CLSS

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

1) When engine is stopped

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

B : From swing lock solenoid valve

S : From control valve
T : To tank
MA: From control valve
MB : From control valve

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

Shuttle valve Shuttle valve

22
REVERSE PREVENTION 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

A1. To L.H. travel motor port PB

A2. From control valve port A5
C1. To R.H. travel motor port PA
B2. From control valve port B5
D1. To R.H. travel motor port PB
E. To L.H. and R.H. travel motors port P
T2. To tank
T1. From L.H. and R.H. travel motors port T
D2. From control valve port B2
B1. To L.H. travel motor port PA
C2. From control valve port A2

25
TRAVEL MOTOR
HMV110-2

P : From travel speed solenoid valve

T : To tank
PA : From control valve
PB : From control valve
MA: MA pressure pickup port
MB: MB pressure pickup port

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

Piston Regulator valve

Spring

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

Suction safety valve

Suction safety valve

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

PST > Spring

spring

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

P : From main pump

T : To tank
P1 : Left reverse
P2 : Left forward
P3 : Right reverse
P4 : Right forward
P5 : Travel signal
P6 : Steering signal

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

1. PPC lock solenoid valve

2. Travel junction solenoid valve
3. Merge-divider solenoid valve
4. Travel speed solenoid valve
5. Swing brake solenoid valve
6. 2-stage relief 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

When abnormally high pressure

is generated

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

Starting engine Engine speed 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

Operation While motor is running

While motor is stopped • The engine throttle and pump controller
• Electric power is applied to both supplies a pulse current to phases A and B,
phases A and B of the motor. and the motor revolves, synchronizing to the
pulse. 74
ENGINE CONTROL

Engine throttle and pump controller

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.

Information line for the computer to communicate

with other devices or computers, i.e., J1587 and
J1939.

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

• Single point service tool connection

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

Engine Other VHMS

Controller Controller Controller

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

High There should be high Ohms

OHMs between data line and
shield/ground .

A=Data
Terminating Terminating
Resistor B=Data Resistor

C =Grounded
Shield 92
 CAN J1939 Network

0.00 There should be low Ohms

OHMs between shield and ground.

A=Data
Terminating Terminating
Resistor B=Data Resistor

C =Grounded
Shield 93
94