Page 1 EC330B/EC360B/EC460B/EC70OB SERVICE TRAINING This material is combined as below. 01_General 02_Engine 02-1_D10B Engine(EC330B-EC360B) 02-2_D12C Engine(EC330B-EC460B) 02-3_D12D Engine(EC330B-EC460B) 02-3_D16E Engine(EC700B) 03_Electric system 03-1_Before IECU application(EC330B-EC460B) 03-2_IECU application(EC330B-EC460B) 03-3_D12D Engine application(EC330B-EC460B) 03-4_EC700B 04_Power Transmission 04-1_Swing motor(EC330B/EC360B) 04-2_Swing motor(EC460B) 04-3_Swing motor(EC700B) 04-4_Travel motor_Old(EC330B/EC360B)
Page 2 Design Change Overview(EC330B-EC360B) 1-Before I-ECU application -D10B Engine, EMS1(Tier 2): Initial Production -D12C Engine, EMS1(Tier 2) -Instrument panel and MDU -Old alternator 2-I-ECU application -D12C Engine, EMS1(Tier 2) -IECU(Programmable) -New alternator 3-D12D application -D12D Engine, EMS2(Tier 3): EU & NA only. Machine serial number starts from 80001...
Page 3 Design Change Overview(EC460B) 1-Before I-ECU application -D12C Engine, EMS1(Tier 2) -Instrument panel and MDU -Old alternator 2-I-ECU application -D12C Engine, EMS1(Tier 2) -IECU(Programmable) -New alternator 3-D12D Engine application -D12D Engine, EMS2(Tier 3): EU & NA only. Machine serial number starts from 80001. -D12D Engine, EMS1(Tier 3 based Tier 2): International region -IECU(Programmable) -New alternator...
Page 4 Design Change Overview(EC700B) -D16E Engine, EMS2(Tier 3) -IECU(Programmable) -New alternator Picture text:...
Page 5 Engine(D10B) Picture text:...
Page 6 Engine specification Model: D10B EAE2 Power(kW): 198 at 1700 rpm Power(hp): 269 hp at 1700 rpm Torque: 1345 Nm at 1400 rpm Bore x Stroke: 120.65mm x 140mm DISPLACEMENT: 9600 cc Type: 4 cycle-diesel-turbo & charge air cooled Picture text:...
Page 7 External view(1) 1. EMS(E-ECU) 2. Fuel inlet 3. Water outlet 4. Engine PTO 5. Fan drive & Pulley 6. Engine oil cooler 7. Engine oil filter(full) 8. Breather 9. Engine oil filter(bypass) 10. Fuel filter 11. Fuel feed pump Picture text:...
Page 8 External view(2) 1. Fuel pump 2. Turbochargher 3. Cooler block heater 4. Cab heater supply 5. Coolant filter heater 6. Starter 7. Fuel shut-off solenoid 8. Dipstick 9. Oil drain valve 10. Oil pan 11. Coolant filter return 12. Cab heater return Picture text:...
Page 9 E-ECU Sensors 1. E-ECU 2,3. Speed sensor 4. Coolant temp. 5. Needle movement 6. Coolant level 7. Inlet air press. & temp. 8. Boost air press. & temp. 9. Oil press. & temp. 10. Fuel press. & temp. Picture text:...
Page 10 E-ECU circuit Communication line is at the Red color connector!(Connector B) Picture text:...
Page 11 Fuel system The injection pump is bolted onto a separate bracket on the left side of the engine.The injectors (1) used are made by Bosch. Their opening pressure is adjusted by means of washers of varying thickness inserted above the spring. The fuel filter (2) is attached to a filter bracket.
Page 12 Fuel system-Injector 1 Needle movement sensor 2 Feed pump 3 Manual feed pump 4 Overflow valve 5 Fuel cut-off valve(Off condition) 6 Fuel cut-off valve(On condition) Picture text:...
Page 13 Fuel system-Injection pump 1 Fuel rack control solenoid 2 Fuel rack(injection quantity control) 3 Injection timing control solenoid 4 Lever 5 Delivery valve 6 Timing sleeve 7 Speed sensor 8 Toothed wheel Picture text:...
Page 14 Fuel system-Injection control Injection timing is adjusted by timing sleeve location. Injection quantity is adjusted by fuel rack operation. Picture text:...
Page 15 Engine(D12C) Picture text:...
Page 16 Power: 239Kw at 1900rpm MAX Torque: 1600Nm at 1400rpm D12 is the model number of the volvo 12 liter engine. The engine is a 6-cylinder, 4-stroke, direct injection diesel with a 12 liter cylinder volume, turbocharger, charged air cooler and electronic controlled fuel injection, EMS (Engine Management System).
Page 17 External view(1) External view & component location 1. E-ECU 2. Dip stick 3. Fuel filter 4. Start motor 5. Breather 6. Oil drain valve 7. Alternator Picture text:...
Page 18 External view(2) External view & component location 1. Turbocharger 2. Air inlet 3. Water outlet 4. Coolant filter connection 5. Water inlet 6. Oil filter(by-pass) 7. Oil filter(full flow) 8. Exhaust outlet Picture text:...
Page 19 E-ECU Sensors The D12C has a total of eight sensors. Three of these have dual functions. This gives a total of 11 functions. The dual function sensors are: 2 Turbo boost pressure/air temperature in inlet manifold. 5 Air temperature before intercooler and pressure drop indicator. Located in the union pipe between the air filter housing and the turbocharger inlet.
Page 20 EECU electric circuit(Old) Communication between the control units go via two data buses. The two data buses have different functions. One is used for the control signals of system and is designated SAE J1939. The other databus, SAE J1708, is used for information and diagnostics. The link also functions as a back up for the other databus if this for any reason does not function.
Page 21 E-ECU Electric circuit(New) New sensor 1. Oil temp. & oil pressure sensor 2. Boost temp. & boost pressure sensor Picture text:...
Page 22 Lubrication system schematic This is a schematic description of the lubricating system. When the engine starts the gear driven pump forces the lubricating oil in to the filter housing. At low oil temperature, for example when cold starting in the winter the bypass valve for the oil cooler will open so the oil will reach the engine faster.
Page 23 Fuel system principle The fuel flow and valve function is schematically described. Light red means suction and dark red means feed pressure. The fuel is sucked up by the feeder pump (1) through the strainer (7) in the tank fitting, past the non- return valve (6).The non-return valve opens and the fuel flows to the control unit and goes through the cooling loop (5) ( if the control unit (4) has cooling ) up to the overflow valve (8) and from there, together with the return fuel which passes through the overflow valve to the feeder pump suction side.
Page 24 Unit injector The unit injector The unit injector is driven by the engine camshaft via a rocker arm. Simply put, a unit injector is a combination of an injection pump and a conventional injector and it consists of three main sections: the pump section(1) the valve section with the solenoid(2) the injection section(3)
Page 25 Engine(D12D) Picture text:...
Page 26 Engine specification (D12D) EC330B-EC360B Excavator uses the D12DEBE3 & D12DEBE2. For those 2 engines, external layout (fuel line, cooling, inlet & exhaust, mounting) is almost same but internal components (ECU, Unit injector, Piston etc.) are totally different. Machine with D12DEBE3 has new serial number started with 80001 and will cover EU & NA region.
Page 27 1.The IEGR double rocker has an extra arm, the follower arm, which creates a small second exhaust valve lift. This extra lift feeds exhaust gases back into the cylinder during the inlet stroke. 2.The most advanced Volvo engine controller, EMS2, will be utilized to provide the highest level of electronic features and to enhance reliability.
Page 28 External view-1(Tier-3) 1. Inlet air temp. & pressure sensor 2. Cam speed sensor 3. Coolant level sensor 4. Boost press. & temp. sensor 5. Fuel feed pressure sensor 6. Water in fuel sensor 7. Coolant temp. sensor 8. Crank speed sensor 9.
Page 29 External view-2(Tier-3) 1. IEGR solenoid 2. Coolant pump 3. Fuel feed pump 4. Fuel lift pump 5. Fuel filter 6. Water seperator 7. Engine oil level & temp. sensor Picture text:...
Page 30 E-ECU circuit (D12D, Tier-3) Picture text:...
Page 31 Main components (D12D, Tier-3 based Tier-2) EMS1 & Delphi E1 injector Picture text:...
Page 32 Sensors location (D12D Tier 3 based Tier2) The picture shows all D12D engine sensors. Inside the EECU there are also sensors for ambient air pressure and the EECU temperature. The sensors differing, compared with the D12C engine, are the crankcase pressure sensor (new), oil pressure sensor (before a combined pressure and temperature sensor), water in fuel sensor (new) and oil level and temperature sensor (before only a level sensor).
Page 33 E-ECU circuit(D12D, Tier 3 based Tier 2) Picture text:...
Page 34 Fuel system The fuel is drawn with help of the fuel feed pump (1) through the tank unit (2), via fuel pre- filter (4) and water separator (5) into the fuel filter housing (3). The fuel is then routed through the engine ECU s cooling loop (6) to the overflow valve (7), where the fuel from the tank is mixed with the fuel returned from the fuel channel (8) in the cylinder head, and then forward to the suction side of the fuel feed pump (1).
Page 35 IEGR(V-ACT) NOx reduction solution is provided by Internal Exhaust Gas Recirculation (IEGR) which is altering engine valve lift. Picture text:...
Page 36 Delphi E3 function(Tier-3) 1. Neither the spill valve (SV) nor the needle control valve (NCV) solenoid is electrically activated. The return spring is forcing the SV to its upper position and the NCV to its lower position. In this position the SV is open and the fuel are routed from the pump chamber back into the low pressure fuel feed line and no internal pressure build-up occurs in the high pressure fuel line.
Page 37 Delphi E3 needle lift A. The spill valve is electrically activated and closes; fuel is forced from the pump chamber via the high pressure fuel line acting on the injection needle lift area. B. The fuel pressure increases and reaches the pressure required to overcome the closing force from the needle closing spring, but as the NCV is still open the needle can not lift.
Page 38 Valve lash adjustment(1) The below lashes is to be set when the engine is cold, approx. 20-25 °C. Engine IEGR Exhaust valve lash valve lash (mm) D12D Gauge 88820003 Rotate the camshaft and position it according to the marking for the cylinder being adjusted. The marking on the camshaft shall be placed between the two marks on the front camshaft bearing cap Before checking the double rocker arm clearance, adjust the exhaust valve lash (also inlet valve lash and preload the injector) according to normal procedure...
Page 39 Valve lash adjustment(2) 1. Adjustment Insert a special adjustment gauge (A) tool (P/N: 88820003-1) between the follower arm contact surface and the cam base circle. Turn the hex key until the gauge is squeezed tight between the cam lobe and the follower arm contact surface.
Page 40 Engine protection function Excavator are using only basic protection function. Picture text:...
Page 41 Engine(D16E) Model: D16EEAE3 Rated output: 346kW @ 1800rpm Picture text:...
Page 42 Engine specification Unit Injector type -------------------------------------- EC700B : D16E EAE3 Type: 4 cycle, Diesel, Turbo charged, Air to Air After cooled No.of cylinder : 6 vertical in line type Bore X Stroke: 144mm X 165mm Max. Power(fan not in operation) 346kW@1800rpm Max.
Page 43 1.The IEGR double rocker has an extra arm, the follower arm, which creates a small second exhaust valve lift. This extra lift feeds exhaust gases back into the cylinder during the inlet stroke. 2.The most advanced Volvo engine controller, EMS2, will be utilized to provide the highest level of electronic features and to enhance reliability.
Page 44 External view(1) 1. Crankcase pressure sensor 2. Engine oil temp. & Level 3. Engine oil press. sensor 4. Water in fuel sensor 5. Fuel feed pressure sensor 6. Boost press. & temp. sensor 7. Fuel feed pump 8. Breather Picture text:...
Page 45 External view(2) 1. Crank speed sensor 2. Cam speed sensor 3. Coolant temp. sensor 4. Coolant level sensor 5. Inlet air temp. & Pressure Picture text:...
Page 46 Electric circuit (D16E) Picture text:...
Page 47 Fuel system The fuel is drawn with help of the fuel feed pump (1) through the tank unit (2), via fuel pre- filter (3) and water separator (4) into the fuel filter housing (5). The fuel is then routed through the engine ECU cooling loop (6) to the distribution housing (7), where the fuel from the tank is mixed with the fuel returned from the fuel channel (8) in the cylinder head, and then forward to the suction side of the fuel feed pump (1).
Page 48 I-EGR Valve operation Picture text:...
Page 49 Valve adjustment - Loosen the hexagon screws that hold the leaf springs. The screws are to be loosened on all six cylinders. - Rotate the cam shaft to adjust the rocker arms. - The dash marking on the cam shaft must be positioned between the two dash marks on the bearing housing.
Page 50 Air intake system (1) Rain cover + Filter (2) Pre-cleaner with scavanger + Filter (3) Oil bath type pre-cleaner + Filter A: check valve Picture text:...
Page 51 Electric system(Before I-ECU) EC330B-EC460B Picture text:...
Page 52 Engine start and stop circuit If battery disconnection switch is off position, we cannot use the whole of electric system. When master switch (Battery disconnection switch) is ON, we can use Room lamp, diesel heater, fuel filler pump, DC-DC converter, Auto greasing system without the key. When the start switch is ON position, BR signal turn on the battery relay.
Page 53 Key switch & Master switch (1) Key switch In key switch, there are three positions. Off, On, Start. (2) Master switch To disconnect the electrical system from the batteries for protection of electrical components when welding, servicing of circuits and as a safety precaution when parking the machine. Mounted on the battery cover.
Page 54 Battery relay & Safety start relay 1. Battery relay This is main relay for electric system. The relay turns the battery current ON or OFF, according to low power signals received from the start switch. Use of the relay permits the start switch to control the power of the batteries with a small capacity wire.
Page 55 Alternator The alternator generates current to activate all the electrical systems, and the extra current charges the battery. The current from D+ flows to the safety start relay to cut off the operation of starter motor and prevent accidentally re-engaging the starter. After the engine starting, the battery charge warning lamp is turned off because the signal from "D+"...
Page 56 Fuse box Fuse failure is often caused by a fine crack in the fuse, and this kind of crack is very hard to detect by visual inspection. Checking fuse continuity with a tester is far superior to eye inspection. Picture text:...
Page 57 Electric Box 1. Resistance box for emergency pump control. 2. Slow blow fuse(80A) 3. Slow blow fuse(140A) 4. Preheater relay 5. Safety start relay 6. Battery relay 7. Slow blow fuse(40A) 8. Relay: R1~R12 Picture text:...
Page 58 Control system circuit(Animation) This is brief circuit diagram to explain the electronic control system. First of all, think about operating power and ground of each ECU. Then move on to each function. After understanding each function and input-output of VECU, Compare those functions with this circuit diagram.
Page 59 Switch 1. Safety limit switch When the safety lever is in the up position, the hydraulic system will work. When the safety lever is in the down position, the servo pressure is cut off to functions, which are operated with control levers and pedals. 2.
Page 60 Speed control switch and Flow control switch 1. Speed control switch 2. Flow control switch Two switches are almost same components. Only different thing is that the flow control switch needs screw driver to adjust the step. Input voltage is 24v and output voltage is 0.5~4.5V. They have a shield ground to prevent noise at signal line.
Page 61 Power shift valve The valve regulates the secondary servo hydraulic pressure to the hydraulic pump regulators to control the swash plate angle and allowable pump output. The secondary servo hydraulic pressure varies in proportion to the current value at the proportional solenoid valve.
Page 62 Pressure Switch 1. Attachment Pilot pressure switch/Travel Pilot pressure switch/Travel alarm(Option) -On: 20 Kgf/cm^2 -Off: 14 Kgf/cm^2 2. Hammer Pilot pressure switch/Boom float Pilot pressure switch -On: 7 Kgf/cm^2 -Off: 5 Kgf/cm^2 Picture text:...
Page 63 Unique number for each control unit PID (Parameter Identification Description): Unique number for each parameter PPID (Proprietary Parameter Identification Description): Volvo-Unique number for each parameter SID (Subsystem Identification Description) Unique number for component PSID (Proprietary Subsystem Identification Description) Volvo-Unique number for component...
Page 64 VECU Input and Output The vehicle control unit is mounted at right wall of cabin. This controls all of functions related with vehicle according to the input signal. There is various input and output signal. The service people have to know about the function first and input-output signal to diagnose and fix the problem.
Page 65 V-ECU There are two connectors for VECU. JA connector has 70 pins and JB has 16 pins. When you replace the VECU, you have to check the part number of VECU because you need to run the conversion kit of VCADS Pro if failed VECU is old one. Picture text:...
Page 66 Engine speed and work mode control In control system, we can have 10-step engine speed and 5 work-modes. By rotating engine speed control switch, Engine rpm and work-mode is set at the same time. You can see the specification at the next page. This function allows the operator to select the engine speed and work mode according to working condition and to optimise the machine performance and fuel efficiency.
Page 67 Engine and pump control specification USA market do not have P mode. Picture text:...
Page 68 F-mode operation F-mode is used for lifting heavy material or finishing touch. Machine needs slow speed and large lifting force to satisfy these conditions. When control switch is in F mode, - VECU turns off power to travel speed solenoid. That means travel speed is fixed to low speed regardless of travel speed select switch position.
Page 69 Emergency control This function is for emergency operation when malfunction of data bus or V-ECU has occurred. 1. When there is communication error, E-ECU realizes this condition and automatically goes to the emergency mode. If emergency switch is in neutral position, engine speed will be emergency low speed and maximum current will be supplied to power-shift valve from V-ECU.
Page 70 Auto-return to idle Without any movement of machine, engine speed automatically goes down to I1 mode. This increase fuel economy and decrease noise. After engine has decelerated, if the operator changes one of input signals, then engine speed return to the previous speed. Default time delay is 5 second.
Page 71 Power boost operation 1. In travel-only mode, we have power boost function to increase travel performance(EC330B/EC360B only). **Power boost is not needed for travel-only mode in EC460B. 2. In F-mode, machine has power boost function. 3. When selection switch is boost or shear position, by pushing RH joystick button we can use power boost function for 9 seconds.
Page 72 Hydraulic oil cooler fan control Hydraulic oil cooler use independent pump and motor for fan driving. Fan speed has two steps (low and high) according to the temperature of hydraulic oil. If temperature goes up to 70 degree, V-ECU turns on solenoid then fan motor speed become high. If temperature goes down to 50 degree, V-ECU turns off solenoid then fan motor speed become low.
Page 73 Automatic travel speed control (1)When machine stands still, machine needs more brake torque during digging to prevent machine drifting toward because of reaction force from bucket. V-ECU realize the stop condition from travel pilot pressure switch, then V-ECU cut off the power to the travel speed solenoid regardless of the position of travel speed selection switch.
Page 74 Safe start and stop control The optimal condition of engine start and stop is automatically set by this function. The engine can be protected from damages that may occur at engine start and stop condition. 1. During starting engine, Engine rpm is fixed to low idle (I2) regardless of engine rpm control switch position to protect engine from sudden rpm increase in cold period or other situation.
Page 75 Pump flow control At job site, customer uses various kind of optional attachment like hammer, shear etc. Every attachment has their unique operating specification especially in flow. Our machine can satisfy this request by using flow control switch and flow control proportional valve. 1.
Page 76 Flow setting video Picture text:...
Page 77 MDU(Machine Display Unit) This animation is to show you how to operate display unit. Push the arrow button step by step. If the key is ON position, all lamps are ON for one second and then engine speed and work-mode are displayed.
Page 78 SDU(Service Display Unit) The service display unit can be connected to service socket above the radio. The display unit is used for the service & troubleshooting. This can give additional information, which cannot be seen on the MDU. Picture text:...
Page 79 Instrument panel The instrument panel shows the information received from the sensors and switches of the machine to alert the operator of any abnormality. The instrument is adjustable for operator viewing angle and is illuminated for night work. All light bulbs should be checked daily and replaced if burnt-out because the indicators alert the operator of a failure in the machine.
Page 80 Instrument panel operation 1. Lamp and buzzer check procedure Before starting the engine, if you turn the start switch to the ON position all lamps are turned ON for 3 seconds. At the same time the buzzer is operated 2 times with the cycle of 1.0 second ON and 1.0 second OFF.
Page 81 Instrument panel circuit Inside of instrument panel, there is an IC chip to control the lamp and warning case. In this page, think about how to operate this circuit to make the function of previous page. Picture text:...
Page 82 Engine oil pressure switch Check the location of this sensor. Picture text:...
Page 83 Coolant level sensor Tolerance of this sensor is very small between ON & OFF. This can cause frequent on & off of warning lamp. To prevent this we have some special program at ECU. To turn on the lamp, coolant switch should maintain off position for some period. Picture text:...
Page 84 Coolant temperature sensor This sensor is used for needle gage of instrument panel. Picture text:...
Page 85 Fuel level sensor This unit sends variable resistance value according to the level of the fuel in the fuel tank to the fuel level gauge on the instrument panel. Picture text:...
Page 86 Switch circuit By using this circuit, you can do continuity test for switches. Picture text:...
Page 87 Fuel filler pump This shows the 50LPM pump with level sensor. This has automatic stop function when fuel level reach to maximum. Picture text:...
Page 88 Wiper Control Circuit A : Upper wiper switch B : Washer switch C : Lower wiper switch D : Wiper controller E,F:Upper and lower limit switch G : Upper motor H : Washer pump During wiping,Y and G are connected. So,even though switch(A or C) is OFF, motor(G or I) will work to its stroke end.
Page 89 Hammer and Shear circuit(Boom floating & 1-switch control) This option is brought with pedal in the X1 cirucit. Single acting(hammer) is operated by joystick button and pedal. In this case, RH joystick 3 can be used for hammer or power boost according to the position of hammer&shear select switch. But double acting(shear) is operated by only the pedal.
Page 90 Hammer and Shear circuit(2-switch control) This option is brought with one more solenoid valve for double acting without the pedal. Single acting(hammer) is operated by joystick button. In this case, RH joystick 3 can be used for hammer. But double acting(shear) is operated by RH joystick 3 & 2. And RH joystick 1 can be used for one-touch power boost.
Page 91 Quick fit and rotator circuit These two systems can be activated after lifting up the safety lever. Lifting safety lever activate pressure switch then turn on the R12. This is safety function for this option hydraulic. Picture text:...
Page 92 Radio circuit Radio system uses 12V power. So we need DC-DC converter. From DC-DC converter, 2 lines are used for operating power and 1 line is used for frequency memory function. If the cassette mute switch is installed and turned to ON, the speaker is cut off even when the cassette power is ON.
Page 93 Electric system(I-ECU application) New I-ECU is introduced for commonality. With the New I-ECU changes, electric circuit changes took place at the same time. Applied Serial no. EC330B: 10417~ EC360B: 11226~ EC460B: 10922~ Picture text:...
Page 94 Machine information system change Picture text:...
Page 95 System layout change 1. A/C switch moves to RH control box. 2. Emergency, Auto/Manual and 1-2 pump select switch move to LH control box. 3. Hour-meter is located at LH control box. 4. No flow control switch. Flow setting will be done at I-ECU. Picture text:...
Page 96 Electronic control system overview Programmable I-ECU added. Picture text:...
Page 97 V-ECU input and output Many input signal was directly connected to instrument panel for old system. Now those signals go to V-ECU, which sends information to I-ECU. Picture text:...
Page 98 Control circuit Picture text:...
Page 99 I ECU 1) Layout A : Central warning lamp B : Coolant temp. & fuel Gauge C : Warning indicator D : MCD(Message Center Display) E : Key button 2) Key OFF condition 3) Key ON (Booting operation) Central warning lamp(2 times), gauge(all segment ON),all indicator lamp ON 4) Key OFF (Shutdown operation) Picture text:...
Page 100 New I-ECU circuit New I-ECU uses only 10 pin connector because I-ECU use the communication line for various signal. Picture text:...
Page 101 MCD Operation (1) : Normal condition (2) : Anti-theft(Code-lock) condition (3) : X1 menu (4) : Error display Picture text:...
Page 102 IECU Operation(Code Lock) (a) : Put 4-digit number!(This PIN code will be saved in the IECU) (b) : Enter the PIN code through IECU(arrow & confirm buttons). (c) : Push the confirm button more than 2 sec. (d) : If the correct code is entered,Indicator Operation menu is displayed. (e) : Alarm sound can be off by pushing confirm button.
Page 103 Pop-up indicator This is not a warning but just indication of activation. Picture text:...
Page 104 Indicator operation Picture text:...
Page 105 X1 flow setting You can select any number from 30 to 500 at flow setting screen. But if you select number that is larger than actual maximum flow, the set value will not be changed as you select. For example, if you select 240 at EC210B, the set value will be changed to 200. Picture text:...
Page 106 Start circuit-New alternator New alternator and old instrument panel. Picture text:...
Page 107 Start circuit-New alternator and New I-ECU New alternator with new I-ECU Picture text:...
Page 108 Alternator change Picture text:...
Page 109 Safety start relay change During the air bleeding procedure from fuel line, we need more cranking time to start engine. But new alternator produces a little bit higher voltage at the terminal L. This deactivate safety relay and interrupt start motor. To prevent this, we add the time delay function at the safety relay. Picture text:...
Page 110 D12D Engine Applicatin(EC330B-EC460B) Applied Serial no.(Tier-3) EC330B: 80001~ EC360B: 80001~ EC460B: 80001~ Applied Serial no.(Tier-3 based Tier-2) EC330B: 10713~ EC360B: 12152~ EC460B: 11515~ Picture text:...
Page 111 VECU input & output 1. Fan speed select solenoid (2 speed) -> Fan speed select PWM (Variable speed) 2. Start lock function 3. Travel speed circuit 4. Travel alarm controlled by V-ECU Picture text:...
Page 112 Control system circuit-Tier3(Old) Serial No.: 80001~ E-ECU: EMS2 Picture text:...
Page 113 Control system circuit-Tier 3(New) Changed items 1. Power supply to Emergency sw -Old: F24, F15 -New: F15 2. WECU: New option Picture text:...
Page 114 Control system circuit-Tier3 based Tier2(Old) EC330B 10713~ EC360B 12152~ EC460B 11515~ Picture text:...
Page 115 Control system circuit-Tier3 based Tier2(New) Changed items 1. Power supply to Emergency sw -Old: F24, F15 -New: F15 2. WECU: New option Picture text:...
Page 116 Start circuit Start lock system change Picture text:...
Page 117 Start circuit(New) 1. Master switch removed 2. Slow blow fuse change: 40A->30A Tier3 -EC330B: 80426~ -EC360B: 80993~ -EC460B: 80661~ Tier3 based Tier2 -EC330B: 10780~ -EC360B: 13096~ -EC460B: 12543~ Picture text:...
Page 118 Electric box The number of relay is reduced. Only 1 relay box. Picture text:...
Page 119 Engine & Pump control spec. 1. EC330B/EC360B Engine control spec. is same with D12C engine 2. EC460B Because of pump change, power shift current value is changed. Picture text:...
Page 120 Travel speed control Electric circuit change. Picture text:...
Page 121 Start lock system Safety start relay is removed. Start lock relay will be off when: - wrong password - Safety lever up - engine running - for 6 second after engine start - for 2 second after engine off If Auto/Maunal switch is at Manual, the power for start lock relay will be supplied by Auto/Manual switch. Picture text:...
Page 122 Power supply to E-ECU Picture text:...
Page 123 Hydraulic oil cooling system V-ECU controls fan speed according to the input from hydraulic oil temperature sensor. In previous machine, there was only 2-speed step but now is variable speed. EC360B EC330B 60oC rpm1000 1000 mA 575 520 90oC rpm2000...
Page 124 Proportional relief valve This valve is inverse proportional valve. As the current goes up, 2ndary pressure drops down. Picture text:...
Page 125 Wiper circuit New wiper controller Picture text:...
Page 126 Care Track(Telematics) The VCE telematics solution will contain three main services; Mapping and Tracking, Operational Management, and Service Management. Within Mapping and Tracking services such as mapping of machines, geo fence and location report will be included. Operational Management will contain performance and utilization reports.
Page 127 - MATRIS information is not available through the China GPS. Installation - GPS-ECU unit, Antenna and cable installation by Dealer. - Base machine production by Volvo. - China GPS Parameter(MXD) must be turned on by VCAD-pro. - Anti-thieft protection(ABP) must be turned off by VCAD-pro.
Page 128 Connector naming method change The way of naming connector is changed. Picture text:...
Page 129 Electric system(EC700B) Picture text:...
Page 130 Engine Start and Stop Circuit(Old) Power from battery => electric greasing system,start key,start motor,battery relay Power from battery relay =>safety start relay 1) Key ON BR=> Battery relay,alternator(15,pre-magnetization) ACC=>VECU,Air conditioner,EMS power relay 2) Key Start R2=> VECU C=> safety start relay 3) Engine running Alternator(L)=>hour meter,safety start relay,VECU(charge lamp off) * Resistor between alternator and BR termainal for quick charge lamp off...
Page 131 Engine Start and Stop Circuit(New) -Relays for EMS power and EMS data(R3, R4 relay) were removed. 1. Circuit animation - if you click the line, the color will be changed. 2. Component location - if you clikc the symbol on the circuit, you can see the location of component. Picture text:...
Page 132 Electric Box Picture text:...
Page 133 VECU input & output This diagram shows the primary input and outputs based on the connection found within the VCEU circuitry. Input factors (communications) can be divided into two broad categories. One category relates to selection switches which send a signal to the VECU initiated by the operator. The other, relates to combined parts that are composed of hydraulic and electric components such as solenoid valves or pressure limit switches.
Page 134 Control System Circuit(Old) Checking points! 1 : Power supply to each ECUs,relays 2 : Auto/manual switch function 3 : Solenoid valve power line inside V-ECU 4 : V-ECU status line to IECU 5 : Boom floating button & solenoid function 6 : Travel speed switch &...
Page 135 Control System Circuit(New) 1. R3 & R4 Relay removal - Direct power supply from the emergency switch. - Serial No. break : 10076~ 2. WECU(Option) Picture text:...
Page 136 Engine and Pump Control specification Picture text:...
Page 137 Swing alarm pressure switch Pin map A : Voltage output (Max. 1.2 A) B : Power supply C : Ground X : connector view P : Pressurized port(Max. 100 bar) VBAT : Battery Voltage Hydraulic pressure sensor : strain gauge sensor Electric switch : Transistor type and Normally open Switching hystereses are On (4.5 bar) and Off (3.5 bar).
Page 138 Fuel Filler Pump A : Pump(100 lpm) location B : Location of fuel level sensor for auto stop D : Fuel level sensor for auto stop E : Circuit Picture text:...
Page 139 Power transmission Picture text:...
Page 140 Swing System(EC330B-EC360B) - Swing motor - Gear box - Pinion - Turning joint - Swing Ring gear Picture text:...
Page 141 External view Motor - Displacement : 250cc/rev - Relief pressure : 260 kgf/cm^2(25.5 MPa) - Time delay : 6.5 (+/- 1.5) sec. Gearbox - Gear ratio : 24.37 - Oil : SAE NO. 90 (6 liter) *Compare the circuit & port on the motor. A,B : Main : Anti-cavitation : Case drain...
Page 142 Sectional view A: swing drive unit B: reduction gear box C: swing motor D: Mechanical brake E: Anti-cavitation check valve F: Relief valve G: Rebound damping valve H: Time delay valve Picture text:...
Page 143 Relief valve operation Most of brake force comes from this relief valve when we stop slewing. Therefore we need smooth build-up of pressure for smooth braking. (1) Low pressure relief (2) Pressure increasing with time (3) Final stage of relief Picture text:...
Page 144 Rebound damping valve operation (1) Neutral position : A & B port is connected through the valve (2) Swing : B port (in), A port (out) , valve is pushed to A port and closed. (3) Hydraulic braking & rebound begin : A port is pressurized by discharged oil. But valve is moving slowly.
Page 145 Parking brake operation The slew brake is spring applied and hydraulically released. Friction plates are splined to cylinder block and rotate with cylinder block. Mating plates are splined to motor casing. 1. When there is no SH signal, parking brake will be engaged by spring force. 2.
Page 146 Swing System(EC460B) - Swing motor(2EA) - Gear box - Pinion - Turning joint - Swing Ring gear Picture text:...
Page 147 External view Motor - Displacement : 121.5cc/rev - Relief pressure : 250 kgf/cm^2 - Time delay : 5 sec. Gearbox - Gear ratio : 20.01 - Oil : SAE NO. 90 (6 liter) *Compare the circuit & port on the motor. A,B : Main : Anti-cavitation : Case drain...
Page 148 Sectional view(1) Rotary group consists of cylinder block and 9 piston assemblies located in the cylinder. Both ends of cylinder block are supported by bearings. Piston assemblies are guided by return plate and spring so they slide smoothly on the swash plate. Valve plate is pressed against the cylinder block surface by the mechanical pressure of spring and hydraulic pressure working on the bushing.
Page 149 Sectional view(2) Gear box reduce the speed and increase torque using planetary gear. Picture text:...
Page 150 Relief valve operation Most of brake force comes from this relief valve when we stop slewing. Therefore we need smooth build-up of pressure for smooth braking. (1) Closing position (2) Low pressure relief (3) Relief pressure increase by moving of piston (4) Final stage of relief Picture text:...
Page 151 Rebound damping valve operation (1) Neutral position (2) Start of swing (3) full swing (4) Joystick return to the neutral. PA pressure goes high. (5) PA will reach to relief valve set pressure and machine will stop. In this point, PA=Relief set pressure and PB=Tank pressure. There is pressure difference between PA &...
Page 152 Parking brake operation The slew brake is spring applied and hydraulically released. Friction plates are splined to cylinder block and rotate with cylinder block. Mating plates are splined to motor casing. 1. When there is no SH signal, parking brake will be engaged by spring force. 2.
Page 153 Swing System(EC700B) - Swing motor(2EA) - Gear box - Pinion - Turning joint - Swing Ring gear Picture text:...
Page 154 Spec & External View Specification Model :MFC250 Displacement :250 cc/rev Type :Fixed swash plate,piston motor Relief valve pressure :250 kgf/cm2 Max. drain pressure :3 kgf/cm2 Brake release pressure :Min. 33 ~ Max. 50 kgf/cm2 Brake delay time :5~8 sec SH : Pilot signal for brake release PG : Brake releasing pressure signal Dr : Drain GA,GB : Gauge port...
Page 155 Sectional View A : Swing drive unit B : Swing reduction gear C : Swing motor D : Mechanical brake E : Anti canvitation check valve F : Relief valve G : Rebounding damping valve H : Time delay valve Picture text:...
Page 156 Relief Valve 1 : Pressure increase 2 : Gradual pressure increase The inner cylinder push the spring seat and during the movement,the pressure increases gradualy. 3 : Setting pressure Picture text:...
Page 157 Travel motor(Old) Picture text:...
Page 158 External view Circuit animation for travel motor Picture text:...
Page 159 Sectional view 1. Set screw for large displacement 2. Set screw for small displacement Picture text:...
Page 160 Brake valve operation (1) Travel The pressure of supply line goes high and this pressure applies to the backside of brake valve and then pushes the brake valve against spring. So return side oil can go to tank. (2) Overrun When machine travels at the down slope, this can cause overrun.
Page 161 Relief valve operation-1 (1) The pressure is lower than the set value. (2) The pressure is reached to the set value. Picture text:...
Page 162 Speed change (1) Low speed -No pressure at pi port -Supply pressure H is supplied to S (2) High speed -Pilot pressure at pi port -Speed change spool is moved downward -Supply pressure H is supplied to L port (3) Automatic downshift -Pilot pressure at pi port -Supply pressure reaches to 265bar(B) -Speed change spool is pushed upward against pi pressure, Supply pressure H is connected to S port.
Page 163 Parking brake 1. Time delay valve Picture text:...
Page 164 Travel system-New(EC330B-EC360B) -Travel motor -Gear box Picture text:...
Page 165 External view Travel motors for EC330B/360B are almost same with EC290B except the displacement & gear ratio. Travel motors - Displacement: 129/178 cc/rev - Relief pressure: 370 kgf/cm^2 (36.3 MPa) - Speed changeover pressure: 265Kgf/cm^2(26.0 MPa) - Brake release pressure: 8 kgf/cm^2(0.83MPa) Gear box - Gear ratio: 65.436...
Page 166 Sectional view(1) 1. Pressure reducing valve for parking brake 2. Counter-balance valve or Brake valve 3. Relief valve 4. High speed set screw 5. Speed changeover valve 6. Swash piston 7. Parking brake Picture text:...
Page 167 Reducing valve operation In order to release parking brake, system uses the pressure from main pressure of supply line. So we need to decrease the pressure by using this valve. (1) Supply pressure goes to brake chamber to release the brake. (2) If the pressure of brake chamber exceed the specified value(spring tension), main pressure push the valve to the right becasue of area difference of valve and disconnect passage between main pressure and brake chamber.
Page 168 Brake valve operation 1. Brake valve is now at neutral position. 2. The pressure of supply line goes high and this pressure applies to the backside of brake valve and then pushes the brake valve against spring. So return side oil can go to tank. 3.
Page 169 Speed changeover 1. When the pilot pressure at port Pi is disconnected, the spool moves upward by the spring force & hydraulic force which is applied to the differential area between red section and yellow section. The oil in chamber of swash piston flows to the drain line, and the swash plate moves to increase swash angle, so the motor rotates at low speed.
Page 170 Travel System(EC460B) - travel motor - Gear box Picture text:...
Page 171 External view *Circuit animation for travel motor Travel motors(Bent axis type) - Displacement: 99/160 cc/rev - Relief pressure: 330bar (33 MPa) - Speed changeover pressure: 240 bar(24.0 MPa) - Brake release valve set pressure: 21+4bar Gear box - Gear ratio: 108.1 - Oil : SAE80W/90 (5 liter) Picture text:...
Page 172 Sectional view(1) When you click the component on the circuit diagram, you can see the location of correspondent component. Picture text:...
Page 173 Sectional view(2) Gear box Picture text:...
Page 174 Brake valve operation 1.Brake valve is now at neutral position 2.Oil supplied to motor but return line is blocked by the brake valve. The pressure of supply line goes high. 3.This high pressure release the parking brake through the reducing valve. 4.This high pressure applies to the backside of brake valve and then pushes the brake valve against spring.
Page 175 Speed change 1. Neutral condition 2.Hydraulic oil flow from supply line opens shuttle ball and flows to the speed change valve. There is no pilot oil pressure from travel speed solenoid valve. The speed change valve move to the right because of spring force and make passage between the supply line and the bottom side of piston.
Page 176 Travel System(EC700B) - travel motor - Gear box Picture text:...
Page 177 Spec & External View Specification Model : MSF-340VP Type : variable swash plate,piston motor Displacement : 304.1(Large) / 196.8(Small) cc/rev Relief valve pressure : 350 kgf/cm2 Speed changeover pressure (High -> low) : 263 kgf/cm2 at Pi=40 kgf/cm2 Brake release pressure : 18.4 kgf/cm2 Drain pressure Continuous...
Page 178 Sectional View Picture text:...
Page 179 Brake Valve Operation 1 : Neutral position 2 : Normal travelling The supplied oil push the counterbalance valve to the right direction. and open its return passage. 3 : Downhill travelling During downhill operation, the motor is driven by machine's weight. The supply port pressure drop and the counter balance valve return to its neutral position(Blocked return passage).
Page 180 Relief Valve Operation 1 : Pressure increase 2 : During the free piston movement,the pressure is maintained stable as low. 3 : If the free piston pushed to its stroke end, the pressure increase to its set pressure. Picture text:...
Page 181 Speed Changeover Valve Operation 1 : Low speed fixed The tilting piston chambers are connected to tank(Max. angle & low speed) 2 : High speed If there is Pi,travel speed valve is pushed to the right. And high pressure is supplied to tilting piston chamber. (Min. angle & high speed) 3 : Automatic down-shift If the main pressure(red color)is increased, travel speed valve is pushed to the left.
Page 182 Parking Brake Operation 1 : The brake chamber is connected to tank and springs push brake piston to the friction plates. 2 : The brake chamber is pressurized and pushed against spring tension. Picture text:...
Page 183 Brake system Picture text:...
Page 184 Steering system Picture text:...
Page 185 Frame & Track Unit Picture text:...
Page 186 Upper frame(D12D engine) 1. Center frame 2. Cabin mouting position 3. Engine mounting position 4. Swing motor mounting position 5. Turning joint mounting position 6. Counterweight mounting position Picture text:...
Page 187 Upper frame(EC700B) 1. Upper frame(EC700B) 2. Low noise kit Picture text:...
Page 188 Lower frame 1. Adjustable Lower frame(EC460B/EC700B) 2. Idler & Track tensioner There is high pressure grease in track adjuster cylinder. Do not remove grease fitting or nut and valve assembly to release grease. To decrease track sag, add multi-purpose grease to track adjuster cylinder through grease nipple(A) using a grease gun with a maximum capacity 690 bar (10000 psi).
Page 189 Track Link 1. Link LH 2. Link RH 3. PIN-Regular 4. PIN-Master 5. Bushing-Regular 6. Bushing-Master 7. Seal 8. Spacer 9. Greasing area 10. Greasing area 11. Do not apply grease here. **EP2 Grease Picture text:...
Page 190 Boom & Arm 1. Boom-Rear Bearing 2. Boom-Center Bearing 3. Arm Cylinder Lug(Boom side) 4. Boom-Front Lug 5. Stiffener 6. Arm Cylinder Lug(Arm side) 7. Boom-Arm Bearing 8. Bucket Cylinder Lug 9. Yoke Bearing 10. Arm front Bearing Picture text:...
Page 191 Air conditioning system Picture text:...
Page 192 Air conditioning system overview - Heating and cooling system is installed in a single unit. - Can select indoor or outdoor air. - Mix door controls target temperature of system by mixing cold and hot air. - There are two filters. Picture text:...
Page 193 Air conditioning system input & output When you equipped with Auto air conditioning system, you can operate system in auto-mode or manual- mode. By pushing AUTO switch, system can be operated automatically. The only thing what operator has to do is setting the target temperature.
Page 194 Aircon system electric circuit(Old) By clicking the line, you can change the color of the line. Picture text:...
Page 195 Aircon system electric circuit(New) An additional 5A(FU24) fuse has been installed in the air conditioning compressor circuit to protect it from excessive current. Picture text:...
Page 196 System status indication The status display has two modes. (Operator mode and Service mode) In operator mode, you can check only target temperature, ambient temperature and error code. In service mode, you can check all of items. Picture text:...
Page 197 Error code Picture text:...
Page 198 Manual mode control Picture text:...
Page 199 Air conditioning switch animation Press button step by step. Picture text:...
Page 200 Controller- Auto and Manual(Option) (1) Auto controller (2) Manual controller Manual type controller is an option for tropical area. It has only cooling unit. There is no heating unit so there is also no mix-door actuator and coolant temperature sensor. And for this option, there is no in-car &...
Page 201 Air conditioner unit 1. Actuator - RH foot 2. Connection point - Refrigerant 3. Actuator - LH foot 4. Connection point - Coolant 5. Actuator - Mix door 6. Actuator - Face door 7. Filter - Main 8. Blower fan 9.
Page 202 Sensors Duct temperature sensor is installed at the core of evaporator. If sensor is failed, compressor clutch will be disabled. 1. Duct temperature sensor 2. In-car temperature sensor 3. Ambient temperature sensor 4. Coolant temperature sensor Picture text:...
Page 203 Actuator 1. Mix door actuator(MO8707) - Inside of mix-door actuator, there is a position sensor. This informs the real-position to controller for precise positioning.(Feedback control) 2. Foot, Face door acutator(MO8704-6) - Opeating angle= 90 degree 3. Intake door acutator(MO8703) - Operating angle= 120 degree Picture text:...
Page 204 Resistor and relays The resistor and 4 relays are used for controlling blower speed. And 1 relay is used for compressor clutch control. Inside of resistor, there is two lead fuses. If there is problem with this resistor, we can use only maximum fan speed.
Page 205 Compressor S: Suction port(bigger port) D: Delivery port(high pressure side,smaller port) New compressor has 2 pin connector.(+,GND) Old type has one pin connector.(+, body GND) Picture text:...
Page 206 Expansion valve This is a kind of feedback system. From output temperature from evaporator, System decides the amount of refrigerant. Output temp. high ---> More flow Output temp. low ---> Less flow Picture text:...
Page 207 Receive dryer Receive dryer - Is a kind of reservoir to store excess liquid refrigerant in the system. - Is a strainer or filter to remove particles from the system. - Has desiccant to absorb moisture from the refrigerant. - Has a built in pressure switch to protect system from excessive high or low pressure. 1.
Page 208 Diesel heater components 1. Timer The timer controls the diesel heater, and displays the operating status. The display shows current date, current time and operating time. 2. Controller & Heating unit The heating unit raises the temperature of the coolant using the fuel combustion unit, consists of the glow plug, the thermostats, the flame sensor, the controller, the electric motor and the fuse.
Page 209 Hydraulic System(EC330B-EC360B) Picture text:...
Page 210 Hydraulic system overview The mechanical power from engine converted to hydraulic power. Machine has two main pumps that are variable displacement piston pump. And it has 3 fixed gear pumps. P3 is for servo system. P4 is for hydraulic oil cooler fan motor. P1 is for X3. Travel: straight travel function Boom-up: 2-pump flow Boom-down: Regeneration...
Page 211 Full option circuit This is the circuit that covers all of option. In the circuit diagram, every component has unique number and there are many parentheses. For example N1(01-Pi2). This means that the port N1 is connected to the port Pi2 of the component 01(Main pump).
Page 212 Brief circuit-1(D10B) Brief circuit for main line Picture text:...
Page 213 Brief circuit-2(D10B) Brief circuit for pilot(servo) line Picture text:...
Page 214 Circuit animation(D10B) This animation can be used when you explain or study the hydraulic circuit. By pressing the lines, character or spool with mouse, you can change the colour of lines and spool location. Picture text:...
Page 215 Full Option Circuit(D12C) Due to D12C application, there was some changes at the hydraulic system. Major change is pump. Picture text:...
Page 216 Brief circuit-1(D12C) Picture text:...
Page 217 Brief Circuit-2(D12C) Picture text:...
Page 218 Circuit Animation(D12C) Picture text:...
Page 219 Hydraulic pump Picture text:...
Page 220 External veiw(D10B) Check the port location and compare with the circuit diagram. Picture text:...
Page 221 Sectional view(D10B) Picture text:...
Page 222 Pump circuit(D10B) Picture text:...
Page 223 External veiw(D12C) Picture text:...
Page 224 Sectional view(D12C) This pump assembly consists of two pumps connected by spline coupling. The suction and delivery ports are integrated at the connecting section of the two pumps: The common suction port serves both the front and rear pumps. The pump consists of rotary group, swash plate group and valve block group. The rotary group consists of front drive shaft, cylinder block, piston and shoe, set plate, spherical bushing, and cylinder spring.
Page 225 New gear pump(D12C) Picture text:...
Page 226 P-Q curve Hp= T X rpm = P X Q Picture text:...
Page 227 Pump control system In this picture, there are 4 pistons. From the top side, First one: Negative control Second one: Power shift control 3rd & 4th: Full horsepower control **Actually 2nd,3rd,4th pistons are integrated into one component. Full Horsepower control As the delivery pressure of the pump P1 and mate pump P2 goes high, the delivery flow rate will be reduced automatically, so the input torque will be regulated to a certain value.
Page 228 Regulator animation By pressing the arrow button, you can increase or decrease control pressure. Pay attention to the movement of feedback lever. Picture text:...
Page 229 Main Control Valve Picture text:...
Page 230 Main Control Valve Push the component in the circuit diagram with mouse then you can see the location of that components or disassembled components and section view. Picture text:...
Page 231 Flow sensing valve operation The function of flow sensing valve is to control the amount of flow from pump according to the joystick stroke. 1. Neutral condition( Central passage fully open -> High Pi -> Minimum flow) 2. Half stroke( Central passage partially open -> Medium Pi -> Medium flow) 3.
Page 232 Main relief valve operation The function of main relief valve is limit the maximum system pressure. PL1-OFF 1. Pump pressure is lower than the set-pressure.(close) 2. Pump pressure is reached to the set-pressure.(pilot poppet open) 3. Main poppet open and pump line has tank-connection. 4.
Page 233 Port relief valve operation The function of port relief valve is to release the shock pressure inside of actuator during neutral condition Overload 1. Cylinder pressure is lower than set-pressure.(close) 2. Cylinder pressure is reached to set-pressure.(pilot poppet open) 3. Small piston which is inside of main poppet moves to right and sit on the pilot poppet. Main poppet open and makes tank-passage.
Page 234 2-stage port relief valve operation (1) 1-way (Hammer) - When x1 selection switch is ON and X1 uses 1way, releif valve goes to low pressure setting without pilot pressure. (2) 2-way (Shear) - When x1 selection switch is ON and X1 uses 2way, releif valve goes to high pressure setting due to pilot pressure ON.
Page 235 Boom up operation 1. Neutral - Center passage open - Holding valve closed 2. Joystick signal on(BU) - Boom1 & Boom2 Spool move to LH side - Center passge close & pressurize 3. Open load check - Oil from parallel passage open load check. 4.
Page 236 Boom down operation 1. Neutral 2. Joystick signal(BD) ON - Spool move and close center passage. - P2c1 oil make drain passage by moving holding spool 3. Oil supplied to the small chamber and return oil try to return to tank 4.
Page 237 Bucket curl 1. Neutral 2. Bucket-IN(BI) signal ON - Spool move - Center passage block 3. Supply oil to the cylinder 4. When using Boom-Up at the same time, PAcs signal limit the stroke of the bucket spool.(Boom priority) Picture text:...
Page 238 Arm-IN operation 1. Neutral - Holding condition 2. Joystick Arm-IN(AI) ON - The Arm1 & Arm2 spool block center passage block - Holding valve spool move to make holding valve free. 3. Load check open and return line is blocked by holding valve. 4.
Page 239 Straight travel 1. All spools are in neutral condition. - 40 bar enters in port-P and Pa which has orifice. - oil from one orifice connected to Py port and then pass through two travel spool and go to the return line.
Page 240 Shunt valve operation-1 When the hydraulic oil temperature is higher than 70 celsius, the solenoid valve relay is at OFF position due to hydraulic oil temperature sensor. P1 pump does not flow through the solenoid valve. All of P2 pump oil flows to shunt valve A' port, then through shunt valve A port, rotating fan motor to high speed.
Page 241 Fan motor Picture text:...
Page 242 Return Piping Return check valve produce some amount of backpressure, which is used for make-up function. 4.5bar check valve is used for bypass function when hydraulic oil cooler is clogged. 27: 3.0k Return check valve 28: 4.5k Return check valve 29: Hydraulic oil cooler 34: Hydraulic tank Picture text:...
Page 243 Option hydraulics Picture text:...
Page 244 X1 line circuit X1 option is used for hammer & shear. - Main line change: When it is used for hammer, return line directly goes to tank. But shear uses double action. So we need 3- way valve - 2-step port relief valve: 2-step port relief valve always maintains high pressure except hammer use.
Page 245 X1 Components 41: Hammer/ Shear select solenoid valve 46: X1 Flow control valve 48: Hammer/ Shear select valve 42: Option pedal Picture text:...
Page 246 Rotator circuit This is X3 option. X3 option is composed of gear pump at PTO, rotator valve and additional case drain line for motor. This is operated using LH joystick button. Picture text:...
Page 247 X3 line piping Picture text:...
Page 248 Boom floating circuit When joystick button is pushed, this signal goes to VECU. VECU energize the solenoid. When joystick is in boom-down position, this signal operate hose rupture valve and boom floating valve. This makes boom cylinder piston side and rod side go to tank. So boom can drop down by its weight. Picture text:...
Page 249 Boom floating components Picture text:...
Page 250 Quick fit The quick-fit attachment is fitted to the arm end and bucket link. The connection between the quick-fit and bucket is like figure. The quick-fit attachment is equipped with a double acting hydraulic cylinder. The quick-fit locking wedge is fitted to the piston rod.
Page 251 S-Quick fit Components Picture text:...
Page 252 U-Quick fit X: Quick fit valve 26: Pilot block Picture text:...
Page 253 Removal counterweight P2 pump oil can be supplied by blocking center bypass valve. For safety, large chamber oil is restricted to out. Picture text:...
Page 254 Hydraulic System(EC330B-EC360B) -D12D engine application Picture text:...
Page 255 Full option circuit Straight travel function is added. Picture text:...
Page 256 Fan motor There is a check valve to prevent motor from cavitation. Picture text:...
Page 257 Straight travel pedal Without operating two travel pedals (C) for straight travel, we can use only option pedal (B). Picture text:...
Page 258 Hydraulic System(EC460B) -D12C engine application Picture text:...
Page 259 Hydraulic system overview The mechanical power from engine converted to hydraulic power. Machine has two main pumps that are variable displacement piston pump. And it has 3 fixed gear pumps. P3 is for servo system. P2 is for hydraulic oil cooler fan motor. P1 is for X3. Travel: straight travel function Boom-up: 2-pump flow Boom-down: Regeneration...
Page 260 Full option circuit(Old) This is the circuit that covers all of option. In the circuit diagram, every component has unique number and there are many parentheses. For example 5B4(48-B). This means that the port 5B4 is connected to the port B of the component 48. This is the way how to read our circuit diagram.
Page 261 Brief circuit-1(Old) Brief circuit for main line Picture text:...
Page 262 Brief circuit-2(Old) Brief circuit for pilot(servo) line Picture text:...
Page 263 Circuit animation(Old) This animation can be used when you explain or study the hydraulic circuit. By pressing the lines, character or spool with mouse, you can change the colour of lines and spool location. Picture text:...
Page 264 Hydraulic circuit-full option(New) 1. Main pump 2. Servo pump 3. Main control valve 4. Boom cylinder 5. Arm cylinder 6. Bucket cylinder 7. Swing motor 8. Swing gear box 9. Swing drive unit 10. Travel motor 11. Travel gear box 12.
Page 265 Brief circuit-1(New) Picture text:...
Page 266 Brief circuit-2(New) Picture text:...
Page 267 Circuit animation(New) Picture text:...
Page 268 Hydraulic pump Picture text:...
Page 269 External veiw Compare the circuit diagram with the external view. Picture text:...
Page 270 Sectional view This pump assembly consists of two pumps connected by spline coupling. The suction and delivery ports are integrated at the connecting section of the two pumps: The common suction port serves both the front and rear pumps. The pump consists of rotary group, swash plate group and valve block group and has booster. The rotary group consists of front drive shaft, cylinder block, piston and shoe, set plate, spherical bushing, and cylinder spring.
Page 271 P-Q curve Picture text:...
Page 272 Gear pump Picture text:...
Page 273 Main Control Valve Picture text:...
Page 274 A click at finger pointer gives you more informations Main Control Valve Animation Push the component in the circuit diagram with mouse then you can see the location of that components. Picture text:...
Page 275 Flow sensing valve operation The function of flow sensing valve is to control the amount of flow from pump according to the joystick stroke. 1. Neutral condition( Central passage fully open -> High Pi -> Minimum flow) 2. Half stroke( Central passage partially open -> Medium Pi -> Medium flow) 3.
Page 276 Main relief valve operation-1(Old) (1) Pump pressure is lower than the set-pressure. (2) Pump pressure is reached to the set-pressure. Main relief valve operation-2(Old) (3) Main poppet open and pump line has tank-connection (4) Boost signal comes from port pc and push the piston to increase the tension of spring. Picture text:...
Page 277 Main relief valve operation(New) The function of main relief valve is limit the maximum system pressure. pc-OFF 1. Pump pressure is lower than the set-pressure.(close) 2. Pump pressure is reached to the set-pressure.(pilot poppet open) Main poppet open and pump line has tank-connection.
Page 278 Port relief valve operation(Old) (1) Cylinder pressure is lower than the set-pressure. (2) Cylinder pressure is reached to the set-pressure. (3) Piston inside of main poppet will move. (4) Main poppet open and make tank-passage. Picture text:...
Page 279 Port relief valve operation(New) The function of port relief valve is to release the shock pressure inside of actuator during neutral condition Overload 1. Cylinder pressure is lower than set-pressure.(close) 2. Cylinder pressure is reached to set-pressure.(pilot poppet open) Small piston which is inside of main poppet move to right and sit on the pilot poppet.
Page 280 Makeup valve operation Picture text:...
Page 281 Boom-2 Spool Change 1. Remove the stroke limiter from Boom2 spool. 2. Remove the make-up valve from Boom2 head side. Picture text:...
Page 282 Center-bypass Valve Change 1. Simplification of the center-bypass valve 2. Remove the make-up valve from Arm2 rod side. Picture text:...
Page 283 Boom up operation 1. Neutral - Center passage open - Holding valve closed 2. Joystick signal on(BU) - Boom1 & Boom2 Spool move - Center passge close & pressurize 3. Open load check - Oil from parallel passage open load check. 4.
Page 284 Boom down operation 1. Neutral 2. Joystick signal(BD) ON - Spool move and close center passage. 3. Oil supplied to the small chamber and return oil try to return to tank 4. 4pc1 oil make passage to the pilot check valve 5.
Page 285 Arm-IN operation 1. Neutral - Holding condition 2. Joystick Arm-IN(AI) ON - The Arm1 & Arm2 spool block center passage block - Holding valve spool move to make holding valve free. 3. Load check open and return line is blocked by holding valve. 4.
Page 286 Straight travel 1. All spools are in neutral condition. - 40 bar enters in port-Pp which has three orifices. - oil from one orifice connected to Py port and then pass through two travel spool and go to the return line.
Page 287 Option hydraulics Picture text:...
Page 288 X1 circuit X1 option is used for hammer & shear. - Main line change: When it is used for hammer, return line directly goes to tank. But shear uses double action. So we need 3- way valve - 2-step port relief valve: 2-step port relief valve always maintains high pressure except hammer use.
Page 289 X1 Components When we select 2-pump flow for option, you have to open the option conflux check valve fully. Flow control starts the function after hammer pressure switch is on. 46: X1 flow control valve 47: X1 2 Pump select solenoid valve 61: X1 pressure switch 73: Option conflux check valve Picture text:...
Page 290 Rotator circuit(X3) This is X3 option. X3 option is composed of gear pump at PTO, rotator valve and additional case drain line for motor. This is operated using LH joystick button. Picture text:...
Page 291 X3 components Picture text:...
Page 292 Boom floating circuit When joystick button is pushed, this signal goes to VECU. VECU energize the solenoid. When joystick is in boom-down position, this signal operate hose rupture valve and boom floating valve. This makes boom cylinder piston side and rod side go to tank. So boom can drop down by its weight. Picture text:...
Page 293 Boom floating components Picture text:...
Page 294 S-Quick fit The quick-fit attachment is fitted to the arm end and bucket link. The connection between the quick-fit and bucket is like figure. The quick-fit attachment is equipped with a double acting hydraulic cylinder. The quick-fit locking wedge is fitted to the piston rod. Servo pressure acts on the piston side of the lock cylinder, locking the bucket in place against the rear hook.
Page 295 S-Quick fit Components Picture text:...
Page 296 U-Quick fit X: Quick fit solenoid valve 26: Pilot block Picture text:...
Page 297 Removable counterweight The counterweight removal equipment consists of control valve, check valve, solenoid valve and stop valve. This equipment makes it easier to remove/install a counterweight to the machine. Picture text:...
Page 298 Removable counterweight components Picture text:...
Page 299 Hydraulic System(D12D) Picture text:...
Page 300 Full option circuit-EC460B(D12D) Picture text:...
Page 301 Hydraulic circuit animation(D12D) Picture text:...
Page 302 Hyd pump change Main pump: Displacement change from 182cc to 192.5cc due to engine max rpm reduction. Gear pump: Displacement increases due to engine max rpm reduction. No tropical option at P2. Picture text:...
Page 303 Pump P-Q curve Picture text:...
Page 304 X1 circuit(D12D) Picture text:...
Page 305 Hydraulic components Layout changes of hydraulic components 26: Pilot block 41: Hammer, Shear select sol. 42: X1 pedal 43,45: X1 shuttle block 47: 2-pump select sol. 48: X1 3-way valve 52: Rotator solenoid 55: Quick fit sol. 87: X1 pilot select valve for 2-step relief valve 88: Thumb sol.
Page 306 Hydraulic System(EC700B) Picture text:...
Page 307 Hydraulic System Overview The mechanical power from engine converted to hydraulic power. Machine has two main pumps that are variable displacement piston pump. And it has 2 fixed gear pumps. it is for servo system and cooling fan. Two-Pump flow - Boom-Up - Arm-IN &...
Page 308 Full Hydraulic Circuit(Old) Main pump 2Servo Pump 3Main control valve 4Boom cylinder 5Arm cylinder 6Bucket cylinder 7Swing motor 8Shockless valve 9Pressure switch Travel motor Travel gear box Swing gear box Turning joint Fan motor Proportional relief valve Pilot filter Accumulator block Strainer in breather Accumulator Solenoid valve(1)
Page 309 Full Hydraulic Circuit(New) **C1 orifice change **Following options are added -U-Quick fit -X3(Rotator) -Bucket-out conflux -Pattern change valve Main pump 2Servo Pump 3Main control valve 4Boom cylinder 5Arm cylinder 6Bucket cylinder 7Swing motor 8Shockless valve 9Pressure switch Travel motor Travel gear box Swing gear box Turning joint Fan motor...
Page 310 Brief Hydraulic Circuit-1(New) Picture text:...
Page 311 Brief Hydraulic Circuit-2(New) Picture text:...
Page 312 Brief Hydraulic Circuit(New) This page is a hydraulic circuit animation! Servo circuit is displayed at a click "servo". Main page is displayed at a click "main". Line click change the color of the line. Hyd. component symbol click may move the circuit symbol. Port name : local port name (Port name) : connected to "Port name",destination Picture text:...
Page 313 Hydraulic Pump Picture text:...
Page 314 External view & Specification Specification Max. displacement : 242 x 2 cc/rev Rated speed : 1800 (CW from shaft end) Max. flow rate : 435 x 2 Min. flow rate : 38 x 2 lpm Max. input torque : 171.1 kgf.m Mean casing pressure : 1 kgf/cm2 Picture text: A : location of main pump,...
Page 315 Sectional View The pump type is variable displacement, swash plate type and tandem piston pump - This pump assembly consists of two pump connected by a spline coupling (P). - The suction and delivery ports are integrated at the connecting section of the two pumps. - The rotary group consists of the front driving shaft (A), cylinder block (2), cylinder spring, piston (K) and shoe (J).
Page 316 Main Pump Control Curve 1 : horizontal-X axis(delivery pressure P=P1=P2) 2 : horizontal-X axis(pilot pressure P=Pi1=Pi2) 3 : vertical-Y axis(delivery flow (Q) quantity) 4 : Flow control curve(Q(3) vs Pi(2)) 5 : Max. flow rate area(No pump control: regulator internal components don't move) 6 : Constant engine power curve 7 : 1st flow reduction area(outer spring compressed) 8 : 2nd flow reduction area(outer and inner springs compressed)
Page 317 Gear pump (1) Gear pump on PTO without X3 - G200(20.3+17.8 cc/rev) (2) Gear pump on PTO with X3 - Model : G200(35.6+20.3 + 17.8) Picture text:...
Page 318 Main Control Valve Picture text:...
Page 319 A click at finger pointer gives you more informations MCV animation Picture text:...
Page 320 Servo system 2. Gear pump 3. Main control valve 14. Cooling fan motor 15. Proportional relief valve 16. Pilot filter 17. Accumulator block 19. Accumulator 20. Solenoid valve 21. Boom & Arm conflux cut-off solenoid valve 25. Shuttle block 26. Pilot block 41.
Page 321 Hydraulic oil cooling system 2. Gear pump 14. Cooling fan motor 15. Proportional relief valve 27. Return check valve(3.0 k) 28. Return check valve(4.5 k) Picture text:...
Page 322 Option hydraulics Picture text:...
Page 323 Hammer and Shear Circuit This page is an animation! If you click some line or valve or button, there may some change! For hammer operation, pilot signal have to be supplied to the 3 way valve(Tank connection) and pilot selector valve(2 step port relief low pressure setting). "Sol b"...
Page 324 X1 Components 20 : Solenoid valve block(A2: Hammer solenoid valve) 26 : Pilot block 39 : Hammer/Shear select solenoid valve 40 : X1 Pedal 41 : X1 Flow control valve 43 : 3 way selector valve 44 : X1 return filter 46 : Pilot selector valve 47 : Solenoid valve(2 switch control) Picture text:...
Page 325 X3 Circuit Gear pump 74 : Check valve 75 : Rotator valve 76 : Rotator solenoid valve Picture text:...
Page 326 U-Quick fit 70 : Quick fit valve 71 : Block 72 : Quick fit cylinder Picture text:...
Page 327 Boom Floating Circuit The button on the joystick can make VECU energize floating solenoid. Floating pressure switch is activated and rupture valve and floating valve is proportionally pressurized according to the joystick operation. Picture text:...
Page 328 Boom Floating Components The large and small chamber pipes are connected to floating valve(B). The 2nd pressure of joystick is connected to rupture valve and floating valve. A : Floating solenoid valve B : Floating valve Picture text:...
Page 329 Removable Counterweight Circuit To use this function, stop valve(4) must be open and center bypass valve must be blocked by pilot signal from selector solenoid valve(3). The flow from B to FB is fast. But its opposite flow is slow from orifice restriction. There is a pressurized flow at port P on the valve(1) all the time.
Page 330 Removable Counterweight Components To use this function, stop valve(4) must be open(O) and center bypass valve must be blocked by pilot signal from pilot selector solenoid valve(3) by toggle switch(S) operation. O : Open(Stop valve,4) X : Closed(Stop valve,4) Y : Pilot selector solenoid valve(3) Z : Removable counterweight valve(1) S : Switch for pilot selector solenoid valve(3) Picture text:...
Page 331 Hydraulic System(COMMON) Picture text:...
Page 332 Cylinder 1. Piston 2. Tube 3. Rod 4. Gland 5. Cushion ring 6. Cushion plunger a. Dust wiper b. Rod packing c. Buffer ring d. Dry bearing e. Contamination seal f. Wear ring g. Piston packing Picture text:...
Page 333 Cushion operation Picture text:...
Page 334 Joystick The remote control valve is a kind of the reducing valve and has four reducing valves controlling the secondary pressure in one valve casing. Its secondary pressure is controlled by adjusting the tilting angle of the handle. And the electric switches are equipped inside of joystick for various option. Picture text:...
Page 335 Travel pedal Basic function is almost same with joystick and this pedal has damping function to prevent oscilation when releasing the lever. Picture text:...
Page 336 Option pedal The component itself is almost same between X1 & X2 pedal but the characteristic curve is a little bit different. Picture text:...
Page 337 Pattern change Picture text:...
Page 338 Boom Hose Rupture Valve Operation P3 port is connected to overload pressure switch(A). With Pi signal,boom lowering is possible. The spool movement makes the tank connection of pilot check valve. Picture text: 1 : Neutral condition 2 : Raising operation 3 : Lowering operation...
Page 339 Arm Hose Rupture Valve Operation With Pi signal, arm in operation is possible. The spool movement makes the tank connection of pilot check valve. Picture text: 1 : Neutral condition 2 : Arm out operation 3 : Arm in operation...

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