PC200-7 CLSS Training
PC200-7 CLSS Training
PC200-7 CLSS Training
1
OUTLINE OF CLSS
2
BASIC PRINCIPLE
1) Control of pump swash plate
Spring setting
22 kg/cm2
∆PLS = Pump discharge pressure
– Actuator load pressure
3
2) PRESSURE COMPENATION VALVE
4
SELF PRESSURE REDUCING VALVE
OPERATION
valve
Spring
5
2) When in neutral or 3) When load pressure P2
load pressure P2 is low is high
valve
spring
P2
forces of spring + area ∅d × pressure PR P2 > forces of spring + area ∅d × pressure PR
6
4) When abnormally high pressure is generated
ball spring
7
Unload valve
1. When unload valve is actuated
8
LS by pass plug
9
LS bypass plug
10
Variable pressure compensation valve
11
7. Variable type pressure compensation valve
(for service valve)
12
5. Pressure compensation valve
13
8. Boom regeneration circuit
14
8. Boom regeneration circuit
15
Pump merge-divider valve
16
LS SELECT VALVE
17
Swing and Travel System
18
SWING MOTOR
KMF125ABE-5
19
Swing motor
1. Brake spring
2. Drive shaft
3. Spacer
4. Case
5. Disc
6. Plate
7. Brake piston
8. Housing
9. Piston
10. Cylinder block
11. Valve plate
12. Reverse prevention valve
13. Center shaft
14. Center spring
15. Safety valve
16. Check valve
17. Check valve spring
18. Shuttle valve
19. Shuttle valve spring
20
OPERATION OF SWING LOCK
1) When swing lock solenoid valve 2) When swing lock solenoid valve
is deactivated is excited
spring
piston
disc
plate
21
OPERATION
1. When starting swing 2. When stopping swing
Relief valve
Check valve Check valve
23
Reverse prevention valve
Operation
1) When brake pressure is being 2) After motor stops
generated at port MB
Spool
Spring
Spring Spool
24
1. Cover
2. Body
3. Slipper seal
4. O-ring
5. Shaft
25
TRAVEL MOTOR
HMV110-2
26
Travel motor
1. Regulator piston
2. Spring
3. Regulator valve
4. Spring
5. Motor case
6. Suction safety valve spring
7. Suction safety valve
8. Check valve
9. Check valve spring
10. Output shaft
11. Rocker cam
12. Retainer guide
13. Pin
14. Piston
15. Retainer
16. Cylinder
17. Valve plate
18. Counterbalance valve
19. Ring
20. Spool return spring
21. Brake piston
22. Plate
23. Disc
24. Ball
27
Rocker cam
Check valve
28
Travel motor
Rocker cam
Check valve
Regulator valve
Piston
29
OPERATION OF PARKING BRAKE
When starting to travel When stopping to travel
Counterbalance
valve
spring
disc plate
piston
30
Operation when pressure oil is supplied
Spool
31
Operation of brake when
traveling downhill
spring
spool
32
2) Safety valve function
1. When travel is stopped (or when travailing downhill rotating to right)
2. when rotating to left
spring
33
2) When starting travel (or during normal travel )
34
TRAVEL JUNCTION VALVE OPERATION
When pilot pressure is turned “ON”
Controller
spool
35
TRAVEL JUNCTION VALVE OPERATION
When pilot pressure is turned “ OFF”
controller
spring
spool
36
37
TRAVEL PPC SHUTTLE VALVE
OPERATION
1. When travel lever is
Orifice
in neutral
Piston
Spool
Operation
Travel + boom raise
Orifice
+ arm in and out
Piston
+ bucket curl and dump
38
TRAVEL PPC SHUTTLE VALVE
OPERATION
1. When travel lever is operated
orifice
piston
spool
piston
Operation
orifice
Travel + boom raise
+ arm in and out
+ bucket curl and dump 39
Valve Control
40
VALVE CONTROL
1. Travel PPC valve
2. Service PPC valve
3. Service pedal
4. L.H. travel lever
5. R.H. travel lever
6. R.H. PPC valve
7. R.H. work equipment control
lever
8. Solenoid valve
9. Accumulator
10. Control valve
11. Hydraulic pump
12. Junction box
13. L.H. work equipment
control lever
14. L.H. PPC valve
Lever positions
(1) Hold
(2) Boom "RAISE"
(3) Boom "LOWER"
(4) Bucket "DUMP"
(5) Bucket "CURL"
(6) Hold
(7) Arm "IN"
(8) Arm "OUT"
(9) Swing "RIGHT"
(10) Swing "LEFT"
(11) Neutral
(12) Travel "REVERSE"
(13) Travel "FORWARD"
41
WORK EQUIPMENT • SWING PPC VALVE
42
WORK EQUIPMENT • SWING PPC VALVE
43
PPC valve
Operation 2) During fine control
1)At neutral (Neutral → Final control)
piston
retainer
metering spring
spool
44
3) During fine control 4) At full stroke
(when control lever is returned)
45
TRAVEL PPC VALVE
46
TRAVEL PPC VALVE
1. Plate
2. Body
3. Piston
4. Collar
5. Metering spring
6. Centering spring
7. Val v e
8. Damper
9. Steering signal
10. Steering signal
valve
spring
47
2. Travel signal/ Steering function
1) When in neutral
48
2) While traveling straight
49
3) When steered or pivot -turned
50
4) When pivot -turned
51
Travel PPC shuttle valve
52
Solenoid valve
T : To tank
A1 : To PPC valve
A2 : To main valve (Travel junction valve)
A3 . To main valve (Merge-divider valve)
A4 : To both travel motors
A5 : To swing motor
A6 : To main valve (2-stage relief valve)
P1 : From main pump
ACC: To accumulator
53
Solenoid valve WHEN SOLENOID IS
TURNED OFF
54
Solenoid valve
WHEN SOLENOID IS TURNED ON
solenoid spool
spring
55
56
FOR BREAKER
1. Drain plug
2. Element
3. Case
4. Head cover
5. Relief valve
SPECIFICATIONS
Rated pressure: 6.9 MPa {70 kg/cm 2 }
Flow : 200 lt/min
Relief valve cracking pressure:
0.34 ア 0.05 MPa
{3.5 ア 0.5 kg/cm 2 }
Filter mesh size: 6 オm
Filtering area : 4,570 cm2
57
BOOM HYDRAULIC DRIFT PREVENTION VALVE
When boom control valve is at RAISE
spring poppet
spool
58
BOOM HYDRAULIC DRIFT PREVENTION VALVE
When boom control valve is at NEUTRAL
POPPET
SPRING
Pilot valve
59
BOOM HYDRAULIC DRIFT PREVENTION VALVE
When boom lever is in “lower” position
POPPET
60
BOOM HYDRAULIC DRIFT PREVENTION VALVE
CHECK
VALVE
Safety valve
CHECK VALVE
61
LIFT CHECK VALVE
1. While engine is stopped
SPRING
VALVE
62
LIFT CHECK VALVE
2. While engine is running
PA = { ( Area of - d) x PR + Force of
spring (2)} / (Area of - d1) spring
63
64
ATTACHMENT CIRCUIT SELECTOR VALVE
OPERATION
1. When attachment other than breaker is installed
spool
spring
65
ATTACHMENT CIRCUIT SELECTOR VALVE
2. When breaker is installed
spool
spring
66
67
68
69
ENGINE CONTROL
70
Engine control
71
Engine control
Stopping engine
72
1. COMPONENT
Fuel control dial
73
Engine control
Governor motor
1. Potentiometer
2. Cover
3. Shaft
4. Dust seal
5. Bearing
6. Motor
7. Gear
8. Connector
75
Engine throttle and pump controller(Input and output signals)
CN-2
CN-3
76
Engine throttle and pump controller
77
Engine throttle and pump controller (Input and output signals)
78
Engine throttle and pump controller (Input and output signals)
79
Types of Networks
Komatsu controllers and controllers
used by Komatsu communicate
using one or more of the following
network structures:
1. Komatsu S-Net (RS-232)
2. SAE J1587/1708
3. CAN SAE 1939
80
Shortcomings of RS-232
RS-232 Is Simple, Universal, Well Understood and
Supported, but RS-232 Has Some Serious
Shortcomings As a Data Interface. The Standards for
RS-232 and Similar Interfaces Usually Restrict RS-
232 to 256kbps or Less and Line Lengths of 15M (50
Ft) or Less.
The Rule of Thumb for the Length a Data Cable
Depends on Speed of the Data & Quality of the
Cable.
81
Controller Area Network (S NET)
82
Data Link
What is a data link?
J1587/J1708/J1939/ CAN.
83
Data Links Can Work With
Various Data Sources
A communication link between
various sources of data on a
vehicle or equipment, following
can be transmitted
– Engine/Transmission /vehicle control
– Change programmable parameters
– Service info (faults, performance data, history
data, etc.)
84
SAE J1939/CAN
• Faster, more robust data transfer for the
control system
• Vehicle integration
O Vehicle information (not only engine)
O Multiplexing
O Multiple modules
85
Example of Vehicle Integration
Typical Machine Wiring
Machine Wiring
With CAN/ J1939
86
Controller Area Network
(CAN)
•A Controller Area Network is an advanced
serial bus system that efficiently supports
distributed, real-time control.
•Originally developed for use in automobiles by
Bosch GmbH, Germany, in the late 1980s.
•CAN is internationally standardized by the
International Standardization Organization (ISO
11898) and the Society of Automotive Engineers
(SAE J1939).
87
CAN J1939 Network
Terminating Terminating
Resistor Resistor
A=Data
Terminating Terminating
Resistor B=Data Resistor
C =Grounded
Shield 88
Backbone - Troubleshooting
• Cannot monitor voltage on data link
with Digital Multi-meter, must use a
oscilloscope
• Check continuity in each line
• Check for 55-65 ohms resistance
lines A&B with 120 ohm resistors
• Insure proper grounding of line” C”
shield
89
CAN J1939 Network
60.00 With 120 Ohm terminating
OHMs resistors there should be 55-65
Ohms between A & B Data
lines.
A=Data
Terminating Terminating
Resistor B=Data Resistor
C =Grounded
Shield
90
CAN J1939 Network
0.00 Each data line should have low
OHMs Ohms Resistance between the
ends of the data line.
A=Data
Terminating Terminating
Resistor B=Data Resistor
C =Grounded
Shield 91
CAN J1939 Network
A=Data
Terminating Terminating
Resistor B=Data Resistor
C =Grounded
Shield 92
CAN J1939 Network
A=Data
Terminating Terminating
Resistor B=Data Resistor
C =Grounded
Shield 93
94