Hydraulic Ver (Eng) Yoshida Kaizo

Title
Hydraulics
1
SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD
Menu
Agenda
Summary of Today
Hydraulics equipments review
with interchangeability
Hydraulics diagram review
1 New feature; Straight Travel
2 New feature; Swing Speed limit
3 New feature; Swing Relief Cut Off
4 New feature; Swing Parking
5 New feature; Bucket Regeneration
6 New feature; Nega-Con Power Save
7 New feature; HYD HP Boost - Arm in
8 New feature; HYD HP Boost - Travel
9 New feature; Cushon valve
10 New feature; Auto Press Boost
11 New feature; Option line
Maintenance Procedure
New Return Filter
Machine Walking Around
Q and ?
Close
2
-
Hyd. Component Review
Title Comp. review
Major Hydraulic Components

Review
3
Section;Data P.4
Interchangeability
4
-
Pump
Hydraulic pump
Position Part name SH200-3 Interchangeability SH200-5 Remarks
KRJ6199 KRJ10290
J Hydraulic pump <-- X --> Spec. changed
KAWASAKI KAWASAKI
Basic system & structure are similar to -3.
Difference
5 % Increase
-3 Hydraulic pump Max. Flow
Increased Expelling volume
2 X 201 L/min ( H mode ) (-3 Model)
103cc/rev 117cc/rev >>>2 X 211 L/min ( H mode ) (-5 Model) for pump flow
New HP setting
P1 Solenoid valve, and shuttle valve
For Swing speed limit, Swing relief cut off,
Option line flow control, and Power save system
P2 Shuttle valve
For Power save system
New valve plate, New pump housing
Low noise 2db reduction
Clearance improve of regulator piston 2 % Improvement
Decrease internal leakage for fuel consumption
5
Section;Hydraulics P.116
Hydraulic pump
Diagram difference
210-5
P1 P2
Shuttle Shuttle
valve valve
P1 Solenoid valve ( Proportional Solenoid Valve )

6
Hydraulic pump Inverse Proportional Solenoid Valve
Diagram difference
I min >>> Give Pressure
210-5
I max >>> No Pressure
N1; Negative Control

Pilot
P1 Proportional Solenoid Valve

I min >>> No Pressure
I max >>> Give Pressure
7
-
Hydraulic pump
Outward difference Shuttle valve
P1 solenoid valve port
200-3 210-5
New housing
8
Hydraulic pump
Outward difference
9
Hydraulic pump
Outward difference
2) Accumulator
3) Pilot filter
1)1)Hydraulic
HydraulicPump
Pump
4)4)55pcs
pcsSolenoid
Solenoidvalve
valve

10
Hydraulic pump
Outward difference
6) P2 Sensor
5) N1 Sensor
7) P1 Sensor
4) 5 pcs Solenoid valve
8) Pilot Pump
11
Hydraulic pump
Outward difference
9) N2 Sensor
11) Hyd Temp Sensor

10) Proportional Solenoid V
12
Section;Hydraulics P.112/117
Hydraulic pump
Internal difference
210-5
13
Section;Hydraulics P.120 to 138
Travel unit
Travel unit
KRA10120 KRA10150
A Travel motor <-- X --> Drive force increased
KAYABA KAYABA
Difference
Hyd oil displacement change
Displacement 162.2 / 95.0 cc /rev (-3 Model)
>>> 168.9 / 100.3 cc /rev (-5 Model) 4 % Increase

for Travel Drive Force
Same travel speed with 3 (5.6/3.4 km/hr)
Compact Reduction

14
Travel unit
210-5
15
Swing unit
Swing unit
KRC0226 KRC10010
C Swing motor assy <-- X --> Spec. changed
TOSHIBA TOSHIBA
LJ01076 LJ014440
C Swing motor <-- X -->
TOSHIBA TOSHIBA
LN00111 LN001820
C Swing reduction <-- X -->
TOSHIBA TOSHIBA

Difference
Working pressure change
29.4 MPa (210-5) <<< 27.9 MPa (210-3)
On 240, the same between -3 and -5
By pass valve less
240-5 has the valve
New gear oil level gauge
240-5, new reduction but similar spec. to -5
Drain port layout change
16
Swing unit
200-3 210-5
17
Swing unit
200-3 210-5
18
Swing unit
Effectiveness measurement
Brake Reverse Brake Reverse

pressure pressure pressure pressure
210-5 200-3
However, the anti-drift valve is installed on SH240-5

same as SH240-3.
19
Swing unit 210-5
200-3
20
Swing unit
KBC0110 KBC10010
C Swing motor assy <-- X --> Spec. changed
KAWASAKI HITACHI
KBC0108 KBC10020
C Swing motor <-- X -->
KAWASAKI KAWASAKI
KBC0127 KBC10030
C Swing reduction <-- X -->
KAWSAKI HITACHI
21
-
Free Swing
Swing unit
210-5
Free Swing
22
Control valve
Control valve
KRJ10420 KRJ10310
J Control valve <-- X --> Spec. changed
KAYABA KAYABA

Difference
New Straight Travel Pilot Line
Bucket Close Regeneration Circuit
Add-on Valves for Option Line

23
Control valve
210-5
24
Control valve
210-5
New Straight Travel Pilot Port
25
Control valve
210-5
Arm Close
Boom Up
Bucket Open
Arm Open
Boom Down
Bucket Close
Main
For Boost For Standard
26
Remote C V
Remote control valve

Remote control valve KRJ5804 KHJ13270
J <-- X --> Spec. changed
(Operating machine) KAWASAKI KAWASAKI

Difference
Spring strength
By Length of Joystick change
Housing shape
By Airtight cab

27
Remote control valve
210-5
28
-
Attach cylinder
Attachment Cylinders
KRV2952 KRV11130
V Boom cylinder KRV2953 <-- X --> KRV11140 Spec. changed
KAYABA KAYABA
KRV2954 KRV11150
V Arm cylinder <-- X --> Spec. changed
KAYABA KAYABA
KRV2955 KRV11160
V Bucket cylinder <-- X --> Spec. changed
KAYABA KAYABA

Difference
Bigger Bore of cylinders
For Real Maneuverability

29
-
Bucket Cylinder on 210
-3: Cylinder bore 115 / Rod bore 80
>>> -5: Cylinder bore 120 / Rod bore 85
Arm Cylinder on 210

30
-
Boom Cylinder on 240
31
Hydraulic diagram
Hyd. diagram Review
Title Diagram review
Hydraulic Diagram
Review
32
-
Hyd. Circuit Review
Title Cir. review
New Hydraulic Circuits

Review
33
Hyd. Circuit Review
List Cir. review
34
Hyd. Circuit Review
Straight Travel
Straight Travel
Advantage;
Reduce shock by attachment operation during traveling.
Background;
At steep slope in a mountain area,

operators dislike the shock for their logging application.
35
-
Hyd. Circuit Review
Straight Travel
210-3
Switched by 1st pressure.

Switched Press. ; 4MPa.
Travel --->Sharp spool shift

Travel
Straight Travel Pilot

Valve
Upper
Press Sensor
Travel
Press Sensor Pilot pump
36
Hyd. Circuit Review
Straight Travel
210-5
New orifice diameter.
--->Reduce shifting shock
Travel
Switched by 2ndary Pressure.
Proportionate movement.
--->Linear spool shift

Travel Press Sensor Upper Press Sensor
37
Hyd. Circuit Review
Straight Travel
4
SH210-5
3
ZX200-3
km/hr 2 PC200-8
SK200-8
1
CAT320D
0
single 1st speed Boom up + 1st
Travel speed Travel
SH210-5 3.4 2.99
ZX200-3 3.5 2.09
PC200-8 2.9 1.91
SK200-8 3.57 1.97
CAT320D 3.6 2.82
38
Hyd. Circuit Review
Straight Travel
8
SH210-5
6
ZX200-3
km/hr 4 PC200-8
SK200-8
2
CAT320D
0
single 2nd speed Boom up + 2nd
Travel speed Travel
SH210-5 5.7 4.62
ZX200-3 5.3 3.1
PC200-8 5.6 2.44
SK200-8 5.96 3.09
CAT320D 5.9 4.63
39
Hyd. Circuit Review
Swing speed limit
Swing Speed Limit

Purpose;
Swing Drift Reduction
( To be same drift amount of -3 model)
For optimum swing speed (Same speed with 3)
Background;
Hydraulic flow of -5 is increased,
but speed up of swing speed makes longer swing drift.
>>> For Real Maneuverability, and safety
40
Hyd. Circuit Review
Swing Speed Limit Max. Pump flow
Swing motor 210-5: 211 L/min >>> 200 L/min SP mode
240-5: 234 L/min >>> 214 L/min SP mode
Nega-Con Signal
240-5: 222 L/min >>> 203 L/min H mode
Steer pilot pressure into negative control

port through electrify into front side
proportional valve.
Then flow will be decreased.
Condition of swing speed limit

Only Swing operation
Cut out condition of swing speed limit

When operate other attachment
Release gradually
P1 shock reduction
Solenoid Valve When operate travel
Release immediately
350mA
meandering prevention
41
Hyd. Circuit Review
Swing Relief Cut Off
Advantage; 2 % Improvement
Economize energy for fuel consumption
Background;
When start to swing,
High pressure for swing motor is needed,
but hydraulic oil flow is not needed so much.
42
Hyd. Circuit Review
210-5 At Swing Start When quick swing operation and
swing with load on bucket.
P1 Pump flow is decreased by P1-
Solenoid works.
Only
Quick Swing and Boom Down.
P1 Solenoid Valve
Computer 740 mA inputted,
Flow DOWN Min Pump Flow of P1
P1 Solenoid Valve
43
Hyd. Circuit Review
210-5 During Swinging During Swinging,
P1 Pump flow is increased by P1-
Solenoid works.
P1 Solenoid Valve
Computer
Down to 350mA,
Flow UP Pump Flow of P1 UP

P1 Solenoid Valve
44
-
Hyd. Circuit Review
Save Energy
210-3 210-5
Flow
Pressure
Nega-Con
Press
Time Time
740mA
mA for P1 Solenoid valve >>>
350mA
45
Hyd. Circuit Review
Swing parking
Swing Parking
Changed points;
A) Time to engage swing parking brake after using arm function
5 sec ( -3 model) >>> 1 sec (-5 model)
Time to engage Swing Parking after swinging
is same. ( 5 sec)
B) Hydraulic Lock of Swing Spool in Control valve
Background;
a) Drift prevention at slope during no equipment operation.
b) By removing Swing Parking button
46
Hyd. Circuit Review
Arm in Regeneration
Arm-In Regeneration
Advantage;
Optimum flow for quicker cylinder movement.
>>>Regenerated flow is increased
about 10 % from 210-3.
Background;
4.0
3.0
Arm in
sec
2.0
Arm out
1.0
0.0
SH210-3 SH210-5
Arm in 3.2 2.9
Arm out 2.5 2.6
47
Hyd. Circuit Review
Arm-In Regeneration
210-5
Check valve
for Regeneration
Narrow Orifice
Wide Orifice
48
Hyd. Circuit Review
Bucket close Regeneration
Bucket-Close Regeneration
Advantage;
Optimum flow for quicker cylinder movement.
>>> Speed of Bucket Close is increased
about 24 % from 210-3.
( Approx. 20% of return flow from rod side)
Background;
6.0
4.0 Bucket close

sec
2.0 Bucket open
0.0
SH210-3 SH210-5
Bucket 4.0 2.8
close
Bucket 2.3 2.2
open

49
Hyd. Circuit Review
Bucket-Close Regeneration
210-5 Check valve
for Regeneration
Orifice
50
Hyd. Circuit Review
Power save
Power save
Advantage; 1 % Improvement
Economize energy for fuel consumption
Background;
By studying of machine history record of 210-3,
30% to 34% of total hours were idling.
Previous Negative control system saves energy also,

but hydraulic flow to make 3MPa of Nega-Con pressure
are needed.
51
Hyd. Circuit Review
Power save
Nega-Con Pressur
210-3 e : 3MPa
Servo Piston
Reduce
flow
52
Hyd. Circuit Review
Power save
210-5
Condition to work;
No signal from Nega-Con Pressure;
Travel, Upper, and Swing Pilot
3 MPa >>> 1 MPa
Pressure Sensors for 1 second.
740 mA--->
Servo Piston
Reduce
flow
53
Hyd. Circuit Review
Hyd HP Boost -Arm in
Hydraulic HP Boost -Arm In-

Advantage;
Smooth Arm cylinder speed down from low load to high load.
Reduced Speed Ratio: 7% Improved.
Background;
Operator feels No power by speed reduction,

not pressure.
54
Sales text
Hyd. Circuit Review
Hydraulic HP Boost -Arm In-
Reduced Speed Ratio:
1150
7% Improved.
Arm Cylinder Speed
1050
950
850 SH210-5
-29.5%
SH210-3
750
-36.5%
650
mm/sec
Low load High load
55
Hyd. Circuit Review
Hyd HP Boost -Travel
Hydraulic HP Boost -Travel-

Advantage;
Smooth travel speed down from flat ground to slope.
Background;
Operator feels No power by speed reduction,

not pressure.
56
Hyd. Circuit Review
Cushion valve
New Cushion Valve

Advantage;
Faster heating Joystick valve up
>>> Approx. 30% faster warming up
Background;
Warming up speed of Joystick heating circuit on 210-3
is slower than our expectation.
57
-
Hyd. Circuit Review
New Cushion Valve
From Oil Cooler Line
210-3
By this orifice,
Warmed oil from oil
cooler line goes to
Tank.
58
-
Hyd. Circuit Review
Cushion valve
New Cushion Valve

From
210-5 Control valve T8
By this orifice,
Warmed oil from T8
port goes to Joystick
valve.
59
Hyd. Circuit Review
Auto power boost
Auto Power Boost

Advantage;
Main relief valve setting is shifted 34.3 MPa to 36.8 MPa
for 8 seconds automatically
depending on working situation
under SP, H and A mode(position 3).
Under A mode(position 4 to 15), always 36.8 MPa.
Judgment term becomes faster. (Approx. 0.1 sec)
Background;
On 210-3 system,
1 second is needed to work Auto power boost.
60
Hyd. Circuit Review
Option
Option Line
Advantage;
Stress free during Breaker operation
by Engine rpm dropping.
Selectable hydraulic flow for option line in the CAB.
Background;
Some operators dislike Engine rpm dropping during Breaker
operation.
Only 1 setting can be memorized in 210-3 system.
61
Hyd. Circuit Review
Option Line
Many attachment with many

setting flow for 20 ton class.
-3 system;
Breaker SW ; ON
Foot pedal ; ON
>>> Drop Eng rpm to a setting.
(-_-)1: Eng drop sound makes discomfort.
(-_-)2: Flow can adjust only for breaker.
(-_-)3: Only one setting can be memorized.
62
Hyd. Circuit Review
Option Line
(^_^)1: No Eng rpm drop for Breaker

(^_^)2: Adjustable flow for breaker and crusher
(^_^)3: 5 setting can be memorized from 10 default
System works condition;

Foot pedal ;On
All Pilot Press Sensors ;Off
Once operate Attachment, Travel, or Swing,

*Breaker mode; Under breaker setting.
*Crusher mode; Exit from this program.
63
Hyd. Circuit Review
Option Line
Engine rev (rpm) Flow (L/min) Pressure (MPa)
1000 140.2 0.40
1100 151.0 0.46
1200 162.7 0.51
1300 170.5 0.56
1400 198.1 0.72
1500 206.3 0.78
1600 213.5 0.83
1750 232.2 0.97
1800 236.3 0.99
Braker mode 1 pump
1.20
1.00
Pressure MPa
0.80
0.60
0.40
0.20
0.00
140.2 151.0 162.7 170.5 198.1 206.3 213.5 232.2 236.3
L/min

64
Hyd. Circuit Review
Option Line
Max. 1 pump flow

Active setting for Option line
Max. 2 pumps flow

P1 Main Pump Pressure
Section;Electrics P.155/ 156
65
Hyd. Circuit Review
Option Line
66
Hyd. Circuit Review
Option -Multi B-
Option Line -Multi <Breaker>-

Neutral Cut Valve Breaker
Breaker Mode Direction Valve
Switch to Breaker Mode
Mode
Select
SW SW
Computer A
MOM MOM
C/V
OP
3POSITION
3 positions
Middle; Normal or Sum Option
Select

Solenoid Valve
SOL
Choose BREAKER,
Solenoid becomes ON

67
Hyd. Circuit Review
Option -Multi C-
Option Line -Multi <Crusher>-

Neutral Cut Valve Crusher
Crusher Mode Direction Valve
Switch to Crusher MODE
Mode
Select
SWSW
Computer A
MOM MOM
C/V
OP
3POSITION
3 positions
Middle; Normal or Sum Option
Select

Solenoid Valve
SOL
Select CRUSHER,
Solenoid becomes OFF

68
Hyd. Circuit Review
2nd Option
Second Option Line

Advantage;
Save space
Increased hydraulic flow
Background;
Second option control valve is located in the Tool Box
on 210-3.
69
-
New Return Filter
Title New filter
New Return Filter

Review
70
-
New Return Filter
210-3
Paper
Return Filter

NEPHRON
Full Flow FILTER
KRJ3836
By pass
71
-
New Return Filter
Catch dust
Fiber Dia. = 20 to 40 micron

Paper material
Superior to Flow
Speed
Hold dust
Glass Fiber material Fiber Dia. = 0.1 to 10 micro
n
72
-
New Return Filter
10000
Quantity of contamination over 5 micron
1000
100
Paper Filter
10
Paper Filter +
Nephron
New Filter
1
0
Time
73
New Return Filter
Beta value=dust number ratio of filter inlet to filter outlet (filtration ratio)
Outlet Test Inlet

sampling filter sampling Inlet outlet
port port 3 10 3 5 3 5 10 3
5
Test dust 10 3
5 10 3 3 5
3 5
m
Number of 10micro meter =3N Number of 10micrometer
Number of 10micrometer d m
o dust = 3Nos Nu
ust = 3Nos N m
m mber of 5micrometer dus
umber of 5micrometer dus
m t = 4Nos Nu
t = 4Nos Num
mber of 3micrometer dus
ber of 3micrometer dust =
t = 5Nos
5Nos
Number of 3micrometer and above dust at inlet 5+4+3

Beta 12
33=
Beta = = = =2
Number of 3micrometer and above dust at outlet 3+2+1 6
Number of 5micrometer and above dust at inlet 4+3

7
Beta 5 = =
+
2+1
=
3
= 2.33
Number of 5micrometer and above dust at outlet
Number of 10micrometer and above dust at inlet

3
Beta
10 = = =3
Number of 10micrometer and above dust at outlet 1

74
New Return Filter
10micro
meter
Beta10 Beta 10
1.4 and above 8 and above
Special paper filter Synthetic fiber filter
Filter media: Special paper Filter media: Synthetic fiber

10contamination catch ratio/flow : 28.6%. 10contamination catch ratio/flow : 87.5%.

75
Section; General Difference from -3 P4
New Return Filter
76
-
New Return Filter
210-5
High-Performance
Return Filter
Faster and same
Full Flow
filtering ability without
KRJ15830 NEPHRON
77
-
Maintenance
Maintenance
Maintenance Section
Review
If we have time
78

Hydraulic Ver (Eng) Yoshida Kaizo

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Hydraulic Ver (Eng) Yoshida Kaizo

Uploaded by

Copyright:

Available Formats

Title

Major Hydraulic Components

P1 Solenoid valve ( Proportional Solenoid Valve )

N1; Negative Control

P1 Proportional Solenoid Valve

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD

4) 5 pcs Solenoid valve

11) Hyd Temp Sensor

>>> 168.9 / 100.3 cc /rev (-5 Model) 4 % Increase

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD

Basic system & structure are similar to -3.

Brake Reverse Brake Reverse

However, the anti-drift valve is installed on SH240-5

Basic system & structure are similar to -3.

Bucket Close Regeneration Circuit

Add-on Valves for Option Line

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD

New Straight Travel Pilot Port

Remote control valve

Basic system & structure are similar to -3.

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD

Basic system & structure are similar to -3.

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD

>>> -5: Cylinder bore 120 / Rod bore 85

Arm Cylinder on 210

>>> -5: Cylinder bore 140 / Rod bore 100

New Hydraulic Circuits

At steep slope in a mountain area,

Switched by 1st pressure.

Travel --->Sharp spool shift

Straight Travel Pilot

New orifice diameter.

--->Reduce shifting shock

--->Linear spool shift

Swing Speed Limit

Steer pilot pressure into negative control

Condition of swing speed limit

Cut out condition of swing speed limit

Flow DOWN Min Pump Flow of P1

Flow UP Pump Flow of P1 UP

B) Hydraulic Lock of Swing Spool in Control valve

b) By removing Swing Parking button

4.0 Bucket close

2.0 Bucket open

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD

Previous Negative control system saves energy also,

Hydraulic HP Boost -Arm In-

Operator feels No power by speed reduction,

Hydraulic HP Boost -Travel-

Operator feels No power by speed reduction,

New Cushion Valve

New Cushion Valve

Auto Power Boost

Many attachment with many

(^_^)1: No Eng rpm drop for Breaker

System works condition;

Once operate Attachment, Travel, or Swing,

Braker mode 1 pump

SUMITOMO (S.H.I) CONSTRUCTION MACHINERY MANUFACTURING CO.,LTD

Max. 1 pump flow

Max. 2 pumps flow

Section;Electrics P.155/ 156

Option Line -Multi <Breaker>-