 Acople (coupling).
2_ 4I6141 Acople (coupling)
4_ 8C9026 Adaptador (adapter)
9_ 6K6307 Sellos tipo anillo (O Ring seal)
1_ 6V9854 Codo giratorio (swivel elbow)
2_ 1P3703 Sello rectangular (rectangular seal)
2_ 1P3704 Sello rectangular (rectangular seal)
4_ 8T4184 Tornillo (bolt)
4_ 8T4223 Arandela (hard washer).
4_ 1P5767 Brida partida (half flange)
4_ 6V0400 Brida partida (half flange)
1_ 1U8293 Adaptador (adapter)
1_ 1U8292 Adaptador (adapter)
1_ 8T5082 Union
2_ 8T8902 Tee
5_ 6V3989 Nipple
5_ 6V4143 Acople
4_ 6V8397 Sellos tipo anillo (O Ring seal)
2_ 6V8716 Seal conector
4_ 8T4194 Tornillo
2_ 6V9508 Tapn con sello
1_ 1777860 Manguera
1_ 8C8762 Codo (elbow)
1_ 6V9829 Tapn
4_ 6V9832 Tapn
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11

Modulo 1
MODULO 1
INTRODUCCIN A LA
EXCAVADORA 330D
Ferreyros S.A.A.
Jorge Gorritti - Octubre 06
Desarrollo Tcnico
Manual del Estudiante 330D - Modulo 1

DSSE0060
Ferreyros S.A.A.
12

Modulo 1
Desarrollo Tcnico

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13

Modulo 1
MODULO 1
INTRODUCCIN A LA EXCAVADORA 330D
El propsito de este mdulo es familiarizar al estudiante con las
caractersticas de la Excavadora, ubicar los componentes principales,
controles e indicadores de la cabina, revisin diaria de mantenimiento y
operacin de la maquina. El mdulo incluye un cuestionario y ejercicios en la
maquina
Este mdulo consta de una leccin y sus laboratorios.
Al termino del mdulo, el estudiante estar en capacidad de
FIN
INICIO
OBJETIVOS
1. Realizar una inspeccin alrededor de la mquina localizando y explicando

todos los rtulos de advertencia y seguridad
............
2. Localizar todos los puntos de servicio, ubicacin de filtros y tomas de

muestras, adems de los procedimientos para revisar los niveles de los
compartimientos y hacer los cambios de fluidos; realizar la revisin diaria
de inspeccin de acuerdo a una hoja de trabajo
3. Identificar cada uno de los controles de operacin de la excavadora:
Palancas y pedales de direccin, control de implementos, indicadores de
alerta e interruptores.
4. Realizar el procedimiento de arranque, apagado seguro de la mquina y
demostrar la operacin de los controles
Ferreyros S.A.A.
Desarrollo Tcnico

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Modulo 1
Leccin 1.1 Familiarizacin

Esta leccin ayuda a familiarizarse con las caractersticas principales de la
Excavadora y con las prcticas bsicas para el mantenimiento correcto de la
mquina
CLASE
LABORATORIOS
Presentacin de los productos y vistas generales de la maquina,

caractersticas generales y especificaciones tcnicas, ubicacin de
componentes principales y criterios de inspeccin.
MATERIAL
NECESARIO
Ferreyros S.A.A.
Discutir en clase las especificaciones de ventas de la excavadora en

la Hoja de Trabajo N 1.2
Recorrer la mquina con la lista de chequeo de mantenimiento diario
y el recorrido de inspeccin en las Hojas de Trabajo N 1.3 y N 1.4.
Identificar los componentes de la cabina en la Hoja de Trabajo N 1.5
Arrancar la Excavadora y probar sus funciones bsicas en la Hoja de
Trabajo N 1.6
_ Excavadora 330D
_ Caja de Herramientas
_ Manual de Estudiante
_.Manual de Operacin y Mantenimiento SSBU 8046
_ Catlogo de Especificaciones AEHQ 5667
Desarrollo Tcnico

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15

Modulo 1
HOJA DE TRABAJO 1.1 SEGURIDAD

INSTRUCCIONES Responda las preguntas.
Dnde encontramos la informacin acerca de la seguridad relacionada con
la utilizacin y mantenimiento de la mquina?
Qu medidas de conservacin deben tomar con las etiquetas y mensajes de

seguridad e informacin?
Soldadura en
mquinas y
motores con
controles
electrnicos
1. Apague el motor. Coloque el interruptor en la posicin DESCONECTADA

2. Si tiene, haga girar interruptor de la batera a la posicin OFF. Si no hay un
interruptor master, desconecte el cable negativo de la batera
3. Conecte el cable de tierra. Posicione la abrazadera lo ms cerca de la
soldadura. Asegrese de que el recorrido elctrico desde el cable a tierra al
componente no pase a travs de ningn cojinete. proteja:
Cojinetes del tren de impulsin ,Componentes hidrulicos , Componentes
elctricos, Otros componentes de la mquina
4. Proteja todos los mazos de cables contra escoria o residuos de soldadura
5. Siga los procedimientos de soldadura para unir los materiales
Anote el
significado de la
etiqueta y ubquela
en la mquina
Ferreyros S.A.A.
Desarrollo Tcnico

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16

Modulo 1
HOJA DE TRABAJO 1.1 SEGURIDAD

(continuacin)
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
NOMBRE
Ferreyros S.A.A.
DESCRIPCION
CHECK EN MAQUINA
Desarrollo Tcnico

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17

Modulo 1
HOJA DE TRABAJO 1.2 ESPECIFICACIONES DE LA MAQUINA

Este laboratorio permite revisar la informacin general de la maquina
MATERIAL
NECESARIO
Catalogo de Especificaciones 330D AEHQ 5667

Manual de Estudiante
INSTRUCCIONES Complete los datos solicitados con la ayuda de la publicacin

SERIE:
mquina
___________
Descripcin
Sistema
Internacional
Modelo Motor
Desplazamiento (Cilindrada)
SERIE:
Motor
Potencia al volante
Altura mxima sin de rateo
___________
Peso de operacin
Velocidad de rotacin
Mxima velocidad de desplazamiento
Caudal mximo sistema principal de

implementos (1 bomba)
Mxima presin hidrulica (modo
pesado)
Longitud de embarque con pluma de
alcance y brazo R3.9DB
Ancho de transporte (zapatas de 34)
pluma de gran volumen y brazo
M2.55TB1
Mximo alcance a nivel del suelo,
pluma alcance, brazo R3.9DB,
cucharn 1,19m3 y acople rpido
Fuerza de excavacin de cucharn
propsito general familia DB (SAE)
brazo R3.2DB
Carga de un cucharn de alto
rendimiento (HDP), 5 dientes, pluma
de alcance, brazo R3.2DB (material de
mxima densidad)
Capacidad de levante, pluma 6.5m,
brazo 3.9m, sin cucharn, a -3m del
nivel del suelo, radio de carga sobre el
lado 7.5m
Tanque de combustible
9
10
11
12
13
14
15
CAPACIDADES
16
Sistema
Ingles
17 Sistema de enfriamiento
18 Aceite del motor
19 Mando de giro
20 Mando final (cada / uno)
21 Sistema hidrulico (incluido tanque)
22 Tanque hidrulico
Ferreyros S.A.A.
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Modulo 1
HOJA DE TRABAJO 1.3 MANTENIMIENTO DIARIO

MATERIAL
NECESARIO
Excavadora 330D
Manual de Operacin y Mantenimiento SSBU8046
INSTRUCCIONES Utilizando una Excavadora y el manual de operacin y mantenimiento realice

las siguientes tareas del Mantenimiento Diario (o cada 10 horas)
ITEM
Descripcin
Alarma de desplazamiento
Probar
Nivel de refrigerante del
sistema de enfriamiento
Comprobar
Nivel de aceite del motor
Comprobar
Separador de agua del
sistema de combustible
Drenar
Agua y sedimentos del
tanque de combustible
Drenar
Nivel de aceite del sistema
hidrulico
Comprobar
Tren de rodaje
Revisar
Indicadores y medidores
Probar
Ajuste de las cadenas
Inspeccionar
Cinturn de seguridad
Inspeccionar
Ncleo del radiador
Limpiar
Ventanas
Limpiar
Varillaje de Pluma, brazo y
cuchara (durante primeras
100 horas trabajo severo)
Lubricar
3
4
7
8
9
10
11
12
13
Pagina
Check en mquina
Cmo y en que condiciones se ajusta la cadena?
Cmo se purga el sistema hidrulico?
Ferreyros S.A.A.
Desarrollo Tcnico

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Modulo 1
HOJA DE TRABAJO 1.3 INSPECCION DIARIA

HO JA DE RUTA DE INSPECCION 330D
10
3
PLAT AFO R M A LAT ER AL
R AD IAD O R
C ABIN A E XT ER IO R
H O R O M ET R O
RU EDA G U IA
ZAPAT AS
CAD EN AS
PER N O S
BAST ID O R
RO D ILLO S
SPR O C KET
MAN D O FIN A L
1
2
R U ED AS G U IA
R O D ILLO S
G U AR D AS
C H ASIS
C U C H AR A
PIN ES
G R ASER AS
C ILIN D R O DE
C U C H AR A
BR AZO
PLU M A
M AN G U ER AS
M O T O R DE G IR O
T O R N AM ESA
T O R ES DE
4 DMOESPLAZA
MIEN T O
C H ASIS
MANG U ER AS
C O N T R APESO
T APAS
5
7
AC EIT E H ID R AU LIC O
FILT R O S
BO MBA S
MAN G U ER AS
VALVU LAS
PASILLO
MOTOR
SO PO R T ES
AC EIT E M O T O R
R EFR IG ER A N T E
T APAS D E
IN YEC T O R ES
AD MISIO N
ESC APE
T U R BO
C ART ER
BO MBA S
EN FR IAD O R
M AN G U ER AS
FAJAS
PO LEAS
VEN T ILAD O R
VALVU LA
PR IN C IPA L
M AN D O FIN A L
SPR O C KET
R O D ILLO S
BAST ID O R
PER N O S
C ADEN AS
ZAPAT AS
R U ED A G UIA
ESC ALER A
BAR AN D A
PLAT AFO R M A LAT ER AL
BAT ERIAS
EN G R ASAD O R
T AN Q UE H ID R AU L IC O
FILT R O S
VALVU LA
9 PR IN C IPA L
FILT R O S
M AN G U ER AS
G R ASERAS
SW IVEL
M O T O R DE G IR O
VALVU LAS D E G IR O
T AN Q U E D E
C O MBU ST IB LE
1 Inspeccione los
cilindros
hidrulicos por
daos o
desgaste
excesivo
6 Inspeccione
escaleras,
guardas, apoya
pies, limpie las
superficies
Ferreyros S.A.A.
7 Inspeccione el
sistema hidrulico por
fugas, repare cualquier
fuga evitando
contaminacin
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Modulo 1
HOJA DE TRABAJO 1.4 PUNTOS DE SERVICIO

- Excavadora 330D
- Manual de Operacin y Mantenimiento SSBU8046
- Manual de Estudiante
INSTRUCCIONES Utilizando la Excavadora y el manual de operacin y mantenimiento ubique
los puntos de servicio en la mquina
MATERIAL
NECESARIO
ITEM
Descripcin
Pagina
Check en mquina /
observacin / horas
TOMA DE MUESTRAS
1
2
3
4
5
Aceite del motor

Aceite sistema hidrulico
Aceite de mandos finales
Aceite de caja de mando rotacin
Refrigerante del motor
CAMBIOS DE FLUIDOS
1
2
3
4
5
6
Mandos finales
Sistema hidrulico
Mando de rotacin
Motor
Refrigerante
Engranaje de rotacin (lubricar)
NIVELES
1
2
3
4
5
6
7
Refrigerante
Aceite del motor
Aceite sistema hidrulico
Aceite de mandos finales
Aceite de mando rotacin
Combustible
Depsito limpia parabrisas
FILTROS Y REJILLAS
1
2
3
4
5
6
7
8
9
10
11
12
13
Ferreyros S.A.A.
Filtro de aire fresco de cabina

Filtro de aire recirculacin cabina
Filtro de aire primario motor
Filtro de aire secundario de motor
Rejilla tanque hidrulico
Filtro de aceite sistema hidrulico (caja de
drenaje)
Filtro de aceite sistema hidrulico (piloto)
Filtro de aceite sistema hidrulico de
retorno
Respiradero crter motor

Filtro de aceite del motor
Filtro separador de combustible
primario
Filtro de combustible secundario
Colador tanque de combustible
Secador refrigerante aire
acondicionado
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Modulo 1
HOJA DE TRABAJO 1.5 CONTROLES DE CABINA

MATERIAL
NECESARIO
Excavadora 330D
INSTRUCCIONES Identifique con flechas los controles indicados y explique sus funciones
2
4
Nmero
Qu hace el
botn rojo?
Nombre
Funcin
Control de traba hidrulica
2
3
Controles de
desplazamiento
Hormetro
Monitor
Controles de palanca
universal
Controles de velocidad del
motor
Interruptor de arranque del
motor
Panel de control derecho
Asiento del operador
10
Radio
6
7
Ferreyros S.A.A.
Check en
mquina
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Modulo 1
HOJA DE TRABAJO 1.5 CONTROLES DE CABINA (continuacin)
Nmero
Nombre
11
Controles auxiliares
12
Control de Velocidad
de desplazamiento
13
AEC Control de
Velocidad Automtica
del Motor
Cancelacin alarma de
traslacin
14
15
16
17
18
Ferreyros S.A.A.
Check en
mquina
Funcin
Control de la
herramienta
Control de
levantamiento pesado
Lavado ventana
superior
Limpia para brisas
superior
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Modulo 1
HOJA DE TRABAJO 1.5 CONTROLES DE CABINA (continuacin)
12
26
14
15
28
19
27
29
Nmero
Check en
mquina
20
17
18
24
21
19
20
21
Nombre
Interruptor de luces
Control de acoplador rpido
Lavado parabrisas inferior
22
Limpia parabrisas inferior
23
Calentador de asiento
24
Control de rotacin precisa
25
28
Control de aire acondicionado

y de la calefaccin
Control Auxiliar:
Manual - Automtico
Control Auxiliar:
Velocidad motor
Conector de diagnstico ET
29
ECM aire acondicionado
26
27
Ferreyros S.A.A.
13
16
22
Funcin
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Modulo 1
HOJA DE TRABAJO 1.6

OPERACIN DE LA EXCAVADORA 330D
Este laboratorio consta de una hoja de trabajo que le permitir desarrollar las
habilidades para operar la maquina.
MATERIAL
Excavadora 330D
INSTRUCCIONES
Utilizando una Excavadora y el Manual de Operacin realice las tareas que se

indican y anote el procedimiento realizado
ARRANQUE 1
Mueva la palanca de bloqueo piloto a la posicin de operacin (abajo),

coloque la llave de encendido en ON qu observa en el monitor?
Si cambia de posicin el acelerador ve algo?

Deje en mnimas RPM y arranque, qu sucede?
Mueva la palanca de bloqueo hidrulico a bloqueado (arriba) y arranque,
qu sucede?
Back up MOTOR 2
Ubique los controles de respaldo detrs del posa-brazos derecho, con la

mquina encendida mueva el control auxiliar a Manual qu ocurre en
el monitor?
Ahora en el control de RPM de Motor, muvalo y anote que sucede
AEC 3
Coloque el AEC (Control Automtico de Velocidad del Motor) en OFF y

acelere a mximas RPM, anote; despus de 2 segundos que sucede,
anote
Cambie el AEC a ON y anote que sucedi luego de 3 segundos
Presione el interruptor encima del joystick derecho (Low Idle) y anote

las RPM, vuelva a pulsarlo qu sucedi?
IMPLEMENTOS 4
Control
Adelante
Con motor en bajas RPM mueva las palancas de control derecha e

izquierda en varias direcciones y anote que implemento se mueve
Atrs
Derecha
Izquierda
Adelante y
derecha
Adelante e
izquierda
Atrs y
derecha
Atrs e
izquierda
DERECHO
IZQUIERDO
Ferreyros S.A.A.
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Modulo 2
MODULO 2
SISTEMAS
ELECTRICO
ELECTRNICO
Y MONITOR
Ferreyros S.A.A.
Jorge Gorritti Octubre 06
Desarrollo Tcnico

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Modulo 2
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Modulo 2
MODULO 2 :
SISTEMAS ELECTRICO, ELECTRNICO Y DE
MONITOREO
Los sistemas electrnicos se usan en todas las mquinas Caterpillar, los
sistemas elctricos alimentan a estos, en la serie D de excavadoras hay
cambios en el sistema monitor respecto a versiones anteriores, para realizar
el diagnstico y calibraciones pueden usar el monitor o el ET
El propsito de este mdulo es familiarizar al estudiante con el sistema
elctrico, electrnico y monitor en la maquina.
Consta de tres lecciones:
-Sistema elctrico.
-Sistema electrnico
-Sistema de monitor.
FIN
INICIO
OBJETIVOS
Al termino del mdulo, el estudiante estar en capacidad de:
Ferreyros S.A.A.
1.
Dado un esquema elctrico de la mquina y el Manual de Estudiante,

obtener la informacin solicitada.
2.
Utilizando la informacin de servicio localizar los componentes de

entrada, control y salida de los ECM, y demostrar la lgica de
operacin
3.
Dados una Excavadora, las hojas de trabajo y el Manual de Servicio

apropiado, utilizar adecuadamente las funciones del Monitor de la
mquina.
4.
Dados una Excavadora, las hojas de trabajo y el Manual de Servicio

apropiado, utilizar adecuadamente las funciones del E.T. Tcnico
Electrnico para obtener cdigos y realizar calibraciones
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Modulo 2
LECCIN 2.1: USO DEL ESQUEMA ELECTRICO

TEXTO DE
REFERENCIA
Localizacin de Fallas en Sensores Analgicos.

Las siguientes mediciones sern tpicas para un sensor analgico de
temperatura con el sensor conectado al control y el interruptor principal
encendido:
Pin A al Pin B: Alimentacin regulada de 5.0 VDC del control
electrnico
Pin C al Pin B: 1.99 - 4.46 DCV del sensor
La seal de voltaje en el pin C ser diferente para cada tipo sensor
que sea utilizado. La salida es proporcional al parmetro medido
(temperatura, presin, etc.) Los tcnicos deben consultar el mdulo
de servicio apropiado para las especificaciones individuales de cada
sensor.
Localizacin de Fallas en Sensores Digitales.

Las siguientes mediciones seran tpicas para un sensor de temperatura
PWM con el sensor conectado al control y el interruptor principal encendido:
Pin A al Pin B = Voltaje de fuente (en motor son 8V)
Pin C al Pin B = De 0.7 - 6.9 DCV (solo motor), voltaje CC
Pin C al Pin B = 4.5 - 5.5 kilociclos, en la escala de frecuencia
Pin C al Pin B= 5% - 95%, en la escala ciclo de carga %
El voltaje CC puede variar entre los diferentes tipos de sensores PWM, pero
la frecuencia debe siempre estar dentro de lo especificado en el sensor, y el
ciclo de carga debe siempre ser mayor a 0% (generalmente entre 5% - 10 %)
en baja y hasta 95% en el alta (pero nunca en 100%)
Ferreyros S.A.A.
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Modulo 2
LABORATORIO 2.1 ESQUEMA ELCTRICO

INSTRUCCIONES
Utilizando el esquema elctrico RENR 9587 de la Excavadora 330D

Responda las siguientes preguntas
1. Qu representan las siguientes lneas?
Negra slida
Roja slida
Intercalada negra
Discontinua cualquier color
Azul slida
2. Qu significa la lnea negra delgada con la designacin L# (ejem
L22, L98..)?
3. Cul es el nmero de parte del manual de servicio?

Electric Starting Motor:
Engine Control:
Alternator:
Machina Control:
4. Complete esta tabla
CABLE
(wire
number)
COLOR
(wire
color)
CIRCUITO
al que pertenece
(circuits)
DESCRIPCIN
(Description)
101
200
321
L969
638
N940
5. Ubique e identifique el conector CONN 1 en coordenadas y silueta en
mquina
6. Ubique el interruptor de nivel de aceite hidrulico en coordenadas y

silueta en mquina
7. Cul es el nmero de parte del switch?
8. Este conector es Sure Seal o Deutsh?, Cmo los diferencia?
9.
La parte del conector unida al switch, tiene pines o sockets, y

cuntos? ; es un receptculo o un plug dicho conector?
10. A qu harness esta unido, y cul es el nmero de parte del arns?
11. Finalmente a dnde se conecta, a que ECM?
Ferreyros S.A.A.
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Modulo 2
LABORATORIO 2.1 ESQUEMA ELCTRICO

(CONTINUACION)
12. Qu significa la NOTA E? En el esquema
13 .Qu indican los siguientes cdigos?

a. MID 036 CID 0042 FMI 05
b. MID 039 CID 0581 FMI 13
c.
E360
Complete la tabla donde corresponda:

COMPONENTE
UBICACIN
ESQUEMA
SILUETA
NUMERO DE
PARTE
A QUE
COMPONENTE SE
CONECTA
MAIN RELAY
FUEL PRESSURE
SWITCH
HYDRAULIC OIL
TEMPERATURE
SENDER
INTAKE MANIFOLD
PRESSURE SENSOR
HYDRAULIC LOCK
SOLENOID
CONTINUACIN
COMPONENTE
HARNESS
NUMERO DE
PARTE
UBICACIN EN
HARNESS
PARMETROS
ACTUACIN
RESISTENCIA
DESACTUACIN
POSICIN
DE
CONTACTOS
MAIN RELAY
FUEL PRESSURE
SWITCH
HYDRAULIC OIL
TEMPERATURE
SENDER
INTAKE MANIFOLD
PRESSURE SENSOR
HYDRAULIC LOCK
SOLENOID
Ferreyros S.A.A.
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Modulo 2
LABORATORIO 2.2 ESQUEMA DE ARRANQUE Y CARGA

INSTRUCCIONES
Ferreyros S.A.A.
Utilizando el esquema elctrico RENR 9587 de la Excavadora 330D

Siga el recorrido de la corriente en el circuito de arranque
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Modulo 2
LABORATORIO 2.3 EVALUACION DE SENSORES

INSTRUCCIONES
Utilizando el esquema elctrico de la excavadora, el manual de servicio

RENR 9848 y las herramientas adecuadas evale los siguientes sensores
A: SUMINISTRO
B: TIERRA
C: SEAL
COMPONENTE
PUNTOS A
MEDIR
--
VALOR
VALOR LEIDO
ESPECIFICADO
SENDER: FUEL LEVEL SENDER

VOLTAJE SUMINISTRO
RESISTENCIA
SENSOR ANALOGICO: ATMOSFERIC PRESSURE SENSOR
VOLTAJE DE SUMINISTRO
SEAL
V
Hz
%
VOLTAJE REFERENCIA
(PULL UP) Si tiene
SENSOR DIGITAL: PUMP DISCHARGE PRESSURE SENSOR
SEAL
V
Hz
%
VOLTAJE REFERENCIA
(PULL UP) Si tiene
SENSOR DE FRECUENCIA: SPEED SENSOR
SEAL
V
Hz
%
RESISTENCIA
SOLENOIDE: SWING BRAKE SOLENOID
RESISTENCIA
Ferreyros S.A.A.
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Modulo 2
LABORATORIO 2.4 EVALUACION DE UN RELAY

Evale el Main Relay de la mquina
Localizacin en el Esquema:
Localizacin en la Mquina (silueta):
Nmero de Parte:
1. Active el relay, si es posible

encienda todos los accesorios
, el motor puede estar apagado
o encendido
2. Conecte el multmetro y lea

en los terminales
24 V: leer ms de 22V
12 V: leer ms de 11V
3. Mida el voltaje en el terminal

de relay la batera
4. Revise los
contactos (switch),
Conecte el
multmetro y realice
Los siguientes pasos
5. Si los contactos estn cerrados se leer menos de 1V. (24V) o 0.5V (12V)
6. Desconecte el terminal (A) de entrada positiva a la bobina, los contactos
cambiarn de posicin, en un buen relay escuchar un clic_king
7. Mida el voltaje a travs de los contactos:
- Rele antes cerrados y ahora abiertos: Leer el voltaje del sistema 24V
(12V)
- Relay antes abiertos y ahora cerrados: Leer 1V (24V) o 0.5V (12V)
8. Cundo (A) es desconectado el voltaje cruzando los terminales debe
alternar entre 24V y 1V (12V y 0.5V)
Ferreyros S.A.A.
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Modulo 2
LABORATORIO 2.5 SISTEMA DE ARRANQUE Y CARGA

INSTRUCCIONES
Ferreyros S.A.A.
Realice las siguientes pruebas del Sistema Elctrico
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Modulo 2
LABORATORIO 2.5
INSTRUCCIONES
Ferreyros S.A.A.
(continuacin)
Responda las siguientes preguntas
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Modulo 2
Leccin 2.2 : Sistema Electrnico

Esta leccin permite identificar la funcin de los componentes electrnicos
CLASE
Presentacion de conceptos generales del sistema
LABORATORIOS Dado el manual del estudiante, las hojas de trabajo y la explicacin en clase,
identificar los componentes de entrada y evaluarlos segn el procedimiento
apropiado en las hojas de laboratorio
.
MATERIAL
NECESARIO
Ferreyros S.A.A.

Manual de Servicio RENR 9848
Excavadora 330D
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Modulo 2
Leccin 2.2.1: Generalidades

El sistema de control electrnico de la mquina controla al sistema hidrulico,
todo sistema electrnico tiene estos componentes:
COMPONENTES DE ENTRADA: Son sensibles a las variaciones fsicas de
temperatura, presin o movimiento, y la Transformaran en seales elctricas
o electrnicas, que recibe el ECM.
ECM : Procesa la informacin de componentes de entrada que le indican el
estado de la maquina. El resultado de la informacin procesada por el ECM
sirve para enviar seales elctricas o electrnicas, a los componentes de
salida.
COMPONENTES DE SALIDA: Transformaran la seal electrnica
proveniente del ECM, en una activacin mecnica o hidrulica que controlara
la bomba y el motor diesel
El ECM de la mquina controla las siguientes funciones:
-
Velocidad del motor diesel

Velocidad de los motores hidrulicos de traslacin
Alarma de traslacin
Freno de parqueo de giro
Funcin de Levante pesado
Funcionamiento de accesorios hidrulicos
Presin de cambio de potencia PS a la bomba
Limita el flujo hidrulico
RPM
Velocidad del
motor para cada
posicin del dial
y cuando no hay
carga
Ferreyros S.A.A.
RPM For The Engine Speed Dial Switch

322D, 324D, 325D, 328D, 330D
"Dial Position"
Engine RPM
Hyd Torque (%)
950
25
1020
40
1160
61
1300
69
1470
78
1590
85
1700
92
1800
92
1900
92
10
1980
100
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Modulo 2
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Modulo 2
Leccin 2.2.2 Componentes Electrnicos

(1) Switch Panel
(3) Hydraulic Oil Filter Plugged
Switch
(5) Fuel Filter Plugged Switch
(7) Water Separator Level
Switch
(9) Fine Swing Switch
(11) Travel Alarm Relay
(13) Starter Switch
(15) One Touch Low Idle
Switch
(17) No.1 Pump Pressure
Sensor
(19) Implement Pressure
Switch
(21) Travel Left Pressure
Switch
(23) Swing Brake Release
Solenoid
(25) Power Shift Pressure
Proportional Reducing Valve
(27) Viscous Clutch
(29) Straight Travel Pressure
Switch
(31) Overload Warning
Pressure Sensor
(33) Fuel Level Sensor
(35) Alternator
(37) Fault Alarm
(39) Engine Coolant Level
Switch
(41) Engine ECM
(43) Engine Coolant
Temperature Sensor
(51) Backup Resistor
(2) Air Cleaner Plugged Switch

(4) ATT Hydraulic Oil Filter
Plugged Switch
(6) No.2 Fuel Filter Plugged
Switch
(8) Overload Warning Switch
(10) Quick Coupler Switch
(12) Machine ECM
(14) Engine Speed Dial
(16) Speed Sensor
(18) No.2 Pump Pressure
Sensor.
(20) Travel Right Pressure
Switch
(22) Backup Switch
(24) Travel Speed Change
Solenoid.
(26) Straight Travel Solenoid
(28) Heavy Lift Solenoid
(30) Ambient Temperature
Sensor
(32) Monitor
(34) Hydraulic Oil Temperature
Sensor
(36) Air Heater controller
(38) Engine Oil Level Switch
(40) Hydraulic Oil Level Switch
(42) User Shutdown Switch
(44) Engine Oil Pressure
Switch
(53) Acceleration/Deceleration
at Backup
(54) Engine Speed Selector

Switch
Ferreyros S.A.A.
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Modulo 2
Leccin 2.2.3 Operacin del Sistema

Instrucciones: Describa la operacin del sistema
Regulacin de velocidad del motor:
Proteccin de sobre velocidad del motor:
AEC: Control Automtico de Velocidad del

Motor
Control velocidad ventilador enfriamiento:
Control de Baja en Vaci Manual (Low Idle)
Modo de levante pesado:
Ferreyros S.A.A.
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41

Modulo 2
REGULACIN DE LA BOMBA:
Control por baja velocidad:
Control velocidad de traslacin:
Operacin freno de parqueo de giro:
Controles de respaldo:
Ferreyros S.A.A.
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Modulo 2
Leccin 2.3 : Sistema Monitor

Esta leccin permite familiarizarse con los componentes principales del
Sistema Monitor en Excavadoras Serie D
CLASE
Presentacion de conceptos generales del sistema
LABORATORIOS Dado el manual del estudiante, las hojas de trabajo y la explicacin en clase,
identificar los componentes de entrada y evaluarlos segn el procedimiento
apropiado en las hojas de laboratorio
.
MATERIAL
NECESARIO
Ferreyros S.A.A.

Manual de Servicio RENR 8068
Manual de Operacin y Mantenimiento SEBU 8046
Excavadora 330D
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Modulo 2
Leccin 2.3.1 Funciones del Monitor

Coloque los
nmeros a las
funciones
( ) Action
Lamp
( )Clock
( ) Engine
Speed Dial
Indicator
( ) Fuel Gauge
( ) Hydraulic
Oil
Temperature
Gauge
( ) Engine
Coolant
Temperature
Gauge
( ) Keypad
El sistema monitor
se comunica con
el CAN Data Link
Item
Nombre
Funcin
Up Key
Right Key
Home Key
Main menu key
Left key
Down key
Cancel key or Back key
OK Key
Ferreyros S.A.A.
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TEXTO DE REFERENCIA:
CATEGORAS DEL SISTEMA DE ADVERTENCIA CATERPILLAR
OPERACIN DE ADVERTENCIA
Categora de
advertencia
Indicaciones de Advertencia
Un mensaje La luz de
La alarma de
en la
accin
accin suena,
pantalla o un destella
la luz de
medidor
ms un
accin
estar en la mensaje
destella y un
zona roja
mensaje
Accin
requerida del
operador
No se requiere
ninguna accin
inmediata. El
sistema necesita
rpida atencin
Cambie la
operacin de la
mquina o
realice el
mantenimiento
del sistema
Realice
inmediatamente
una parada
segura del motor
Posible
Resultado
No se producir
ningn efecto
perjudicial o
daino
Se producirn
daos en los
componentes de
la mquina
Se producirn
lesiones al
operador o daos
importantes en los
componentes
Encendido: Al poner el interruptor de arranque en ON:

- Aparece el smbolo CAT por 1 segundo y la luz de accin o Indicador de Alerta enciende
- Se indican el nivel de combustible, temperatura de aceite hidrulico y refrigerante del motor y
la posicin del control de velocidad del motor
- Se indica la configuracin de los joystick por 3 segundos
- Se revisan las horas de cambio de filtros y fluidos, si alguno esta en rango de cambio
aparece Check FLTR / FLUID INFO por 5 segundos
Ferreyros S.A.A.
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CATEGORAS DE ADVERTENCIA 1
El Nivel 1 intenta alertar al operador de la existencia de una condicin que
conviene este enterado
Un Authorized Key:
mquina con sistema
de seguridad, use llave
adecuada
Reverse Fan Error /
Starting:
Error en el ventilador
reversible, saldr otro
mensaje relacionado /
inicio de
funcionamiento, no
opere hasta termine
Fuel Level Low:
Bajo nivel de
combustible
Battery Voltaje
Irregular:
malfuncionamiento del
sistema de carga
Lube Level Low /
Autolube Error / Lube
Starting
Bajo nivel,
malfuncionamiento,
inicio de lubricacin
Hyd Return Fltr

Plugged
Filtro de retorno
hidrulico restringido
Att Fltr Plugged:

Filtro de aceite
hidrulico restringido
Intake Air Fltr

Plugged:
Filtro de aire restringido
Fuel Fltr Plugged:

Filtro de combustible
restringido
Water Separator Full

Separador de agua
lleno
Lever is not neutral /

Counterweight
removal / Not
configured / Not
calibrated / Cycle the
lock lever
Mueva palanca a neutral

No opere la mquina hasta
reinstalar contrapeso
Configure o Calibre la mquina
Mueva la traba hidrulica en todo
su rango
NOTAS:
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En el Nivel 2, normalmente son altas temperaturas del sistema por una sobre
operacin, se requiere cambiar la forma de operacin de la mquina
Inlet Air Temp. High
Alta temperatura del
aire de admisin,
investigue
Engine shutdown
activating:
Motor detenido por
algn error
Hyd Oil Temp High
Alta temperatura del
aceite hidrulico, opere
a low idle
ECM Error / Engine
ECM Error / Monitor
Error
Malfuncionameinto
Coolant Temp. High:

Alta temperatura
refrigerante, opere a
bajas RPM
Eng Overspeed
Warning
Velocidad muy alta del
motor, cambie la
operacin
Fuel Press High
Presin muy alta
Service Required /
Tool Control
Malfunction:
Detenga e investigue
El Nivel 3 indica que el operador debe tomar una accin inmediata para evitar
dao severo a la mquina, esto es detener el equipo con seguridad
Lift Overload Warning
Carga muy grande
para la mquina,
peligro de volteo,
reduzca l carga
Coolant Level Low:
Detenga mquina por
bajo nivel de
refrigerante
Hyd Oil Level Low:
Detenga mquina por
bajo nivel de aceite
hidrulico
Eng Oil Press Low

Baja presin, detenga la
mquina e investigue
Eng Level Low:

Detenga mquina por
bajo nivel de aceite del
motor
Fuel Press High
Presin muy alta
NOTAS:
Ferreyros S.A.A.
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LECCIN 2.3.2 MENUS DEL MONITOR

Men Principal
Ferreyros S.A.A.
Tiene cuatro opciones principales
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LABORATORIO 2.6 SISTEMA MONITOR

INSTRUCCIONES
Responda las siguientes preguntas con el procedimiento resumido

1.Qu muestra la pantalla del monitor cuando pone el interruptor de
respaldo en manual?
2.Cmo se puede cambiar el idioma?
3.Cmo sabe el operador cuando se requiere dar servicio al filtro de

combustible?
4.Luego de realizar el mantenimiento Cmo reajusto los intervalos de

mantenimiento a cero?
5.Cmo se cambia el tipo de herramienta?
6.Cul es el procedimiento para activar el Ventilador en Reversa?
7.Cmo puede ver las RPM del motor?
8.Cmo veo los cdigos de diagnstico?
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9. Qu tipos de informacin obtengo del modo de Estado?
10. Realice el procedimiento de calibracin de todas las vlvulas

Step
Operation
Press the "OK" key (15) in order to go to the next step.
Raise the boom and the stick to the maximum position. Then press the
"OK" key (15).
Set the lever for hydraulic oil to the UNLOCK position.
Press the OK key (15) in order to go to the next step.
Hold the left lever in the BACK position.
Press the "OK" key (15) in order to go to the next step.
10
11
12
13
14
Sustain the left lever BACK.
Release all levers and release all pedals.
Press the OK key (15) in order to go to the next step.
End of the calibration.
11. Para qu sirve el modo Override?
12. Cmo cambio el valor de presin de sobrecarga (Overload Warning)
Ferreyros S.A.A.
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LABORATORIO 2.7 BARRIDO DE LA PRV

INSTRUCCIONES
Realice esta prueba siguiendo el procedimiento del Manual de Servicio

RENR 9848
Esta prueba permite que la corriente hacia la PRV Vlvula Reductora
Proporcional cambie a un rango especfico, se usa para confirmar la
activacin de la PRV
(1) Power shift

pressure
solenoid
(2) Tap for the
power shift
pressure
1
2
CADA 20
SEGUNDOS
ESPECIFICACION
Motor en OFF
Conecte una tee de prueba en el conector de la PRV (1)
Instale un manmetro de 800 PSI (4900 kPa) en (2)
El interruptor de respaldo (backup) en AUT
Motor en velocidad 10
Aceite hidrulico a temperatura de operacin 50C (122 F)
Controles en neutral
Entre con el MONITOR al modo de servicio DEVICE TEST MODE y
seleccione POWER SHIFT PRES o realice la prueba en
PROCEDIMIENTOS con el ET: SWEEP
MINIMO
CORRIENTE
(AMPERIOS)
Aprox.
0.2
MAXIMO
0.75
Ferreyros S.A.A.
LECTURAS
PRESION
PSI (kPa)
Aprox.
70 (482)
LECTURAS
500 (3447)
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LABORATORIO 2.8 DIAGNOSTICO

INSTRUCCIONES
Responda las siguientes preguntas con el procedimiento resumido

MID
030
036
039
122
Use el ET para
acceder al grupo 1
FMI
Tipo de falla
00 Datos validos pero sobre el
rango de operacin normal
01 Datos validos pero debajo del
rango de operacin normal
02 Datos errticos, intermitentes o
incorrectos
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
Descripcin
Monitor
Motor
Mquina
Satlite
(Product
Link)
124 Seguridad
MSS)
Causas
Seal debajo de lo normal, Corto a batera de la seal,
Necesita calibracin sensor
Tiempo retrasado, Seal debajo de rango
Falla en la conexin, seal intermitente o erratica, el

software fue cambiado, seal con ruido electromagntico,
seal fuera de rango
Voltaje sobre lo normal o corto Sensor o switch daado, arns daado, ECM fallo, sensor
alto
con voltaje alto, corto a un voltaje alto, circuito abierto
causa un voltaje pull up
Voltaje debajo de lo normal o
Sensor o switch daado, arns daado, ECM fallo, sensor
corto bajo
con voltaje bajo, circuito con corto a tierra
Corriente debajo de lo normal o Circuito abierto o pobre conexin del arns, switch quedo
circuito abierto
abierto
Corriente sobre lo normal o
Corto a tierra del arns, relay con corto, ECM fallado
circuito con corto a masa
Sistema mecnico no responde Componente responde inapropiadamente o queda pegado
adecuadamente
en una posicin, componente fallado, motor apagado,
mquina usada inadecuadamente
Periodo, pulso o frecuencia
Conexin del arns intermitente o pobre, motor con fallas,
anormal
seal con ruido por interferencias, perdida de dispositivos
mecnicos
Actualizacin anormal
ECM no se comunica correctamente con el Data Link, ratio
de transmisin de datos anormal, CAT CAN Data Link
fallado, mal funcionamiento del software
Anormal rango de cambio
Cambios muy rpidos de la seal, fuera del limite
Modo de falla no identificable
Falla mecnica o dao en mltiples circuitos
Mal dispositivo o componente
Falla en el control electrnico, en el Data Link o varios
controles con error de software
Fuera de calibracin
Datos fuera de rango, requieren calibracin
No usado
No usado
Parmetro no disponible
El control no soporta ese parmetro
Modulo no responde
El control no responde a los datos
Falla en suministro al sensor
Falla en el suministro
Condicin no conocida
No usado
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Component Identifier (CID)

Machine ECM (MID 039)
TABLAS PARA DIAGNOSTICO
For troubleshooting, see the procedure with the same diagnostic

code.
CID / FMI
Description
CID 0362 Engine Fan Speed Control Solenoid
CID 0041 8 Volt DC Supply
FMI 03
Voltage Above Normal
FMI 06
FMI 05
Current Below Normal
CID 0096 Fuel Level Sensor
FMI 06
Current Above Normal
FMI 04
Voltage Below Normal
CID 0374 Swing Brake Solenoid
FMI 05
FMI 03
CID 0110 Engine Coolant Temperature Sensor
FMI 05
FMI 04
FMI 06
FMI 09
Abnormal Update Rate
CID 0544 Engine Cooling Fan Speed Sensor
CID 0167 Alternator Charging Voltage Sensor
FMI 08
FMI 12
CID 0581 Power Shift Solenoid
Bad Device or Component
Abnormal Frequency, Pulse Width or Period
CID 0168 Electrical System Voltage
FMI 03
FMI 05
FMI 05
CID 0171 Ambient Air Temperature Sensor
FMI 06
FMI 03
CID 0586 Engine Speed Dial Switch
FMI 04
FMI 05
CID 0190 Engine Speed Sensor
FMI 12
FMI 08
CID 0588 Monitoring System Display
CID 0246 Proprietary CAN Data Link
FMI 09
FMI 12
FMI 12
CID 0247 SAE J1939 Data Link
CID 0598 Travel Speed Solenoid
FMI 12
FMI 03
CID 0248 Cat Data Link
FMI 05
FMI 12
FMI 06
CID 0254 Electronic Control Module
CID 0600 Hydraulic Oil Temperature Sensor
FMI 12
FMI 04
CID 0262 5 Volt DC Sensor Power Supply

FMI 06
CID 0271 Action Alarm

FMI 06
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CID 0735 Heavy Lift Solenoid
CID 1594 Attachment Valve #2 Extend Pressure Solenoid
FMI 03
FMI 03
FMI 05
FMI 05
FMI 06
FMI 06
CID 1130 Left Attachment Pedal Position Sensor
FMI 03
FMI 03
FMI 04
FMI 05
FMI 08
FMI 06
CID 1160 Hydraulic Lock Solenoid
CID 1596 Attachment Valve #1 Retract Pressure Solenoid
FMI 03
FMI 03
FMI 05
FMI 05
FMI 06
FMI 06
CID 1178 Machine Overload Warning Pressure Sensor
FMI 03
FMI 03
FMI 04
FMI 05
FMI 08
FMI 06
CID 1522 Relief Valve #2 Check Valve Solenoid
FMI 03
FMI 03
FMI 05
FMI 05
FMI 06
FMI 06
CID 1523 Relief Valve #1 Check Valve Solenoid
CID 1609 F2 Type Valve Load Sense Pressure Sensor
FMI 03
FMI 03
FMI 05
FMI 04
FMI 06
FMI 08
CID 1525 Straight Travel Solenoid
CID 1657 Left Joystick Thumbwheel
FMI 03
FMI 03
FMI 05
FMI 04
FMI 06
FMI 08
CID 1590 Main Pump Flow Limitation Pressure Solenoid
CID 1658 Right Joystick Thumbwheel
FMI 03
FMI 03
FMI 05
FMI 04
FMI 06
FMI 08
CID 1665 Variable Relief Valve #1 Pressure Solenoid
FMI 03
FMI 03
FMI 05
FMI 05
FMI 06
FMI 06
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CID 1666 Variable Relief Valve #2

Pressure Solenoid
FMI 03
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Modulo 2
Calibration Error ID List

ID
Calibration Error Description
$0001
ECM Fault
$0002
Active Diagnostic Present
$0003
Another Calibration is Active
$0004
Calibration Active by Another ECM
$0005
Loss of Calibration Interlock
$0006
Calibration Aborted by Tool/Monitor
$0007
Requested Display Not Supported
$0008
Unavailable Display
$0009
Calibration Aborted by ECM
$000A
Calibration Failure
$000B
Calibration Not Supported
$0100
Out-of-Range Low - Incr/Decr Parameter
$0101
Out-of-Range High - Incr/Decr Parameter
$0102
Invalid Action/Key Stroke Command
$0103
Calibration Value Out-of-Range
$0104
Calibrated Range Too Small
$0105
Calibrated Range Too Large
$0106
Calibration Value Not Saved
$1000
See Service Manual
$1010
Engine Stopped (No Engine RPM)
$1011
Engine Running (Engine RPM Present)
$1012
Engine RPM Incorrect
$1013
Engine High Idle RPM Too Fast
$1014
Engine Low Idle RPM Too Slow
$1015
Abnormal Engine RPM Signal
$1016
Speed Sensor Circuit is Open
$1017
Service Brake Pedal Pressed
$1018
Parking Brake Not Engaged
CID 2300 Switch Panel
$1019
Parking Brake Engaged
FMI 09
$101A
Implement is Swinging/Traveling
$101B
Machine Speed Not Zero
FMI 05
FMI 06

CID 1931 Auxiliary Circuit Flow

Combining Solenoid
FMI 03
FMI 05
FMI 06

CID 2265 Hydraulic Pump #1 Outlet

Pressure Sensor
FMI 03
FMI 04
FMI 08

Abnormal Frequency, Pulse
Width or Period
CID 2266 Hydraulic Pump #2 Outlet

Pressure Sensor
FMI 03
FMI 04
FMI 08

Abnormal Frequency, Pulse
Width or Period
CID 2280 Travel Alarm Relay

FMI 03
Ferreyros S.A.A.
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Event Identification List

EID
Event Description
Fuel Filter Restriction Derate
15
High Engine Coolant Temperature

Derate
179
Alternator Not Charging
180
Auto Lube Distribution Line Plugged
181
Limited Mobility Mode
16

Shutdown
17

Warning
23
High Hydraulic Oil Temperature

Derate
25
High Inlet Air Temperature Derate
27
High Inlet Air Temperature Warning
234
39
Low Engine Oil Pressure Derate
235
43
Low System Voltage Warning
50
High System Voltage Warning
53
Low Fuel Pressure Warning
59
Low Engine Coolant Level Warning
182
190
232
236
237
265
Suction Valve Off

Engine Overspeed Warning
High Fuel/Water Separator Water Level
Low Auto Lube Grease Level

Low Hydraulic Oil Level
Return Hydraulic Oil Filter Plugged
Machine Overloaded
User Defined Shutdown
95
Fuel Filter Restriction Warning
96
High Fuel Pressure
100
Low Engine Oil Pressure Warning
273
119
Low Fuel Level
600
High Hydraulic Oil Temperature Warning
171
Low Engine Oil Level
862
Attachment Hydraulic Oil Filter Plugged
172
High Air Filter Restriction
863
Abnormal Machine Auto Lube System

Operation
Ferreyros S.A.A.
272
Inlet Air Restriction Warning

Unauthorized Key
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MODULO 3
MOTOR
Ferreyros S.A.A.
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MODULO 3 MOTOR
El propsito de este mdulo es mostrar el funcionamiento del sistema
mecnico y electrnico del motor HEUI C9 de tecnologa ACERT identificando
sus componentes y procedimientos de ajuste.
Este mdulo consta de lecciones y sus laboratorios.
Al trmino del mdulo, el participante estar en capacidad de
FIN
INICIO
OBJETIVOS
1. Dado una hoja de trabajo, Manual de Servicio y una Excavadora, realizar el

seguimiento al 100% del flujo de los sistemas de motor: enfriamiento,
admisin y escape, combustible y lubricacin.
2. Dados una hoja de trabajo, Manual de Servicio y una Excavadora, explicar

el funcionamiento del Sistema de Combustible HEUI.
3. Dados una hoja de trabajo con un listado de componentes del sistema

electrnico de motor y una Excavadora, identificar los mismos con una
eficacia del 100%.
4. Dados una hoja de trabajo, una Excavadora 330D, Manual de Servicio,

Electronic Technician ET y herramientas adecuadas, realizar pruebas de
diagnstico en el motor C9
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LECCIN 3.1 SISTEMAS DE MOTOR C9

Esta leccin permite familiarizarse con los sistemas principales del motor y su
funcionamiento.
CLASE
LABORATORIOS
La clase consiste en la presentacin de vistas generales del motor, de sus

sistemas principales.
-
MATERIAL
NECESARIO
Ferreyros S.A.A.
Identificar componentes de los sistemas de acuerdo a la Hoja de

Trabajo 3.1
Trazar los flujos principales de los sistemas de motor de acuerdo a la
Hoja de Trabajo 3.2
_ Excavadora 330D (o motor C9 de repuesto)

_ Manual de Servicio Motor SENR9829, SENR9830, SENR5089
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TEXTO DE REFERENCIA: ACERT

ACERT significa Tecnologa de Reduccin de Emisiones y Combustin
Avanzada (Advanced Combustin Emissions Reduction Technology)
Ofrece mejor economa de combustible y desgaste reducido, manteniendo las
normas de emisin de gases de escape U.S. EPA Tier 3
Entre las principales caractersticas estn:
-
9% ms potencia (HP) comparado al C-9

Nuevo diseo de inyector (HEUI B)
Nuevo diseo de bomba hidrulica (10 ccs por rev y 4060 PSI max,
solo presuriza el volumen de aceite necesario para la operacin
reduciendo hasta 5% el consumo de combustible)
Engranaje de tiempo de inyeccin de 48 dientes
ECM Adem A4
HOJA DE TRABAJO 3.1 CONFIGURACION

Procedimiento
Complete lo requerido
__ Vlvulas de
Escape
__ Vlvulas de
Admisin
Calibre o dimetro del cilindro

Carrera del pistn
Cilindrada
Nmero de cilindros
Configuracin de los cilindros
Vlvulas por cilindro
Luz vlvula de admisin
Luz vlvula de escape
Tipo de combustin
Orden de encendido
Sentido de rotacin (visto desde la
volante)
Ferreyros S.A.A.
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HOJA DE TRABAJO 3.2 SISTEMAS PRINCIPALES DE MOTOR

- Excavadora 330D
- Manual de Servicio SENR9830
- Manual de Estudiante
INSTRUCCIONES Utilice los esquemas siguientes para buscar en la maquina e identificar los
componentes de los sistemas de motor: Admisin y escape, lubricacin,
enfriamiento, tambin identifique el flujo en los distintos sistemas.
MATERIAL
NECESARIO
3.2.A : SISTEMA DE ADMISIN Y ESCAPE
Mltiple de Escape
Ingreso de aire
Calentador de Aire de Admisin
Salida gases de escape
Post Enfriador
Compresor
Vlvula de Escape
Turbina
Vlvula de Admisin
En el post enfriador el aire reduce su temperatura de 150C (300 F) a 43 C
(110 F) incrementando la eficiencia
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La vlvula de derivacin
(wastegate) redirige una
porcin de los gases de
escape fuera del turbo
cargador, esto limita la
RPM del turbo y presin
de refuerzo
Wastegate
Calentador de aire de admisin
( ) Relay para el calentador de aire

( ) Sensor de temperatura de admisin
Condiciones de operacin:
(1) Ciclo de encendido: luego recibir voltaje el ECM, el
calentador y la lampara pasan a ON por 2 segundos
(2) Precalentador: (baja altura) si la suma de la temperatura
de refrigerante ms la T del aire es menor a 25C
(109F), el ECM activa las resistencias por 30 segundos,
(en altura), si la suma de la temperatura de refrigerante
ms la T del aire es menor a 53C (160F), el ECM
activa las resistencias por 30 segundos
(3) Modo de arranque: Al detectar RPM del motor, aun
permanece activado el calentador hasta superar 25C
(baja altura) o 63C (en altura)
(4) Motor funcionando: Al llegar a Baja en Vaco RPM
permanece encendido por 7 minutos mientras la
temperatura sea menor a 35C (127F) baja altura o
63C (177 F) en altura
(5) Ciclo de post calentamiento, bajo las mismas
condiciones anteriores, el calentador y su lmapra
estarn encendidos 10 segundos y apagados 10
segundos por otros 13 minutos
Ferreyros S.A.A.
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3.2.B : SISTEMA DE LUBRICACION
Unit injector hydraulic pump

High pressure relief valve
Oil passage to the rocker
arms
High pressure oil line
Valve mechanism cover
High pressure oil passage
Oil supply line to the unit
injector hydraulic pump
Cylinder head gallery
Oil gallery plug
Piston cooling jets
Camshaft bearings
Oil filter bypass valve
Oil cooler bypass valve
Ferreyros S.A.A.
Main oil gallery

Passage to front housing
Turbocharger oil supply line
Passage to camshaft idler
gear bearing
Passage
Passage to oil pump idler
rear bearing
Engine oil filter
Engine oil cooler
Main bearings
Engine oil pump
Oil pump bypass valve
Passage to engine oil pan
Engine oil pan
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FLUJO A TRAVES DEL SISTEMA DE LUBRICACION
Bomba Hidrulica de los Inyectores Unitarios

Respiradero
Manguera
La bomba hidrulica de los Inyectores es bomba de pistones axiales movida
por engranajes, esta eleva la presin de aceite tpica de operacin a una
presin de actuacin que es requerida por los inyectores unitarios.
El circuito de baja presin trabaja entre 240kPa (35PSI) a 480 kPa (70 PSI),
el circuito de alta presin opera en el rango de 6 MPa (870 PSI) y 25 MPa
(3626 PSI)
Oil cooler bypass valve

Oil filter
Oil filter bypass valve
Oil cooler
Si la diferencia de presiones cruzando el enfriador de aceite alcanza 155 +/17 kPa (22 +/- 2 PSI) la vlvual de derivacin se abre
Cuando la diferencia de presiones en el filtro de aceite llega a 70 kPa (25 PSI)
se abre al vlvula bypass, esto siempre sucede en el arranque inicial
Ferreyros S.A.A.
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3.2.C. SISTEMA DE ENFRIAMIENTO
La lnea de venteo (shunt line) desde la bomba hacia el tanque de expansin

permite dirigir las burbujas de aire formadas evitando cavitacin
( ) Water pump
( ) Bypass inlet
Si no instalamos termostato
la mayor parte del flujo va
por el bypass hacia la
bomba siempre, en climas
clidos el motor se
sobrecalentar y en climas
fros no alcanzar su
temperatura normal de
operacin
( ) Coolant
supply line
( ) Coolant
return line
Ferreyros S.A.A.
Desarrollo Tcnico

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Modulo 3
HOJA DE TRABAJO 3.2 (continuacin)

Coloque el nmero y ubique los
componentes en la mquina
ECM mquina
Condensador y recibidor del
aire acondicionado
Reservorio limpia parabrisas
Interruptor desconexin batera
y breakers
Filtro de aire motor
Solenoide de ayuda de
arranque con ter
Bateras
Enfriador de aceite hidrulico
Sensor de presin de combustible
Bomba manual de cebado
combustible
Filtro secundario de combustible
Vlvula de cambio de patrn joystick
Post enfriador ATAAC
Base filtro primario combustible
Radiador
Recipiente de expansin refrigerante
del motor
Filtro primario separador agua
combustible
Motor C9 ACERT
Varilla nivel aceite de motor
Calentador de aire de
admisin
Tapa llenado aceite motor
Toma de muestra
refrigerante del motor
Toma de muestra aceite del

motor
Filtro de aceite del motor
Bomba hidrulica del
ventilador
Ferreyros S.A.A.
Desarrollo Tcnico

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Modulo 3
LECCIN 3.2
SISTEMAS DE COMBUSTIBLE
ELECTRNICO HEUI
CON
CONTROL
Esta leccin permite familiarizarse con el sistema de combustible con control

electrnico HEUI instalado en las Mquinas Caterpillar
CLASE
La clase consiste en la presentacin y en la revisin del funcionamiento del

sistema de inyeccin electrnica HEUI.
LABORATORIOS
-
MATERIAL
NECESARIO
Ferreyros S.A.A.
Identificar los componentes del sistema electrnico de acuerdo a la

Hoja de Trabajo
Discutir el uso del ET utilizando la Hoja de Trabajo
_ Excavadora 330D
_ Manual de Servicio Motor C9 SENR9830
_ PC laptop con ET Instalado
_ Comm Adapter II
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Componentes del Circuito
Fig. 3.1 Sistema de Combustible HEUI (Motor C-9)
El sistema de combustible HEUI Caterpillar es un sistema de combustible

controlado electrnicamente. La bomba de inyeccin, las tuberas de
combustible y los inyectores usados en los motores mecnicos se han
reemplazado por un inyector unitario electrnico hidrulico en cada cilindro.
Los componentes electrnicos del sistema de combustible HEUI son muy
similares a los usados en el sistema de combustible EUI. Sin embargo, en el
sistema HEUI, los inyectores no se accionan mediante un rbol de levas.
Una bomba hidrulica de presin alta, que recibe aceite de la bomba de
lubricacin del motor, suministra aceite a un accionador hidrulico encada
inyector. Los inyectores reciben seales electrnicamente (lo mismo que en
los sistemas EUI) para permitir que el aceite hidrulico depresin baja mueva
el mbolo del inyector de combustible.
Los principales componentes del sistema HEUI incluyen la bomba de
activacin hidrulica, el ECM, los inyectores HEUI, el mazo de cables, los
sensores y los interruptores.
El sistema de aceite HEUI tambin incluye un sistema de suministro de aceite
a baja presin controlado mecnicamente muy similar a los sistemas EUI.
Ferreyros S.A.A.
Desarrollo Tcnico

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Modulo 3
HOJA DE TRABAJO 3.3

SISTEMA DE COMBUSTIBLE HEUI
PROCEDIMIENTO
Trace el recorrido del flujo de combustible.de baja presin y aceite de alta

presin
Cules son las tres funciones del combustible a baja presin?
Cules son las dos funciones del sistema de Actuacion de Aceite?
Ferreyros S.A.A.
Desarrollo Tcnico

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Modulo 3

PROCEDIMIENTO
Describa el funcionamiento de la bomba
NOTAS
Ferreyros S.A.A.
Desarrollo Tcnico

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Modulo 3

PROCEDIMIENTO
Ubique los componentes en el orden correcto
(1) Solenoid
(2) Armature spring
(3) Armature
(4) Seated pin
(5) Spool spring
(6) Spool valve
(7) Check ball for
intensifier piston
(8) Intensifier piston
(9) Return spring
(10) Plunger
Ferreyros S.A.A.
(11) Barrel
(12) Nozzle case
(13) Inlet fill check
(14) Stop
(15) Nozzle spring
(16) Check piston
(17) Sleeve
(18) Reverse flow check
valve
(19) Nozzle check
(20) Nozzle tip
Desarrollo Tcnico

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Modulo 3
Leccin 3.3: Sistema Electrnico de Control

Esta leccin ayuda a familiarizarse con las caractersticas principales del
sistema de control electrnico del motor, sus componentes, las funciones
controladas por el ADEM III y el manejo del ET para el diagnstico.
CLASE
Presentacin de vistas del circuito y de elementos del Sistema Electrnico de

Control del Motor, sistemas que controla el ADEM III y explicacin de sus
distintas funciones
LABORATORIO
DE CLASE
_
Identificar los componentes electrnicos de Entrada y Salida del

Motor, utilizando el Esquema Elctrico RENR9587, el Manual de
Solucin de Problemas de Motor C9 RENR 5089 y la Hoja de Trabajo
en Clase y Campo
Discutir sobre los resultados de una evaluacin del motor utilizando el

ET,
Identificar en la mquina los componentes electrnicos de Entrada y

Salida del Motor, utilizando el Manual de Solucin de Problemas de
Motor C-9 y la Hoja de Trabajo en Clase y Campo
Realizar una evaluacin del motor con el ET, utilizando el Manual de

Solucin de Problemas de Motor C-9, una laptop con ET licenciado y
la Hoja de Trabajo en Clase y Campo.
LABORATORIO
DE CAMPO
Ferreyros S.A.A.
Desarrollo Tcnico

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Modulo 3
Texto de Referencia:
SISTEMA ELECTRNICO DE CONTROL DEL MOTOR
- Esquema de los elementos de Entrada y Salida del Sistema Electrnico
Los motores C9 ACERT estn diseados para ser controlados

electrnicamente.
El sistema de Control Electrnico consiste en un Mdulo de Control
Electrnico (ECM), 6 Inyectores Unitarios Electro-Hidrulicos (HEUI), una
Vlvula de Control de Presin de Actuacin de Inyeccin (IAPCV), cables,
switches y sensores. Un solenoide en cada inyector controla la cantidad de
combustible suministrada por el inyector y la sincronizacin de la inyeccin
de combustible. La IAPCV controla la presin de actuacin de inyeccin.
El ECM monitorea cada sensor y suministra la seal a cada solenoide,
proporcionando un control completo del motor.
Ferreyros S.A.A.
Desarrollo Tcnico

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Modulo 3
El ECM del Motor se denomina ADEM A4 (Advanced Diesel Engine Management

El ECM gobierna las RPM del motor mediante el control de la cantidad de combustible suministrada
por los inyectores. Las RPM deseadas se determinan de acuerdo a la seal del sensor de posicin
del pedal des acelerador y el switch de alta en vaco, adems de la lectura de otros sensores.
Algunos cdigos de falla pueden ocasionar un de-rateo que afecta las RPM deseadas del motor.
Las RPM reales del motor son medidas por el sensor Speed/Timing (Velocidad y Calibracin) El
ECM determina cunto combustible inyectar para mantener las RPM deseadas del motor de
acuerdo a las RPM reales censadas.
El ECM controla la sincronizacin, duracin (cantidad de combustible) y la presin del combustible
inyectado mediante la variacin de seales hacia los inyectores y hacia la IAPCV. Los inyectores
inyectarn combustible solamente si el solenoide del inyector es energizado.
El ECM enva una seal de 105V a los solenoides para energizarlos. Controlando la sincronizacin y
la duracin de la seal de 105V y la presin de inyeccin, el ECM puede controlar estos parmetros
basado en las RPM del motor, la carga y otros factores
El ECM tiene lmites programados de fbrica correspondientes a la cantidad de combustible a
inyectar.
El FRC Fuel Limit es un lmite de combustible para propsitos de control de humos de escape que
se basa en la mxima relacin aire / combustible permisible. Cuando el ECM censa una mayor
seal de la Presin de Salida del Turbo (Presin de Refuerzo) que indica ms aire disponible, el
lmite de la FRC se incrementa para permitir que ingrese mayor cantidad de combustible al cilindro.
El Rated Fuel Limit es un lmite basado en el rango de potencia del motor. Proporciona las curvas
de Potencia y Torque para una familia especfica de motores y su rango.
La sincronizacin de la inyeccin depende de las RPM del motor, la carga y otros factores
operacionales. El ECM sabe dnde est el PMS de cada cilindro gracias a la seal proporcionada
por el sensor Speed/Timing. El ECM decide cundo debe ocurrir la inyeccin en relacin con el PMS
y suministra la seal al inyector en el momento deseado.
El ECM del motor almacenar como eventos las siguientes condiciones:
_
Alta Temperatura de Refrigerante (107C)
_
Baja Presin de Aceite de Motor (Segn Mapa)
_
Alta Presin de Actuacin de Inyeccin
_
Problema en el Sistema de Presin de Actuacin de Inyeccin
_
Sobre revolucin de Motor
_
Restriccin en los Filtros de Aire (30 de agua)
_
Paradas definidas por el usuario
El ECM del Motor tambin tiene las siguientes funciones:
Encendido del Motor.- El ECM suministrar automticamente la correcta cantidad de combustible y
ter para encender el motor. No acelere la mquina cuando se est encendiendo el motor. Si la
mquina no enciende en 20 segundos, suelte la llave de encendido y deje que el arrancador enfre
por 2 minutos antes de usarlo de nuevo.
Modo Fro.- El ECM limita la potencia del motor durante la operacin del modo fro, tambin
modifica el tiempo de inyeccin, este modo ofrece los siguientes beneficios: Incrementa la
capacidad de arranque en clima frio, reduce el tiempo de calentamiento, reduce el humo blanco.
El modo fro es activado cuando la temperatura baja de 18C (64F) y permanece hasta superar los
20C (68F) o hasta que el motor funcione 14 minutos
Ayuda de Arranque.- Los siguientes dispositivos son usados como ayuda de arranque en climas
fros: Calentador de aire de admisin (controlado por el ECM), inyeccin de ter (controlado por el
ECM o por el operador.
Ferreyros S.A.A.
Desarrollo Tcnico

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Modulo 3
HOJA DE TRABAJO 3.4

COMPONENTES ELECTRNICOS MOTOR HEUI
MATERIAL
NECESARIO
Excavadora 330D con motor C9 ACERT

Manual de Servicio SENR5089
INSTRUCCIONES .Coloque nmero a los componentes electrnicos y ubquelos en la

excavadora
(1) Engine coolant temperature

sensor
(2) Fuel pressure sensor
(3) J500/P500 Injection actuation
pressure control valve (internal to the
pump)
(4) Injection actuation pressure (IAP)
sensor
(5) Intake manifold (boost) pressure
sensor
(6) Intake manifold air temperature
sensor
(7) J300/P300 Injector valve cover
connector
(8) Atmospheric pressure sensor
Ferreyros S.A.A.
(9) Fuel temperature sensor

(10) Primary engine speed/timing
sensor
(11) Secondary engine speed/timing
sensor
(12) Engine oil pressure sensor
(13) J2/P2 ECM connector
(14) ECM
(15) J1/P1 ECM connector
Desarrollo Tcnico

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14

Modulo 3
13
10
12
11
Ubique el resto de componentes de motor en la mquina

Porque el ECM tiene enfriamiento por combustible?
Ferreyros S.A.A.
Desarrollo Tcnico

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Modulo 3
HOJA DE TRABAJO 3.5 Evaluacin con el ET

INSTRUCCIONES Obtenga los datos solicitados usando el ET y comprelos con las
especificaciones del manual de servicio y el TMI
Descarga de Datos del ET con el Motor Apagado

Tabla - Datos de Configuracin del ECM del Motor
Pantalla de Datos de Configuracin del ECM

Descripcin
Valor
Unidad Cambios
Identificacin del Producto
Identificacin del Equipo
Nmero de Serie del Motor
Nmero de Parte del ECM
Nmero de Serie del ECM
Nmero de Parte del software
Mdulo de Personalidad (Flash-File)
Fecha de Publicacin del Mdulo
Descripcin del Mdulo de
Personalidad
FLS (Ajuste a plena carga)
FTS (Ajuste al par mximo)
Fuel Ratio Control offset (FRC)
Control del Ventilador del Motor
Ferreyros S.A.A.
Desarrollo Tcnico

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Modulo 3
Tabla - Totales Actuales del ECM de Motor
La cantidad de
combustible total es
el mejor indicador
del desgaste del
motor
Totales Actuales
Descripcin
Valor
Unidad
Tiempo Total
Combustible Total
Revoluciones Total
Uso de ter
Tabla .- Cdigos de Diagnstico en el ET
Cdigo
Ferreyros S.A.A.
CODIGOS DE DIAGNOSTICO ACTIVOS

Descripcin
Cdigo
CODIGOS DE DIAGNOSTICO ALMACENADOS

Descripcin
Veces Primera Ultima
Cdigo
EVENTOS ALMACENADOS
Descripcin
Veces Primera Ultima
Desarrollo Tcnico

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Modulo 3
Tabla - Evaluacin del Circuito Elctrico de los Inyectores HEUI
Recuerde que debe

escuchar el sonido
de los solenoides al
actuar
Prueba de los Solenoides de los Inyectores

Inyector
Resultado
Inyector
Resultado
1
4
2
5
3
6
Tabla - Parmetros de Anulacin en el Motor (Override)
Parmetros de Anulacin
Descripcin
Valor
Unidad
Modo
Calentador de Aire de Admisin

Velocidad del Ventilador del Motor
Pre lubricacin del Motor
Inyeccin de ter
Descarga de Datos del ET con el Motor Encendido

Tabla Prueba de Presin de Actuacin de Inyeccin
Descripcin
Mximo
Mnimo
Inyectores
con Fugas
RPM del Motor

Temperatura Refrigerante Motor
Presin de Actuacin de Inyeccin
Presin Deseada de Actuacin de
Inyeccin
Corriente de Actuacin de Inyeccin
Estado de Actuacin de Inyeccin
Tabla 2.- Prueba de Corte de Cilindros Manual
Prueba de Corte de Cilindros

Recuerde que el
motor debe estar a
temperatura de
operacin (mayor a
70C).
Cilindro
Los datos los debe

apuntar en la hoja
ya que no es una
prueba automtica..
Grupo 1
Grupo 2
Grupo 3
Promedio
Diferencia(%)
1
2
4
5
6
PROMEDIO
RPM
Motor
Duracin
De inyeccin
Posicin de
combustible
Ferreyros S.A.A.
Desarrollo Tcnico

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Modulo 3
Tabla - Valores Actuales
Valores Actuales (STATUS)

Descripcin del Parmetro
Valor
Unidad
Tabla - Valores Importantes
Pruebas del Motor en la Mquina

Alta
RPM del Motor
Baja
RPM a plena carga
Presin de Boost a plena carga
RPM de Calado
Temperatura en la tina superior del radiador
Temperatura de ingreso a la bomba de agua
1500 RPM
Presin de Aceite
Vaco
Alta
Presin de Combustible
Baja
Ferreyros S.A.A.
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Modulo 3
PRUEBAS de RENDIMIENTO del motor
PRUEBA DE
CALADO
Curva de torque
Reserva
de
torque
Curva de
potencia
RPM
motor
Low Idle
Baja en
vaco
Full
Torque
(TC)
Torque
Mximo
Stall
Calado
motor en
mquina
Full
Load
Potencia
Mxima
High Idle
Alta en
vaco
Las curvas de rendimiento del motor se obtienen de pruebas hechas en

dinammetro, Torque vs RPM y se deriva Potencia vs RPM
Para evaluar el rendimiento de un motor que esta instalado en una mquina
RPM de Calado
se define la Prueba de Calado del motor.
solo se aplica en
motores instalados
Esta prueba establece unas condiciones en la mquina (como 3ra velocidad
en mquinas
en avance y freno de servicio aplicado para equipos con tren de potencia) y
debe evaluarse la RPM de Calado (stall)
Este valor de RPM es menor a la RPM de potencia mxima pero mayor a la
RPM de torque mximo:
Resultados::
Si la RPM es menor a las especificaciones del fabricante, hay un

problema en el motor
Si la RPM es mayor a las especificaciones del fabricante, hay un
problema en el tren de potencia
NOTAS:
Ferreyros S.A.A.
Desarrollo Tcnico

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Modulo 3
Las especificaciones obtenidas en las pruebas del dinammetro hechas en

fbrica las encontramos en la hoja test spec del SIS o TMI de Caterpillar
Measure: Unidades de medida
Nominal: Valor medio entre el mximo (Ceiling) y mnimo (Floor)
Todos los valores son referidos al punto de Potencia Mximo o plena carga
(FLS: Full Load Speed) excepto cuando indique lo contrario
Hoja de
Especificaciones:
Test Spec Data

Description
Measure
Nominal
Ceiling
Floor
hp
286
289
283
Full Load Speed
RPM
1800
1810
1790
Corr Full Load Power

TEST SPEC:
0K6787
High Idle Speed
RPM
1980
1990
1970
MOTOR C9
ACERT
Low Idle Speed
RPM
800
810
790
THK04537
Adjusted Boost
IN_HG
44.4
51.1
37.8
Torque Check Speed
RPM
1400
1410
1390
Corr Torque at TC RPM
LB/FT
1,000
1,070
930
ADJ Boost at TC RPM
IN_HG
48.9
56.2
41.5
192
197
186
Oil Pressure
PSI
52
87
36
Oil Pressure Low Idle
PSI
31
87
11
Fuel Pressure
PSI
80
106
53
Temp Jacket Water Pump Inlet
En la hoja de especificaciones encontramos algunos valores definidos para el

punto de Torque Mximo (TC) como la presin de refuerzo (ADJ Boost at TC),
estos valores no deben ser empleados como comparativos con la prueba de
calado ya que las condiciones son diferentes, el punto de calado esta ms
cerca al punto de Potencia mxima.
PRUEBA DE
REFUERZO
La presin de refuerzo es un parmetro que podemos usar para ubicar

exactamente el Punto de Calado del Motor en la Mquina.
Durante la prueba de calado el consumo de combustible es mximo conforme
la carga aumenta, los gases de escape hacen girar la turbina a mxima rpm,
la presin generada por la rotacin del compresor tiene all su valor ms alto,
la presin de admisin sube (p. Boost) en este punto comprobamos las RPM
de calado
Este valor de presin de refuerzo durante el calado, como referencia, es
cercano al valor obtenido para potencia mxima en el dinammetro
P. Boost Stall >=< Adjusted Boost

NOTAS:
Ferreyros S.A.A.
Desarrollo Tcnico

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Modulo 3
HOJA DE TRABAJO 3.6

PRUEBA DE RENDIMIENTO DEL MOTOR EN EXCAVADORAS
En esta prueba se llegar al punto de Potencia Mxima del Motor (FLS) y
anotar el valor de la Presin del Sistema (presin de las 2 bombas)
A diferencia de la prueba de calado (donde se verifica la RPM) aqu se
verificar si la Presin esta dentro de especificaciones.
Procedimiento
Resultados:
-
Motor en OFF
Conecte 2 manmetros para medir la presin de las bombas
Conecte un manmetro para medir la Presin PS (Power Shift)
Conecte un manmetro para medir la presin de refuerzo boost
(opcional, ver siguiente mtodo)
Desconecte el conector del solenoide de la Vlvula Reductora
Proporcional PRV (El ECM no podra reducir la carga hidrulica)
Redusca la presin de la vlvula de alivio principal (gire 3 vueltas
antihorario) al mnimo, en excavadoras con sistema de levante
pesado no debe moverse el tornillo de heavy lift
Encienda el motor, AEC en OFF, Velocidad en 10 (Dial 10)
Caliente el aceite hidrulico a 55 +/- 5 C
En el MONITOR lea la RPM del motor diesel, la presin PS es cero
Lleve el control de la pluma a mxima elevacin y mantengalo
Aumente la presin de la vlvula de alivio (gire lentamente en sentido
horario), observe las RPM y Presin de refuerzo.
Cuando las RPM disminuyen al valor a plena carga (FLS) o la presin
de refuerzo llega a su mximo valor, anote el valor de presin del
sistema (2 bombas principales)
Mueva a neutro el control de la pluma y retorne la vlvula de alivio a
su valor original
Si la Presin del sistema es menor a las especificaciones del
fabricante, hay un problema en el motor
Si la Presin del sistema es mayor a las especificaciones del
fabricante, hay un problema en el sistema hidrulico
..
MODELO
RPM a plena carga

o RPM Potencia
Mxima (FLS)
Potencia
Mxima
(HP)
Presin del
sistema
(PS = 0)
Presin de
Refuerzo
(Boost)
Flujo de las 2
bombas
312C
1950
91
2150
109
90 +/- 10 kPa
13 +/- 2 PSI
65+/- 10 kPa
9.4 +/- 2 PSI
254+/- 6 L
315C
318C
1800
125
320C
1800
138
322C
1800
162
325C
1800
187
330C
1800
247
13700 +/- 500 kPa

1990 +/- 70 PSI
14800+/- 500 kPa
2150 +/- 70 PSI
13700+/- 500 kPa
1990 +/- 70 PSI
13800+/- 500 kPa
2000 +/- 70 PSI
15000+/- 500 kPa
2170 +/- 70 PSI
16300+/- 500 kPa
2360 +/- 70 PSI
18000+/- 500 kPa
2600 +/- 70 PSI
320D
330D
1800
286
Ferreyros S.A.A.
ANOTE
300+/- 6 L
SUS
374+/- 6 L
120 +10 - 20 kPa

17.4 +/- 2 PSI
135 +10 - 20 kPa
19.6 +/- 2 PSI
410+/- 6 L
440+/- 6 L
470+/- 6 L
117 175 kPa

17 25.4 PSI
560+/- 6 L
150 +/- 22.5 kPa

21.7 +/- 2 PSI
560+/- 6 L
Desarrollo Tcnico
RESULTADOS

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Modulo 3
HOJA DE TRABAJO 3.7

PRUEBA DE REFUERZO EN EXCAVADORAS
Use un manmetro La presin de refuerzo
debe ser verificada en
el mltiple de admisin
despus del post
Enfriador.
En motores electrnicos puede ver esta presin con el ET o el Monitor, pero

un manmetro es la manera ms confiable
P. Boost a FLS
En excavadoras el valor mximo de presin de refuerzo ocurre a la RPM de

plena carga o RPM de Potencia Mxima (Full Load Speed FLS) del motor
Para todas las mquinas con Control de Potencia (Presin de Cambio de
Potencia PS Power Shift), el refuerzo pico ocurre al mismo tiempo que la
presin PS compensa reduciendo el flujo de las bombas para mantener las
RPM del motor a mxima velocidad (Dial en 10) entregando la mxima
potencia
Cargue el motor de la excavadora con el sistema hidrulico (calado: la

presin es aliviada en ambas bombas), hasta llegar a las RPM de plena carga
(FLS) y observe.
- Si el sistema hidrulico NO llega a cargar el motor a la velocidad a
plena carga, es probable que exista un problema en el sistema
hidrulico, las bombas principales deben ser investigadas
- Si el sistema hidrulico SI carga el motor pero por debajo de la
velocidad a plena carga, y adems el refuerzo pico (p. Boost mxima)
ocurre a la velocidad de plena carga, entonces hay un problema
hidrulico que causa que las bombas pidan mucha carga al motor.
- Si el sistema hidrulico SI carga el motor a velocidad a plena carga o
por debajo, pero no crea refuerzo pico (p. Boost no sube al valor de
especificaciones) a velocidad a plena carga, entonces el motor debe
ser examinado
Excavadora 330D: RPM mnima: 1720 (nueva), 1670 (reconstruida), 1620 (lmite de servicio)
CON EL ET
GRAFIQUE UN
DATA LOGGER:
- RPM
- P. Boost
- P. Bombas
- P. PS
Power Shift
- Oli Temp.
- Fuel Consu
Ferreyros S.A.A.
ANALICE:
Desarrollo Tcnico

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Modulo 3
HOJA DE TRABAJO 3.8

SENSORES VELOCIDAD TIEMPO
INSTRUCCIONES Realice la calibracin segn el procedimiento del manual SENR 5089
Sensor superior
Primario, para
RPM baja
(arranque)
Sensor inferior
Secundario, para
RPM alta
(funcionamiento)
...( 4) ............................( 5 ) ................................... ( 6 )

La ( 4) probeta de calibracin (magnetic pickup) debe instalarse en el puerto
del bloque de cilindros (2), un extremo del cable ( 5) se conecta a la probeta
El otro extreme debe conectarse al conector (6) P400 ( de dos pines) que
esta a la izquierda y sobre el ECM (3)
Ferreyros S.A.A.
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Modulo 3
Los sensores Speed/Timing Sensors usan la ranura en la rueda de

sincronizacin como referencia de tiempo.
La calibracin del tiempo proporciona inyeccin de combustible precisa
corrigiendo las ligeras tolerancias entre cigeal, engranajes de
sincronizacin, rueda y sensores de tiempo
Hacer la calibracin con el ET
Prueba de Sensor Velocidad Tiempo

SENSOR
RPM
arranque
UPPER
PRIMARIO
(CRANK)
LOWER
SECUNDARIO
(RUN)
RESISTENCIA (OHM)
LECTURA
ESPECIFICACIN
75 A 230
600 A 1800
Calibracin del Tiempo

Motor a 110 +/- 50 RPM, siga los pasos del ET
Resultado
Ferreyros S.A.A.
Desarrollo Tcnico

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Modulo 3
HOJA DE TRABAJO 3.9

GRADO DE ACEITE
INSTRUCCIONES Realice la calibracin segn el procedimiento del manual de servicio
(3) 10W30 oil

grade plug
(Green wire)
(4) 15W40 oil
grade plug (Red
wire)
(5) 0W20 oil
grade plug
(Black wire)
El motor C9 ACERT puede ser afectado por diferentes grados de viscosidad

del aceite usado.
La variacin de viscosidad por los cambios de temperatura pueden afectar el
tiempo de inyeccin, porque es actuado hidrulicamente.
Estas variaciones pueden afectar la habilidad del motor en el arranque en fro.
Cuando se cambien el grado de aceite, el operador debe asegurarse que el
plug (conector) correspondiente este insertado en el harness
La pantalla de estado del ET (ET Status Screen) debe confirmar la seleccin
actual del plug entre estas tres alternativas.
LECTURA ACTUAL: ...............................................
Ferreyros S.A.A.
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Modulo 3
TRIM CODE EN MOTORES ACERT
Identifica la
descarga y
caracterstica de
tiempo del
inyector, debe
programarse en el
ECM
(defecto 1100)
Precisa el
suministro de
combustible
En motores
ACERT el
procedimiento es
diferente, debe
bajarse un
archivo (no hay
cdigo
estampado)
Ubicar el nmero de
serie del inyector y el
Cdigo de Confirmacin
EJM 4382
En el SIS WEB
abra
Injector Trim Files
Ferreyros S.A.A.
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Modulo 3
Ingrese un dato
de bsqueda
Guarde el
archivo ms
reciente
Con el ET en
calibracin del
inyector
seleccinelo y
oprima Change
Seleccione el
archivo guardado
previamente
Ingrese el cdigo
de confirmacin
4382
Una vez cargado dara un mensaje OK, en caso de error se activar un cdigo
de falla
Ferreyros S.A.A.
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Modulo 4
MODULO 4
SISTEMA HIDRULICO
Ferreyros S.A.A.
Jorge Gorritti- Octubre 06
Desarrollo Tcnico
Manual del Estudiante 330D - Modulo 4A

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Modulo 4
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Modulo 4
MODULO 4:
SISTEMA HIDRULICO
En este mdulo se mostrar el funcionamiento de la bomba hidrulica y del
sistema hidrulico.
Se estudiar la operacin de la bomba, identificar sus componentes y los
puntos de ajuste adems de explicar los grficos de flujo, presin y sus
puntos crticos, tambin identificaremos el resto de componentes del sistema
hidrulico, seguiremos el recorrido del flujo de aceite para traslacin, giro,
implementos y sistema piloto, se realizarn las pruebas de rendimiento,
presin y flujo, se ejecutarn los procedimientos de ajustes segn el manual
de servicio.
OBJETIVOS
FIN
INICIO
Este mdulo consta de lecciones y sus laboratorios
1. Dada una hoja de trabajo, el esquema hidrulico y el manual de servicio

identificar todos los componentes de la bomba hidrulica
2. Dados el manual de servicio y el esquema hidrulico colorear los flujos de

aceite para las operaciones de la bomba
3. Dados el manual del estudiante y el esquema hidrulico, ubicar todos los

componentes del sistema hidrulico en la hoja de trabajo y en la mquina
4. Dados un esquema de sistema hidrulico y plumones de color, trazar el

flujo de aceite en una determinada posicin de movimiento.
5. Dados una hoja de trabajo, Excavadora 330D, el Manual de Pruebas y

Ajustes y herramientas apropiadas, realizar los procedimientos de las
pruebas operacionales: tiempo de ciclo y corrimiento de cilindros, pruebas
de presin: vlvulas de alivio y pruebas de flujo: rendimiento de la bomba
con el medidor de flujo, realizar los ajustes que sean requeridos
Ferreyros S.A.A.
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Modulo 4
LECCIN 4.1: INFORMACION GENERAL

Esta leccin permite familiarizarse con el sistema hidrulico general y el
sistema piloto
CLASE
LABORATORIOS
La clase consiste en la presentacin del sistema hidrulico

-
MATERIAL
NECESARIO
Ferreyros S.A.A.
Identificar componentes del sistema hidrulico y el sistema piloto de

acuerdo a la Hoja de Trabajo
Trazar los flujos principales de los sistemas de acuerdo a la Hoja de
Trabajo
_ Excavadora 330D
_ Manual de Servicio RENR 9584 y RENR9585
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Modulo 4
HOJA DE TRABAJO 4.1: SISTEMA HIDRAULICO

INSTRUCCIONES
Complete lo solicitado
La excavadora es controlada por los siguientes cuatro sistemas:
-
El sistema hidrulico principal controla los cilindros, los motores de

traslacin y el motor de giro
El sistema hidrulico piloto que suministra aceite a la bomba principal
y los circuitos de control
El sistema de control electrnico que regula el motor diesel y las
bombas
El sistema de enfriamiento proporciona aceite al motor del ventilador
( .) Drive pump
() Idler pump
() Proportional
reducing valve
(power shift
pressure)
() Delivery line
(idler pump)
() Delivery line
(drive pump)
(...) Main relief

valve
(...) Right control
valve body
(...) Left control
valve body
Ubique los componentes en su esquema hidrulico
Ferreyros S.A.A.
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Modulo 4
INSTRUCCIONES
Trace el recorrido del flujo de los sistemas principales (use un color distinto)
Nombre
Sistema
Nombre
Sistema
#
#
Acumulador aceite piloto
Vlvula bypass enfriador
Cilindro de pluma
Vlvula reduccin caida y
alivio lnea pluma
Cilindro de cucharn
Vlvula reduccin caida y
alivio lnea brazo
Cilindro de brazo
Vlvula control principal
Filtro de drenaje
Vlvula joystick izquierdo
Filtro de retorno
Vlvula joystick derecho
Filtro piloto
Vlvula piloto traslacin
Mltiple de control piloto
Vlvula prioridad
Motor del ventilador
Multiple de lanzaderas
Motor de giro
Vlvula lanzadera
Motor de traslacin
Vlvula solenoide levante
pesado
Bomba de pistones del
Vlvula giro fino
ventilador
Bomba de pistones principal
Vlvula de contrabalanceo
Unin giratoria
Ferreyros S.A.A.
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Modulo 4

INSTRUCCIONES
Trace el recorrido del flujo de los sistemas principales (use un color distinto)
Desde las bombas principales a los bancos derecho e izquierdo de la vlvula
de control principal y de all a los accionadotes
Ponga nombre a los carretes principales
Ferreyros S.A.A.
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Modulo 4
HOJA DE TRABAJO 4.2 CONTROL ELECTRNICO

INSTRUCCIONES:
Explique las funciones del sistema
El ECM tiene 3 leds:

(izquierda a derecha)
VERDE-AMARILLO-ROJO
Funcin:
- Verde ON: todo
correcto
- -Amarillo ON:
problema con Data
Link
- Rojo ON: falla del
ECM
(1) Machine ECM
(4) Clench pressure sensor
(attachment)
(7) Swing pressure switch
(10) Straight travel pressure switch
(13) Fuse panel
(16) Engine
(19) Battery
(22) Monitor
(25) Travel speed solenoid valve
(28) Flow limiter valve (attachment
pump)
(31) Attachment pedal pressure switch
(Right)
(2) Engine speed dial

(5) Manual low idle switch
(3) Switch panel

(6) Implement pressure switch
(8) Right travel pressure switch

(11) Right pump pressure sensor
(14) viscous clutch
(17) Main pumps
(20) Engine start switch
(23) Heavy lift solenoid valve
(26) Swing brake solenoid valve
(29) Pressure switch (attachment
pump)
(32) Proportional reducing valve for
auxiliary hydraulics
(9) Left travel pressure switch

(12) Left pump pressure sensor
(15) Fan speed sensor
(18) Engine speed pickup
(21) Backup switch
(24) Straight travel solenoid valve
(27) Hydraulic lockout solenoid
(30) Attachment pedal pressure switch
(Left)
(33) Power shift solenoid valve
Consiste del ECM y del MONITOR

Sistema de Control Funciones:
- Controla el flujo de descarga de las bombas:
Electrnico
Ferreyros S.A.A.
Controla la velocidad del motor
Controla algunos componentes electrnicos del sistema hidrulico
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Modulo 4
HOJA DE TRABAJO 4.3 SISTEMA PILOTO
Funciones:
La presin es limitada por la vlvula de alivio piloto, el aceite realiza las

siguientes funciones:
- 1.Crea presin piloto para controlar el flujo de salida de las bombas
- 2.Crea presin piloto de control para implementos, giro y traslacin
- 3.Crea presin piloto para controlar automticamente los dispositivos

(46) Valve (hydraulic lockout)

(54) hydraulic lockout valve
Instrucciones
Ubique los puertos

en el esquema
hidrulico principal
y en la mquina
Ferreyros S.A.A.
Pilot line
Control Valve
Machine Operation
(76)
Boom I control valve
BOOM LOWER
(77)
Bucket control valve
BUCKET CLOSE
(78)
Swing control valve
SWING LEFT
(79)
Boom II control valve
BOOM RAISE
(80)
Stick II control valve
STICK IN
(81)
Right travel control valve
REVERSE RIGHT TRAVEL
(82)
Left travel control valve
REVERSE LEFT TRAVEL
(83)
Stick I control valve
STICK IN
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HOJA DE TRABAJO 4.4 CIRCUITO DEL SISTEMA PILOTO

Circuitos:
1. Control de Cambio de Potencia (Power Shift Pressure System)
Funcionamiento:
(49) Drive pump

(63) Proportional reducing valve (PS
pressure)
(68) Machine ECM
(72) Idler pump pressure sensor
Ferreyros S.A.A.
(58) Idler pump

(59) Pilot pump
(69) Monitor
(71) Drive pump pressure sensor
(73) Engine speed pickup (flywheel
housing)
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Modulo 4
2.Circuito de vlvula de control piloto
Siga el recorrido del

flujo en su esquema
3.Circuito de interruptores activados por presin
y anote el
funcionamiento
4.Circuito de la vlvula de marcha recta
5.Freno de parqueo de giro
6.Prioridad pluma
7.Prioridad giro
8.Cambio automtico de velocidad de traslacin
( ) Bomba
piloto de
engranajes
5
4
( ) Filtro piloto
( ) SOS
( ) Toma de
presin piloto
( ) Vlvula de
alivio piloto
( ) Acumulador
(...) Mltiple
piloto
Ferreyros S.A.A.
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Modulo 4
HOJA DE TRABAJO 4.4 CIRCUITOS DEL SISTEMA PILOTO

Instrucciones:
Siga el recorrido del flujo de las vlvulas
DESBLOQUEADO
BLOQUEADO
VLVULA DE
CONTROL PILOTO
(JOYSTICK)
Ferreyros S.A.A.
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Modulo 4

Instrucciones:
Siga el recorrido del flujo de las vlvulas

Vlvula Reductora de Presin (PRV)
( ) Solenoid
3
( ) Valve body
( ) Line (pilot
oil flow)
1
2
AUMENTO DE
SEAL.
Ms corriente.
Ms presin PS
(1) Solenoid
(2) Spring
(3) Valve body
(4) Spool
(5) Passage (return
oil flow)
(6) Passage (power
shift pressure to
pump regulators)
(7) Spool chamber
(8) Passage (pilot
oil flow)
REDUCCIN DE
SEAL.
Menos corriente.
Menos presin PS
Ferreyros S.A.A.
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Modulo 4

Instrucciones:
Ubique las vlvulas en el esquema y en la mquina
Ferreyros S.A.A.
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Modulo 4
LECCIN 4.2: BOMBA HIDRULICA PRINCIPAL

Esta leccin permite familiarizarse con la bomba hidrulica principal
CLASE
LABORATORIOS
MATERIAL
NECESARIO
Ferreyros S.A.A.

-
Identificar los componentes de la bomba principal y su funcionamiento

Trazar los flujos principales para las diferentes posiciones de trabajo
Usando la curva P-Q explicar las regulaciones en la hoja de trabajo
_ Excavadora 330D
_ Manual de Servicio RENR 9584
Desarrollo Tcnico
Manual del Estudiante 330D - Modulo 4B

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Modulo 4
LECCION 4.2.1: BOMBA HIDRAULICA PRINCIPAL

La serie D de excavadoras Caterpillar usa un nueva diseo Kawasaki de
grupo de bomba hidrulica principal formada por 2 bombas gemelas de 74
gpm (280L/min) cada una.
Continua usando un control NFC y es similar a la bomba usada en la 345C
(1) regulador
bomba derecha
(8) regulador
bomba izquierda
(6) tornillo de
ajuste de mnimo
ngulo del plato
oscilante bomba
izquierda
La bomba derecha (4) vista desde el motor, esta conectada a la volvante por
un acople flexible, la bomba izquierda (5) es conducida por la bomba derecha,
cada bomba tiene su propio regulador (usado para controlar el flujo), toma de
presin y sensor de presin
La vlvula reductora proporcional PRV (2) esta montada al centro, esta toma
la presin piloto y genera la presin de Cambio de Potencia (power shift)
hacia los reguladores como seal de control; tiene una toma de presin (7)
(1) tornillo de
ajuste NFC
bomba derecha
(2) tornillo de
control de
potencia
bomba derecha
Los reguladores tienen 4 ajustes externos:

- Ajuste de mximo ngulo
- Ajuste de mnimo ngul
- Ajuste de potencia (horsepower control)
- Ajuste NFC (negative flow control)
Ferreyros S.A.A.
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Modulo 4
HOJA DE TRABAJO 4.4 BOMBA PRINCIPAL

Procedimiento
Identifique los componentes en la tabla
Nombre
Seal de flujo negativo NFC
bomba derecha (negative flow
control pressure for drive pump)
Puerto de salida bomba piloto
(Outlet port pilot pressure)
Bomba izquierda (Idler pump)
Puerto de salida bomba
izquierda (Outlet port idler
pump)
Puerto de admission (Inlet port
supply oil from the hydraulic
tank)
Ferreyros S.A.A.
Nombre
Vlvula reductora proporcional PRV

(Proportional reducing valve -power
shift pressure)
Seal de flujo negativo NFC bomba
izquierda (negative flow control
pressure for idler pump)
Bomba derecha (Drive pump)
Puerto de salida bomba derecha
(Outlet port drive pump)
Carcasa (Housing)
Nombre
Bomba piloto (Pilot pump)
Puerto de salida presin de

cambio de potencia PS(Port
power shift pressure)
Puerto de drenaje (Case
drain port)
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Modulo 4
HOJA DE TRABAJO 4.4: BOMBA PRINCIPAL

(CONTINUACIN)
INSTRUCCIONES:
Nombre
(3) Idler pump

(8) Drive pump
(11) Pilot pump
(16) Gear
(17) Drive shaft
Identifique los componentes en la tabla
Nombre
(18) Drive shaft

(19) Gear
(20) Swashplate
(21) Plate
(22) Retainer
Nombre
(23) Piston slipper

(24) Piston
(25) Barrel
(26) Port plate
(27) Passage
La potencia entra por el eje a la bomba delantera

Ambas bombas estn conectadas al bloque y son idnticas, la bomba
derecha es accionada por el motor, el engranaje permite girar la bomba
izquierda, la bomba piloto esta en el mismo eje de la bomba conducida
El ngulo de la placa de desgaste o plato oscilante determina la carrera de los
pistones, el flujo lo determinan los reguladores
Ferreyros S.A.A.
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Modulo 4
LECCION 4.2.2: PRINCIPIO DE OPERACIN DE LA BOMBA

Cada regulador de una (1) bomba recibe 4 seales de presin diferentes para
controlar el flujo de salida:
-
Presin de cambio de potencia (power shift presure PS)

Presin del sistema (de esa bomba)
Censado cruzado de presin de la otra bomba (Cross sensing
pressure)
Presin de control de flujo negativo (negative flow control pressure
NFC)
Principio de Funcionamiento:
Asumiendo que el control del ngulo del plato es por medio de un piston
hidrulico, el resorte en el extremo de cabeza del pistn mueve el ngulo del
plato a mximo flujo, cuando llega presin a la cmara del extremo del
vstago el resorte se comprime y reduce el ngulo del plato a mnimo flujo
El pistn tiene 2 topes mecnicos, los tornillos de mximo y mnimo caudal
La tensin del resorte se puede regular por medio de 1 tornillo denominado
control de potencia, en algunas excavadoras hay 2 resortes y cada uno
tiene su propio tornillo, el resorte ms grande es para bajas presiones y el
ms pequeo para altas presiones con sus tornillos respectivos
La seal NFC puede tener un tornillo o lainas para regularse, estas variarn la
velocidad de respuesta de la bomba ante el movimiento de los carretes del
banco principal
Para reducir el flujo de la bomba, cualquiera de las 4 seales antes
mencionadas puede hacerlo, la presin de alguna de ellas entra en la camara
del vstago
Este principio es el mismo para todas las excavadoras, lo que varia es el
diseo de los componentes y mecanismos del regulador de la bomba
Ferreyros S.A.A.
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Modulo 4
LECCION 4.2.3: OPERACIN DE LA BOMBA

Identifique los componentes del sistema de regulacin de la bomba
1. Presin de cambio de potencia (power shift presure PS)

Ms corriente = >
Ms PS = >
La vlvula reductora proporcional PRV recibe una seal de control del ECM
para regular la presin de cambio de potencia (power shift presure PS) en
relacin con la velocidad RPM del motor.
Menos flujo =>

Menos
requerimiento de
HP hidrulica
La seal PS a los reguladores permite a la mquina mantener la RPM

deseada del motor para mxima productividad.
Si la RPM del motor es menor (baja) que la velocidad deseada debido a una
alta carga hidrulica de las bombas, el ECM aumenta la presin PS (la lectura
del sensor de RPM es tomada 2.5 segundos luego de salir los joystick de
neutro), la PS reduce el ngulo del plato de la bomba, esto disminuye el flujo
de las bombas reduciendo la carga hidrulica al motor, en consecuencia el
motor mantiene la RPM deseada
Si solo se requiere flujo de una bomba, la PS ser reducida permitiendo a
esta bomba tomar la mayor potencia del motor, si se requiere flujo de ambas
bombas, la PS se incrementar para que ambas bombas reciban una carga
equivalente
HP (Potencia Hidrulica) = Presin (P) x Caudal (Q)
Ferreyros S.A.A.
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2. Censado Cruzado de Presin (Cross sensing control)

Control de
Potencia
Constante
Ambos reguladores tienen este control, para mantener la potencia del motor
hacia las bombas en un ratio constante, los reguladores reciben la presin
de la bomba conductora y conducida, esto es llamado Control de Potencia
Constante
3. Presin de Control de Flujo Negativo (NFC)
Mayor NFC =>

Menos flujo
Es la primer seal de control para el flujo de la bomba, es generada en la

vlvula de control principal, con los joystick en neutral, el flujo pasa por los
carretes de centro abierto y retorna al tanque por el orificio de control NFC,
esta restriccin causa una seal de presin llamada NFC
Cuando un regulador recibe una alta presin NFC mantiene la bomba en
espera (standby) cerca al desplazamiento mnimo de la bomba
Al mover un control fuera de neutro, el pasaje de centro abierto es cerrado
proporcionalmente al movimiento del carrete, esto reduce la seal NFC hacia
el regulador que incrementa proporcionalmente el flujo.
Si el carrete se mueve al tope, cerrando el pasaje de la NFC, esta presin es
igual a la del circuito de retorno a tanque (definida por la vlvula check de
retorno)
Dentro del regulador, la alta seal NFC es mayor a la seal de Control de
Potencia Constante y reduce el flujo al mnimo
Curva con
POTENCIA
CONSTANTE
Curva caracterstica de una bomba:

El cambio de flujo de una bomba es representado por la curva caracterstica
(B) P-Q (presin vs caudal) desde el punto (A) donde el ngulo del plato de la
bomba empieza a disminuir.
Cada punto de esta curva representa el flujo y la presin cuando la potencia
es mantenida constante
HP (Potencia Hidrulica) = Presin (P) x Caudal (Q) = cte
Ferreyros S.A.A.
Desarrollo Tcnico

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Modulo 4
HOJA DE TRABAJO 4.5: CONTROLES DE LA BOMBA

NOTAS:
NOTAS
NOTAS
1
2
3
4
5
6
7
8
Ferreyros S.A.A.
Carrete NFC
Carrete de
Control de
Potencia
Palanca de NFC
Palanca de
respuesta
(feedback)
Servo pistn
Pistn de control
de torque
Varilla de control
de torque
Palanca de
control de torque
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Modulo 4
HOJA DE TRABAJO 4.5: CONTROLES DE LA BOMBA

INSTRUCCIONES
(1) Spool
(2) Shoulder
(3) Piston
(4) Passage
(5) Plate
(6) Feedback lever
(7) Spring
Ferreyros S.A.A.
Identifique los componentes en el diagrama
(8) Spring
(10) Passage (power shift
pressure)
(PS) Power shift pressure
(CF) Cross sensing control
pressure
(PD) Delivery pressure (drive
pump)
(11) Chamber
(12) Piston
(13) Swashplate
(14) Chamber
(15) Rod
(16) Regulator
(17) Negative flow control line
(18) Rod
(13) Swashplate
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Modulo 4
LECCION 4.2.4: ETAPAS DE OPERACION

INSTRUCCIONES:
Trace el recorrido del flujo y explique el funcionamiento
STAND BY
La figura superior muestra la porcin NFC del regulador.

Con los controles en neutro, alta seal NFC llega a la izquierda del carrete
NFC empujandolo contra la fuerza del resorte, el tornillo de ajuste cambia el
efecto de la presin NFC en el carrete, aumentando el seteo (giro horario)
requiere ms presin NFC antes de mover el carrete, esta condicin causa un
rpido aumento del ngulo (upstroke) con menos modulacin cuando se
activa una vlvula de control.
Disminuyendo el seteo (girar tornillo antihorario) hace que se necesite menos
presin NFC para mover el carrete, esta condicin hace que el aumento del
ngulo del plato de la bomba (upstroke) sea ms lento con ms modulacin
al activar una funcin hidrulica
En esta condicin, el carrete de control de potencia (horsepower control
spool) dirige una seal de presin hacia el extremo de mnimo ngulo del
servo pistn, esto lo mueve hacia la derecha contra el tope de mnimo ngulo.
Ferreyros S.A.A.
Desarrollo Tcnico

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Modulo 4
ETAPAS DE OPERACIN : UP STROKE

INSTRUCCIONES:
UPSTROKE
AUMENTO DE
FLUJO
Incremento de flujo causado por disminucin de la presin NFC.

El resorte mueve el carrete NFC a la izquierda, esto mueve tambin el pin de
la palanca (feedback lever) y el carrete de control de potencia hacia la
izquierda.
La camara de mnimo angulo del servo pistn es abierta a drenaje a travs
del orificio a la derecha del carrete de control de potencia, la presin del
sistema entra al extremo de mximo ngulo del servo pistn moviendolo a la
izquierda aumentando el ngulo de la bomba.
Al moverse el servo pistn tambin lo hace la palanca y jala a la derecha el
carrete de control de potencia hasta encuentre un punto de equilibrio con el
orificio de drenaje, la salida de flujo desde el extremo de mnimo ngulo del
servo pistn es ahora dosificada por el carrete de control y el manguito de
control (sleeve)
Si la NFC cae al mnimo, aumenta el ngulo del plato hasta el servo pistn
toque el tornillo de mximo ngulo
Ferreyros S.A.A.
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Modulo 4
ETAPAS DE OPERACIN: DE STROKE

INSTRUCCIONES:
DISMINUCIN DEL
FLUJO
INICIO DE DESANGULAMIENTO
(BEGINNING OF
DESTROKE)
La figura superior muestra el carrete de control de potencia (horsepower

control spool) y el pistn de control de torque (no mostrado en figuras
anteriores), en la posicin de aumento de flujo pero al inicio del
desangulamiento, se asume que la presin PS es constante
Hay dos tornillos de ajuste de potencia:
- El tornillo grande ajusta el punto inicial de desangulamiento (starts
destroke)
- El tornillo pequeo regula el ratio o velocidad con que la bomba
desangula
Ferreyros S.A.A.
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Disminucin del flujo de la bomba causado por un incremento en la carga hidrulica

- La presin PS desde la PRV entra a la izquierda del pistn de control de torque
- La presin de esta bomba entra al resalte de la derecha del pistn de control de torque
- La presin de la otra bomba entra al resalte de la izquierda del pistn de control de torque
(cross sensing signal pressure)
- La combinacin de estas 3 seales mueve el piston de control de torque a la derecha contra
la fuerza del resorte de Control de Potencia
- El carrete de control de potencia dirige una seal hacia el extremo de mnimo ngulo en el
servo pistn para iniciar el des-angulamiento de la bomba
DISMINUCIN DEL
FLUJO
FINAL DEL DESANGULAMIENTO
(END OF
DESTROKE)
Cuando el servo pistn se mueve a la derecha, la palanca (feedback) mueve

el carrete de control de potencia hacia la izquierda, as la presin del sistema
es dosificada a travs de dos orificios hacia y desde el extremo de mnimo
ngulo del servo pistn, el flujo de la bomba es mantenido constante hasta
que una de las seales de presin cambie.
Un incremento en la presin PS actua de la misma manera que el incremento
en la presin del sistema descrito
Ferreyros S.A.A.
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Modulo 4
HOJA DE TRABAJO 4.6

INSTRUCCIONES:
REGULACIN DE LA BOMBA
Anote la interpretacin y las correcciones que hara
P-Q Curve for
Right Pum p Excavator
60
Flow (GPM)
50
High
Low
40
30
Test
20
10
0
800
1250
1425
2300
2850
3700
4250
Pressure (psi)
P-Q Curve for
60
Flow (GPM)
50
High
Low
40
30
Test
20
10
0
800
1250
1425
2300 2850
3700 4250
Pressure (psi)
P-Q Curve for
60
Flow (GPM)
50
High
Low
40
30
Test
20
10
0
800
1250
1425
2300 2850
3700 4250
Pressure (psi)
Ferreyros S.A.A.
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Modulo 4
LECCIN 4.3: SISTEMA DE IMPLEMENTOS

Esta leccin permite familiarizarse con el sistema hidrulico de implementos
CLASE
LABORATORIOS

-
MATERIAL
NECESARIO
Ferreyros S.A.A.
Identificar los componentes del sistema y su funcionamiento en las

hojas de trabajo
Trazar los flujos principales para las diferentes posiciones de trabajo
_ Excavadora 330D
_ Manual de Servicio RENR 9584, RENR 9585
_ Manual de Estudiante y copias de circuitos para trazar
Desarrollo Tcnico
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HOJA DE TRABAJO 4.6:

VALVULA DE CONTROL PRINCIPAL
INSTRUCCIONES:
Ferreyros S.A.A.
Complete los nmeros y ubique las componentes en la mquina
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Modulo 4

INSTRUCCIONES:
Complete los nmeros
Lnea de seal NFC

banco derecho
Vlvula del accesorio
Vlvula de control de
brazo 2
Vlvula de control oruga

derecha
Vlvula de control pluma

1
Vlvula de control del
cucharn
oruga izquierda
Lnea de drenaje vlvula de

alivio NFC banco derecho
Vlvula de alivio NFC lado
derecho
Vlvula de control de la
Pluma 2
giro
Lnea de seal
regeneracin de brazo
Vlvula de control del
Brazo 1
Vlvula auxiliar para control

de herramientas
Vlvula de control del Brazo
I
Vlvula de alivio principal
Vlvula de alivio de lnea

pluma extremo de vstago
(boom cylinder rod end)
cucharn extremo de
cabeza (bucket cylinder
head end)
Vlvula solenoide de
marcha recta
Vlvula de marcha recta
brazo extremo de cabeza
(stick cylinder head end)
circuito auxiliar
Lnea de seal NFC banco
izquierdo
Vlvula de alivio NFC lado
izquierdo
La vlvula principal esta al centro de la estructura superior entre las bombas y

los actuadores (cilindros y motores), esta controla su funcionamiento
dependiendo de la operacin de la excavadora
Recibe seal de aceite piloto desde la cabina para mover el carrete de control
adecuado.
PUERTOS DE LA VALVULA DE CONTROL
(AR1) Right travel control valve (REVERSE TRAVEL)
(AR3) Bucket control valve (BUCKET CLOSE)
(AR5) Stick II control valve (STICK IN)
(BR2) Attachment control valve (port)
(BR4) Boom I control valve (BOOM RAISE)
(AL1) Left travel control (REVERSE TRAVEL)
(AL3) Stick I control valve (STICK IN)
(BL1) Left travel control valve (FORWARD TRAVEL)
(BL3) Stick I control valve (STICK OUT)
(aR2) Pilot port at attachment control valve
(aR4) Pilot port at boom I control valve (BOOM LOWER)
(aL1) Pilot port at left travel control valve (REVERSE
TRAVEL)
(aL3) Pilot port at stick I control valve (STICK IN)
(bR1) Pilot port at right travel control valve (FORWARD
TRAVEL)
(bR3) Pilot port at bucket control valve (BUCKET OPEN)
(bR5) Pilot port at stick II control valve (STICK OUT)
(bL2) Pilot port at swing control valve (SWING RIGHT)
(bL4) Pilot port at boom II control valve (STICK IN)
(HL) Negative flow signal pressure port (left pump)
(Pi1) Pilot port (boom regeneration valve)
(Pi3) Pilot port (variable swing priority valve)
(R2) Return port
Ferreyros S.A.A.
(AR2) Attachment control valve (port)

(AR4) Boom I control valve (BOOM LOWER)
(BR1) Right travel control valve (FORWARD TRAVEL)
(BR3) Bucket control valve (BUCKET OPEN)
(BR5) Stick II control valve (STICK OUT)
(AL2) Swing control valve (SWING LEFT)
(AL4) Boom II control valve (BOOM RAISE)
(BL2) Swing control valve (SWING RIGHT)
(aR1) Pilot port at right travel control valve (REVERSE
TRAVEL)
(aR3) Pilot port at bucket control valve (BUCKET CLOSE)
(aR5) Pilot port at stick II control valve (STICK IN)
(aL2) Pilot port at swing control valve (SWING LEFT)
(aL4) Pilot port at boom II control valve (BOOM RAISE)
(bR2) Pilot port at attachment control valve
(bR4) Pilot port at boom I control valve (BOOM RAISE)
(bL1) Pilot port at left travel control valve (FORWARD
TRAVEL)
(bL3) Pilot port at stick I control valve (STICK OUT)
(DST) Drain port (straight travel control valve)
(HR) Negative flow signal pressure port (right pump)
(Pi2) Pilot port (stick regeneration valve)
(Pi4) Pilot port (straight travel solenoid valve)
(R3) Return port
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Modulo 4

INSTRUCCIONES:
Ferreyros S.A.A.
Ubique los componentes en la mquina
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Modulo 4

CIRCUITO DE LA EXCAVADORA
INSTRUCCIONES:
Trace el recorrido del flujo

CONTROLES EN NEUTRAL
VALVULA DE CONTROL DEL CUCHARON ACTIVADA
Ferreyros S.A.A.
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Modulo 4
Ubique las lneas y conexiones
SWIVEL
Unin giratoria
(1) Retainer
(2) Cover
(3) Drain port
(4) Drain hole
(5) Port
(6) Seal
(7) Port
(8) Port
(9) Housing
(10) Port
(11) Port
(12) Flange
(13) Seal
(14) Rotor
(15) Port
(16) Port
(17) Port
(18) Port
(19) Port
(20) Port
(21) Swivel
Es una conexin giratoria de lneas hidrulicas entre el bastidor superior e
inferior de la excavadora
Identification Of Port And Circuit
Ferreyros S.A.A.
Ports (Housing)
Ports (Rotor)
Circuit
17
Right travel (reverse)
10
20
Right travel (forward)
19
Left travel (forward)
16
Left travel (reverse)
18
Drain
11
15
Change of Travel speed
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Modulo 4
HOJA DE TRABAJO 4.8

PRUEBAS DE VELOCIDAD DEL MOTOR
Procedimiento
Realice las pruebas solicitadas siguiendo el procedimiento del manual de

servicio RENR9585
SIEMPRE REFIERASE AL SIS WEB O CONSULTE A SU COMUNICADOR
TECNICO POR LA LTIMA ACTUALIZACIN DISPONIBLE
NOTA
CALIENTE EL ACEITE HIDRULICO

55 +/- 5 C (131 +/- 9 F)
Item
Especificaciones
Nuevo
Alta en vaco (1)
Reconstruido
Lectura
Lmite de
servicio
1880 +/- 50 RPM (2)
1680 a 1930(1)
1980 +/- 50 RPM (3)
1780 a 2030(3)
Baja en vaco
800 +/- 50 RPM
800 +/- 100
Baja en vaco de un
toque
1100 +/- 50 RPM
1100 +/- 100
Mxima velocidad
con carga (4)
Velocidad reducida
AEC sin carga (6)
1720 RPM (5)
1670 RPM (5)
1300 +/- 50 RPM
1620 (5)
1300 +/- 100
(1) AEC en OFF

(2) 3 segundos despus de poner la velocidad en 10
(3) RPM del motor entre los 3 segundos despus de poner la
velocidad del motor en 10
(4) Presin es aliviada de ambas bombas (CALADO)
(5) Mnima RPM
(6) AEC en ON
Ferreyros S.A.A.
Desarrollo Tcnico
Manual del Estudiante 330D - Modulo 4D

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Modulo 4
HOJA DE TRABAJO 4.9 PRUEBAS DE TRANSITO

Procedimiento

servicio RENR 9585
Temperatura
A: Distancia
preliminar
5 m.
55 +/- 5 C
131 +/- 9 F
B: Distancia de
medicin 20 m.
C: Altura del
cucharn al piso
0.5 a 1 m
La distancia recorrida debe ser como mnimo 25 metros, trace una lnea en el
piso y arranque el motor
Coloque la velocidad del motor en 10, AEC en OFF
Cucharn vaco, posicione las orugas paralelo a la lnea, interruptor de
velocidad en HIGH
Opere ambos pedales, empiece a medir el tiempo luego de 5m y mida la
desviacin
Tiempo de Traslacin (20 ltimos metros)

Velocidad de traslacin
HIGH
LOW
Fordward
Reverse
Fordward
Reverse
Nuevo
15.2 segundos
o menos
24 segundos o
menos
Reconstruido
16.2 segundos o
menos
25.5 segundos o
menos
Lmite de
servicio
17.2 segundos o
menos
27 segundos o
menos
Lectura
Distancia de desviacin (de la lnea recta al final)

Velocidad de traslacin
HIGH
LOW
Fordward
Reverse
Fordward
Reverse
Nuevo
Reconstruido
Lmite de
servicio
800 mm (31.5 ) 1200 mm (47.2 ) 1500 mm (59.1)
o menos
o menos
o menos
800 mm (31.5 ) 1200 mm (47.2 ) 1500 mm (59.1)
o menos
o menos
o menos
Cada en
Pendiente
Lectura
Coloque la mquina en una

pendiente de 12, cucharn
vaco e implementos segn
la figura
Mida la cada luego de 3
minutos
Especificacin de caida: 0 mm
Ferreyros S.A.A.
Lectura:
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Modulo 4
HOJA DE TRABAJO 4.10

PRUEBAS DE GIRO Y SOBRE GIRO
Procedimiento

servicio RENR9585
Temperatura
55 +/- 5 C
131 +/- 9 F
A: Bastidor superior
B: Bastidor inferior
C: Marca
Coloque una marca
Mquina nivelada, Cucharn vaco

Mueva el joystick completamente en una direccin y detngase en neutro a
los 180, Mida la distancia de las marcas y el tiempo
Distancia de sobre
giro
Lectura:
Derecha
Izquierda
Sobregiro (Overswing)
Item
Giro a la
derecha
Giro a la
izquierda
Tiempo de giro
180
Lectura:
Derecha:
Izquierda:
Reconstruido
Limite de
Servicio
1300 mm (51.2
pulgadas) o menos
1400 mm (55.1
pulgadas) o menos
1600 mm (63
pulgadas) o
menos
Tiempo de giro (Swing Time)

Item
Giro a la
derecha
Giro a la
izquierda
Ferreyros S.A.A.
Nuevo
Nuevo
Reconstruido
Limite de
Servicio
4.9 segundos
o menos
5.4 segundos o
menos
6.0 segundos
o menos
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Modulo 4

PRUEBAS DE CORRIMIENTO DE LOS CILINDROS
Procedimiento

servicio RENR9585
Temperatura:
Mquina nivelada, extienda los implementos, eleve la pluma hasta que el pin
que sostiene al brazo esta a la misma altura del pin soporte de la pluma.
Extienda el cilindro de la cuchara y retraiga el del brazo, extienda el cilindro
del brazo 70 mm (2.8 pulgadas), mida las distancias entre los pines de los
cilindros, espere unos minutos y mida, anote la diferencia
Cucharn vaco, 5 minutos
Cylinder Drift (Empty Bucket)
Lecturas:
Item
Boom Cylinder
Stick Cylinder
Bucket
Cylinder
New
Rebuild
Service Limit
6.0 mm (0.24 inch) or

less
12.0 mm (0.47 inch) or

less
24.0 mm (0.94 inch) or

less
10.0 mm (0.39 inch)

or less
15.0 mm (0.59 inch) or

less
25.0 mm (0.98 inch) or

less
10.0 mm (0.39 inch)

or less
15.0 mm (0.59 inch) or

less
25.0 mm (0.98 inch) or

less
Cucharn lleno, 3 minutos

330D (2520kg 5555lb) 330DL (2700kg 5950 lb)
Cylinder Drift (Loaded Bucket)
Item
Boom
Cylinder
Stick
Cylinder
Bucket
Cylinder
Ferreyros S.A.A.
New
Rebuild
Service Limit
6.0 mm (0.24
inch) or less
12.0 mm (0.47
inch) or less
24.0 mm (0.94
inch) or less
12.0 mm (0.47
inch) or less
18.0 mm (0.71
inch) or less
30.0 mm (1.18
inch) or less
18.0 mm (0.71
inch) or less
15.0 mm (0.59
inch) or less
25.0 mm (0.98
inch) or less
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PRUEBAS DE VELOCIDAD DE LOS CILINDROS
servicio RENR9585
Procedimiento
Velocidad de
cilindros de la pluma
(A) Extensin
(B) Retraccin
Mquina horizontal,
cucharn vaco, retraiga
cilindros del brazo y
cucharn, coloque cucharn
en el suelo y mida el tiempo
Velocidad de
cilindros del brazo
(A) Extensin
(B) Retraccin
Mquina horizontal, cucharn
vaco, posicione la superficie
superior del cucharn paralela
al suelo, mida el tiempo
Velocidad de
cilindros del
cucharn
(A) Extensin
(B) Retraccin
Mquina horizontal, cucharn
vaco, posicione la superficie
superior de la pluma paralela
al suelo y el brazo
perpendicular, mida el tiempo
VELOCIDAD DE OPERACIN DE LOS CILINDROS

Item
Pluma
Brazo
Cucharn
Nuevo
Recostruido,
valor mximo
Limite
mximo de
servicio
Extensin
3.4 +/- 0.5 seg
4.0 seg
4.5 seg
Retraccin
2.6 +/- 0.5 seg
3.3 seg
3.8 seg
Extensin
3.4 +/- 0.5 seg
4.0 seg
4.5 seg
Retraccin
2.8 +/- 0.5 seg
3.5 seg
4.0 seg
Extensin
4.4 +/- 0.5 seg
5.0 seg
5.5 seg
Retraccin
2.5 +/- 0.5 seg
3.2 seg
3.7 seg
Ferreyros S.A.A.
Lectura
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HOJA DE TRABAJO 4.13 PRUEBAS DE PRESION

Procedimiento

servicio RENR9585
UBICACIN DE LAS VALVULAS DE ALIVIO

ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Ferreyros S.A.A.
CHECK
VALVULA
(A) Main relief valve
(B) Boom cylinder line (head end)
(C) Boom cylinder line (rod end)
(D) Stick cylinder line (head end)
(E) Stick cylinder line (rod end)
(F) Bucket cylinder line (head end)
(G) Bucket cylinder line (rod end)
(H) Swing (right)
(I) Swing (left)
(J) Left travel crossover relief valve for forward travel
(upper valve)
(K) Left travel crossover relief valve for reverse travel
(lower valve)
(L) Right travel crossover relief valve for forward travel
(upper valve)
(M) Right travel crossover relief valve for reverse travel
(lower valve)
(N) Pilot relief valve
(O) Main control valve
(P) Pilot filter
(Q) Travel motor (right)
(R) Travel motor (left)
(S) Swing motor
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(continuacin)
Procedimiento

servicio RENR9585
Caliente el aceite a la temperatura de operacin: 55 +/- 5 C (131 +/- 9 F)
Para ajustar las presiones se requiere la normal operacin del motor y la
bomba
Si no se llegan a estos valores, debe realizarse la prueba de flujo para revisar
la caracterstica de la curva Flujo / Presin de la bomba
VLVULA DE ALIVIO
(A) Main relief valve

(B) Boom cylinder line (head end)
ESPECIFICACIONES
NUEVO O
RECONSTRUIDO
5100 +/- 72 PSI
(35000 +/- 500 kPa)
5200 +/- 72 PSI
(36000 +/- 500 kPa)
HEAVY LIFT
5500 +/- 145 PSI
(38000 +/- 1000 kPa)
LIMITE DE SERVICIO
5400 +/- 150 PSI

(37000 +/- 1000 kPa)
5000 a 5500 PSI

(34600 a 38000 kPa)
5500 +/- 145 PSI

(38000 +/- 1000 kPa)
5150 a 5650 PSI

(35600 a 39000 kPa)
5400 +/- 150 PSI

(37000 +/- 1000 kPa)
5000 a 5500 PSI

(34600 a 38000 kPa)
4050 +/- 220 PSI

(27900 +/- 1500 kPa)
3750 a 4200 PSI

(25900 a 28900 kPa)
5340 +/- 220 PSI

(36800 +/- 1500 kPa)
4900 a 5555 PSI

(33800 a 38300 kPa)
4800 a 5150 PSI

(33000 a 35500 kPa)
5150 a 5650 PSI
(35600 a 39000 kPa)
(C) Boom cylinder line (rod end)

(D) Stick cylinder line (head end)
(E) Stick cylinder line (rod end)
(F) Bucket cylinder line (head end)
(G) Bucket cylinder line (rod end)
(H) Swing relief pressure (right)
(I) Swing relief pressure (left)
(J) Left travel crossover relief valve (forward
- upper valve)
(K) Left travel crossover relief valve (reverse
- lower valve)
(L) Right travel crossover relief valve
(forward - upper valve)
(M) Right travel crossover relief valve
(reverse - lower valve)
(N) Pilot relief valve
Ferreyros S.A.A.
595 +/- 29 PSI

(4100 +/- 200 kPa)
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Procedimiento
Presin Piloto
Lectura:
_____________
(continuacin)
servicio RENR9585
Arranque el motor
Temperatura de operacin
AEC en OFF y velocidad 10
Mida la presin en (30) debe ser
595 +/- 29 PSI (4100 +/- 200 kPa)
(28) Locknut
(29) Setscrew
(30) Pressure tap
(31) Pilot filter
-Arranque el motor
-Temperatura 55 +/5 C (131 +/-9 F)
-Power Mode, AEC
en OFF y velocidad
10
- Retraiga Cucharn
-Mida la presin en
(1) o (2) debe ser:
Vlvula de alivio
principal
SIN HEAVY LIFT
Lectura:
______________
(1) Pressure tap (drive pump delivery pressure)

(2) Pressure tap (idler pump delivery pressure)
(3) Pressure tap (power shift pressure)
Modo Potencia (sin HEAVY LIFT) = 5076 +/- 73 PSI (35000 +/- 500kPa)
CON HEAVY LIFT
-Arranque el motor
-Temperatura 55 +/5 C (131 +/-9 F)
-Heavy Lift Mode,
AEC en OFF y
velocidad 10
- Eleve la pluma
-Mida la presin en
(1) o (2) debe ser:
Lectura:
______________
(A) Interruptor de Levante Pesado

Modo Levante Pesado (HEAVY LIFT) = 5220 +/- 73 PSI (36000 +/- 500kPa)
Ferreyros S.A.A.
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Procedimiento
Seteo temporal
vlvula de alivio
principal
(continuacin)
servicio RENR9585
MODO POTENCIA
(maquinas sin heavy lift)
Temporalmente aumente
el seteo de la vlvula de
alivio principal vuelta
(4) Adjustment
screw
(5) Locknut
(6) Main relief valve
MODO LEVANTE PESADO

(maquinas con heavy lift)
Ajustar el alivio
principal no afecta el
seteo de levante
pesado.
Aumentar el seteo
de levante pesado
aumenta el de alivio
y viceversa
Vlvulas de alivio
de lnea
Temporalmente aumente
el seteo de la vlvula de
alivio principal modo
levante pesado vuelta
Pruebas con heavy lift

Ajustar (6)
(5) Locknut for the
heavy lift
(6) Adjustment
screw for the heavy
lift
(7) Locknut for the
main relief valve
(8) Adjustment
screw for the main
relief valve
Conecte manmetros de 8700 PSI en (1) y (2) y 870PSI en (3)

Arranque el motor llegue a la temperatura de operacin del sistema
hidrulico, interruptor AEC en OFF y velocidad 10 del motor
En el MONITOR entre la modo de servicio y fije la PRV segn la tabla fixed
power shift pressure
Realice los calados y anote los valores
Ferreyros S.A.A.
Desarrollo Tcnico

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146

Modulo 4

Procedimiento
(continuacin)
servicio RENR9585
(12) Line
relief valve
(boom
cylinder head
end)
(13) Line
relief valve
(bucket
cylinder head
end)
(14) Line
relief valve
(stick cylinder
rod end)
(17) Line relief

valve (boom
cylinder rod
end)
(18) Line relief
valve (bucket
cylinder rod
end)
(19) Line relief
valve (stick
cylinder head
end)
Line Relief Valve Pressure Settings

Standard Configuration
Cylinder
Cylinder
Position
Retracted
Bucket
Extended
Heavy Lift Option
Power Shift
Pressure
Relief Pressure
Setting
Power Shift
Pressure
Relief Pressure
Setting
3200 50 kPa
(464 7 psi)
Speed Dial 3
37000 1000 kPa

(5350 145 psi)
3200 50 kPa
(464 7 psi)
Speed Dial 3
37000 1000 kPa

(5350 145 psi)
3200 50 kPa
(464 7 psi)
Speed Dial 3
37000 1000 kPa

(5350 145 psi)
3200 50 kPa
(464 7 psi)
Speed Dial 3
37000 1000 kPa

(5350 145 psi)
2370 50 kPa
(344 7 psi)
Speed Dial 10
38000 1000 kPa

(5500 145 psi)
2370 50 kPa
(344 7 psi)
Speed Dial 10
38000 1000 kPa

(5500 145 psi)
2370 50 kPa
(344 7 psi)
Speed Dial 10
38000 1000 kPa

(5500 145 psi)
2370 50 kPa
(344 7 psi)
Speed Dial 10
38000 1000 kPa

(5500 145 psi)
2500 50 kPa
(450 7 psi)
Speed Dial 10
37000 1000 kPa

(5350 145 psi)
2500 50 kPa
(450 7 psi)
Speed Dial 10
37000 1000 kPa

(5350 145 psi)
LECTURAS
Retracted
Boom
LECTURAS
Extended
LECTURAS
Retracted
Stick
LECTURAS
Extended
LECTURAS
Ferreyros S.A.A.
Desarrollo Tcnico

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147

Modulo 4

Procedimiento
Vlvula de alivio
de giro
Lectura:
Giro a la derecha
___________
Giro a la izquierda
(continuacin)
servicio RENR9585
Conecte 1 manmetro de 8700 PSI en (2)
En el monitor seleccione SWING BREAK
SOL override ON para conectar el freno de
parqueo giro
Arranque motor, AEC en OFF y velocidad en
10, lentamente mueva el joystick a giro
derecha al tope y anote, repita para giro a la
izquierda, lea el valor, debe ser:
27900 1000 kPa (4050 145 psi)
___________
(22) Adjustment plug

(23) Locknut
(25) Relief valve (left swing)
(35) Locknut
(36) Relief valve (right swing)
Vlvula de alivio
cruzada de
traslacin
Lecturas:
Conecte un manmetro de 8700 PSI en (1) para la vlvula del motor de

traslacin derecho, 870 PSI en (3) y 8700 PSI en (2) para el otro motor
Aumente temporalmente el alivio principal
Bloque el sprocket
Arranque motor, AEC en OFF y
velocidad en 10 hasta temperatura
de operacin
___________
Con el MONITOR fije la PRV a

2850 kPa 415 PSI
Mueva el control hacia marcha delante de
la oruga bloqueada, Mida la presin,
Mueva hacia atrs el control, mida, repita
Para la otra oruga
Reversa:
El valor debe ser: 36800 1500 kPa (5350 220 psi).
Oruga derecha
Avance:
___________
Oruga izquierda
Avance:
___________
Reversa:
___________
Ferreyros S.A.A.
(18) Locknut
(19) Adjustment screw
(20) Crossover relief
valve (forward left
travel)
(21) Crossover relief
valve (reverse left
travel)
(22) Locknut
Desarrollo Tcnico

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148

Modulo 4
HOJA DE TRABAJO 4.14 PRUEBAS DE FLUJO DE DRENAJE

Procedimiento
Drenaje de caja
motor de
traslacin
Motor derecho:
_________
Motor izquierdo:
_________
Realice las pruebas solicitadas siguiendo el procedimiento del manual

de servicio RENR9585
Bloquee una oruga
Instale la lneas como se muestra
Arranque el motor, EAC en OFF
Velocidad en 10, mantenga la
en no carga a 1880 RPM y
temperatura de operacin
Mueva el control de traslacin de la
Oruga evaluada a tope por 1 minuto
A la presin de:
36800 1470 kPa (5350 215 psi)
-
Motor de traslacin nuevo..... .......15 L/min (4.0 US gpm)

Motor de traslacin reconstruido.. 18 L/min (4.78 US gpm)
(3) 6V-9509 Face
seal plug
(4) 6V-8398 O-Ring
seal
(5) Case drain hose
(6) Connector
(7) Remote drain
hose
(8) Container for
measuring
Drenaje de caja
motor de giro
Flujo:
_________
Desconecte lnea (1) de la T

y ponga un tapn en (2), una
la lnea a la manguera que va al
Depsito medible.
En el monitor seleccione SWING
BREAK SOL override ON para
mantener el freno de parqueo de
giro conectado
Arranque el motor, AEC en OFF
Velocidad en 10, mantenga
en no carga a 1880 RPM y
temperatura de operacin
Mueva el joystick de giro contra el
freno por 1 minuto, repita tres veces la medicin
Para una presin de 31400 1000 kPa (4550 145 psi) los valores son:
- Motor de giro nuevo..... .......30 L/min (7.9 US gpm)
- Motor de giro reconstruido.. 35 L/min (9.2 US gpm)
Ferreyros S.A.A.
Desarrollo Tcnico

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Modulo 4
FLOW METER
Especificaciones:
Flujo:
En cualquier
13 a 475 L/min (3.5 a 125 gpm)
sistema hidrulico
este equipo mide de Presin:
0 a 500 bar (0 a 6800 PSI)
manera digital:
Temperatura
10 a 120C (50 a 250 F)
- Flujo
Velocidad
- Presin
- Temperatura 0 a 6000 RPM
- Velocidad
Siempre conecte con
la vlvula abierta
METODOS DE PRUEBA
En lnea.
Cierre la vlvula creando presin, compare con la
especificacin de la bomba, 20% a 30% de
perdida indica dao o desgaste
En Tee
Mueva un accionador, cierre la vlvula, la
presin aumenta hasta que se abre el alivio, el
flujo cae a cero
Mueva todos los accionadores, uno por vez, las
lecturas deben ser similares o existe una fuga
Direccional en lnea
Verifique fugas internas en cilindros y control
Opere el control donde conecto el medidor, cierre
la vlvula totalmente, la lectura es el alivio
Compare el flujo especificado en el motor contra
la lectura bajo carga normal de motor
Accionadores
Conecte el medidor en vez de los accionadores
y cierre la vlvula, si es diferente a
especificaciones o pruebas anteriores indica
fugas en el control o accionadores
Ferreyros S.A.A.
Desarrollo Tcnico

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150

Modulo 4
HOJA DE TRABAJO 4.15 PRUEBAS DE FLUJO

Procedimiento

servicio RENR9585
Control de Flujo de Potencia Constante
Procedimiento
Identifique los componentes y trace el recorrido del flujo (use el cdigo de

colores)
Nota: No desconecte la NFC porque afectar los resultados
Arranque el motor, EAC en OFF Velocidad en 10, temperatura de operacin
En el MONITOR fije la PRV hasta un valor en el manmetro de
2400 50 kPa (350 10 psi).
Con el flowmeter aumente la presin de la bomba evaluada (manmetro) y
anote los valores de flujo en la tabla respectiva
Corrija el flujo para los valores especificados a 1800RPM
( Flujo medido x 1800 RPM )
Flujo corregido = ----------------------------------------( RPM leda )
Grafique los valores ledos y trace la curva comparndola a la especificacin
(10) Portable hydraulic tester

(flow meter)
(22) Multitach
(26) Valve
( ) Pressure tap (left pump
delivery pressure)
( ) Pressure tap (right pump
delivery pressure)
( ) Pressure tap (power shift
pressure)
Ferreyros S.A.A.
Desarrollo Tcnico

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151

Modulo 4

(continuacin)
servicio RENR9585
Prueba de Flujo de Bombas
Puntos a Medir
9000 kPa
12000 kPa
16000 kPa
26000 kPa
30000 kPa
Bomba derecha
1300 PSI
1750 PSI
2300 PSI
3750 PSI
4350 PSI
Flujo medido
L/min (US gpm)
Temperatura
C (F)
RPM Motor
Procedimiento
Flujo corregido
L/min (US gpm)
Especificaciones
NUEVO L/min (US gpm)

LIMITE DE SERVICIO
L/MIN (US GPM)
Bomba izquierda
273 +/- 10
72.0 +/- 2.60
262
69
259 +/- 10
68 +/- 2.6
217
57
224+/- 10
59 +/- 2.6
188
49
181 +/- 10
48 +/- 2.6
137
36
168 +/- 10
44 +/- 2.60
127
34
273 +/- 10
72.0 +/- 2.60
262
69
259 +/- 10
68 +/- 2.6
217
57
224+/- 10
59 +/- 2.6
188
49
181 +/- 10
48 +/- 2.6
137
36
168 +/- 10
44 +/- 2.60
127
34
Flujo medido
L/min (US gpm)
Temperatura
C (F)
RPM Motor
Flujo corregido
L/min (US gpm)
Especificaciones
NUEVO L/min (US gpm)

LIMITE DE SERVICIO
L/MIN (US GPM)
Grafique y
analice
Ferreyros S.A.A.
Desarrollo Tcnico

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Modulo 4

Procedimiento
(continuacin)
servicio RENR5435
Control de Flujo Negativo
Procedimiento

colores)
En el MONITOR fije la PRV hasta un valor en el manmetro de
1080 kPa (155 PSI).
Con el flowmeter aumente la presin de la bomba evaluada (manmetro) a
6900 kPa (1000 psi) y anote el valor de flujo en la tabla
Flujo corregido = ----------------------------------------( RPM leida )
Los valores deben ser tomados mientras aumenta la presin
(10) Portable hydraulic tester

(flow meter)
(22) Multitach
(26) Valve
( ) Pressure tap (left pump
delivery pressure)
( ) Pressure tap (right pump
delivery pressure)
( ) Pressure tap (power shift
pressure)
Ferreyros S.A.A.
Desarrollo Tcnico

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153

Modulo 4

Procedimiento
NFC a
(continuacin)
servicio RENR9585
Prueba de Flujo Negativo
Punto a Medir
Bomba derecha
155 PSI
Flujo medido L/min (US gpm)
1080 kPa
Temperatura C (F)
RPM Motor
Flujo corregido L/min (US gpm)
Especificaciones L/min (US gpm)
NUEVO
LIMITE SERVICIO
150 +/- 15
40 +/- 4
120
32
Bomba izquierda
Temperatura C (F)
RPM Motor
NUEVO
LIMITE DE SERVICIO
150 +/- 15
40 +/- 4
120
32
Ubique el punto y
analice
Ferreyros S.A.A.
Desarrollo Tcnico

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Modulo 4

Procedimiento
Procedimiento
(continuacin)
servicio RENR9585
Flujo de Bomba Piloto

colores)
Con el flowmeter aumente la presin de la bomba piloto (manmetro) a 4100
200 kPa (595 29 psi).y anote el valor de flujo en la tabla
Flujo corregido = ----------------------------------------( RPM leda )
Los valores deben ser tomados mientras aumenta la presin
Prueba de Flujo Bomba Piloto
Punto a Medir
4100
200 kPa
Bomba Engranajes
(595 29 psi).
Temperatura C (F)
RPM Motor
NUEVO
LIMITE SERVICIO
Ferreyros S.A.A.
40.1
11
33
8.7
Desarrollo Tcnico

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155

ENCUESTA FINAL
NOMBRE (OPCIONAL): _____________________________________________________________

FECHA: __________________CURSO:__________________INSTRUCTOR:_______________
Marque X en la tabla de 10% a 100% (10% mnimo, 100% mximo)
10
20
30
40
50
60
70
80
90
100
1. Del Instructor
Tiene dominio y conocimiento del tema y el material usado?
Fomenta la participacin del grupo?
Es clara su exposicin y usa buen mtodo de instruccin?
Absuelve las consultas que se hacen?
2. Del Material del curso

Tiene buena presentacin?
Contiene informacin necesaria e importante?
Facilita el desarrollo de los temas?
Facilita el desarrollo de la parte prctica?
3. Del desarrollo del curso

Se tocaron todos los temas?
La profundidad de los temas tericos fue suficiente?
Los objetivos de cada mdulo son claros y satisfactorios?
Se cumpli con los objetivos del curso?
El tiempo de aula fue suficiente?
El tiempo de la parte prctica fue suficiente?
La parte prctica fue importante y bien desarrollada?
Las instalaciones del aula, los laboratorios y el uso del equipo
audiovisual fue de calidad?
4. Del estudiante
Estaba debidamente preparado (cumpla los pre -requisitos)
para recibir este curso?
Se cumplieron sus expectativas?
Cunto elevo el curso su conocimiento sobre el tema?
En cuanto ayudara el curso a su trabajo especfico?
Tendr acceso a las herramientas usadas en el curso?
Podr aplicar lo aprendido en su trabajo diario?
Mantuvo su inters y atencin durante el curso?
Cunto fue el grado de participacin del grupo?
5. Cuestiones
Cul fue lo ms til del curso?
_________________________________________________________________________________
Cul fue lo menos til del curso y que dudas le quedaron?
Qu sugerira agregar o retirar del curso para mejorarlo?
Qu cursos o herramientas necesita para mejorar?
Otros comentarios?
Ferreyros S.A.A.
Desarrollo Tcnico
Manual del Estudiante 330D - Encuesta

DSSE0060
Ferreyros S.A.A.
155

ENCUESTA FINAL
Desarrollo Tcnico
Manual del Estudiante 330D - Encuesta
DESARROLLO TECNICO
OCTUBRE, 2006
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i02578588
General Information
SMCS - 4000; 4250; 4265; 4284; 4300; 4801; 5050
ReferenceFor testing and adjusting of the hydraulic system, refer to Testing and Adjusting,
"Excavator Hydraulic System" for your machine.
ReferenceFor systems operation of the electronic control unit and electronic system, refer to
Systems Operation/Testing and Adjusting, "Machine Electronic Control System" for your machine.
ReferenceFor more information on specifications with illustrations, refer to Specifications,
"Excavator Machine System Specifications" for your machine.
ReferenceFor more information on the hydraulic schematics, refer to Schematic, "Excavator
Hydraulic System" for your machine.
ReferenceFor more information on electrical schematics, refer to Schematic, "Excavator Electrical
System" for your machine.

Tue Oct 17 17:22:45 EST 2006
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i02613686
Main Hydraulic System

SMCS - 5050; 5051; 5069; 5117; 5472
S/N - EAH1-UP
S/N - FFK1-UP
S/N - MEY1-UP
S/N - NBD1-UP
Main Hydraulic Schematic
Pgina 2 de 8
Pgina 3 de 8
Illustration 1
(1) Swing motor
(2) Left travel motor
(3) Right travel motor
(4) Stick cylinder
(5) Travel brake valve (left)
(6) Travel brake valve (right)
(7) Bucket cylinder
(8) Boom cylinder
(9) Swivel
(10) Pilot control valve (travel)
(11) Stick drift reduction valve
(12) Main control valve
(13) Boom drift reduction valve
(14) Pressure switch
(16) Pilot control valve (swing and stick)
(17) Pilot control valve (boom and bucket)
(20) Accumulator
(21) Reducing valve (boom priority mode or swing priority mode)
(22) Pressure sensor (drive pump)
(24) Valve
(25) Solenoid valve (hydraulic lockout)
(26) Drive pump (view from shaft end)
Pgina 4 de 8
(28) Pilot oil manifold

(29) Drain filter
(30) Pilot relief valve
(31) Pilot filter
(32) Idler pump (view from shaft end)
(33) Pilot pump
(34) Slow return check valve
(35) Bypass check valve
(36) Pressure sensor (idler pump)
(37) Proportional reducing valve (power shift pressure)
(38) Oil cooler
(39) Return filter
(40) Hydraulic tank
(41) Gear pump (fan motor)
(42) Relief valve (fan pump)
(43) Fan motor (hydraulic oil cooler)
Hydraulic Pump Flow and Pressure Control System
Illustration 2
g01228123
Pump compartment
(26) Drive pump
Pgina 5 de 8
(32) Idler pump

(44) Delivery line (idler pump)
(45) Delivery line (drive pump)
This machine is driven and controlled by the following systems.

z
The main hydraulic system controls the cylinders, the travel motors and the swing motor.
The pilot hydraulic system supplies oil to the main pumps, the main control valve, the swing
brake and the travel motors.
The electronic control system controls the outputs of the engine and pump.
The hydraulic oil cooling system provides oil to the fan motor in order to cool the hydraulic
oil.
The main hydraulic system delivers oil flow from idler pump (32) and drive pump (26) in order to
control the following components: bucket cylinder (7), stick cylinder (4), boom cylinders (8), right
travel motor (3), left travel motor (2) and swing motor (1).
Illustration 3
Main control valve
g01228403

(45) Right control valve body
(46) Left control valve body
Idler pump (32) and drive pump (26) are bent axial piston type pumps. The performance of both
pumps is equal.
Drive pump (26) is directly connected to the engine by a flexible coupling. The drive pump delivers
oil to the left control valve body (46) of the main control valve. Idler pump (32) is mechanically
connected to the drive pump through gears. The idler pump delivers oil to the right control valve
Pgina 6 de 8
body (45) of the main control valve. Gear type pilot pump (33) supplies oil to the pilot hydraulic
system. Gear type pilot pump (33) is mechanically connected to idler pump (32) through gears. Gear
pump (41) supplies oil to the oil cooling system. Gear pump (41) is mechanically connected to the
engine through gears. All engine output is used to drive these four pumps.
As the load pressure increases during working conditions, the main pumps increase the delivery
pressure and the pumps decrease the flow rate. The hydraulic horsepower remains constant even
though the delivery pressure and the flow rates change. The hydraulic horsepower is approximately
identical to the engine horsepower.
When no work is being performed, pump oil flows through main control valve (12) and into
hydraulic tank (40). The main control valve sends a negative flow control signal to each main pump
regulator in order to destroke the pump to the minimum output flow.
If an operation is being performed, main control valve (12) directs pump oil to the respective
cylinders (boom, bucket, and stick) and/or motors (swing and travel). Main control valve (12)
contains numerous valve stems, passages, check valves, and orifices in order to carry out a single
operation or a combined operation. The working pressure of the main hydraulic system is regulated
by main relief valve (18).
Illustration 4
Cab
g01173678
(47) Monitor panel

(48) Joystick (stick and swing)
(49) Joystick (boom and bucket)
(50) Left travel lever/pedal
(51) Right travel lever/pedal
(52) Straight travel pedal
The pilot hydraulic system receives oil flow from pilot pump (33). The pilot hydraulic system
controls the following functions.
Pgina 7 de 8
1. The pilot hydraulic system controls the operation of the implement control valves.
Pilot oil flows from pilot pump (33) through pilot manifold (28). The pilot oil then flows to the
pilot control valves for machine operation (implement operations, swing operations and travel
operation). These pilot control valves are activated by the joysticks and the travel
levers/pedals.
When joystick (48), joystick (49), left travel lever/pedal (50) and/or right travel lever/pedal
(51) are moved from the NEUTRAL position, the pilot oil flows through the pilot control
valves to the corresponding spools at the main control valve (12) .
The pilot pressure oil at that end of the valve spool forces the valve spool to shift. The pilot oil
on the other end of the valve spool drains to the hydraulic tank. When the valve spool shifts,
oil is then delivered from idler pump (32) or drive pump (26) to the cylinders and motors.
Thus, pilot oil drives each system of the main control valve.
2. The pilot hydraulic system controls the output flow of the main pumps.
During machine operation, pilot pressure is sent to the main pump regulators as a signal
pressure. This signal pressure is called power shift pressure. The engine and pump controller
receives input signals from various components on the machine. The engine and pump
controller processes the input signals. The engine and pump controller then sends an electrical
signal to proportional reducing valve (37) at the idler pump regulator in order to regulate the
power shift pressure. The power shift pressure controls the output flow of idler pump (32) and
drive pump (26). Power shift pressure adjusts the output flow of the main pumps in accordance
with the engine speed. For more information concerning power shift pressure, refer to Systems
Operation, "Pilot Hydraulic System".
3. The pilot hydraulic system generates signal pressure in order to perform the following
operations.
a. Pilot signal pressure activates the Automatic Engine Speed Control (AEC) system. This
causes functions to automatically reduce the engine speed when no hydraulic operation
is called for.
b. Pilot signal pressure releases the swing parking brake.
c. Pilot signal pressure will automatically change the travel speed to either HIGH or LOW
in accordance with the hydraulic system load.
d. Pilot signal pressure operates the straight travel control valve. This maintains straight
travel during the operation of an implement.
e. Pilot signal pressure controls the operation of the valves that can be used during a
loading operation or a trenching operation.
For more information concerning the pilot hydraulic system, refer to Systems Operation, "Pilot
Hydraulic System".

Tue Oct 17 17:32:10 EST 2006
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i02613752
Pilot Hydraulic System

SMCS - 5050-PS
S/N - EAH1-UP
S/N - FFK1-UP
S/N - MEY1-UP
S/N - NBD1-UP
Pgina 2 de 11
Pgina 3 de 11
Illustration 1
(1) Swing brake
(2) Displacement change valve (left travel motor)
(3) Displacement change valve (right travel motor)
(4) Line (pilot oil from swing brake solenoid valve)
(5) Travel pilot control valve
(6) Pilot line (BOOM LOWER)
(7) Pilot line (boom drift reduction valve)
(8) Pilot line (STICK IN)
(9) Pilot line (stick drift reduction valve)
(13) Solenoid valve (straight travel)
(14) Pilot line (pilot pressure to left travel pressure switch)
(15) Pilot line (pilot oil to travel pilot control valve)
(16) Right travel control valve
(17) Boom I control valve
(18) Straight travel control valve
(19) Travel pressure switch (left)
(20) Pilot line (pilot pressure to right travel pressure switch)
(21) Travel pressure switch (right)
(22) Pilot line (pilot oil to pilot control valve for the stick and swing)
(23) Pilot line (pilot oil to pilot control valve for the boom and bucket)
(24) Left travel control valve
(25) Pilot control valve for stick and swing
(26) Pilot control valve for boom and bucket
(27) Variable swing priority valve
Pgina 4 de 11
(28) Pilot line (STICK OUT)

(30) Pilot line (SWING RIGHT)
(31) Pilot line (SWING LEFT)
(32) Pilot line (BUCKET CLOSE)
(33) Pilot line (BOOM RAISE)
(35) Pilot line (BUCKET OPEN)
(36) Pilot line (pilot oil from boom pilot control valve)
(38) Pilot line (pilot oil to the pressure reducing valve for boom priority)
(39) Pilot line (pilot pressure to implement/swing pressure switch)
(40) Implement/swing pressure switch
(41) Pilot line (pilot pressure to displacement change valves)
(42) Pilot line (pilot oil to pressure reducing valve for swing priority)
(43) Pilot line (pilot oil to pilot control valves)
(44) Pilot line (pilot oil to straight travel control valve)
(47) Pressure reducing valve for swing priority
(48) Pressure reducing valve for boom priority
(49) Drive pump
(50) Passage (power shift pressure)
(51) Pilot manifold
(53) Passage
(55) Passage
(56) Passage
Pgina 5 de 11
(57) Passage
(58) Idler pump
(59) Pilot pump
(60) Pilot line (pilot oil flow to pilot oil manifold)
(61) Pilot filter
(65) Passage
(66) Pilot line (pilot oil flow from pilot pump to pilot oil filter)
(67) Pilot line (pilot oil flow to pump regulators)
Illustration 2
Ports and solenoids at the pilot manifold

Pgina 6 de 11

Pilot Oil Circuit

The pilot circuit pressure is limited by pilot relief valve (64) .
The oil delivery from pilot pump (59) performs the following main functions.
z
Create pilot oil pressure in order to control the output flows of the main pumps.
Provide pilot oil pressure to the pilot control valves for implements, swing and travel in order
to perform machine operations.
Create pilot oil pressure in order to automatically operate the control devices.
The pilot circuit is classified into the following circuits and each circuit performs one of the above
functions.
z
Power shift pressure system
Pilot control valve circuit
Pressure switch circuits
Straight travel valve circuit
Swing brake
Boom priority
Swing priority
Automatic travel speed change
Power Shift Pressure System
Pgina 7 de 11
Illustration 3
(49) Drive pump
(58) Idler pump
(63) Proportional reducing valve (PS pressure)
(59) Pilot pump
(68) Machine ECM
Pgina 8 de 11
(69) Monitor
(73) Engine speed pickup (flywheel housing)
(74) Pump (fan motor)
During machine operation, machine ECM (68) receives input signals from the following
components:
z
Engine speed dial (70)
Engine speed pickup (73) that is located on the flywheel housing
Idler pump pressure sensor (71)
Drive pump pressure sensor (72)
Monitor in the cab (69)
The machine ECM (68) continually monitors all of the input signals. The input signals are processed
by the machine ECM and an output signal is sent to proportional reducing valve (63) at the pump
regulator. The proportional reducing valve assists in controlling the output flow of idler pump (58)
and drive pump (49) .
The oil delivery from pilot pump (59) flows through the pilot filter to proportional reducing valve
(63) at the pump regulator. The electrical signal that is sent from machine ECM (68) causes
proportional reducing valve (63) to regulate the pilot pressure to a reduced pressure. This reduced
pressure is called power shift pressure (PS). The proportional reducing valve sends the reduced pilot
oil pressure through the idler pump regulator and through the drive pump regulator. The output flow
of idler pump (58) and drive pump (49) is controlled in accordance with the power shift pressure.
The power shift pressure is used to regulate the maximum allowable hydraulic pump output.
The output signal that is sent from the machine ECM to the proportional reducing valve will change
when the machine ECM detects a change in any of the input signals. The power shift pressure that is
sent to the regulators at the idler pump and the drive pump will change in order to regulate the
maximum allowable hydraulic pump output. The desired engine speed is maintained.
A decrease in engine speed increases the power shift pressure. An increase in power shift pressure
causes destroke condition of the idler pump and the drive pump. The maximum allowable hydraulic
power output is decreased.
An increase in engine speed decreases the power shift pressure. A decrease in power shift pressure
causes an upstroke condition of the idler pump and the drive pump. The maximum allowable
hydraulic power output is increased.
Note: For more information concerning the operation of the machine ECM, refer to Systems
Operation/Testing and Adjusting, "Electronic Control System".
Pgina 9 de 11
Pilot Control Valve Circuits

Oil from pilot pump (59) flows through pilot line (66), pilot filter (61) and pilot line (60) to pilot
manifold (51). When the control lever for the hydraulic lockout is shifted to the UNLOCKED
position, the machine ECM energizes the hydraulic lockout valve (54). The pilot oil then shifts valve
(46). The pilot oil now flows through valve (46) and pilot line (43). The pilot oil now flows to pilot
control valves (5), (25) and (26) for implements, swing and travel in order to perform machine
operations. When the joysticks and/or travel levers/pedals are moved, the pilot oil flows to main
control valve (11) in order to control the machine functions.
Illustration 4
Pilot lines at the main control valve (top view)
g00932058
When joystick (25) and/or joystick (26) are operated, the pilot control valves send pilot pump oil
through the pilot lines to pilot ports at the main control valve in order to shift the spools in the main
control valve. Refer to Illustration 4 and Table 1 for the location of the pilot lines and machine
operations.
Table 1
Pilot line
Control Valve
Machine Operation
(76)
BOOM LOWER
(77)
BUCKET CLOSE
(78)
Swing control valve
SWING LEFT
(79)
BOOM RAISE
(80)
STICK IN
(81)
(82)
REVERSE LEFT TRAVEL
(83)
STICK IN
Pilot oil from the pilot control valves flows through pilot lines to the ports on the bottom of the main
control valve in order to perform the opposite operation.
Pgina 10 de 11
The following example is given for the BOOM LOWER operation and the BOOM RAISE operation.
Machine operations for a stick operation, bucket operation, travel operation and swing operation are
accomplished in the same manner as the boom operation.
When the joystick for the boom is moved to the BOOM RAISE position, pilot oil from pilot control
valve (26) flows through pilot line (37) to boom I control valve (17). The pilot pressure shifts the
boom I control valve. The oil delivery from the idler pump flows to the head end of the boom
cylinders in order to perform the BOOM RAISE operation.
When the joystick for the boom is moved to the BOOM LOWER position, pilot oil from pilot
control valve (26) flows through pilot line (6) to boom I control valve (17). The pilot pressure shifts
the boom I control valve. The pilot oil also flows through pilot line (7) in order to open boom drift
reduction valve (12). The return oil from the head end of the boom cylinders flows through the boom
drift reduction valve and the boom I control valve to the hydraulic tank. The BOOM LOWER
operation is now performed.
Pressure Switch Circuits

Pressure switches (19) and (21) are connected to travel pilot control valve (5). Pressure switch (40) is
connected to pilot control valve (25) and pilot control valve (26). When all of the joysticks and/or
travel levers/pedals are in the NEUTRAL position, the pilot oil pressure to the pressure switches is
low. Pressure switches (19), (21) and (40) are OFF. The machine ECM recognizes the OFF condition
of all of the pressure switches. The AEC system is activated in order to lower the engine rpm.
If any of the joysticks and/or travel levers/pedals are moved from the NEUTRAL position, the
increased pilot oil pressure is sent to the pressure switches. If pressure switch (19), (21) and/or (40)
is ON, the machine ECM activates the AEC system in order to increase the engine rpm.
Straight Travel Valve Circuit

When a swing operation and/or implement operation is performed during a travel operation, the
increase of pilot pressure in pilot line (39) activates implement/swing pressure switch (40). The
implement/swing pressure switch sends an electrical signal to the machine ECM. The machine ECM
energizes straight travel solenoid (13). Pilot pressure now activates straight travel control valve (18).
The straight travel control valve maintains straight travel even though there is a swing operation or
an implement operation during travel. For more information concerning the operation of the straight
travel control valve, refer to Systems Operation, "Control Valve (Straight Travel)".
Swing Brake
When the control lever for the hydraulic lockout is placed in the UNLOCKED position, pilot oil in
passage (57) flows through valve (46) and passage (53) to swing brake solenoid valve (45). When
any of the joysticks are moved from the NEUTRAL position, the increase of pilot pressure in pilot
line (39) activates implement/swing pressure switch (40). The implement/swing pressure switch
sends an electrical signal to the machine ECM. An electrical signal from the machine ECM energizes
the swing brake solenoid valve (45). Pilot oil in line (4) flows to swing brake (1). This oil releases
the swing brake. For more information concerning the operation of the swing brake, refer to Systems
Operation, "Pilot Valve (Swing Brake)".
Boom Priority
During combined operations of BOOM RAISE and STICK IN, the pilot oil pressure in pilot line (36)
Pgina 11 de 11
and pilot line (38) activates the pressure reducing valve for boom priority. The pressure reducing
valve for boom priority allows priority flow to the head end of the boom cylinders during these
combined hydraulic operations by disabling the stick II control valve. For more information
concerning the pressure reducing valve for boom priority, refer to Systems Operation, "Boom
Hydraulic System".
Swing Priority
During a swing operation, pilot oil flows from pilot control valve (25) to the pressure reducing valve
for swing priority (47). The pressure reducing valve for swing priority shifts. The pilot oil flow in
pilot line (42) from pilot oil manifold (51) is blocked by the pressure reducing valve for swing
priority. Most of the drive pump delivery flow goes to the swing motor. For more information
concerning the pressure reducing valve for swing priority, refer to Systems Operation, "Swing
Hydraulic System".
Automatic Travel Speed Change Valve

Pilot oil in passage (56) flows to travel speed solenoid valve (52). When the travel speed switch on
the right console is set at the HIGH SPEED position, the travel speed solenoid valve opens. This
allows pilot oil to flow through travel speed solenoid valve (52) and through line (41). The oil then
flows to the displacement change valve for the left travel motor (2) and the displacement change
valve for the right travel motor (3). As the displacement change valve operates, the travel speed is
maintained at the HIGH SPEED position.
When the travel speed switch on the right console is set at the HIGH SPEED position, the pressure
sensors for the pump delivery pressure control the travel speed in accordance with the travel load.
For example, low speed during a high load condition and high speed during a low load condition.
For more information concerning the operation of the displacement change valves, refer to Systems
Operation, "Displacement Change Valve".

Tue Oct 17 17:42:17 EST 2006
Pgina 1 de 11
Cerrar SIS
Pantalla anterior

i02614799
Pilot Hydraulic System - Heavy Lift

SMCS - 5050-PS
S/N - MEY1-UP
S/N - NBD1-UP
Pgina 2 de 11
Pgina 3 de 11
Illustration 1
(1) Swing brake
Pgina 4 de 11

(49) Drive pump
(51) Pilot manifold
(53) Passage
(55) Passage
(56) Passage
Pgina 5 de 11
(57) Passage
(58) Idler pump
(59) Pilot pump
(61) Pilot filter
(65) Passage
Illustration 2

Pgina 6 de 11

Pilot Oil Circuit

z
functions.
z
Swing brake
Boom priority
Swing priority
Heavy lift
Pgina 7 de 11
Illustration 3
(49) Drive pump
(58) Idler pump
(59) Pilot pump
(68) Machine ECM
Pgina 8 de 11
(69) Monitor
components:
z
Operation/Testing and Adjusting, "Machine Electronic Control System".
Pgina 9 de 11

Oil from pilot pump (59) flows through pilot line (66), pilot filter (61) and pilot line (60) to pilot
manifold (51). When the control lever for the hydraulic lockout is shifted to the UNLOCKED
position, the machine ECM energizes the hydraulic lockout valve (54). The pilot oil then shifts valve
(46). The pilot oil now flows through valve (46) and pilot line (43). The pilot oil now flows to pilot
control valves (5), (25) and (26) for implements, swing and travel in order to perform machine
Illustration 4
g00932058
operations.
Table 1
Pilot line
Control Valve
Machine Operation
(76)
BOOM LOWER
(77)
BUCKET CLOSE
(78)
Swing control valve
SWING LEFT
(79)
BOOM RAISE
(80)
STICK IN
(81)
(82)
REVERSE LEFT TRAVEL
(83)
STICK IN
Pgina 10 de 11
valve (26) flows through pilot line (37) to boom I control valve (17). The pilot pressure shifts the
control valve (26) flows through pilot line (6) to boom I control valve (17). The pilot pressure shifts
reduction valve (12). The return oil from the head end of the boom cylinders flows through the boom
drift reduction valve and the boom I control valve to the hydraulic tank. The BOOM LOWER

Pressure switches (19) and (21) are connected to travel pilot control valve (5). Pressure switch (40) is
connected to pilot control valve (25) and pilot control valve (26). When all of the joysticks and/or
low. Pressure switches (19), (21) and (40) are OFF. The machine ECM recognizes the OFF condition
of all of the pressure switches. The AEC system is activated in order to lower the engine rpm.
increased pilot oil pressure is sent to the pressure switches. If pressure switch (19), (21) and/or (40)

increase of pilot pressure in pilot line (39) activates implement/swing pressure switch (40). The
energizes straight travel solenoid (13). Pilot pressure now activates straight travel control valve (18).
The straight travel control valve maintains straight travel even though there is a swing operation or
an implement operation during travel. For more information concerning the operation of the straight
travel control valve, refer to Systems Operation, "Control Valve (Straight Travel)".
Swing Brake
passage (57) flows through valve (46) and passage (53) to swing brake solenoid valve (45). When
line (39) activates implement/swing pressure switch (40). The implement/swing pressure switch
the swing brake solenoid valve (45). Pilot oil in line (4) flows to swing brake (1). This oil releases
Operation, "Pilot Valve (Swing Brake)".
Boom Priority
Pgina 11 de 11
Hydraulic System".
Swing Priority
for swing priority (47). The pressure reducing valve for swing priority shifts. The pilot oil flow in
Hydraulic System".

Pilot oil in passage (56) flows to travel speed solenoid valve (52). When the travel speed switch on
allows pilot oil to flow through travel speed solenoid valve (52) and through line (41). The oil then
valve for the right travel motor (3). As the displacement change valve operates, the travel speed is
Heavy Lift
The machine is equipped with a heavy lift feature that allows higher system pressure in the main
hydraulic circuit. A switch on the console activates a solenoid valve. The solenoid valve directs pilot
oil pressure to the pilot oil port on the main relief valve. The pilot oil pressure is ported through the
valve in order to move a piston that creates a higher spring force on the main relief valve. The
increase of spring force on the main relief valve causes the relief pressure in the main hydraulic
system to rise.
For more information concerning the operation of the heavy lift system, refer to Systems Operation,
"Relief Valve (Main) (Heavy Lift)".

Tue Oct 17 17:53:34 EST 2006
Pgina 1 de 11
Cerrar SIS
Pantalla anterior

i02618018
Pilot Hydraulic System - Heavy Lift and Fine Swing

SMCS - 5050-PS
S/N - B6H1-UP
S/N - EDX1-UP
S/N - JLP1-UP
S/N - MWP1-UP
Pgina 2 de 11
Pgina 3 de 11
Illustration 1
(1) Swing brake
Pgina 4 de 11

(49) Drive pump
(51) Pilot manifold
(53) Passage
(55) Passage
(56) Passage
Pgina 5 de 11
(57) Passage
(58) Idler pump
(59) Pilot pump
(61) Pilot filter
(65) Passage
Illustration 2

Pgina 6 de 11

Pilot Oil Circuit

z
functions.
z
Swing brake
Boom priority
Swing priority
Heavy lift
Pgina 7 de 11
Illustration 3
(49) Drive pump
(58) Idler pump
(59) Pilot pump
(68) Machine ECM
Pgina 8 de 11
(69) Monitor
components:
z
Operation/Testing and Adjusting, "Machine Electronic Control System".
Pgina 9 de 11

Oil from pilot pump (59) flows through pilot line (66) , pilot filter (61) and pilot line (60) to pilot
manifold (51) . When the control lever for the hydraulic lockout is shifted to the UNLOCKED
position, the machine ECM energizes the hydraulic lockout valve (54) . The pilot oil then shifts
valve (46) . The pilot oil now flows through valve (46) and pilot line (43) . The pilot oil now flows to
pilot control valves (5) , (25) and (26) for implements, swing and travel in order to perform machine
Illustration 4
g00932058
operations.
Table 1
Pilot line
Control Valve
Machine Operation
(76)
BOOM LOWER
(77)
BUCKET CLOSE
(78)
Swing control valve
SWING LEFT
(79)
BOOM RAISE
(80)
STICK IN
(81)
(82)
REVERSE LEFT TRAVEL
(83)
STICK IN
Pgina 10 de 11
valve (26) flows through pilot line (37) to boom I control valve (17) . The pilot pressure shifts the
control valve (26) flows through pilot line (6) to boom I control valve (17) . The pilot pressure shifts
reduction valve (12) . The return oil from the head end of the boom cylinders flows through the
boom drift reduction valve and the boom I control valve to the hydraulic tank. The BOOM LOWER

Pressure switches (19) and (21) are connected to travel pilot control valve (5) . Pressure switch (40)
is connected to pilot control valve (25) and pilot control valve (26) . When all of the joysticks and/or
low. Pressure switches (19) , (21) and (40) are OFF. The machine ECM recognizes the OFF
condition of all of the pressure switches. The AEC system is activated in order to lower the engine
rpm.
increased pilot oil pressure is sent to the pressure switches. If pressure switch (19) , (21) and/or (40)

increase of pilot pressure in pilot line (39) activates implement/swing pressure switch (40) . The
energizes straight travel solenoid (13) . Pilot pressure now activates straight travel control valve
(18) . The straight travel control valve maintains straight travel even though there is a swing
operation or an implement operation during travel. For more information concerning the operation of
the straight travel control valve, refer to Systems Operation, "Control Valve (Straight Travel)".
Swing Brake
passage (57) flows through valve (46) and passage (53) to swing brake solenoid valve (45) . When
line (39) activates implement/swing pressure switch (40) . The implement/swing pressure switch
the swing brake solenoid valve (45) . Pilot oil in line (4) flows to swing brake (1) . This oil releases
Operation, "Pilot Valve (Swing Parking Brake)".
Boom Priority
Pgina 11 de 11
Hydraulic System".
Swing Priority
for swing priority (47) . The pressure reducing valve for swing priority shifts. The pilot oil flow in
Hydraulic System".

Pilot oil in passage (56) flows to travel speed solenoid valve (52) . When the travel speed switch on
allows pilot oil to flow through travel speed solenoid valve (52) and through line (41) . The oil then
valve for the right travel motor (3) . As the displacement change valve operates, the travel speed is
Heavy Lift
The machine is equipped with a heavy lift feature that allows higher system pressure in the main
hydraulic circuit. A switch on the console activates a solenoid valve. The solenoid valve directs pilot
oil pressure to the pilot oil port on the main relief valve. The pilot oil pressure is ported through the
valve in order to move a piston that creates a higher spring force on the main relief valve. The
increase of spring force on the main relief valve causes the relief pressure in the main hydraulic
system to rise.
For more information concerning the operation of the heavy lift system, refer to Systems Operation,
"Relief Valve (Main) (Heavy Lift)".

Tue Oct 17 17:56:33 EST 2006
Pgina 1 de 3
Cerrar SIS
Pantalla anterior

i02467598
Accumulator (Pilot)
SMCS - 5077
Illustration 1
(5) Accumulator
g00681745
(16) Line (pilot oil from pilot oil manifold)

(17) Mounting block
The accumulator stores pilot pressure oil for use at the main control valves. During some operations,
the pilot system needs more oil because there is insufficient flow from the pilot pump. Accumulator
(5) will provide pilot pressure oil to the pilot system when the pilot pump flow is inadequate.
Insufficient supply of pilot oil flow to the pilot system may be caused by the following two reasons:
z
Implements are lowered while the engine is stopped and oil supply to the main control valves
is stopped.
Combined operations
Illustration 2
Pgina 2 de 3
Accumulator
(5) Accumulator
(16) Line (pilot oil flow from pilot oil manifold to the mounting block for the accumulator)
(17) Mounting block
(18) Passage
(19) Inlet port
(20) Pressure oil chamber
(21) Vessel
(22) Bladder
(23) Gas chamber
(24) Passage
(25) Passage
Pgina 3 de 3
(26) Passage
(27) Inlet port (pilot oil manifold)
(28) Passage
(29) Check valve
Pilot oil from the pilot filter enters inlet port (27) of the pilot oil manifold. Pilot oil flows through
passage (28) and opens check valve (29). Pilot oil now flows through passages (24) and (26) to the
pilot control valves (joysticks and travel levers/pedals).
The pilot oil also flows through passage (25) and line (16) to the mounting block for the
accumulator. The pilot oil now flows through passage (18) and inlet port (19) into pressure oil
chamber (20). The pilot oil acts against bladder (22) and the nitrogen gas in gas chamber (23) is
compressed. Check valve (29) prevents a backflow of the stored oil in the accumulator. The stored
oil is used for solely operating the stems of the main control valve.

Tue Oct 17 18:05:21 EST 2006
Pgina 1 de 1
Cerrar SIS
Pantalla anterior

i02467491
Gear Pump (Pilot)

SMCS - 5073; 5085
Illustration 1
Pilot pump
g01230561
The pilot pump is a gear type pump that supplies oil flow to the pilot system. The pilot pump is
located inside the main pump compartment and mounted externally to the main pump. The pilot
pump shaft is mechanically connected to the idle pump shaft. The pump delivery rate with load is
approximately 34 L/min (9.0 US gpm).

Tue Oct 17 17:59:58 EST 2006
Pgina 1 de 2
Cerrar SIS
Pantalla anterior

i02467567
Hydraulic Filter (Pilot)

SMCS - 5068; 5092
Illustration 1
(1) Pilot oil filter
g00847833
The oil delivery from the pilot pump flows through pilot oil filter (1) and into the components in the
pilot system.
Illustration 2
(1) Pilot oil filter
Pgina 2 de 2
g01230619
(2) Filter element

(3) Bypass relief valve
Filter element (2) in pilot oil filter (1) removes contaminants from the pilot oil.
If the pilot oil is extremely cold or if the flow of pilot oil through filter element (2) becomes
restricted by contaminants, the oil bypasses filter element (2) through bypass relief valve (3). Bypass
relief valve (3) is built into the base for the pilot oil filter.

Tue Oct 17 18:01:09 EST 2006
Pgina 1 de 4
Cerrar SIS
Pantalla anterior

i02478040
Solenoid Valve (Proportional Reducing) - Power Shift System

SMCS - 5479
Illustration 1
g01237694
Proportional reducing valve (power shift solenoid)
(1) Solenoid
(3) Valve body
(9) Line (pilot oil flow)
The proportional reducing valve for the power shift pressure is located on the main pump housing.
The proportional reducing valve is a solenoid operated control valve. The proportional reducing
valve receives supply oil from the pilot pump. The solenoid receives a pulse width modulated signal
(PWM signal) from the machine ECM. The PWM signal that is sent from the machine ECM causes
the proportional reducing valve to regulate the pilot pressure to a reduced pressure. This reduced
oil pressure to the regulators at the idler pump and the drive pump. The output flow of the idler pump
and the drive pump is controlled in accordance with the power shift pressure. The power shift
pressure is used to control the maximum allowable hydraulic pump output.
Illustration 2
Proportional reducing valve (increase in PWM signal)
Pgina 2 de 4
g01237695
(1) Solenoid
(2) Spring
(3) Valve body
(4) Spool
(5) Passage (return oil flow)
(6) Passage (power shift pressure to pump regulators)
(7) Spool chamber
(8) Passage (pilot oil flow)
Pgina 3 de 4
A decrease in engine speed causes an increase in power shift pressure and a decrease in pump flow.
While the engine is operating, the machine ECM senses a decrease in engine speed. A decrease in
engine speed causes the machine ECM to increase the PWM signal that is sent to solenoid (1). The
magnetic force of the solenoid increases. As the magnetic force of the solenoid becomes greater than
the force of spring (2), spool (3) moves in a downward direction against the force of the spring. The
downward movement of spool (3) blocks the flow of oil from passage (6) to passage (5). Pilot oil in
line (9) now flows through passage (8), into spool chamber (7) and into passage (6) at a reduced
pressure (power shift pressure). The increased power shift pressure in passage (6) acts on the idler
pump regulator and the drive pump regulator. The idler pump and the drive pump destroke as a result
of an increase in power shift pressure.
Illustration 3
g01237696
Proportional reducing valve (decrease in PWM signal)

(1) Solenoid
Pgina 4 de 4
(2) Spring
(3) Valve body
(4) Spool
(5) Passage (return oil flow)
(6) Passage (power shift pressure to pump regulators)
(7) Spool chamber
(8) Passage (pilot oil flow)
An increase in engine speed causes a decrease in power shift pressure and an increase in pump flow.
While the engine is operating, the machine ECM senses an increase in engine speed. An increase in
engine speed causes the machine ECM to decrease the PWM signal that is sent to solenoid (1). The
magnetic force of the solenoid decreases. As the force of spring (2) becomes greater than the
magnetic force of the solenoid, spool (3) moves in an upward direction. The upward movement of
spool (3) blocks the flow of pilot oil from passage (8). Power shift pressure oil in passage (6) now
drains into spool chamber (7) and into passage (5). The decreased power shift pressure in passage (6)
that is acting on the idler pump regulator and the drive pump regulator causes the idler pump and the
drive pump to move to an upstroke position. The idler pump and the drive pump upstroke as a result
of a decrease in power shift pressure.
ReferenceFor more information concerning power shift pressure (PS), refer to Systems Operation,
"Pilot Hydraulic System".

Tue Oct 17 18:15:11 EST 2006
Pgina 1 de 2
Cerrar SIS
Pantalla anterior

i01630729
Relief Valve (Pilot)

SMCS - 5072
Illustration 1
(1) Inlet port (oil flow from pilot pump)
g00847828

(3) Port (oil flow to hydraulic tank)
(4) Outlet lines (regulated pilot oil pressure)
Pilot relief valve (2) is located on the mounting base for the pilot oil filter. The pilot relief valve
limits the pressure in the pilot system. The pilot relief valve setting is adjustable.
The pilot oil flows from the pilot pump to inlet port (1). When the pressure in the pilot oil system
reaches the pressure setting of pilot relief valve (2), part of the pilot oil flow is returned to the
hydraulic tank through port (3). The pressure of the pilot system oil in outlet lines (4) is equal to the
pressure setting of the pilot relief valve.
Reference: For more information concerning the pilot relief valve setting, refer to Testing and
Adjusting, "Relief Valve (Pilot) - Test and Adjust".

Pgina 2 de 2
Tue Oct 17 18:03:48 EST 2006
Pgina 1 de 4
Cerrar SIS
Pantalla anterior

i02354379
Pilot Valve (Joystick)

SMCS - 5705-V4
Illustration 1
Cab
g01175873
(1) Joystick (left)

(2) Joystick (right)
control valve.
Pgina 2 de 4
Illustration 2
Pilot control valve
(1) Joystick
(2) Rod
(3) Return passage
(4) Passage
Pgina 3 de 4
(5) Spool
(6) Plate
(7) Rod
(8) Spring
(9) Seat
(10) Seat
(11) Spring
(12) Spring
(13) Return chamber
(14) Return passage
(15) Passage
(16) Spool
(17) Port (return pressure to valve)
(18) Passage (pilot supply pressure)
(19) Port (reduced pressure to valve)
(20) Port (pilot supply)
(21) Port (tank)
When joystick (1) is moved to the right, plate (6) tilts to the right. Plate (6) pushes down on rod (7).
Seat (10) moves down against the force of metering spring (11) and spring (12). The force of
metering spring (11) shifts spool (16) downward. Passage (15) opens. The pilot oil flows through
passage (20), passage (18), passage (15), and port (19) to the main control valve. The pilot oil
pressure shifts the spool of the main control valve. This enables the implement operation or swing
operation.
The return pilot oil at the opposite end of the spool in the main control valve returns to the pilot
control valve through port (17). Since rod (2) is not pushed down by plate (6), return passage (3) is
open and passage (4) is closed. The return pilot oil flows through return passage (3), return chamber
(13), and port (21) to the hydraulic tank.
The force of metering spring (11) varies with the position of the joystick. Since spool (16) is moved
by the force of metering spring (11), the pilot oil pressure that flows through passage (15) to the
main control valve directly corresponds with the position of the joystick. Spool modulation in the
main control valve directly corresponds with the amount of movement of the joystick.
When the joystick is moved slightly from the NEUTRAL position, metering spring (11) moves spool
(16) slightly. Low pilot oil pressure is sent to the spool of the main control valve. The main control
valve spool shifts a slight amount. The volume of oil delivery to the cylinders and/or motors is small.
The speed of the cylinders and/or motors is slow. As the joystick is moved farther from the
Pgina 4 de 4
NEUTRAL position, the force of metering spring (11) on spool (16) increases. The pilot oil pressure
that is sent to the main control valve increases. The spool in the main control valve shifts farther and
the speed of the cylinders and/or motors increases. Thus, cylinder speed and motor speed is
controlled by the amount of movement and the position of the joystick.
When the joystick is moved slightly from the NEUTRAL position, only metering spring (11) acts on
spool (16). Fine control of the cylinders and/or motors is accomplished since the pilot oil pressure
that is sent to the main control valve is decreased. As the joystick is moved farther from the
NEUTRAL position, the bottom of rod (7) comes in contact with spring (8). Now, the combined
force of metering spring (11) and spring (8) act on spool (16). The pilot oil pressure increases
rapidly. The cylinders and/or motors respond more rapidly.
When the joystick is released, the joystick will return to the NEUTRAL position due to the force of
spring (12).

Tue Oct 17 18:12:40 EST 2006
Pgina 1 de 6
Cerrar SIS
Pantalla anterior

i02353810
Solenoid Valve (Hydraulic Lockout)

SMCS - 5479
Illustration 1
g01175796
Pilot oil manifold

Pgina 2 de 6
(2) Solenoid valve for hydraulic lockout
Illustration 2
Cab
g01113479
(3) Hydraulic lockout lever (LOCKED position)
Illustration 3
Cab
g01113885
(3) Hydraulic lockout lever (UNLOCKED position)
Illustration 4
(3) Hydraulic lockout lever
Pgina 3 de 6
g01113912
(4) Plunger
(5) Bar
(6) Limit switch
Limit switch (6) and plunger (4) are located on a bracket with hydraulic lockout lever (3). The limit
switch is activated by hydraulic lockout lever (3) .
When hydraulic lockout lever (3) is shifted to the LOCKED position, solenoid valve (2) of pilot oil
manifold (1) is not energized. Pilot oil is not supplied to the pilot control valves. Thus when the
joysticks and/or the travel levers/pedals are operated, the cylinders or the motors are not activated
also.
The engine will not start unless hydraulic lockout lever (3) is in the LOCKED position. If some one
unexpectedly operates the machine, the machine will not operate.
When hydraulic lockout lever (3) is placed in the UNLOCKED position, solenoid valve (2) is
energized and pilot oil passes through the solenoid valve. Pilot oil now flows to the pilot control
valves.
Pgina 4 de 6
Illustration 5
Partial diagram of solenoid valve (hydraulic lockout) (UNLOCKED circuit)
(7) Solenoid
(8) Spring
(9) Spool
(10) Control valve
(11) Passage
(12) Passage
(13) Passage
(14) Passage (return oil)
(15) Passage (pilot oil to swing brake solenoid valve)
(17) Pilot oil flow to pilot valves (joysticks)
Pgina 5 de 6
(19) Passage
When hydraulic lockout lever (3) is placed in the UNLOCKED position, plunger (4) of limit switch
(6) is depressed by control lever (3). Limit switch (6) is in the ON state.
The hydraulic lockout valve (2) consists of solenoid (7) and control valve (10). When hydraulic
lockout lever (3) is in the UNLOCKED position, solenoid (7) controls valve (10). When solenoid (7)
is energized, spool (9) moves in a downward direction against the force of spring (8). Passage (12)
opens. Pilot pressure oil from passage (13) flows through passage (11) to valve (18). The spool in
valve (18) moves in a downward direction. Pilot pressure oil in passage (19) flows through valve
(18). Pilot oil is now delivered through passage (15) to swing brake solenoid valve (16). Pilot
pressure oil in passage (19) is also delivered to the pilot control valves (joysticks and travel
levers/pedals) through line (17).
Illustration 6
g01218083
Partial drawing of solenoid valve (hydraulic lockout) (LOCKED position)

(7) Solenoid
(8) Spring
(9) Spool
Pgina 6 de 6
(11) Passage
(12) Passage
(13) Passage
(20) Passage
When hydraulic lockout lever (3) is moved to the LOCKED position, plunger (4) of limit switch (6)
is not depressed by control lever (3). Limit switch (6) is in the OFF state.
When hydraulic lockout lever (3) is in the LOCKED position, solenoid (7) is not energized. Spool
(9) is forced upward by spring (8). Passage (20) opens and passage (12) closes. Passage (13) is not
open to passage (11). Pilot oil supply to line (17) is stopped. Pilot oil supply to the pilot control
valves (joysticks and travel levers/pedals) is blocked. The cylinders and the motors can not be
activated.

Tue Oct 17 18:07:25 EST 2006
Pgina 1 de 5
Cerrar SIS
Pantalla anterior

i02482038
Main Hydraulic Pump

SMCS - 5070-MV
Construction
Illustration 1
Pgina 2 de 5
Main pumps
(1) Port (negative flow control pressure for drive pump)
(2) Outlet port (pilot pressure)
(3) Idler pump
(4) Outlet port (idler pump)
(5) Inlet port (supply oil from the hydraulic tank)
Pgina 3 de 5

(7) Port (negative flow control pressure for idler pump)
(8) Drive pump
(9) Outlet port (drive pump)
(10) Housing
(11) Pilot pump
(14) Port (power shift pressure)
(15) Case drain port
The main pump consists of drive pump (8) and idler pump (3). The drive pump and the idler pump
are contained in an integral housing. Both pumps are variable displacement piston pumps. The drive
pump and the idler pump are identical in construction and operation.
Supply oil from the hydraulic tank enters inlet port (5). The single inlet port is common to main
pumps (8) and (3) as well as pilot pump (11). The drive pump delivers oil through outlet port (9).
The idler pump delivers oil through outlet port (4). The pilot pump delivers oil through outlet port
(2) .
Both the drive pump and the idler pump have a regulator as part of the pump control system. The
flow control of the pumps is performed by the operation of the regulators. The control system is
identical for both pumps.
Proportional reducing valve (6) for the power shift pressure is located on the head of the main pump.
The proportional reducing valve is controlled by the machine ECM. The proportional reducing valve
controls the signal from the power shift pressure for both the drive pump and the idler pump.
Negative flow control pressure from the main control valve enters the drive pump regulator at port
(1). Negative flow control pressure from the main control valve enters the idler pump regulator at
port (7) .
Case drain oil from the pump housing flows from port (15) to the case drain filter.
Operation
Illustration 2
Pgina 4 de 5
Main pumps (sectional view)

(3) Idler pump
(8) Drive pump
(11) Pilot pump
(16) Gear
(17) Drive shaft
(18) Drive shaft
(19) Gear
(20) Swashplate
(21) Plate
(22) Retainer
(23) Piston slipper
(24) Piston
(25) Barrel
(26) Port plate
Pgina 5 de 5
(27) Passage
Gear (19) of drive shaft (18) meshes with gear (16) of drive shaft (17). Gear (16) and gear (17) have
the same number of teeth. Drive shaft (18) of drive pump (8) is connected to the engine by a
coupling. When the engine is running, drive shaft (17) and drive shaft (18) rotate at the same speed.
Therefore, drive pump (8) and idler pump (3) rotate at the same speed.
Pilot pump (11) is directly connected with drive shaft (17) .
Barrel (25) contains nine pistons (24). Piston slippers (23) are connected to pistons (24) by retainers
(22). The piston slippers are pressed against plate (21). Plate (21) lies on swashplate (20). Barrel (25)
is splined to drive shaft (18). As drive shaft (18) rotates, the barrel, the pistons and the piston slippers
rotate around swashplate (20) .
The angle of swashplate (20) determines the length of stroke of piston (24). As the angle of the
swashplate increases, the length of stroke of the pistons increases and the output flow of the pump
increases. As piston slipper (23) rotates around the swashplate, the piston moves out of barrel (25).
The piston draws oil from passage (27) of port plate (26) during this movement. As the piston slipper
continues to rotate around the swashplate, the piston moves into the barrel. The piston delivers oil to
outlet port (13) during this movement. The oil delivery from ports (4) and (9) flows to the main
control valve.

Tue Oct 17 18:18:35 EST 2006
Pgina 1 de 10
Cerrar SIS
Pantalla anterior

i02585451
Pump Control (Main Hydraulic) - Main Pump Regulator

SMCS - 3222; 5070; 5086
Operation
The regulators for the drive pump and the idler pump are identical in construction and operation. The
following description is given for the drive pump regulator.
The main pump regulators are controlled in the following manner.
Power Shift System - The pump regulators are controlled by the electronic control system. The
engine and pump controller continually monitors the engine speed and the load on the engine. The
engine and pump controller sends an electrical signal to the proportional reducing valve for power
shift pressure. The proportional reducing valve assists in controlling the output flow of the pumps by
changing the hydraulic signal pressure (power shift pressure) that flows to the pump regulators.
Cross sensing control - The pump regulators are controlled by cross sensing control. In order to
maintain the engine horsepower to the pumps at a constant rate, the pump regulators receive average
delivery pressure of the drive pump and the idler pump through the cross sensing control. This is
called constant horsepower control.
Negative Flow Control - When the joysticks and/or the travel levers/pedals are in the NEUTRAL
position or when the joysticks and/or the travel levers/pedals are partially moved from the
NEUTRAL position, the pump regulators receive negative flow control pressure from the main
control valve. The main pumps are controlled by negative flow control pressure at this time.
ReferenceFor more information concerning the power shift system, refer to Systems Operation,
"Pilot Hydraulic System".
ReferenceFor more information concerning the negative flow control operation at the main control
valve, refer to Systems Operation, "Negative Flow Control System".
Illustration 1
P-Q characteristic curve
Pgina 2 de 10
g00687567
(A) Pressure/flow point (destroke point)

(B) P-Q characteristic curve
The output characteristics of each pump depends on the following pressures.

z
Pump output circuit pressure
Power shift pressure
Negative flow control pressure
The flow rate of each pump is represented on P-Q characteristic curve (B) from pressure/flow point
(A) . Each point on the P-Q characteristic curve represents the flow rate and pressure when pump
output horsepower is maintained at a constant rate.
Pump Regulator
Illustration 2
Pgina 3 de 10
Idler pump regulator

(1) Spool
(2) Shoulder
Pgina 4 de 10
(3) Piston
(4) Passage
(5) Plate
(6) Feedback lever
(7) Spring
(8) Spring
(CF) Cross sensing control pressure
(PD) Delivery pressure (drive pump)
(11) Chamber
(12) Piston
(13) Swashplate
(14) Chamber
(15) Rod
(16) Regulator
(18) Rod
Pump delivery pressure (PD) acts on pilot piston (3) and spool (1) of regulator (16) . Power shift
pressure (PS) enters regulator (16) through a passage through the main pump housing. The oil then
goes through passage (10) to piston (9) .
During constant horsepower flow control, pump delivery pressure (PD) is acting on the right
shoulder of pilot piston (3) . Also during constant horsepower flow control, power shift pressure (PS)
and cross sensing control pressure (CP) from the idler pump is acting on the left end of piston (3) .
When the total force of the three pressures is less than the force of spring (7) and spring (8) , pilot
piston (3) remains stationary. Swashplate (13) maintains the maximum angle for maximum pump
flow. When the total force of the three pressures is greater than the force of spring (7) and spring
(8) , pilot piston (3) is shifted in order to decrease the swashplate angle which will destroke the
pump.
During negative flow control, negative flow control pressure (PN) from line (17) acts on the left end
surface of pilot piston (18) . Pilot piston (18) shifts in order to move feedback lever (5) , spool (1)
and related components. Negative flow control is maximum when all the control levers are in the
NEUTRAL position which requires no pump flow.
Regulator Operation (full stroke position)
Illustration 3
Pgina 5 de 10
Drive pump regulator

(1) Spool
(2) Shoulder
(3) Piston
(4) Passage
(5) Plate
(6) Feedback lever
(7) Spring
(8) Spring
(9) Piston
Pgina 6 de 10

(11) Chamber
(12) Piston
(13) Swashplate
(14) Chamber
Main pump delivery pressure (PD) acts on shoulder (2) of pilot piston (5) . Power shift pressure (PS)
from passage (10) acts on piston (9) and on the left end of pilot piston (3) . When the total force of
main pump delivery pressure (PD) , power shift pressure (PS) , and cross sensing control pressure
(CF) is less than the total force of spring (7) and spring (8) pilot piston (3) remains stationary. Plate
(5) , feedback lever (6) , and spool (1) remain stationary. Passage (4) remains blocked. Main pump
delivery pressure (PD) cannot enter piston chamber (11) while there is main pump delivery pressure
(PD) in piston chamber (14) . Piston (12) is shifted all the way to the left. Swashplate (13) is held at
a maximum angle which allows the pump to maintain maximum output flow. Main pump delivery
pressure (PD) , power shift pressure (PS) , and cross sensing control pressure (CF) flow to the
regulator from passages within the main pump housing.
Regulator Operation (minimum stroke position)
Illustration 4
Pgina 7 de 10
Pump regulator (machine at idle condition)

(1) Spool
(2) Shoulder
(3) Piston
(4) Passage
(5) Plate
(6) Feedback lever
(7) Spring
(8) Spring
(9) Piston
Pgina 8 de 10

(11) Chamber
(12) Piston
(13) Swashplate
(14) Chamber
(15) Rod
When all of the controls are in the NEUTRAL position, no load is present to the drive pump which
causes a increase in power shift pressure (PS) and a increase in drive pump delivery pressure (PD)
inside the pump. The larger pressures from power shift pressure (PS) , delivery pressure (PD) , and
cross sensing control pressure (CF) combine in order to overcome the forces of spring (7) and spring
(8) which shifts piston (3) .
Piston (3) shifts rod (15) to the right, rotating lever (6) , which rotates lever (5) . Lever (5) is
connected to spool (1) . When lever (5) is rotated spool (1) shifts to the right. This opens passage
(4) . Delivery pressure (PD) now flows to chamber (11) . Lever (5) is also connected to piston (12) .
When lever (5) is rotated a force is placed against piston (12) . The combined force of delivery
pressure (PD) and force from lever (5) causes piston (12) to shift to the right. Piston (12) then rotates
swashplate (13) to zero angle. The pump displacement is now minimal.
Regulator Operation (standby position)
Illustration 5
Pgina 9 de 10
Drive pump regulator

(1) Spool
(2) Shoulder
(3) Piston
(4) Passage
(5) Plate
(6) Feedback lever
(7) Spring
(8) Spring
(9) Piston
Pgina 10 de 10

(11) Chamber
(12) Piston
(13) Swashplate
(14) Chamber
The regulator is in the standby mode when all the controls are in the NEUTRAL position and the
engine and pump controller raises the power shift pressure to a level that is dependent on the engine
speed. Power shift pressure (PS) acts on piston (9) . Cross sensing control pressure from the idler
pump acts on piston (3) as well as delivery pressure (PD) . Negative flow control pressure is at
maximum pressure, which acts against piston (18) . The engine speed keeps delivery pressure (PD)
higher than the negative flow control pressure, power shift pressure (PS) , and cross sensing flow
pressure (CF) . Spring (7) and spring (8) also act with delivery pressure to keep piston (12) from
shifting to the right. The swashplate is at a maximum angle. Standby keeps the pump at a maximum
angle, although little pressure is needed to destroke the pump.

Tue Oct 17 18:21:39 EST 2006
Pgina 1 de 11
Cerrar SIS
Pantalla anterior

i02483768
Negative Flow Control System

SMCS - 5050-NE
Introduction
The right pump and the left pump receive signal oil pressure from the center bypass passages of the
main control valve. This signal oil pressure that is created in the center bypass passages of the main
control valve is called negative flow control pressure. Negative flow control pressure flows to the
regulators at the right pump and the left pump in order to control the output flow of the pumps.
Negative flow control pressure is created during the following machine operating conditions.
z
All of the joysticks and travel levers/pedals are in the NEUTRAL position.
Any of the joysticks and/or travel levers/pedals are partially moved from the NEUTRAL
position in order to perform a fine control operation.
A boom lower operation is performed alone.
Illustration 1
g00690034
Main control valve (top view)

(12) Negative flow control line to left pump
Pgina 2 de 11
(13) Negative flow control line to right pump
The right body of the control valve receives supply oil from the right pump. Negative flow control
pressure from the right body of the main control valve flows through negative flow control line (13)
to the right pump. The left body of the control valve receives supply oil from the left pump. Negative
flow control pressure from the left body of the main control valve flows through negative flow
control line (12) to the left pump. The negative flow control operation of the right pump and the left
pump is identical.
Pgina 3 de 11
Pgina 4 de 11
Illustration 2
Negative flow control operation (control valves in the NEUTRAL position)
(1) Center bypass passage
(2) Return line
(4) Passage
(5) relief valve (negative flow control)
(7) Negative flow control orifice
(8) Port
(10) Passage
(11) Return passage
(14) Left pump
(15) Right pump
(16) Pilot pump
Illustration 3
Bucket control valve (NEUTRAL position)
Pgina 5 de 11
g01210684
Illustration 3 shows the negative flow control operation at the main control valve when all of the
control valves are in the NEUTRAL position. When all of the joysticks and the travel levers/pedals
are in the NEUTRAL position, the spools of the individual control valves are in the NEUTRAL
position. Oil flow to the cylinders and motors is blocked. Center bypass passages (1) and (3) are
open.
All of the oil delivery from right pump (15) flows through center bypass passage (3), passage (4) and
negative flow control orifice (9) to return line (2). Negative flow control orifice (9) restricts the oil
flow. The pressure in passage (4) increases. Increased negative flow control pressure now flows
through passage (10) and negative flow control line (13) to the pump regulator. The negative flow
control operation of the right pump regulator causes the swashplate of the right pump to move to the
minimum angle position. The output flow of the right pump is decreased due to the increased
negative flow control pressure that is created in center bypass passage (3) .
Since center bypass passage (1) is also open, the negative flow control operation of the left pump
regulator is identical to the negative flow control operation of the right pump regulator.
ReferenceFor more information concerning the negative flow control operation of the main pump
regulators, refer to Systems Operation, "Pump Control (Main Hydraulic)".
Pgina 6 de 11
Pgina 7 de 11
Illustration 4
Negative flow control operation (bucket control valve in the BUCKET CLOSE position)
(2) Return line
(4) Passage
(8) Port
(10) Passage
(11) Return passage
(14) Left pump
(15) Right pump
(16) Pilot pump
Illustration 5
Bucket control valve (BUCKET CLOSE position)
Pgina 8 de 11
g01210689
Illustration 5 shows the negative flow control operation at the main control valve when only the
bucket control valve is in the BUCKET CLOSE position.
All of the control valves in the left body of the main control valve are in the NEUTRAL position.
Center bypass passage (1) is open. All of the oil delivery from the left pump flows through center
bypass passage (1) to negative flow control orifice (7). Since all of the oil delivery from left pump
(14) is restricted by negative flow control orifice (7), negative flow control pressure (PN) in center
bypass passage (1) is at maximum pressure. The negative flow control pressure flows through
negative flow control line (12) to the left pump regulator. The negative flow control operation of the
left pump regulator causes the swashplate of the left pump to move to the minimum angle position.
The output flow of the left pump is decreased due to the increased negative flow control pressure
that is created in center bypass passage (1) .
The joystick for the bucket has been moved fully to the BUCKET CLOSE position. Pilot oil has
fully shifted the bucket control valve. The oil delivery from right pump (15) flows into the right body
of the main control valve. The oil delivery flows through center bypass passage (3) to the bucket
control valve. Since the spool in the bucket control valve is fully shifted, center bypass passage (3) is
blocked. All of the oil delivery from the right pump flows to the head end of the bucket cylinder. No
oil flows to negative flow control orifice (9) and no negative flow control pressure is created in
center bypass passage (3). Since no negative flow control pressure is sent to the right pump
regulator, the right pump regulator moves the swashplate of the right pump toward the maximum
Pgina 9 de 11
angle position. The output flow of the right pump is increased since no negative flow control
pressure is created in center bypass passage (3) .
Fine Control Operation
Illustration 6
Bucket control valve (fine control)
g01210692

(21) Parallel feeder passage
(22) Port
(23) Spool
(24) Passage
(P) Pilot pressure
When the joystick for the bucket is in the NEUTRAL position, spool (23) is in the NEUTRAL
position. The oil delivery from the right pump flows through center bypass passage (3) to negative
flow control orifice (9). When the joystick for the bucket is partially moved from the NEUTRAL
position in order to perform a fine control operation, pilot pressure (P) enters the control valve at the
Pgina 10 de 11
pilot port. Pilot pressure shifts spool (23) slightly to the left. The movement of spool (23) partially
opens passage (24). Center bypass passage (3) is partially blocked.
The oil delivery from the right pump is now divided into two flow paths. A portion of the oil
delivery from the right pump flows through center bypass passage (3) to negative flow control
orifice (9). The remainder of the oil delivery from the right pump flows through parallel feeder
passage (21) and passage (24) to port (22). The oil flow from center bypass passage (3) to negative
flow control orifice (9) decreases. The flow resistance through the negative flow control orifice
decreases and the negative flow control pressure (PN) in passage (4) decreases. The negative flow
control pressure that is sent to the regulator at the right pump decreases. The pump regulator causes
the swashplate of the right pump to move toward the maximum angle position. The output flow of
the pump is increased due to the decrease in negative flow control pressure (PN) .
When the joystick for the bucket is moved to the full stroke position, spool (23) shifts fully to the
left. Center bypass passage (3) is now blocked by spool (23). Since there is no oil flow through
center bypass passage (24), no negative flow control pressure is created. The swashplate of the right
pump is moved to the maximum angle position. The output flow of the right pump is maximum. The
output flow of the right pump is now controlled by the constant horsepower flow control.
The ability to modulate the negative flow control pressure by partial movement of the joystick
enables fine control of the implements.
Relief Valve (Negative Flow Control)
Illustration 7
(2) Return line
Pgina 11 de 11
g01210695

(4) Passage
(5) Relief valve for negative flow control
(11) Return passage
(17) Plug
(18) Spring
(19) Relief valve body
(20) Valve
(PN) Negative flow control pressure
The following description is given for the operation of the relief valve that is located in the right
body of the main control valve. The operation of the relief valve for the negative flow control that is
located in the left body of the main control valve is identical.
Relief valve (5) for the negative flow control consists of plug (17), spring (18), relief valve body (19)
and valve (20). When any one of the joysticks and/or travel levers/pedals is at the full stroke
position, the oil flow through center bypass passage (3) is blocked. No oil flows to the relief valve
for the negative flow control.
When all of the joysticks and/or travel levers/pedals are suddenly returned to the NEUTRAL
position, all of the output flow from the right pump flows through center bypass passage (3). The
negative flow control pressure in center bypass passage (3) and passage (4) suddenly increases.
When the negative flow control pressure becomes higher than the pressure setting of relief valve (5)
for the negative flow control, valve (20) shifts to the left against the force of spring (18). Oil in
center bypass passage (3) is now allowed to flow past valve (20) into return passage (11) to the
hydraulic tank. This prevents the hydraulic shock that occurs due to sudden changes in negative flow
control pressure.
After the hydraulic shock is relieved by the relief valve for the negative flow control, the force of
spring (18) shifts valve (20) to the right. All of the output flow from the right pump flows through
center bypass passage (3), negative flow control orifice (9) and return line (2) to the hydraulic tank.
Negative flow control pressure (PN), that is created in center bypass passage (3), reaches maximum
pressure since all of the oil flow is restricted by negative flow control orifice (9). The negative flow
control pressure flows to the right pump regulator. The regulator at the right pump causes the
swashplate of the right pump to move to the minimum angle position. The output flow of the right
pump is decreased due to the increase in negative flow control pressure (PN) .

Tue Oct 17 18:35:57 EST 2006
Pgina 1 de 5
Cerrar SIS
Pantalla anterior

i02580933
Relief Valve (Line)

SMCS - 5117
Each line relief valve contains a makeup valve. The line relief valves are located between each
cylinder and the respective control valve.
When the control valves for the cylinders are in the NEUTRAL position and an external force acts
on one end of the cylinder, the oil pressure increases on the opposite end of the cylinder. The oil
pressure also increases in the passage of the line relief valve that is connected to the cylinder. The
line relief valve relieves the high pressure. The line relief valves limit the circuit pressure to the
specified pressure settings.
ReferenceRefer to Testing and Adjusting, "Specifications" for the line relief valve pressure settings.
Pgina 2 de 5
Illustration 1
Line relief valve (CLOSED position)
(1) Passage
(2) Valve
(3) Valve
(4) Spring chamber
(5) Valve
(6) Spring
(7) Piston
(8) Return passage
(9) Passage
The high pressure between the cylinder and the control valve is transmitted to passage (1) . This
pressurizes the line relief valve. The pressure oil flows from passage (1) through passage (9) of
piston (7) . The oil then flows into spring chamber (4) . When the oil pressure is lower than the line
relief valve pressure setting, valve (5) remains in the CLOSED position by the force of spring (6) .
The oil pressure in passage (1) and the oil pressure in spring chamber (4) are equal. The surface area
of the right side of valves (2) and (3) is larger than the surface area of the left side. The force on the
Pgina 3 de 5
right side of valves (2) and (3) is greater than the force on the left side. Valves (2) and (3) are forced
to the left. The pressure oil does not flow from passage (1) to passage (8) .
Illustration 2
Line relief valve (OPEN position)

(1) Passage
(3) Valve
(4) Spring chamber
(5) Valve
(6) Spring
(7) Piston
(8) Return passage
(9) Passage
(10) Valve chamber
(11) Passage
Pgina 4 de 5
(12) Passage
When the high pressure oil in passage (1) reaches the line relief valve pressure setting, valve (5)
overcomes the force of spring (6) and opens. The high pressure oil flows from valve chamber (10)
through passage (12) to return passage (8) . The pressure now becomes low pressure. The pressure in
passage (1) pushes piston (7) to the right until the piston comes in contact with the left end of valve
(5) . The oil in passage (1) flows around the end of piston (7) and the oil enters spring chamber (4) .
Since the flow around the outside of piston (7) is restricted, the oil in spring chamber (4) becomes
low pressure oil. As a result, valve (3) is pushed to the right. Passage (11) opens. the oil flows from
passage (1) to passage (8) .
Illustration 3
Line relief valve (makeup operation)
(1) Passage
(2) Valve
(3) Valve
(4) Spring chamber
(8) Return passage
(9) Passage
Pgina 5 de 5
(13) Shoulder
The line relief valve functions as a makeup valve in the following manner.
When oil from one end of the cylinder is discharged through the line relief valve, a vacuum
condition is created on the opposite end of the cylinder. Makeup oil is needed to prevent the vacuum
condition in the cylinder.
When the vacuum condition occurs on the end of the cylinder that is connected to passage (1) , a
vacuum condition also occurs in spring chamber (4) . The pressure of the oil in passage (8) acts on
shoulder (13) of valve (2) . Since a vacuum condition is present in spring chamber (4) , the pressure
in spring chamber (4) is lower than the pressure of the return oil in passage (8) . Valves (2) and (3)
are pushed to the right by the pressure of the return oil in passage (8) . Return oil flows from passage
(8) to passage (1) as makeup oil in order to remove the vacuum condition in the cylinder.

Tue Oct 17 19:20:12 EST 2006
Pgina 1 de 7
Cerrar SIS
Pantalla anterior

i02371737
Relief Valve (Main)

SMCS - 5069
S/N - EAH1-UP
S/N - FFK1-UP
S/N - MEY1-UP
S/N - NBD1-UP
Pgina 2 de 7
Illustration 1
Pgina 3 de 7
Cross section of straight travel control valve and main relief valve
(4) Check valve
(5) Check valve
(7) Delivery line (left pump)
(8) Delivery line (right pump)
(9) Left pump
(10) Right pump
(11) Internal passage
Main relief valve (6) is located in the left side of the main control valve. The main relief valve limits
the maximum operating pressure of the travel hydraulic circuit and the implement hydraulic circuits
when the machine is at a load condition.
The oil delivery from right pump (10) enters main control valve (2) through delivery line (8). The oil
delivery from left pump (9) enters main control valve (2) through delivery line (7). Right pump oil
and left pump oil flows through check valves (4) and (5) to passage (11). Check valves (4) and (5)
ensure that only the higher oil pressure from the right pump or the left pump flows through passage
(11) to main relief valve (6) .
Closed Position
Pgina 4 de 7
Illustration 2
Main relief valve (closed position)
(11) Passage
(12) Seat
(13) Valve
(14) Spring
(15) Spring chamber
(16) Seat
(17) Poppet
(18) Spring
Pgina 5 de 7
(19) Passage
(20) Orifice
(21) Return passage
Poppet (17) is positioned to the left against seat (16) by the force of spring (18). Valve (13) is
positioned to the left against seat (12) by the force of spring (14) .
System pressure oil in passage (11) flows through orifice (20) into spring chamber (15). The force of
the system pressure oil acts on poppet (17). When the force of system pressure oil in passage (11) is
less than the force of spring (18), poppet (17) remains against seat (16). The pressure in passage (11)
and the pressure in spring chamber (15) are now equal. System pressure oil in spring chamber (15)
and the force of spring (14) maintain valve (13) against seat (12). There is no oil flow from passage
(11) to return passage (21). When main pump oil pressure in passage (11) is less than the main relief
pressure setting, main relief valve (6) remains in the closed position.
Open Position
Pgina 6 de 7
Illustration 3
Main relief valve (open position)
(11) Passage
(12) Seat
(13) Valve
(14) Spring
(15) Spring chamber
(16) Seat
(17) Poppet
(18) Spring
Pgina 7 de 7
(19) Passage
(20) Orifice
(21) Return passage
(22) Passage
(23) Valve chamber
(24) Locknut
System oil pressure in passage (11) and spring chamber (15) nears the main relief valve pressure
setting. The force of the system oil pressure in spring chamber (15) becomes greater than the force of
spring (18). Poppet (17) away from seat (16). System oil pressure now flows through seat (16) into
valve chamber (23). The oil in valve chamber (23) now flows through passage (22) into return
passage (21). This low pressure oil now returns to the hydraulic tank.
At the same time as the oil in spring chamber (15) flows through seat (16), the system pressure oil in
passage (11) flows through orifice (20). As the system oil pressure flows through orifice (20) into
spring chamber (15) the pressure of the oil in spring chamber (15) decreases. The reduced pressure
oil in spring chamber (15) allows the high pressure oil in passage (11) to force valve (13) away from
seat (12). The high pressure oil in passage (11) now flows into passage (19) and return passage (21)
to the hydraulic tank.
The amount of spring force of spring (18) that acts on poppet (17) determines the main relief valve
pressure setting. Adjustments to the main relief valve pressure setting are made by changing the
spring force of spring (18). The position of adjustment screw (25) determines the spring force of
spring (18) .
ReferenceRefer to Testing and Adjusting, "Relief Valve (Main) - Test and Adjust" for adjustment
procedures.

Tue Oct 17 18:41:49 EST 2006
Pgina 1 de 13
Cerrar SIS
Pantalla anterior

i02613506
Main Control Valve

SMCS - 5051
Illustration 1
g01239945
Hydraulic schematic
(2) Line relief valve (stick cylinder rod end)
(4) Line relief valve (boom cylinder head end)
(5) Return port
(7) Stick regeneration valve
(8) Load check valve
(12) Attachment control valve
(13) Bucket control valve
Pgina 2 de 13

(16) Stick II control valve
(17) Relief valve (negative flow)
(19) Relief valve (negative flow)
(21) Boom II control valve
(22) Stick I control valve
(24) Swing control valve
(27) Boom regeneration valve
(28) Line relief valve (boom cylinder rod end)
(30) Line relief valve (stick cylinder head end)
(33) Stick unloading valve
(34) Line relief valve (bucket cylinder rod end)
(35) Line relief valve (bucket cylinder head end)
(37) Pressure port (left pump)
(38) Negative flow control line (left pump)
(39) Pressure port (right pump)
(40) Negative flow control line (right pump)
(41) Left pump
(42) Pilot pump
(43) Right pump
Pgina 3 de 13
(44) Hydraulic tank
Illustration 2
Main control valve ports

(AR1) Right travel control valve (REVERSE TRAVEL)
(AR2) Attachment control valve (port)
(AR3) Bucket control valve (BUCKET CLOSE)
(AR4) Boom I control valve (BOOM LOWER)
(AR5) Stick II control valve (STICK IN)
(BR1) Right travel control valve (FORWARD TRAVEL)
Pgina 4 de 13
(BR2) Attachment control valve (port)

(BR3) Bucket control valve (BUCKET OPEN)
(BR4) Boom I control valve (BOOM RAISE)
(BR5) Stick II control valve (STICK OUT)
(AL1) Left travel control (REVERSE TRAVEL)
(AL2) Swing control valve (SWING LEFT)
(AL3) Stick I control valve (STICK IN)
(AL4) Boom II control valve (BOOM RAISE)
(BL1) Left travel control valve (FORWARD TRAVEL)
(BL2) Swing control valve (SWING RIGHT)
(BL3) Stick I control valve (STICK OUT)
(aR1) Pilot port at right travel control valve (REVERSE TRAVEL)
(aR2) Pilot port at attachment control valve
(aR3) Pilot port at bucket control valve (BUCKET CLOSE)
(aR4) Pilot port at boom I control valve (BOOM LOWER)
(aR5) Pilot port at stick II control valve (STICK IN)
(aL1) Pilot port at left travel control valve (REVERSE TRAVEL)
(aL2) Pilot port at swing control valve (SWING LEFT)
(aL3) Pilot port at stick I control valve (STICK IN)
(aL4) Pilot port at boom II control valve (BOOM RAISE)
(bR1) Pilot port at right travel control valve (FORWARD TRAVEL)
(bR2) Pilot port at attachment control valve
(bR3) Pilot port at bucket control valve (BUCKET OPEN)
(bR4) Pilot port at boom I control valve (BOOM RAISE)
(bR5) Pilot port at stick II control valve (STICK OUT)
(bL1) Pilot port at left travel control valve (FORWARD TRAVEL)
(bL2) Pilot port at swing control valve (SWING RIGHT)
(bL3) Pilot port at stick I control valve (STICK OUT)
(bL4) Pilot port at boom II control valve (STICK IN)
Pgina 5 de 13
(DST) Drain port (straight travel control valve)

(HL) Negative flow signal pressure port (left pump)
(HR) Negative flow signal pressure port (right pump)
(Pi1) Pilot port (boom regeneration valve)
(Pi2) Pilot port (stick regeneration valve)
(Pi3) Pilot port (variable swing priority valve)
(Pi4) Pilot port (straight travel solenoid valve)
(R2) Return port
(R3) Return port
Introduction
Illustration 3
g00689566

Pgina 6 de 13

(28) Line relief valve (boom cylinder rod end)
(30) Line relief valve (stick cylinder head end)
(45) Right body
(46) Left body
Illustration 4
Main control valve (bottom view)
g00689579

(4) Line relief valve (boom cylinder head end)
Illustration 5
g00689582
Bottom view of main control valve
Pgina 7 de 13

(2) Line relief valve (stick cylinder rod end)
Main control valve (6) is located in the hydraulic system between the main pumps and actuators
(cylinders and motors). Depending on the machine operation, the oil flow from right pump (43) , left
pump (41) and pilot pump (42) to the hydraulic circuits are controlled by the operation of each
component in the main control valve. By this control, the speed and direction of the cylinders and the
motors can be controlled and adjusted. The pump delivery pressure can be controlled and adjusted.
The main control valve includes right body (46) and left body (45) . The main control valve is
coupled together with bolts in order to make one assembly.
1. The right travel control valve (11) , attachment control valve (12) , bucket control valve (13) ,
boom I control valve (15) and stick II control valve (16) are located in right body (46) . The
right pump oil is delivered through pressure port (39) , center bypass passage (14) and return
port (5) to hydraulic tank (44) . In addition, the following components are located in right body
(46) .
a. The line relief valve (bucket cylinder rod end) (34) and the line relief valve (bucket
cylinder head end) (35) limit the pressure in the bucket circuit due to external forces.
b. When the joysticks and/or travel levers/pedals are in the NEUTRAL position, or when
the joysticks and/or travel levers/pedals are partially moved from the NEUTRAL
position, negative flow control relief valve (19) and the negative flow control orifice
(29) decrease the pump flow.
c. Boom drift reduction valve (3) prevents boom drift when the joystick for the boom is in
the NEUTRAL position. The line relief valve (boom cylinder head end) (4) is mounted
on the boom drift reduction valve. The line relief valve (boom cylinder rod end) (28) is
also located on the right body.
d. Boom regeneration valve (27) supplies return oil from the head end of the boom
cylinders to the rod end of the boom cylinders when the boom is lowered.
e. Load check valves (26) are part of the following control valves: attachment control
valve (12) , bucket control valve (13) , boom I control valve (15) and stick II control
valve (16) .
1. Straight travel control valve (18) , left travel control valve (25) , swing control valve (24) ,
stick I control valve (22) and boom II control valve (21) are located in left body (45) . The left
pump oil is delivered through pressure port (37) , center bypass passage (23) and return port
(5) to hydraulic tank (44) .
Note: In addition, the following components are located in left body (45) .
a. Stick drift reduction valve (1) prevents stick drift when the joystick for the stick is in the
NEUTRAL position. The line relief valve (stick cylinder rod end) (2) is mounted on the
stick drift reduction valve. The line relief valve (stick cylinder head end) (30) is also
located on the left body.
b. When the joysticks and/or travel levers/pedals are in the NEUTRAL position, or when
the joysticks and/or travel levers/pedals are partially moved from the NEUTRAL
Pgina 8 de 13
position, negative flow control relief valve (17) and the negative flow control orifice
(20) decrease the pump flow.
c. Stick regeneration valve (7) supplies return oil from the rod end of the stick cylinder to
the head end of the stick cylinder during the stick in function.
d. Stick unloading valve (33) reduces the back pressure in the rod end of the stick cylinder
during the stick in function.
e. Load check valves (8) are part of the following control valves: swing control valve (24)
and stick I control valve (22) .
f. Main relief valve (32) limits the main hydraulic system pressure.
z
When the main control valve is in the NEUTRAL position, no pump oil flows to the cylinders
and the motors. Main control valve operation in the NEUTRAL position is described later in
this section.
The main control valve controls the negative flow control signal. For more information on the
negative flow control operation, refer to Systems Operation, "Negative Flow Control System".
The main control valve prevents cylinder drift with the load check valves. For more
information on the load check valves, refer to Systems Operation, "Check Valve (Load)".
The main control valve limits the circuit pressure with relief valve operation. For more
information on the limitation of circuit pressure, refer to Systems Operation, "Relief Valve
(Main)" and Systems Operation, "Relief Valve (Line)".
The description of other components that are installed on the main control valve or in the main
control valve will be listed separately. Refer to the appropriate sections that are in this manual for
further information on the components.
Main Control Valve Operation in NEUTRAL Position
Pgina 9 de 13
Illustration 6
Main control valve (neutral position)
(7) Inlet port
Pgina 10 de 13

(14) Right body
(15) Left body
(17) Return port
(19) Return passage
(21) Inlet port
(23) Return passage
The right pump supplies oil to right body (14) through inlet port (7) . The oil then flows through
center bypass passage (20) and parallel feeder passage (6) . The left pump supplies oil to left body
(15) through inlet port (21) . The oil then flows through center bypass passage (22) and parallel
feeder passage (10) .
When all of the joysticks and/or travel levers/pedals are in the NEUTRAL position, right pump oil
flows through center bypass passage (20) , negative flow control orifice (18) , return passage (19) ,
return passage (23) and return port (17) back to the hydraulic tank. Left pump oil from inlet port (21)
flows through center bypass passage (22) , negative flow control orifice (16) and return port (17)
back to the hydraulic tank. Oil in parallel feeder passages (6) and (10) remains blocked by each
control valve spool.
Activation of any joystick and/or travel levers/pedals provides two paths for right pump oil. One path
flows through center bypass passage (20) to right travel control valve (5) . The other path flows
through parallel feeder passage (6) , attachment control valve (4) , bucket control valve (3) and boom
I control valve (2) . Activation of any joystick and/or travel levers/pedals also provides two paths for
left pump oil. One path flows through center bypass passage (22) to left travel control valve (9) and
stick I control valve (12) . The other path flows through parallel feeder passage (10) to swing control
valve (11) .
Individual Valve Operation
Illustration 7
Pgina 11 de 13
g00747317
Bucket control valve (NEUTRAL position)

(2) Port
(5) Passage
(6) Port
(7) Line relief valve (bucket cylinder head end)
(8) Pilot port
Pgina 12 de 13
(9) Pilot port

(10) Return passage
(11) Spool
(13) Spring
The bucket control valve is used as a typical example for describing the operation of individual
control valves.
When the joysticks and/or travel levers/pedals are in the NEUTRAL position, pilot oil does not flow
to port (8) and port (9) . Spool (11) is centered in the NEUTRAL position by the force of spring
(13) . The right pump oil flows through center bypass passage (12) to the hydraulic tank.
Illustration 8
g00747318
Bucket control valve BUCKET CLOSE

(2) Port
Pgina 13 de 13
(5) Passage
(6) Port
(8) Pilot port
(10) Return passage
(11) Spool
(14) Passage
(15) Passage
When the joystick for the bucket is moved to the BUCKET CLOSE position, pilot oil is supplied to
pilot port (8) . Spool (11) moves to the left. Center bypass passage (12) is closed and passage (15)
becomes opened. Port (14) is now connected to return passage (10) .
Oil that is in parallel feeder passage (3) flows through load check valve (4) , passage (5) and passage
(15) . The oil then flows to port (6) . The bucket cylinder rod extends. When the bucket cylinder rod
extends, the displaced oil in the rod end flows to port (2) .
Oil flows through port (2) to return passage (14) and back to the hydraulic tank.

Tue Oct 17 18:27:36 EST 2006
Pgina 1 de 5
Cerrar SIS
Pantalla anterior

i02365009
Check Valve (Load)

SMCS - 5472
The load check valve performs the following two functions.
z
The load check valve prevents unexpected movement of an implement when a joystick is
initially activated at a low pump delivery pressure.
The load check valve prevents oil loss from a high pressure circuit to a lower pressure circuit.
Pgina 2 de 5
Illustration 1
Boom I control valve (partial shift)
(1) Port (boom cylinder head end)
(2) Passage
(3) Spring
Pgina 3 de 5
(5) Port (boom cylinder rod end)

(6) Return passage
(8) Spring
(9) Pilot port
(10) Spool
When the joystick for the boom is in the NEUTRAL position, spring (8) positions spool (10) in the
center position. The right pump is at a destroked position. The right pump is delivering standby
pressure to the boom I control valve. The pump delivery pressure in center bypass passage (11) and
parallel feeder passage (7) is lower than the pressure in the boom cylinder head end at port (1). Load
check valve (4) is in the CLOSED position.
Slight movement of the joystick for the boom toward the BOOM RAISE position causes low pilot
oil pressure to enter port (9). Spool (10) shifts slightly to the right. The right pump begins to move to
an upstroke position. A passage partially opens allowing the oil from the rod end of the boom
cylinders in port (5) to flow to return passage (6). A passage partially opens allowing the oil from the
head end of the boom cylinders in port (1) to flow through passage (2). The work load pressure from
the head end of the boom cylinders and the force of spring (3) now acts on load check valve (4).
Since the pump delivery pressure is lower than the work load pressure in passage (2), load check
valve (4) remains in the closed position. The oil in the boom cylinder head end is blocked.
Pgina 4 de 5
Illustration 2
Boom I control valve (full shift)
(2) Passage
(3) Spring
Pgina 5 de 5
(5) Port (boom cylinder rod end)

(6) Return passage
(8) Spring
(9) Pilot port
(10) Spool
As the joystick for the boom is moved farther from the NEUTRAL position, the pilot oil pressure at
pilot port (9) increases. Spool (10) shifts farther to the right. The right pump upstrokes farther. The
pump delivery pressure in center bypass passage (11) and parallel feeder passage (7) increases. Load
check valve (4) will not open until the pump delivery pressure becomes greater than the combined
force of the work load pressure in passage (2) and the force of spring (8). Unexpected downward
movement of the boom during a BOOM RAISE operation is prevented.
Load check valve (4) also prevents oil loss from a high pressure circuit to a lower pressure circuit.
For example, the work tool is moved under a light load, and the boom cylinders are raised at the
same time. The high pressure oil of the boom cylinders wants to flow toward the low pressure side of
the work tool. The load check valve prevents the boom from lowering.

Tue Oct 17 19:23:34 EST 2006
Pgina 1 de 16
Cerrar SIS
Pantalla anterior

i02613507
Boom Hydraulic System

SMCS - 5050-BM
Boom Raise (High Speed)
Pgina 2 de 16
Pgina 3 de 16
Illustration 1
Hydraulic schematic for BOOM RAISE (high speed)
(1) Boom cylinders
(2) Line (oil flow from boom cylinder rod end)
(3) Line (oil flow to boom cylinder head end)
(4) Valve
(6) Return line
(7) Port
(9) Return passage
(10) Line
(12) Passage
(13) Check valve
(15) Port
(18) Return passage
(20) Port
(21) Pilot line
(23) Pilot line
(24) Pilot line
(25) Pilot line
Pgina 4 de 16
(27) Left pump

(28) Right pump
(29) Pilot pump
(33) Spring
(37) Spring
A BOOM RAISE operation at high speed is accomplished when the oil delivery from both left pump
(27) and right pump (28) is supplied to the head end of boom cylinders (1) . Boom I control valve
(19) and boom II control valve (16) operate during the high speed operation. A BOOM RAISE
operation at low speed is accomplished when the oil delivery from only right pump (28) is supplied
to the head end of boom cylinders (1) . During the low speed operation, boom I control valve (19)
operates alone.
Illustration 2
Main control valve compartment
g00747466

Illustration 3
g00694273
Pgina 5 de 16
Boom drift reduction valve (bottom view)

The oil delivery from right pump (28) flows through parallel feeder passage (17) in main control
valve (11) to boom I control valve (19) . The oil delivery from left pump (27) flows through parallel
feeder passage (8) in main control valve (11) to boom II control valve (16) .
When the joystick for the boom is moved to the full BOOM RAISE position, the pilot oil flows from
pilot control valve (22) through pilot line (24) . The pilot oil flow then divides into two flow paths.
Part of the pilot oil flows through pilot line (21) to port (7) of main control valve (11) . The
remainder of the pilot oil flows through pilot line (23) to port (20) of the main control valve.
A portion of the oil in pilot line (23) also flows through pilot line (25) to the pressure reducing valve
for boom priority (26) . During a combined operation of BOOM RAISE and STICK IN, BOOM
RAISE and STICK OUT, or BOOM RAISE and BUCKET CLOSE, the pilot oil flow to the pressure
reducing valve for boom priority (26) causes the boom circuit to receive oil flow priority. This
allows the boom to raise at a high speed.
Illustration 4
g01211087
Boom I control valve (BOOM RAISE position)

Pgina 6 de 16
(18) Return passage

(20) Port
(30) Port
(31) Passage
(32) Passage
(33) Spring
(34) Passage
(35) Spool
The pilot oil flow from port (20) shifts spool (35) of boom I control valve (19) against the force of
spring (33) . The oil delivery from the right pump in parallel feeder passage (17) flows through load
check valve (14) , passage (31) , passage (34) and port (30) to boom drift reduction valve (5) . The
oil delivery from the right pump shifts valve (4) in boom drift reduction valve (5) to the right. The oil
delivery from the right pump then flows through line (3) to the head end of boom cylinders (1) .
Note: For more information on the boom drift reduction valve, refer to Systems Operation, "Boom
Drift Reduction Valve".
Illustration 5
g01211088
Pgina 7 de 16
Boom II control valve (BOOM RAISE position)

(7) Port
(13) Check valve
(15) Port
(36) Passage
(37) Spring
(38) Spool
(39) Passage
The pilot oil flow in port (7) of boom II control valve (16) shifts spool (38) against the force of
spring (37) . The oil delivery from the left pump in parallel feeder passage (8) now flows through
passage (36) , passage (39) , check valve (13) and flows out of port (15) to line (10) . The oil
delivery from the left pump combines with the oil delivery from the right pump at boom drift
reduction valve (5) . The combined pump oil flows through passage (12) and line (3) to the head end
of boom cylinders (1) .
Note: The swing priority valve does not affect the boom II control valve.
Return oil from the rod end of boom cylinders (1) flows through line (2) to boom I control valve
(19) . The oil then flows through passage (32) , return passage (18) , return passage (9) and return
line (6) to the hydraulic tank.
Boom Raise (Low Speed)

When the joystick for the boom is moved less than half of the travel distance for BOOM RAISE, low
pilot oil pressure is supplied to boom I control valve (19) and boom II control valve (16) .
When the boom is raised at a low speed, boom I control valve (19) opens and boom II control valve
(16) remains closed. The force of spring (33) in boom I control valve (19) is less than the force of
spring (37) in boom II control valve (16) . Because of the low pilot oil pressure, boom I control valve
(19) will open and boom II control valve (16) will remain closed.
The oil delivery from right pump (28) now flows to the head end of boom cylinders (1) . Without the
oil delivery from left pump (27) , the cylinder rod movement slows down when the boom is raised.
The low speed operation of the boom is performed.
Boom Priority
Pgina 8 de 16
Pgina 9 de 16
Illustration 6
Hydraulic schematic for BOOM RAISE and STICK IN
(1) Boom cylinders
(41) Pilot control valve (stick and swing)
During combined operations of BOOM RAISE and STICK IN, the pilot oil pressure from the pilot
control valve for the boom (22) activates the pressure reducing valve for boom priority (26) . The
pressure reducing valve for boom priority (26) causes oil flow priority to the head end of the boom
cylinders (1) during this combined hydraulic operation.
When the joystick for the stick is moved to the STICK IN position, a portion of the pilot oil from the
pilot control valve for the stick (41) flows through the pressure reducing valve for the boom priority
(26) to the stick II control valve (40) . As the joystick for the boom is moved farther from the
NEUTRAL position during a BOOM RAISE operation, pilot oil pressure from the pilot control
valve for the boom (22) increases. This gradual increase in pilot oil pressure causes the spool in the
pressure reducing valve for the boom priority (26) to gradually shift.
A portion of the pilot oil that flows to stick II control valve (40) from the pilot control valve for the
stick (41) is routed to the hydraulic tank. The pilot oil pressure that acts on stick II control valve (40)
decreases. Stick II control valve (40) shifts toward the NEUTRAL position. The amount of oil flow
from the main pumps to the stick hydraulic circuit decreases. This causes a greater portion of the oil
flow from the main pumps to flow to the head end of the boom cylinders (1) .
Since the pilot oil pressure from the pilot control valve for the boom (22) directly corresponds to the
amount of movement or position of the joystick a gradual change to boom priority occurs. Thus,
boom priority is controlled by the position of the joystick for the boom and boom priority
automatically activates when the joystick reaches a certain position during a BOOM RAISE
operation.
The above information describes the condition of BOOM RAISE and STICK IN. During any
combined function of BOOM RAISE and STICK IN, BOOM RAISE and STICK OUT, or BOOM
RAISE and BUCKET CLOSE, the pressure reducing valve for boom priority allows priority flow to
the head end of the boom cylinders by reducing pilot pressure to the stick I, stick II, or bucket
control valves.
ReferenceFor more information concerning boom priority, refer to Systems Operation, "Pilot
Hydraulic System".
Boom Lower
Pgina 10 de 16
Pgina 11 de 16
Illustration 7
Hydraulic schematic for BOOM LOWER
(1) Boom cylinders
(2) Line (oil flow to boom cylinder rod end)
(3) Line (oil flow from boom cylinder head end)
(4) Valve
(18) Return passage
(27) Left pump
(28) Right pump
(29) Pilot pump
(33) Spring
(40) Orifice
(41) Boom regeneration valve
(42) Port
(43) Orifice
(46) Port
(48) Valve
(49) Passage
(50) Drain line
(51) Passage
Pgina 12 de 16
(52) Pilot line

(53) Pilot line
During a BOOM LOWER operation, the oil delivery from only right pump (28) is supplied to boom
cylinders (1) through boom I control valve (19) . Boom I control valve (19) operates alone. Boom II
control valve (16) is not operational in the BOOM LOWER operation.
The BOOM LOWER operation contains a regeneration circuit. When the joystick for the boom is
moved to the BOOM LOWER position, orifice (43) in boom I control valve (19) and boom
regeneration valve (41) are operational in the boom hydraulic circuit. The return oil flow from the
head end of boom cylinders (1) flows through boom regeneration valve (41) to the rod end of the
boom cylinders. The boom regeneration valve is described later in this section.
control valve (22) flows through pilot line (52) . The pilot oil flow then divides into three flow paths.
Part of the pilot oil flows through port (46) to boom I control valve (19) . Part of the pilot oil flows
through port (42) to boom regeneration valve (41) . The remainder of the pilot oil flows through pilot
line (53) of boom drift reduction valve (5) .
Since the pilot oil pressure has caused the spool in boom I control valve (19) to shift against the
force of spring (33) , the oil delivery from the right pump that flows through center bypass passage
(45) is restricted by orifice (43) . The negative flow control pressure in negative flow control line
(44) decreases. The right pump upstrokes because of the negative flow control operation.
ReferenceFor more information concerning the negative flow control operation, refer to Systems
Operation, "Negative Flow Control System".
Illustration 8
Boom I control valve (BOOM LOWER position)
Pgina 13 de 16
g01211090

(18) Return passage
(30) Port
(32) Port
(33) Spring
(35) Spool
(42) Orifice
(45) Orifice
(46) Port
(49) Passage
The pilot oil flow from port (46) shifts spool (35) in boom I control valve (19) against the force of
spring (33) . The oil delivery from the right pump in parallel feeder passage (17) flows through load
Pgina 14 de 16
check valve (14) , passage (49) and port (32) . The oil delivery from the right pump then flows
through line (2) to the rod end of boom cylinders (1) .
The return oil from the head end of boom cylinders (1) flows through line (3) into boom drift
reduction valve (5) . Since valve (48) is shifted by the pilot pressure from pilot line (53) , passage
(49) is open to drain line (50) . The return oil pressure shifts valve (4) to the right. The return oil in
line (3) enters passage (51) .
A portion of the return oil flows into port (30) of boom I control valve (19) . The return oil flow is
restricted by orifice (40) . The return oil pressure in passage (51) increases. Most of the return oil
flows through boom regeneration valve (41) . The return oil is now supplied to the rod end of the
boom cylinders through line (2) .
Boom Regeneration Valve
Pgina 15 de 16
Illustration 9
Boom regeneration valve (slow boom down)
(42) Pilot port
(56) Passage
(57) Check valve
(58) Spool (boom regeneration valve)
(59) Passage
Illustration 10
Boom regeneration valve (fast boom down)
Pgina 16 de 16

(42) Pilot port
(56) Passage
(57) Check valve
(58) Spool (boom regeneration valve)
(59) Passage
The boom hydraulic circuit contains a regeneration circuit. This regeneration circuit allows the return
oil from the head end of the boom cylinders to be supplied to the rod end of the boom cylinders
during the BOOM LOWER operation.
When the joystick for the boom is moved to the BOOM LOWER position, pilot oil flow from the
pilot control valve (boom and bucket) enters pilot port (42) . Spool (58) in the boom regeneration
valve shifts downward. The return oil from the head end of the boom cylinders flows through
passage (59) and through the throttling slots on the spool for the boom regeneration valve to check
valve (57) . Check valve (57) opens and the return oil flows through passage (56) . The return oil
from the head end of the boom cylinders in passage (56) combines with the oil delivery from the
right pump. This combined oil now flows to the rod end of the boom cylinders.
The oil delivery from only the right pump is used for the BOOM LOWER operation. Since the boom
regeneration valve supplies return oil from the head end to the rod end of the boom cylinders, more
efficient use of the oil delivery from the right pump is achieved during a BOOM LOWER operation.

Tue Oct 17 19:38:28 EST 2006
Pgina 1 de 7
Cerrar SIS
Pantalla anterior

i02421038
Control Valve (Boom Lowering)

SMCS - 5147-BM
S/N - B6H1-UP
S/N - EDX1-UP
S/N - JLP1-UP
S/N - MEY1-UP
S/N - MWP1-UP
S/N - NBD1-UP
The boom lowering control valves are located on the head end of the boom cylinders.
The boom lowering control valve has two functions:
z
The boom lowering control valve prevents the boom from falling if a hydraulic supply line
fails or if a supply tube to a boom cylinder fails.
The boom lowering control valve allows the operator to manually lower the boom when the
engine is shut down.
Reference: For information on lowering the boom manually, see Operation and Maintenance
Manual, "Equipment Lowering with Engine Stopped".
Pgina 2 de 7
Pgina 3 de 7
Illustration 1
Partial schematic
(1) Boom cylinders
(2) Boom lowering control valves
(4) Pilot control valve
BOOM RAISE Operation
Illustration 2
Boom lowering control valve

(2) Passage
Pgina 4 de 7
(4) Check valve

(5) Spring
(6) Port
(7) Line relief valve
(8) Port
(11) Spool
(12) Passage
(13) Orifice
(23) Valve
When the operator moves the joystick to the BOOM RAISE position, oil from the main control valve
flows through port (8) in the boom lowering control valve. As the oil pressure increases, check valve
(4) shifts against the force of spring (5). This allows oil to flow through port (6), passage (2), and
port (1) to the head end of the boom cylinders. The rod is extended and the boom raises.
BOOM LOWER Operation
Illustration 3
Boom lowering control valve
Pgina 5 de 7

(2) Passage
(7) Line relief valve
(8) Port
(9) Passage
(10) Port (pilot)
(11) Spool
(12) Passage
(13) Orifice
(23) Valve
When the operator moves the joystick to the BOOM LOWER position, pilot oil flows from the pilot
control valve to port (10) of the boom lowering control valve. The pilot pressure moves spool (11) to
Pgina 6 de 7
the left. Orifice (13) opens allowing oil to flow to passage (12) .
As the joystick is moved further to the BOOM LOWER position, the pilot pressure in port (10)
increases. Spool (11) shifts further to the left which allows more oil from passage (2) to flow to
passage (12). Oil from the head end of the boom cylinder flows through port (1), to port (8), and then
to the main control valve. The boom cylinder rod retracts and the boom lowers.
Manual Boom Lower
Illustration 4
(1) Port
g01213309
(15) Port
(21) Seat
(22) Locknut
(23) Valve
(24) Ball
As seat (21) is turned counterclockwise, ball (24) will shift. As ball (24) is shifted, oil is allowed to
flow through port (1) and valve (23) to port (15). Oil from the head end of the boom cylinder flows
Pgina 7 de 7
through port (15) to the hydraulic tank. This allows the boom to lower.

Tue Oct 17 19:53:36 EST 2006
Pgina 1 de 4
Cerrar SIS
Pantalla anterior

i02429879
Boom Drift Reduction Valve

SMCS - 5143-BM
The boom drift reduction valve is placed in the boom circuit between the main control valve and the
boom cylinders. When the joystick for the boom is in the NEUTRAL position, the boom drift
reduction valve stops oil leakage from the head end of the boom cylinders. Stopping oil leakage
prevents boom drift.
Boom Raise
Pgina 2 de 4
Illustration 1
Boom drift reduction valve (BOOM RAISE)
(1) Passage
(2) Valve
(3) Spring
(4) Spring chamber
Pgina 3 de 4
(5) Passage
(6) Port
(7) Port
(8) Port
(9) Passage
(11) Spool
(15) Port
When the joystick is moved to perform a BOOM RAISE operation, pilot oil is not sent from the pilot
control valve to port (15) of boom drift reduction valve (16). Spool (11) does not shift.
The oil flow from the boom II control valve enters port (6) of the boom drift reduction valve. The oil
flow from the boom I control valve enters port (7) of the boom drift reduction valve. The combined
oil flow from ports (6) and (7) flows into passage (1). As the oil pressure in passage (1) increases,
valve (2) shifts against the force of spring (3). The oil in spring chamber (4) flows through passages
(5) and (9) to port (8). The oil delivery in passage (1) now flows through port (8) to the head end of
the boom cylinders.
Boom Lower
Illustration 2
Boom drift reduction valve (BOOM LOWER)
Pgina 4 de 4
g01176885
(1) Passage
(2) Valve
(3) Spring
(4) Spring chamber
(5) Passage
(6) Passage
(7) Port
(8) Port
(11) Spool
(13) Drain line
(15) Port
(18) Port
(20) Spring chamber
(21) Plug
When the joystick is moved to perform a BOOM LOWER operation, pilot oil is sent from the pilot
control valve to port (15) of boom drift reduction valve (16). Spool (11) shifts downward until the
spool contacts plug (21). The oil in spring chamber (4) flows through passage (5), the passage in
spool (11), spring chamber (20), passage (6), port (18) and drain line (13) to the hydraulic tank.
The return oil from the boom cylinder head end enters port (8). Since the pressure in spring chamber
(4) is low, the oil in port (8) shifts valve (2) against the force of spring (3). The oil from the head end
of the boom cylinders flows through port (8), passage (1) and passage (7) to the boom I control
valve.

Tue Oct 17 19:49:51 EST 2006
Pgina 1 de 15
Cerrar SIS
Pantalla anterior

i02485801
Stick Hydraulic System

SMCS - 5050
Stick Out
Pgina 2 de 15
Pgina 3 de 15
Illustration 1
Hydraulic schematic for STICK OUT
(1) Stick cylinder
(2) Line (oil flow from stick cylinder rod end)
(3) Line (oil flow to stick cylinder head end)
(4) Valve
(7) Line
(8) Passage
(9) Return passage
(10) Return passage
(11) Return passage
(16) Check valve
(17) Passage
(19) Check valve
(23) Return line
(24) Pilot line
(25) Pilot line
(26) Pilot line
Pgina 4 de 15

(28) Drive pump
(29) Idler pump
(30) Pilot pump
Illustration 2
Main control valve
g00695552

Illustration 3
Main control valve (bottom view)
g00695556
When the stick hydraulic circuit is operated independently of other hydraulic circuits, stick I control
valve (21) and stick II control valve (13) are operational for both the STICK IN operation and the
STICK OUT operation. When the stick I control valve and the stick II control valve are operated, the
oil delivery from idler pump (29) and drive pump (28 ) is combined. The oil delivery from both
pumps flows to stick cylinder (1) in order to perform a stick operation.
Pgina 5 de 15
The oil delivery from drive pump (28) flows through parallel feeder passage (22) in main control
valve (6) to stick II control valve (13). The oil delivery from idler pump (29) flows through center
bypass passage (18) in main control valve (6) to stick II control valve (21) .
When the joystick for the stick is moved to the STICK OUT position, the pilot oil flows from pilot
control valve (27) through pilot line (26). The pilot oil flow then divides into two flow paths. Part of
the pilot oil flows through pilot line (24) to stick I control valve (21) in main control valve (6). The
remainder of the pilot oil flows through pilot line (25) to stick II control valve (13) in the main
control valve.
The pilot oil in pilot line (24) shifts the spool of stick I control valve (21). The oil delivery from idler
pump (29) that is in center bypass passage (18) flows through load check valve (15), passage (17)
and passage (8). The oil delivery from the idler pump then enters stick drift reduction valve (5).
Valve (4) shifts to the left and the oil delivery flows through line (3) to the rod end of stick cylinder
(1) .
The pilot oil in pilot line (25) shifts the spool of stick II control valve (13). The oil delivery from
drive pump (28) in center bypass passage (12) cannot flow through the stick II control valve to
center bypass passage (14) and return passage (11). Part of the oil delivery from the drive pump now
flows through check valve (16) and the stick II control valve to line (7). The remainder of the oil
delivery from the drive pump flows through parallel feeder passage (22), check valve (19) and the
stick II control valve to line (7). All of the oil delivery from the drive pump in line (7) flows to stick
drift reduction valve (5) and combines with the oil delivery from the drive pump. The combined
pump oil flows to the rod end of stick cylinder (1). This combined pump oil causes the cylinder to
retract at an increased rate of speed.
Return oil from the head end of the stick cylinder flows through line (2) and return passage (9) to
stick I control valve (21). The return oil then flows through return passage (10) and return line (23)
to the hydraulic tank.
Stick In (Fast)
Pgina 6 de 15
Pgina 7 de 15
Illustration 4
Hydraulic schematic for STICK IN (fast with regeneration)
(1) Stick cylinder
(2) Line (oil flow to stick cylinder rod end)
(3) Line (oil flow from stick cylinder head end)
(4) Valve
(9) Passage
(10) Return passage
(11) Return passage
(16) Check valve
(19) Check valve
(23) Return line
(28) Drive pump
(29) Idler pump
(30) Pilot pump
(33) Pilot line
(34) Pilot line
Pgina 8 de 15
(35) Pilot line

(36) Pilot line
(37) Passage
(38) Pilot line
(39) Pilot line
(41) Pilot line
(42) Line
(43) Passage
(44) Passage
(45) Passage
(46) Passage
(47) Passage
(48) Check valve
The STICK IN operation contains a regeneration circuit. When the joystick for the stick is moved to
the STICK IN position, stick regeneration valve (31) and stick unloading valve (32) are operational
in the stick hydraulic circuit. The return oil from the rod end of stick cylinder (1) is supplied to the
head end of the stick cylinder. The regeneration circuit makes more effective use of the return oil
from the stick cylinder. This allows the oil delivery from the idler pump and the drive pump to
perform other implement functions during a STICK IN operation.
When the joystick for the stick is moved to the STICK IN position, pilot oil from pilot control valve
(27) flows through pilot line (33). The pilot oil flow then divides into several flow paths. Part of the
pilot oil flows through pilot line (34), pilot line (35) and pilot line (36) to stick I control valve (21).
The pilot oil in pilot line (36) also flows through passage (37) in stick drift reduction valve (5). Part
of the pilot oil flows through pilot line (38) to stick regeneration valve (31). The remainder of the
pilot oil flows through pilot line (39), the pressure reducing valve for boom priority (40) and pilot
line (41) to stick II control valve (13) .
Since the pilot oil pressure has caused the spool in stick I control valve (21) to shift downward, the
oil delivery from the idler pump flows through center bypass passage (18), load check valve (15),
stick I control valve (21) and passage (9) to line (2) .
The pilot oil pressure in pilot line (41) has caused the spool in stick II control valve (13) to shift
downward. Part of the oil delivery from the drive pump that is in center bypass passage (12) flows
through check valve (16) and stick II control valve (13) to line (42). The remainder of the oil
delivery from the drive pump flows through parallel feeder passage (22), check valve (19) and stick
II control valve (13) to line (42). All of the oil delivery from the drive pump in line (42) flows to line
(2) and combines with the oil delivery from the idler pump. The combined pump oil flows to the
head end of stick cylinder (1) .
Pgina 9 de 15
The return oil from the rod end of the stick cylinder flows through line (3) to stick drift reduction
valve (5). Valve (4) in the stick drift reduction valve shifts to the left and the return oil enters passage
(43). Part of the return oil in passage (43) flows through stick I control valve (21), return passage
(10) and return line (23) to the hydraulic tank. The remainder of the return oil flows through the
regeneration circuit to the head end of the stick cylinders.
Stick In (Slow)
Pgina 10 de 15
Pgina 11 de 15
Illustration 5
Hydraulic schematic for STICK IN (slow without regeneration)
(1) Stick cylinder
(2) Line (oil flow to stick cylinder rod end)
(3) Line (oil flow from stick cylinder head end)
(4) Valve
(9) Passage
(10) Return passage
(11) Return passage
(16) Check valve
(19) Check valve
(23) Return line
(28) Drive pump
(29) Idler pump
(30) Pilot pump
(33) Pilot line
(34) Pilot line
Pgina 12 de 15
(35) Pilot line

(36) Pilot line
(37) Passage
(38) Pilot line
(39) Pilot line
(41) Pilot line
(42) Line
(43) Passage
(44) Passage
(45) Passage
(46) Passage
(47) Passage
(48) Check valve
As the joystick for stick in is moved slowly, the pilot pressure will not shift stick II control valve
(13) or stick regeneration valve (31) .
Stick Regeneration Valve
Pgina 13 de 15
Illustration 6
Stick regeneration valve

(9) Passage
(38) Pilot line
(43) Passage
(48) Check valve
The stick hydraulic circuit contains a regeneration circuit. This regeneration circuit allows the return
oil from the rod end of the stick cylinder to be supplied to the head end of the stick cylinder during
the STICK IN operation.
When the joystick for the stick is moved to the STICK IN position, pilot oil flow from the pilot
control valve (stick and swing) flows through pilot line (38). Stick regeneration valve (31) shifts
downward. The return oil from the rod end of the stick cylinder flows through passage (43) and
through the throttling slots on valve (31) to check valve (48). Check valve (48) opens and the return
oil flows through passage (9). The return oil from the rod end of the stick cylinder in passage (9)
Pgina 14 de 15
combines with the oil delivery from the idler pump and the drive pump. This combined oil flow now
flows into the head end of the stick cylinder.
Stick Unloading Valve
Illustration 7
Stick unloading valve

(9) Passage
(38) Pilot line
(43) Passage
(44) Passage
Pgina 15 de 15
(46) Passage
(47) Passage
(49) Passage
(50) Spring
Stick unloading valve (32) works in conjunction with stick regeneration valve (31) in order to relieve
high pressure in the head end of the stick cylinder during a STICK IN operation.
When the joystick for the stick is moved to the STICK IN position, pilot oil flow from the pilot
control valve (stick and swing) flows through pilot line (38). Stick regeneration valve (31) shifts
downward. The return oil from the rod end of the stick cylinder flows through passage (43) and
through the throttling slots on valve (31) to check valve (48). Check valve (48) opens and the return
oil flows through passage (9). The return oil from the rod end of the stick cylinder in passage (9)
combines with the oil delivery from the idler pump and the drive pump. This combined oil flow now
flows into the head end of the stick cylinder.
Because of the volume of oil that is forced into the head end of the stick cylinder during the
regeneration cycle of the STICK IN operation, the pressure of the oil in the head end of the stick
cylinder increases. The high pressure oil flows through passage (9) and passage (44). The high
pressure oil now acts on the end of stick unloading valve (32). When the force of the high pressure
oil becomes greater than the force of spring (50), the stick unloading valve shifts downward. The
return oil from the rod end of the stick cylinder in passage (43) flows past the throttling slots on stick
regeneration valve (31), through passage (49), through stick unloading valve (32) and passage (47)
and into the return circuit to the hydraulic tank. The return oil from the rod end of the stick cylinder
is quickly unloaded. At this time, the regeneration circuit for the stick cylinder is inoperable.
When the oil pressure at the head end of the stick cylinder decreases, the oil pressure that acts on the
end of stick unloading valve (32) also decreases. The force of spring (50) shifts the stick unloading
valve upward. The return oil from the rod end of the stick cylinder is supplied to the head end of the
stick cylinder. The regeneration circuit is again operable.

Tue Oct 17 19:58:28 EST 2006
Pgina 1 de 4
Cerrar SIS
Pantalla anterior

i01310189
Stick Drift Reduction Valve

SMCS - 5143-JJ
The stick drift reduction valve is placed in the stick circuit between the main control valve and the
stick cylinder. When the joystick for the stick is in the NEUTRAL position, the stick drift reduction
valve stops oil leakage from the rod end of the stick cylinder. Stopping oil leakage prevents stick
drift.
Stick Out
Illustration 1
Pgina 2 de 4
Stick drift reduction valve (STICK OUT)

(1) Passage
(2) Valve
(3) Spring
(4) Spring chamber
(5) Passage
(6) Port
(7) Port
(8) Port
(9) Passage
(11) Spool
(15) Port
Pgina 3 de 4
When the joystick is moved to perform a STICK OUT operation, pilot oil is not sent from the pilot
control valve to port (15) of stick drift reduction valve (16). Spool (11) does not shift.
The oil flow from the stick II control valve enters port (6) of the stick drift reduction valve. The oil
flow from the stick I control valve enters port (7) of the stick drift reduction valve. The combined oil
flow from ports (6) and (7) flows into passage (1). As the oil pressure in passage (1) increases, valve
(2) shifts against the force of spring (3). The oil in spring chamber (4) flows through passages (5)
and (9) to port (8). The oil delivery in passage (1) now flows through port (8) to the rod end of the
stick cylinder.
Stick In
Illustration 2
Stick drift reduction valve (STICK IN)

(1) Passage
(2) Valve
Pgina 4 de 4
(3) Spring
(4) Spring chamber
(5) Passage
(6) Port
(7) Port
(8) Port
(11) Spool
(13) Drain line
(15) Port
(18) Port
(20) Spring chamber
(21) Passage
(22) Plug
When the joystick is moved to perform a STICK IN operation, pilot oil is sent from the pilot control
valve to port (15) of stick drift reduction valve (16). Spool (11) shifts downward until the spool
contacts plug (22). The oil in spring chamber (4) flows through passage (5), the orifice in spool (11),
spring chamber (20), passage (21), port (18) and drain line (13) to the hydraulic tank.
The return oil from the stick cylinder rod end enters port (8). Since the pressure in spring chamber
(4) is low, the oil in port (8) shifts valve (2) against the force of spring (3). The oil from the rod end
of the stick cylinder flows through port (8), passage (1) and passage (7) to the stick I control valve.

Tue Oct 17 20:04:08 EST 2006
Pgina 1 de 5
Cerrar SIS
Pantalla anterior

i02613508
Bucket Hydraulic System

SMCS - 5050-YB
Pgina 2 de 5
Pgina 3 de 5
Illustration 1
(1) Pilot line
(2) Line
(3) Line
(4) Bucket cylinder
(6) Return line
(10) Spring
(11) Orifice
(13) Spring
(17) Return passage
(18) Pilot line
(21) Drive pump
(22) Idler pump
(23) Pilot pump
The oil delivery for the bucket hydraulic circuit is supplied by idler pump (22) only.
Illustration 2
Pgina 4 de 5
g00697166
The oil delivery from idler pump (22) flows through center bypass passage (8) in main control valve
(5) to bucket control valve (9) . The oil delivery from drive pump (21) flows through center bypass
passage (7) in main control valve (5) . Illustration 1 shows the main control valve when only the
bucket hydraulic circuit is activated.
When the hydraulic activation control lever is in the UNLOCKED position, the oil delivery from
pilot pump (23) flows through pilot oil manifold (20) to pilot control valve (15) . When the joystick
for the bucket is moved to the BUCKET CLOSE position, pilot oil flows through pilot control valve
(15) and pilot line (1) to bucket control valve (9) . The pilot oil pressure shifts the spool in the bucket
control valve against spring (13) . The pilot oil on the other end of the spool in the bucket control
valve flows through pilot line (18) and pilot control valve (15) to the hydraulic tank.
Since the spool in the bucket control valve is fully shifted, center bypass passage (8) is blocked.
None of the oil delivery from the idler pump flows to negative flow control orifice (14) and no
negative flow control pressure is created in center bypass passage (8) . Since no negative flow
control pressure is sent through negative flow control line (19) to the idler pump regulator, the idler
pump regulator moves the swashplate of the idler pump toward the maximum angle position. The
output flow rate of the idler pump is increased and flows through parallel feeder passage (16) , load
check valve (12) , bucket control valve (9) and line (3) to the head end of bucket cylinder (4) .
Since the oil delivery for the bucket hydraulic circuit is supplied by the idler pump only, the negative
control pressure in center bypass passage (7) is high. Drive pump (21) remains at the destroked
position.
The return oil from the rod end of the bucket cylinder flows through line (2) , orifice (11) in bucket
control valve (9) , return passage (17) and return line (6) to the hydraulic tank. Orifice (11) restricts
the return oil from the rod end of the bucket cylinder.
The BUCKET OPEN operation is similar to the BUCKET CLOSE operation.
When the joystick for the bucket is moved to the BUCKET OPEN position, pilot oil flow from pilot
control valve (15) flows through pilot line (18) to the bucket control valve. The spool in the bucket
control valve shifts against the force of spring (10) . The oil delivery from the idler pump now flows
to the rod end of the bucket cylinder.
Pgina 5 de 5
When the joystick for the bucket is in the NEUTRAL position, springs (10) and (13) maintain the
spool in the bucket control valve in the NEUTRAL position. The oil flow from the head end and the
rod end of the bucket cylinder is blocked.

Tue Oct 17 20:08:27 EST 2006
Pgina 1 de 11
Cerrar SIS
Pantalla anterior

i02363790
Relief Valve (Cushion Crossover) - Anti-Reaction Valves

SMCS - 5111; 5454
Illustration 1
Swing motor
g01180670
(1) Block
(2) Swing motor
(3) Anti-reaction valve (left swing)
(4) Anti-reaction valve (right swing)
(5) Fine swing solenoid valve
At the stop of a swing operation, it is difficult to smoothly stop the upper structure and implements at
the desired position. This is due to the mass (weight and size) of the upper structure. The outlet port of
the swing motor is blocked. This causes an oscillation or a rocking motion in the swing motor. Anti-
https://127.0.0.1:1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 17/10/2006
Pgina 2 de 11
reaction valves (3) and (4) provide a more exact swing movement. The anti-reaction valves also prevent
shock load at the stop of a swing operation. Anti-reaction valves (3) and (4) are located in block (1).
Block (1) is mounted on swing motor (2).
Illustration 2
g01180870
Anti-reaction valve (neutral position)

(1) Block
(3) Anti-reaction valve
(5) Fine swing solenoid
(6) Passage
Pgina 3 de 11
(7) Port
(8) Passage
(9) Passage
(10) Passage
(11) Port
(12) Passage
(13) Spring
(14) Valve seat
(15) Passage
(16) Plunger
(17) Passage
(18) Spring
(19) Piston chamber
(20) Passage
(21) Spring chamber
(22) Spring
(23) Valve seat
(24) Plunger
(25) Spring
(26) Piston
(31) Passage
(36) Motor rotary group
During a swing operation of the upper structure, the oil delivery from the left pump flows through
passage (8) or passage (10) in block (1) to motor rotary group (36). When the swing joystick is in the
NEUTRAL position, the swing control valve is in the NEUTRAL position. The oil delivery from the left
pump is blocked at the swing control valve. No oil delivery flows to the motor rotary group. The return
oil from the swing motor is also blocked at the swing control valve.
Plunger (24) in anti-reaction valve (3) shifts downward by the force of spring (25) until the plunger is
stopped by piston (26). Valve seat (23) shifts downward by the force of spring (22) until the valve seat
Pgina 4 de 11
comes in contact with plunger (24). Plunger (16) and valve seat (14) in anti-reaction valve (4) are shifted
downward in the same manner as anti-reaction valve (3).
Illustration 3
g01180873
Anti-reaction valve (swing operation)

(1) Block
(6) Passage
Pgina 5 de 11
(7) Port
(8) Passage
(9) Passage
(10) Passage
(11) Port
(12) Passage
(13) Spring
(14) Valve seat
(15) Passage
(16) Plunger
(17) Passage
(18) Spring
(19) Piston chamber
(20) Passage
(21) Spring chamber
(22) Spring
(23) Valve seat
(24) Plunger
(25) Spring
(26) Piston
(31) Passage
(34) Spring chamber
When the swing joystick is moved from the NEUTRAL position in order to perform a swing operation,
the swing control valve shifts. The oil delivery from the left pump flows through the swing control valve
and port (11) in block (1). The oil delivery then flows through passage (10), passage (12) and motor
rotary group (36). Return oil from the motor rotary group flows through passage (6), passage (8), port
(7) and the swing control valve to the hydraulic tank. The motor rotary group rotates.
A portion of the pressure oil from the left pump at port (11) also flows to anti-reaction valves (3) and
Pgina 6 de 11
(4) .
At anti-reaction valve (3), pressure oil from the left pump and the force of spring (22) shifts valve seat
(23) downward against plunger (24). Plunger (24) shifts downward against piston (26) .
Pressure oil from the left pump also flows through passage (9). The pressure oil enters spring chamber
(34) of anti-reaction valve (4). Plunger (16) shifts upward against the force of spring (18). Valve seat
(14) is moved upward against the force of spring (13) by plunger (16).
Illustration 4
g01180874
Anti-reaction valve (swing stop)

Pgina 7 de 11

(7) Port
(8) Passage
(9) Passage
(10) Passage
(11) Port
(13) Spring
(14) Valve seat
(15) Passage
(16) Plunger
(17) Passage
(18) Spring
(19) Piston chamber
(20) Passage
(21) Spring chamber
(22) Spring
(23) Valve seat
(24) Plunger
(25) Spring
(27) Orifice
(26) Piston
(28) Valve chamber
(29) Passage
(30) Ball
(31) Passage
(32) Orifice
(33) Ball
Pgina 8 de 11
(35) Valve chamber

When the swing joystick is returned to the NEUTRAL position, the oil delivery from the left pump to
motor rotary group (36) is blocked at the swing control valve. The motor rotary group continues to
rotate due to the mass (weight and size) of the upper structure. Since the return oil flow from the motor
rotary group is also blocked at the swing control valve, the oil pressure in passage (8) increases. The oil
pressure in passage (10) decreases. The increased oil pressure in passage (8) then enters anti-reaction
valve (4). The oil flows through passage (15) and passage (17). The oil then enters piston chamber (19).
The oil pressure in piston chamber (19) forces plunger (16) upward against the force of spring (18).
Valve seat (14) shifts upward against the force of spring (13) .
A portion of the increased oil pressure in passage (8) flows through passage (31) and passage (20). The
oil then enters spring chamber (21) in anti-reaction valve (3). The oil pressure in spring chamber (21)
forces plunger (24) and valve seat (23) upward against the force of springs (22) and (25) .
As the motor rotary group of the swing motor continues to attempt to stop, the oil pressure in passage
(8) gradually decreases. The oil pressure in piston chamber (19) decreases. The force of spring (18)
causes plunger (16) to shift downward at a rapid rate. Valve seat (14) shifts downward by the force of
spring (13). Since orifice (27) restricts the flow of oil from valve chamber (28), valve seat (14) moves in
a downward direction more slowly than plunger (16) .
The contact between plunger (16) and valve seat (14) is no longer maintained. The oil pressure in
passage (15) forces ball (30) against the top end of plunger (16). The oil in passage (8) now flows
through passages (29) and (9) to passage (10) .
During the separation of plunger (16) and valve seat (14) in anti-reaction valve (4), anti-reaction valve
(3) activates also. In anti-reaction valve (3), The pressure of the oil that flows from spring chamber (21)
to passage (8) decreases. The force of spring (25) causes plunger (24) to shift downward. The force of
spring (22) causes valve seat (23) to shift downward. Since orifice (32) restricts the flow of oil from
valve chamber (35), valve seat (23) shifts more slowly than plunger (24). The contact between plunger
(24) and valve seat (23) is no longer maintained. The oil pressure in passage (20) forces ball (33) against
the valve seat (23). Now, the oil flow from passage (8) through passage (31) to passage (10) is blocked
by ball (33) .
Since passages (8) and (10) are connected by activation of anti-reaction valve (4), the swing movement
of the upper structure stops with a minimal shock load at a desired position. A more exact swing
movement is possible. A slight shock load may occur due to the gear backlash of the swing drive.
Illustration 5
Anti-reaction valve (reverse rotation)
Pgina 9 de 11
g01180875

(7) Port
(8) Passage
(9) Passage
(10) Passage
(11) Port
Pgina 10 de 11
(13) Spring
(14) Valve seat
(15) Passage
(16) Plunger
(17) Passage
(18) Spring
(19) Piston chamber
(20) Passage
(21) Spring chamber
(22) Spring
(23) Valve seat
(24) Plunger
(25) Spring
(27) Orifice
(26) Piston
(28) Valve chamber
(29) Passage
(30) Ball
(31) Passage
(32) Orifice
(33) Ball
(35) Valve chamber
When motor rotary group (36) is slightly rotated in the reverse direction due to the gear backlash, oil
pressure in passage (10) increases and oil pressure in passage (8) decreases. Anti-reaction valves (3) and
(4) function in order to stop the swing movement of the upper structure with a slight reversed motion.
The increased oil pressure in passage (10) causes a shock load. The absorption of the shock load is
described in the following manner.
Pgina 11 de 11
In anti-reaction valve (3), plunger (24) and valve seat (23) separate from each other. Ball (33) is forced
against plunger (24) by the pressure oil in passage (10). Oil can now flow from passage (10) through
passages (20) and (31) to passage (8) .
In anti-reaction valve (4), plunger (16) and valve seat (14) separate from each other. Ball (30) is forced
against valve seat (14) by the pressure oil in passage (29). The flow of oil from passage (10) through
passage (9) to passage (8) is blocked.
The oil pressure in passage (10) decreases and the rotation of motor rotary group (36) is prevented. The
swing movement is gradually stopped.

Tue Oct 17 21:44:06 EST 2006
Pgina 1 de 4
Cerrar SIS
Pantalla anterior

i02373421
Solenoid Valve (Fine Swing)

SMCS - 5479
Illustration 1
g01130113
Side of swing motor
Pgina 2 de 4
(1) Block
(2) Swing motor
(35) Fine swing solenoid valve
Illustration 2
g00479488
Fine swing solenoid valve

(1) Block
(8) Passage
(9) Passage
(10) Passage
Pgina 3 de 4
(31) Passage
(35) Solenoid
(36) Fine swing valve
(37) Passage
(38) Passage
(39) Spool
(40) Spring
(41) Orifice
(42) Orifice
Illustration 3
The fine swing control switch is on the right side instrument panel.
g01130114
The fine swing control is installed in order to ensure an exact movement of the swing with minimal
shock load. This is done by equalizing the oil pressure in passage (8) and (10) .
When fine swing solenoid (35) is de-energized, spool (39) is in the NEUTRAL position. Spool (39) is
located in valve (36). The NEUTRAL position creates a closed connection between passages (37) and
(38). In this position, the swing circuit operates in the normal manner.
When the fine swing control switch is ON, solenoid (35) is energized. Spool (39) shifts downward
against the force of spring (40). With the spool in this position, passage (8) is open to passage (10)
Pgina 4 de 4
through passages (37) and (38). Orifices (41) and (42) control the flow rate. Orifices (41) and (42) are
located in block (1) .
Because the right and the left swing circuits are now connected to each other, some of the outlet oil is
allowed to flow to the inlet side. The operation of the swing circuit is more precise with this connection.
Note: When the fine swing control switch is ON, the swing brake is OFF.

Tue Oct 17 21:59:11 EST 2006
Pgina 1 de 5
Cerrar SIS
Pantalla anterior

i02469129
Oil Makeup (Swing System)

SMCS - 5080-ZW
Illustration 1
Pgina 2 de 5
g01231058
Pressure circuit for SWING RIGHT (partial schematic)

(1) Passage (supply oil)
(2) Makeup port
(3) Relief valve
(4) Passage
(6) Swing motor
Pgina 3 de 5

(8) Relief valve
(9) Passage
(10) Makeup line
(11) Check valve
(12) Port (supply oil)
(13) Port (return oil)
(14) Check valve
(15) Check valve
(16) Return line
(19) Return line
When the swing joystick is moved to the NEUTRAL position during the swing right operation, the
swing control valve shifts to the NEUTRAL position. Since the swing control valve is in the NEUTRAL
position, the oil delivery through port (12) to motor rotary group (5) is blocked at the swing control
valve. The return oil from the motor rotary group through port (13) is also blocked at the swing control
valve. The upper structure will attempt to continue to rotate after the swing joystick is returned to the
NEUTRAL position. This causes an internal leak of oil in the swing motor. As a result, a vacuum
condition occurs at passage (1). In order to prevent this vacuum condition, makeup oil is delivered from
the return hydraulic system to the swing motor.
Illustration 2
g00850298
(10) Makeup line
Pgina 4 de 5

(19) Return line
Illustration 3
Slow return check valve
g01231308
(10) Makeup line

(16) Return line
(19) Return line
When all of the control valves for implements, swing and travel are in the NEUTRAL position, the oil
delivery from the idler pump and the drive pump flows through return line (16) to the hydraulic tank.
Slow return check valve (18) is located between return line (16) and the hydraulic tank. Slow return
check valve (18) maintains the return oil pressure at 290 kPa (42 psi) in return line (16). If a vacuum
condition occurs at the swing motor during the stop of a swing operation, the slow return check valve
causes return oil from return line (16) to flow to motor rotary group (5) as makeup oil. The slow return
check valve eliminates the vacuum condition in the swing motor due to internal leakage.
If the swing joystick is moved suddenly toward the NEUTRAL position from the FULL STROKE
position, the swing control valve partially closes. Until the swing control valve reaches the NEUTRAL
position, the return oil from the swing motor continues to flow through passage (7) and port (13) to
return line (16). The return oil pressure in passage (7) increases but the return oil pressure in passage (7)
remains lower than the pressure setting of swing relief valve (8). Swing relief valve (8) remains in the
CLOSED position.
Pgina 5 de 5
A vacuum condition occurs at port (12) and passage (1) due to the insufficient oil delivery from the
drive pump and due to the tendency of the motor rotary group to continue to rotate. Since relief valve (8)
remains in the CLOSED position, makeup oil does not flow through relief valve (8), passage (9) and
check valve (11) to passage (1) to motor rotary group (5) .
Makeup oil is supplied to motor rotary group (5) from return line (16). Return oil flows from return line
(16) through makeup line (10), port (2), passage (9), check valve (11) and passage (1) to motor rotary
group (5). The vacuum condition in passage (1) is eliminated by the makeup oil from the return
hydraulic system.
During a left swing operation, the return ports and the supply ports of the swing motor are reversed.
Makeup oil flows through check valve (14) if a vacuum condition occurs in passage (7) during a swing
left operation.

Tue Oct 17 21:40:35 EST 2006
Pgina 1 de 6
Cerrar SIS
Pantalla anterior

i02468619
Relief Valve (Swing)

SMCS - 5454
Illustration 1
Pgina 2 de 6
g01231058
Pressure circuit for SWING RIGHT operation (partial schematic)

(1) Passage (supply oil)
(2) Makeup port
(3) Relief valve
(4) Passage
(6) Swing motor
Pgina 3 de 6

(8) Relief valve
(9) Passage
(10) Makeup line
(11) Check valve
(12) Port (supply oil)
(13) Port (return oil)
(14) Check valve
(15) Check valve
(16) Return line
(19) Return line
Illustration 2
g00773573
Swing motor
(2) Makeup port
(3) Relief valve
(6) Swing motor
(8) Relief valve
Pgina 4 de 6
(10) Makeup line
Illustration 3
Swing relief valve
g01231050
(4) Return passage

(7) Passage
(20) Orifice
(21) Spring
(22) Stem
(23) Piston chamber
(24) Passage
(25) Piston
(26) Passage
(27) Piston chamber
(28) Orifice
(29) Passage
Pgina 5 de 6
Relief valves (3) and (8) are located in the head of swing motor (6). These relief valves limit the
pressure in the left and right swing circuits to the swing relief valve setting. This provides a cushion
effect at a start or stop of the swing operation.
When the swing joystick is returned to the NEUTRAL position during the swing right operation, the
swing control valve shifts to the NEUTRAL position. Since the swing control valve is in the NEUTRAL
position, the oil delivery through port (12) to the motor rotary group (5) is now blocked at the swing
control valve. The return oil from the motor rotary group through port (13) is also blocked at the swing
control valve.
The mass (weight and size) of the upper structure causes the upper structure to attempt to continue to
rotate after the swing joystick is returned to the NEUTRAL position. The motor rotary group is also
attempting to continue to rotate. The motor rotary group attempts to draw oil through port (12) and
attempts to displace the oil through port (13) .
The oil supply to motor rotary group (5) is insufficient. A vacuum condition occurs in passage (1).
Return oil is supplied to the motor rotary group as makeup oil in order to prevent the vacuum condition.
For more information concerning the makeup operation, refer to Systems Operation, "Oil Makeup
(Swing System)".
Since the flow of return oil from the motor rotary group through port (13) is blocked at the swing control
valve, the pressure of the blocked oil in passage (7) increases. The increased oil pressure in passage (7)
acts on swing relief valve (8). The increased pressure oil forces stem (22) of relief valve (8) to the right
(open position) against the force of spring (21). When stem (22) shifts, oil flows through passage (9),
check valve (11) and passage (1) to motor rotary group (5). The shock load is absorbed at the stop of a
swing movement.
At swing relief valve (8), the increased oil pressure in passage (7) flows through orifice (20) in stem (22)
and passage (26) to piston chamber (27). The force of spring (21) is less than the relief valve pressure
setting. This causes stem (22) to move to the right (open position) before the oil pressure in passage (7)
reaches the relief valve pressure setting. At the same time, the pressure oil in piston chamber (27) flows
through passages (24) and (29). Piston (25) moves to the left against the force of spring (21). The oil in
piston chamber (23) flows through orifice (28) and into piston chamber (27). Orifice (28) restricts the oil
flow into piston chamber (27) .
The swing relief valve maintains the operating pressure of the swing hydraulic circuit at a lower pressure
than the swing relief valve setting until the pressure in the swing hydraulic circuit forces piston (25) to
the right against adjustment plug (30). When piston (25) contacts adjustment plug (30), the pressure in
piston chamber (27) increases. The oil pressure in passage (7) reaches the swing relief valve setting. The
oil in passage (7) flows around stem (22) and into return passage (4) .
After stem (22) begins to open and before piston (25) completes the movement to the left, the pressure
in the swing hydraulic circuit increases gradually. The pressure in the swing hydraulic circuit does not
reach a peak pressure. This is called a two-stage relief operation. The two-stage relief operation absorbs
the shock load at the stop of a swing operation.
After the start of a swing right operation, the oil delivery from the drive pump flows through port (12)
and passage (1) to motor rotary group (5). The mass (weight and size) of the upper structure causes an
increase of oil pressure in passage (1). Stem (22) of swing relief valve (3) opens slightly. A portion of
the high pressure oil in passage (1) flows through makeup port (2) to return line (19). This gives a
Pgina 6 de 6
smoother acceleration at the start of a swing operation.

Tue Oct 17 21:36:26 EST 2006
Pgina 1 de 15
Cerrar SIS
Pantalla anterior

i02614801
Swing Hydraulic System

SMCS - 5050
S/N - EAH1-UP
S/N - FFK1-UP
S/N - MEY1-UP
S/N - NBD1-UP
Pgina 2 de 15
Pgina 3 de 15
Illustration 1
Hydraulic schematic for SWING RIGHT
(1) Pilot line
(2) Passage
(3) Swing parking brake
(4) Swing motor
(6) Relief valve
(8) Return line
(9) Line
(10) Line
(11) Passage
(16) Passage
(17) Passage
(21) Passage
(22) Passage
(24) Pilot line
(26) Line
Pgina 4 de 15

(28) Drive pump
(29) Idler pump
(30) Pilot pump
(32) Line
(34) Hydraulic tank
(36) Drain line
(37) Pilot line
(38) Pilot line
(47) Line
(48) Passage
(49) Line
The oil delivery for the swing hydraulic circuit is supplied by idler pump (28) only. When either one
of the joysticks is moved from the NEUTRAL position, swing parking brake (3) is released. Motor
rotary group (5) starts to rotate. The swing motor is mounted on top of the swing drive. The swing
drive is installed on the upper structure. The swing drive reduces the motor speed by two stages. The
swing drive rotates the upper structure.
ReferenceFor more information concerning the operation of the swing motor, refer to Systems
Operation, "Swing Motor".
ReferenceFor more information concerning the operation of the swing drive, refer to Systems
Operation, "Swing Drive".
ReferenceFor more information concerning the operation of the swing parking brake and the swing
brake solenoid valve, refer to Systems Operation, "Pilot Valve (Swing Parking Brake)".
Illustration 2
Main control valve compartment
Pgina 5 de 15
g00849940
(4) Swing motor

(8) Return line
(9) Line
(10) Line
Illustration 3
g00697650
The oil delivery from idler pump (28) flows through center bypass passage (52) in main control
valve (14) to swing control valve (18). The oil delivery from idler pump (29) flows through center
bypass passage (53) in main control valve (14). Illustration 1 shows the main control valve when
only the swing hydraulic circuit is activated.
When the hydraulic lockout lever is in the UNLOCKED position, the oil delivery from pilot pump
(30) flows to pilot oil manifold (35) and swing brake solenoid valve (31). The oil delivery from the
pilot pump also flows to pilot control valve (23) .
Pgina 6 de 15
When the swing joystick is moved to the SWING RIGHT position, the implement/swing pressure
switch senses the increase in pilot oil pressure. The implement/swing pressure switch changes to the
ON position. The implement/swing pressure switch sends an input signal to the machine ECM. The
machine ECM then energizes swing brake solenoid valve (31). The swing brake solenoid valve
shifts. Pilot oil flows through pilot line (1) to swing parking brake (3). The swing parking brake
releases in order to enable a swing operation.
The oil delivery from pilot pump (30) flows from pilot control valve (23) through pilot line (26) and
into swing control valve (18). The spool in swing control valve (18) shifts upward. The pilot oil on
the other end of the spool in the swing control valve flows through pilot line (37) and pilot control
valve (23) to hydraulic tank (34) .
Since the spool in swing control valve (18) is fully shifted, center bypass passage (52) is blocked.
None of the oil delivery from the idler pump flows to negative flow control orifice (54) and no
negative flow control pressure is created in center bypass passage (52). Since no negative flow
control pressure is sent through negative flow control line (55) to the idler pump regulator, the idler
pump regulator moves the swashplate of the idler pump toward the maximum angle position. The
output flow rate of the idler pump increases. The oil delivery from the idler pump flows through
parallel feeder passage (13), load check valve (12), passage (17), swing control valve (18), passage
(16) and line (9) to the swing motor. The oil enters the swing motor and flows to motor rotary group
(5). The motor rotary group rotates.
The oil delivery for the swing hydraulic circuit is supplied by the idler pump only. Since only a
swing operation is being performed, the control valves that receive the oil delivery from idler pump
(29) are in the NEUTRAL position. The negative flow control pressure in center bypass passage (53)
is not blocked by any of the control valves. Idler pump (29) remains at the destroked position.
Return oil from motor rotary group (5) flows through line (10) to the main control valve. The return
oil flows through swing control valve (18), return passage (11), return line (8) and slow return check
valve (33) to hydraulic tank (34). The upper structure swings to the right (clockwise direction).
The SWING LEFT operation is similar to the SWING RIGHT operation.
When the swing joystick is moved to the SWING LEFT position, pilot oil from pilot control valve
(23) flows through pilot line (37) and into swing control valve (18). The spool in the swing control
valve shifts downward. The oil delivery from the idler pump in parallel feeder passage (13) flows
through passage (17) and line (10). The oil delivery enters motor rotary group (5). For a swing left
operation, the supply ports and return ports are reverse of the swing right operation. This causes the
upper structure to swing to the left (counterclockwise direction).
When the swing joystick is returned to the NEUTRAL position, the springs on each end of the swing
control valve maintain the spool in the swing control valve in the NEUTRAL position. The oil flow
to the swing motor and the oil flow from the swing motor is blocked by the swing control valve.
Swing Priority
The pilot oil pressure from the pilot control valve directly corresponds to the amount of movement or
position of the joystick. The pilot oil pressure from the pilot control valve acts on the pressure
reducing valve for swing priority and the variable swing priority valve. As the swing joystick is
moved farther from the NEUTRAL position, the pilot oil pressure increases. This gradual increase in
Pgina 7 de 15
pilot oil pressure causes a gradual change to swing priority. Thus, swing priority is controlled by the
position of the swing joystick and swing priority automatically activates when the joystick reaches a
certain position.
When swing priority is activated, the output flow from the idler pump supplies hydraulic oil to the
swing hydraulic circuit. Since swing priority increases the swing acceleration, swing priority is
useful for loading operations. Swing priority is also useful for leveling operations and trenching
operations when higher swing force is required.
Illustration 4
Stick I control valve (swing priority OFF)
(22) Passage
Pgina 8 de 15
(24) Pilot line (swing pilot pressure)

(38) Pilot line (pilot system pressure)
(39) Pin hole
(40) Spool
(41) Spring
(42) Passage (stick I)
(43) Spool
(44) Drain line
(45) Check valve
(46) Orifice
(47) Line
(48) Passage
(50) Spring
(51) Passage
(56) Drain Line
Pgina 9 de 15
Illustration 5
Pgina 10 de 15
SWING RIGHT operation (swing priority OFF)

(4) Swing motor
(21) Passage
(22) Passage
(24) Pilot line
(26) Pilot line
(28) Drive pump
(29) Idler pump
(30) Pilot pump
(38) Pilot line
(41) Spring
(47) Line
(48) Passage
(50) Spring
When the swing joystick is in the NEUTRAL position, no pilot oil pressure acts on spool (40) of
pressure reducing valve for swing priority (27). Full pilot oil pressure flows through pilot line (38),
the pressure reducing valve for swing priority (27), line (47) and passage (22) to variable swing
priority valve (20). Spool (43) in the variable swing priority valve is shifted upward against the force
of spring (41). The oil delivery from idler pump (29) in parallel feeder passage (13) flows through
parallel feeder passage (15) and variable swing priority valve (20). The oil delivery enters stick I
control valve (19) .
When the swing joystick is moved slightly from the NEUTRAL position in order to perform a
SWING RIGHT operation, reduced pilot oil pressure from pilot control valve (23) flows through
pilot line (26). The pilot oil then divides into two flow paths. Part of the pilot oil flows through
passage (21) to swing control valve (18). The spool in the swing control valve shifts a slight amount
that corresponds to the amount of movement of the swing joystick. The remainder of the pilot oil
flows through pilot line (24) and passage (48). The pilot oil pressure acts on the shoulder of spool
Pgina 11 de 15
(40) in the pressure reducing valve for swing priority (27). Spool (40) shifts against the force of
spring (50) .
Since the reduced pilot oil pressure in passage (22) is still higher than the force of spring (41), spool
(43) in variable swing priority valve (20) remains shifted upward. The oil delivery from idler pump
(29) to stick I control valve (19) is not restricted. Swing priority is not activated.
Illustration 6
Stick I control valve (swing priority ON)
(22) Passage
(24) Pilot line (swing pilot pressure)
Pgina 12 de 15

(38) Pilot line (pilot system pressure)
(39) Pin hole
(40) Spool
(41) Spring
(42) Passage (stick I)
(43) Spool
(44) Drain line
(45) Check valve
(46) Orifice
(47) Line
(48) Passage
(50) Spring
(51) Passage
(56) Drain line
Pgina 13 de 15
Illustration 7
Pgina 14 de 15
SWING RIGHT operation (swing priority ON)

(4) Swing motor
(21) Passage
(22) Passage
(24) Pilot line
(26) Pilot line
(28) Drive pump
(29) Idler pump
(30) Pilot pump
(38) Pilot line
(41) Spring
(45) Check valve
(46) Orifice
(47) Line
(48) Passage
(50) Spring
As the swing joystick is moved to the FULL STROKE position during a SWING RIGHT operation,
the pilot oil pressure in passage (21) increases. The spool in swing control valve (18) shifts fully
upward. The pilot oil pressure in pilot line (24) and passage (48) also increases. Spool (40) in the
pressure reducing valve for swing priority (27) shifts fully against the force of spring (50) .
Passage (51) restricts the pilot oil flow from pilot line (38) through the pressure reducing valve for
swing priority (27). The pilot oil pressure in line (47) and passage (22) also decreases. Spool (43) in
variable swing priority valve (20) is pushed downward by the force of spring (41) .
The oil delivery from idler pump (29) in parallel feeder passage (15) is restricted by orifice (46) in
Pgina 15 de 15
check valve (45). A portion of the oil delivery from the idler pump flows into passage (42). Swing
priority is now activated. Most of the oil delivery from the idler pump is dedicated to the swing
system and flows through the swing control valve to the swing motor. As a result, swing priority and
higher swing force can be achieved with the swing joystick.
A portion of the pilot oil at passage (51) flows through passage (39) to spool (40). Pilot oil pressure
that flows from passage (22) into variable swing priority valve (20) corresponds to the position of the
swing joystick.

Tue Oct 17 20:13:50 EST 2006
Pgina 1 de 5
Cerrar SIS
Pantalla anterior

i01638171
Swing Motor
SMCS - 5058-ZW
Illustration 1
Pgina 2 de 5
Swing motor
(1) Relief valve
(2) Relief valve
(3) Motor head
(4) Port (pilot system oil)
(5) Separator plate
(6) Friction plate
(7) Plate
(8) Body
Pgina 3 de 5
(9) Drive shaft

(10) Check valve
(11) Makeup port
(12) Drain port
(13) Passage (supply oil or return oil)
(14) Check valve
(16) Port (supply oil or return oil)
(17) Port (supply oil or return oil)
(19) Valve plate
(21) Brake spring
(22) Brake piston
(23) Piston
(24) Cylinder barrel
(25) Retainer plate
(26) Shoe
The swing motor may be divided into the following three groups :
z
The rotary group consists of the following components : cylinder barrel (24), pistons (23),
shoes (26), retainer plate (25) and drive shaft (9) .
The parking brake consists of the following components : brake spring (21), brake piston (22),
separator plate (5) and friction plate (6) .
The relief valves and the makeup valves consists of the following components : relief valve
(1), relief valve (2), check valve (10) and check valve (14) .
Supply oil from the drive pump is delivered to port (16) or port (17). During a SWING RIGHT
operation, the oil delivery enters motor head (3) at port (17) and flows through passage (18). The oil
then flows through passage (13) in valve plate (19) and passes through passage (20) in cylinder
barrel (24). This oil pressurizes piston (23) in motor head (3).
Illustration 2
Pgina 4 de 5
g00682196
Motor passages
(A) Bottom center position
(B) Inlet side (high pressure)
(C) Top center position
(D) Outlet side (low pressure)
(13) Passage (valve plate)
(15) Return passage
(16) Port
(17) Port
Pgina 5 de 5
(18) Supply passage

(20) Passage (cylinder barrel)
(27) Passage (valve plate)
(28) Direction of motor rotation (counterclockwise rotation)
Shoe (26) is pressed against the upper surface of plate (7) by the force of piston (23). The shoe and
the piston slide along the slope of plate (7) in a counterclockwise direction. This sliding force causes
cylinder barrel (24) to rotate in a counterclockwise direction (28). As each piston reaches the bottom
center position (A), oil flows through passage (27) in valve plate (19). This oil then flows through
passage (15) of motor head (3) to the hydraulic tank. As cylinder barrel (27) continues to rotate
counterclockwise, the piston and the shoe continue to move up the inclined surface of plate (28).
Since cylinder barrel (24) is splined to drive shaft (9), the drive shaft rotates in the same direction as
the cylinder barrel.
For a SWING LEFT operation, swing pump supply oil is delivered to port (16). The supply ports and
the return ports are reversed. Cylinder barrel (24) turns clockwise.
The case drain oil from the swing motors returns through drain port (12) of motor head (3) to the
hydraulic tank.
Reference: For more information concerning the swing parking brake, refer to Systems Operation,
"Pilot Valve (Swing Parking Brake)".
Reference: For more information concerning the swing relief valves, refer to Systems Operation,
"Relief Valve (Swing)".

Tue Oct 17 20:43:24 EST 2006
Pgina 1 de 5
Cerrar SIS
Pantalla anterior

i02467880
Pilot Valve (Swing Parking Brake)

SMCS - 5059; 5483
Illustration 1
g00682419
Swing brake solenoid valve (2) is located on the pilot oil manifold. When any one of the joysticks is
moved from the NEUTRAL position, the swing brake solenoid valve is energized in order to release
the swing brake. When the swing brake solenoid valve is energized, pilot oil flows to the swing
motor in order to release the swing brake.
Note: Operation of the travel levers/pedals will not release the swing brake.
Pgina 2 de 5
Illustration 2
Swing brake (disengaged position)
(3) Spool
(4) Spring
(5) Passage
(6) Passage
(9) Spool chamber
Pgina 3 de 5
(10) Line
(11) Body (swing motor)
(12) Friction plate
(13) Separator plate
(14) Piston chamber
(15) Port (swing motor)
(17) Brake piston
(18) Brake spring
(19) Motor head
The swing brake is located between motor head (19) of swing motor and body (11). The swing brake
consists of the following components : brake spring (18), brake piston (17), separator plate (13) and
friction plate (12). Friction plate (12) is splined to cylinder barrel (16). Separator plate (13) is splined
to body (11). Separator plate (13) and friction plate (12) move in an axial direction.
When the joysticks are moved from the NEUTRAL position, the implement/swing pressure switch
senses the increase in pilot oil pressure at the pilot control valves. The implement/swing pressure
switch changes to the ON position. The implement/swing pressure switch sends an input signal to the
machine ECM. The machine ECM energizes swing brake solenoid valve (2) .
When swing brake solenoid valve (2) is energized, spool (3) moves in a downward direction against
the force of spring (4). Pilot oil in passage (7) flows through spool chamber (6) and line (10) to port
(15) of the swing motor. The pilot oil now enters piston chamber (14). The pilot pressure causes
brake piston (17) to move upward against the force of brake spring (18). The force that holds
separator plate (13) and friction plate (12) together is released. When the swing brake is released, the
swing operation of the upper structure is enabled.
Note: If the swing brake becomes inoperable due to failure of swing brake solenoid valve (2), the
swing brake can be released by turning the temporary brake release screw in a clockwise direction
until the temporary brake release screw stops.
Pgina 4 de 5
Illustration 3
Swing brake (engaged position)
(3) Spool
(4) Spring
(5) Passage
(6) Passage
(9) Spool chamber
Pgina 5 de 5
(10) Line
(11) Body (swing motor)
(12) Friction plate
(13) Separator plate
(14) Piston chamber
(15) Port (swing motor)
(17) Brake piston
(18) Brake spring
(19) Motor head
When the joysticks are returned to the NEUTRAL position, supply oil from the drive pump to the
swing motor is stopped. The implement/swing pressure switch senses the decrease in pilot oil
pressure at the pilot control valves. The implement/swing pressure switch changes to the OFF
position. The machine ECM senses the change of signal at the implement/swing pressure switch. The
machine ECM de-energizes swing brake solenoid valve (2) .
Spool (3) is moved upward by the force of spring (4). Spool (3) blocks pilot oil flow from port (7) to
piston chamber (14). Brake spring (18) forces brake piston (17) downward. The oil in piston
chamber (14) flows through port (15) and line (10) to pilot oil manifold (8). The oil then flows into
spool chamber (6) and passage (9) of spool (3). The oil then flows through passage (5) to the
hydraulic tank. As brake piston (17) moves downward, separator plate (13) and friction plate (12) are
forced together. Since separator plates (13) are splined to body (11), the rotation of cylinder barrel
(16) in the swing motor is stopped. Rotation of the upper structure is prevented.
Since the machine ECM does not de-energize the swing brake solenoid valve until approximately 6.5
seconds after the swing joystick is returned to the NEUTRAL position, the rotation of the swing
motors stops before the swing brake is engaged. If the solenoid is de-energized before the rotation of
the swing motors stops, damage and wear to the swing brakes would result.

Tue Oct 17 20:46:09 EST 2006
Pgina 1 de 4
Cerrar SIS
Pantalla anterior

i01468748
Cylinders (Boom, Stick and Bucket)

SMCS - 7562
Pgina 2 de 4
Illustration 1
(1) Rod end port
(2) Head end port
(3) Boom cylinder
(4) Tube
(5) Rod
(6) Snubber
(7) Piston
(8) Stick cylinder
(9) Snubber
Pgina 3 de 4
(10) Bucket cylinder
Illustration 2
Snubber operation
g00766296
(6) Snubber
(11) Passage
When boom cylinders (3) or stick cylinder (8) moves close to the end of the extension stroke,
passage (11) is restricted by snubber (6). The movement of the piston rod slows down before the
piston rod stops.
Illustration 3
Snubber operation (retracting rod)
Pgina 4 de 4
g00766297
(9) Snubber
(12) Passage
When stick cylinder (8) moves close to the end of the retraction stroke, passage (12) is restricted by
snubber (9). The movement of the piston rod slows down before the piston rod stops. The shock load
is absorbed when the piston is slowed down.

Tue Oct 17 20:10:48 EST 2006
Pgina 1 de 8
Cerrar SIS
Pantalla anterior

i02614030
Main Hydraulic System - Heavy Lift and Fine Swing

SMCS - 5050; 5051; 5069; 5117; 5472
S/N - B6H1-UP
S/N - EDX1-UP
S/N - JLP1-UP
S/N - MWP1-UP
Main Hydraulic Schematic
Pgina 2 de 8
Pgina 3 de 8
Illustration 1
(1) Swing motor
(2) Left travel motor
(3) Right travel motor
(4) Stick cylinder
(5) Travel brake valve (left)
(6) Travel brake valve (right)
(7) Bucket cylinder
(8) Boom cylinder
(9) Swivel
(10) Pilot control valve (travel)
(20) Accumulator
(21) Reducing valve (boom priority mode or swing priority mode)
(22) Pressure sensor (drive pump)
(24) Valve
(25) Solenoid valve (hydraulic lockout)
(26) Drive pump (view from shaft end)
Pgina 4 de 8

(29) Drain filter
(31) Pilot filter
(32) Idler pump (view from shaft end)
(33) Pilot pump
(35) Bypass check valve
(36) Pressure sensor (idler pump)
(38) Oil cooler
(39) Return filter
(40) Hydraulic tank
(41) Gear pump (fan motor)
(42) Relief valve (fan pump)
(43) Fan motor (hydraulic oil cooler)
Hydraulic Pump Flow and Pressure Control System
Illustration 2
g01228123
Pump compartment
(26) Drive pump
Pgina 5 de 8
(32) Idler pump

(44) Delivery line (idler pump)
(45) Delivery line (drive pump)
This machine is driven and controlled by the following systems.

z
The main hydraulic system controls the cylinders, the travel motors and the swing motor.
The pilot hydraulic system supplies oil to the main pumps, the main control valve, the swing
brake and the travel motors.
The electronic control system controls the outputs of the engine and pump.
The hydraulic oil cooling system provides oil to the fan motor in order to cool the hydraulic
oil.
The main hydraulic system delivers oil flow from idler pump (32) and drive pump (26) in order to
control the following components: bucket cylinder (7) , stick cylinder (4) , boom cylinders (8) , right
travel motor (3) , left travel motor (2) and swing motor (1) .
Illustration 3
Main control valve
g01228403

(45) Right control valve body
(46) Left control valve body
Idler pump (32) and drive pump (26) are bent axial piston type pumps. The performance of both
pumps is equal.
Drive pump (26) is directly connected to the engine by a flexible coupling. The drive pump delivers
oil to the left control valve body (46) of the main control valve. Idler pump (32) is mechanically
connected to the drive pump through gears. The idler pump delivers oil to the right control valve
Pgina 6 de 8
body (45) of the main control valve. Gear type pilot pump (33) supplies oil to the pilot hydraulic
system. Gear type pilot pump (33) is mechanically connected to idler pump (32) through gears. Gear
pump (41) supplies oil to the oil cooling system. Gear pump (41) is mechanically connected to the
engine through gears. All engine output is used to drive these four pumps.
As the load pressure increases during working conditions, the main pumps increase the delivery
pressure and the pumps decrease the flow rate. The hydraulic horsepower remains constant even
though the delivery pressure and the flow rates change. The hydraulic horsepower is approximately
identical to the engine horsepower.
When no work is being performed, pump oil flows through main control valve (12) and into
hydraulic tank (40) . The main control valve sends a negative flow control signal to each main pump
regulator in order to destroke the pump to the minimum output flow.
If an operation is being performed, main control valve (12) directs pump oil to the respective
cylinders (boom, bucket, and stick) and/or motors (swing and travel). Main control valve (12)
contains numerous valve stems, passages, check valves, and orifices in order to carry out a single
operation or a combined operation. The working pressure of the main hydraulic system is regulated
by main relief valve (18) .
Illustration 4
Cab
g01173678
(47) Monitor panel

(48) Joystick (stick and swing)
(49) Joystick (boom and bucket)
(50) Left travel lever/pedal
(51) Right travel lever/pedal
(52) Straight travel pedal
The pilot hydraulic system receives oil flow from pilot pump (33) . The pilot hydraulic system
controls the following functions.
Pgina 7 de 8
1. The pilot hydraulic system controls the operation of the implement control valves.
Pilot oil flows from pilot pump (33) through pilot manifold (28) . The pilot oil then flows to
the pilot control valves for machine operation (implement operations, swing operations and
travel operation). These pilot control valves are activated by the joysticks and the travel
levers/pedals.
When joystick (48) , joystick (49) , left travel lever/pedal (50) and/or right travel lever/pedal
(51) are moved from the NEUTRAL position, the pilot oil flows through the pilot control
valves to the corresponding spools at the main control valve (12) .
The pilot pressure oil at that end of the valve spool forces the valve spool to shift. The pilot oil
on the other end of the valve spool drains to the hydraulic tank. When the valve spool shifts,
oil is then delivered from idler pump (32) or drive pump (26) to the cylinders and motors.
Thus, pilot oil drives each system of the main control valve.
2. The pilot hydraulic system controls the output flow of the main pumps.
During machine operation, pilot pressure is sent to the main pump regulators as a signal
pressure. This signal pressure is called power shift pressure. The engine and pump controller
receives input signals from various components on the machine. The engine and pump
controller processes the input signals. The engine and pump controller then sends an electrical
signal to proportional reducing valve (37) at the idler pump regulator in order to regulate the
power shift pressure. The power shift pressure controls the output flow of idler pump (32) and
drive pump (26) . Power shift pressure adjusts the output flow of the main pumps in
accordance with the engine speed. For more information concerning power shift pressure, refer
to Systems Operation, "Pilot Hydraulic System".
3. The pilot hydraulic system generates signal pressure in order to perform the following
operations.
a. Pilot signal pressure activates the Automatic Engine Speed Control (AEC) system. This
causes functions to automatically reduce the engine speed when no hydraulic operation
is called for.
b. Pilot signal pressure releases the swing parking brake.
c. Pilot signal pressure will automatically change the travel speed to either HIGH or LOW
in accordance with the hydraulic system load.
d. Pilot signal pressure operates the straight travel control valve. This maintains straight
travel during the operation of an implement.
e. Pilot signal pressure controls the operation of the valves that can be used during a
loading operation or a trenching operation.
For more information concerning the pilot hydraulic system, refer to Systems Operation, "Pilot
Hydraulic System".

Tue Oct 17 17:36:42 EST 2006
Pgina 8 de 8
Pgina 1 de 5
Cerrar SIS
Pantalla anterior

i02580756
Electronic Control System

SMCS - 1900
Pgina 2 de 5
Illustration 1
(1) Machine ECM
(3) Switch panel
(4) Clench pressure sensor (attachment)
(5) Manual low idle switch
Pgina 3 de 5
(6) Implement pressure switch

(7) Swing pressure switch
(8) Right travel pressure switch
(9) Left travel pressure switch
(10) Straight travel pressure switch
(11) Right pump pressure sensor
(12) Left pump pressure sensor
(13) Fuse panel
(14) viscous clutch
(15) Fan speed sensor
(16) Engine
(17) Main pumps
(18) Engine speed pickup
(19) Battery
(20) Engine start switch
(21) Backup switch
(22) Monitor
(23) Heavy lift solenoid valve
(27) Hydraulic lockout solenoid
(28) Flow limiter valve (attachment pump)
(29) Pressure switch (attachment pump)
(30) Attachment pedal pressure switch (Left)
(31) Attachment pedal pressure switch (Right)
(32) Proportional reducing valve for auxiliary hydraulics
(33) Power shift solenoid valve
Illustration 2
(1) Machine ECM
g01173858
Illustration 3
(22) Monitor
g01173869
Pgina 4 de 5
The electronic control system consists of monitor (22) in the cab and the machine ECM (1) that is
located in the compartment behind the cab. The electronic control system controls the engine speed
and the pumps through the machine ECM.
Machine ECM (1) receives input signals from various components on the machine. The machine
ECM continuously monitors the input signals in order to control the output flow rate of the main
pumps, engine speed and various components of the machine hydraulic systems.
Pgina 5 de 5
The machine ECM has the following three major functions.

z
The electronic control system controls the output flow rate of the main pumps. The machine
ECM sends an electrical signal to the power shift solenoid that is based on engine speed and
the position of the engine speed dial. This allows the main pumps to supply the optimum
output that matches the hydraulic load to the machine and the engine speed. When a large load
is placed on the machine, the system allows the pumps to destroke. The system utilizes the
available maximum engine horsepower.
The electronic control system controls the engine speed. This is called Automatic Engine
Speed Control (AEC). When there is a very small load condition or no load condition, the
system automatically decreases the engine speed. The AEC system is designed to reduce fuel
consumption and noise.
The electronic control system controls various components of the machine hydraulic systems.
The machine ECM sends output signals to the swing brake solenoid valve, the travel speed
solenoid valve and the straight travel solenoid.
Note: If a problem occurs in the electronic control system, temporary operation of the machine is
possible by use of the backup switches that are located in the cab. For more information concerning
the backup system, refer to Operation and Maintenance Manual, "Backup Controls".
ReferenceFor more information concerning the operation of the electronic control system, refer to
Systems Operation/Testing and Adjusting, "Machine Electronic Control System".

Tue Oct 17 17:39:32 EST 2006

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Bsqueda del medio - RENR9584 - 330D Excavator Hydraulic System

Fecha de publicacin -01/09/2006

Fecha de actualizacin -11/09/2006

Copyright 1993 - 2006 Caterpillar Inc.

Tue Oct 17 17:22:45 EST 2006

MANUAL DEL ESTUDIANTE

CURSO: Excavadora 330D

Curso : Excavadora 330D

Material del Estudiante

Laboratorios durante el Curso.............................................................................

AGENDA DEL CURSO

MODULO 1: INTRODUCCION A LA EXCAVADORA

MODULO 2: SISTEMAS ELECTRICO, ELECTRNICO Y MONITOR

Curso : Excavadora 330D

Material del Estudiante

Leccin 2.3: Sistema Monitor..............................................................................

Leccin 2.3.1: Funciones del Monitor.......................................................

Texto de Referencia: Motores ACERT........................................................

Leccin 3.2: Sistema de Combustible con Control Electrnico HEUI...............

Texto de Referencia: Componentes del Circuito......................................

Leccin 3.3: Sistema Electrnico de Control......................................................

Texto de Referencia: Circuito de Control..................................................

Curso : Excavadora 330D

Material del Estudiante

MODULO 4: SISTEMA HIDRULICO

Hoja de Trabajo 4.1: Sistema Hidrulico...................................................

Leccin 4.2: Bomba Hidrulica Principal............................................................

Leccin 4.2.1: Bomba Hidrulica Principal................................................

Leccin 4.3: Sistema de Implementos.................................................................

Hoja de Trabajo 4.7: Vlvula de Control Principal....................................

Curso : Excavadora 330D

Material del Estudiante

DESCRIPCION DEL CURSO

Este curso ha sido diseado para mecnicos, tcnicos de servicio,

El curso se desarrollar 50% en el aula y 50% en la mquina de acuerdo a la

Curso : Excavadora 330D

Material del Estudiante

MODULO 1: INTRODUCCION A LA MAQUINA

MODULO 2: SISTEMA ELECTRICO Y MONITOR

Uso del esquema elctrico

MODULO 3: MOTOR C9 ACERT

Localizacin de componentes de los sistemas del motor C9

MODULO 4: SISTEMA HIDRULICO

Localizacin de componentes del sistema hidrulico en el

Curso : Excavadora 330D

Material del Estudiante

Al trmino de este curso, los estudiantes estarn en capacidad de realizar los

Ubicar los componentes mayores y puntos de servicio de acuerdo al

Realizar el mantenimiento programado e inspeccin diaria de la

Comprobar el sistema de arranque y carga.

Explicar el funcionamiento de los sistemas del motor C9 ACERT

Evaluar el motor con el ET.

Ubicar los componentes elctricos y electrnicos de la Excavadora

Diagnosticar el sistema electrnico de la excavadora usando el ET o

Explicar el funcionamiento del Sistema Hidrulico

Ubicar los componentes hidrulicos en el esquema y la mquina

Realizar las pruebas operacionales, pruebas de presin y pruebas de

Los estudiantes debern tener conocimientos bsicos de:

Curso : Excavadora 330D

Material del Estudiante

AGENDA DEL CURSO

Presentacin Inicial, Expectativas

Mdulo 2, Electrnico y Monitor

Mdulo 4, Sistema Hidrulico