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SUNWARD Medium Excavator Hydraulic System

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Table of Contents
1
3 Hydraulic System Overview

目 2 Main Pump Control Principle

录 3 MCV Control Principle

Content
Hydraulic Actuators of Excavator
4
3
Hydraulic System Overview 山河智能
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Power Train

Hydraulic System Implements

Engine Cylinders
Main Pump MCV

Slew
Mechanism

Slew Motor

Undercarriage

Diesel Hydraulic Tank PCV Travel Motor

Tank
 Hydraulic System Overview 山河智能

Features of Sunward hydraulic system ：Sunward medium excavator utilized a hydraulic

system with dual-pump, double-circuit, of which power can be regulated by negative flow for less
energy loss caused by relief, and regulated under constant power by crossed mutual work pressure,
as well as power transition by pressure induced by proportional solenoid valve .

Dual Pump :The Sunward excavator employs dual-tandem-pump to deliver oil to all hydraulic
implements,each pump has its own duties,generally,the front pump deliver oil to left travel
motor,swing motor and arm cylinder,while the rear pump deliver oil to right travel motor,boom cylinder
and bucket cylinder .

Double-circuit :Just like a cow hoof, the main control valve (MCV) is composed of two parralelled
sections, each section has its own duty, the front pump supply oil through the left section to hydraulic
actuators and the rear pump supply oil through the right section to hydraulic actuators, and each oil
circuit of the two sections are relatively separate.
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Medium Excavator Hydraulic System Overview 山河智能
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Front Pump Rear Pump

Regulator Regulator

Pilot Pump Pilot Pump Pressuer Sensor

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Features:
Front Pump Regulator Rear Pump Regulator
● Front and rear pump deliver
pressurized oil to each actuator
● Pilot pump provides pressure
oil to pilot control circuit to shift
spools.
● The regulator is used to
realize the automatic regulating
of displacement of the pumps
● Proportional solenoid valve is
used to remotely set power of
Front Pump Middle Body Rear Pump Pilot Pump
the main pump.
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1: Front pump
2: Rear pump
3:Pilot Pump

4: Psv Coil

5: regulator
A1: Front pump outlet port
A2: Rear Pump outlet port

B1: main pump suction port

Dr: drainage port
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Pi1: Front pump negative flow inlet

Pi2: Rear pump negative flow inlet
Psv: Proportional Solenoid Valve
A1: Front Pump testing port
A2: Rear Pump testing port
a3: pilot pump pressure testing port
A3: Pilot pump outlet port

B3: pilot pump inlet port

DR3: pilot pump drainage

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Pump displacement variation control

Pump displacement are mainly governed by 4 factors:,autologous circuit pressure, opposite
pump circuit pressure,negative flow and the proportional solenoid valve.

Autologous
Circuit Pressure
Oppsite Pump
Pressure
Psv

Negative Flow
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Negative Flow Control ： We set a bypass

throttle valve at downstream of oil return line in each
section of main valve ,so that we can get a pressure
signal from each of the two circuits.This pressure signal
can feedback to the regulator of the main pump,and it
will control the swashplate inclination and displacement
of the main pump,so that it can regulate the speed of the
work equipment. Usually,the bigger angle you push the
joystick to ,the higher pilot pressure will be ,and the
bigger angle swash plate will incline to,and the more oil
will be diacharged by the pump within unit time,and vice
versa.
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Negative Flow Control ：

Servo Spool & Sleeves

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Crossed Mutual Regulation： Each of the two pumps has its own regulator ,and the
regulator can be regulated by the pressure of both pumps circuit, that’s to say the pressure
of each pump circuit can regulate the swashplate inclination and displacement of both pumps.

Constant power control: once the work mode and gear of the throttle dial is
selected,the engine power output will be constant. if the load of one of the pumps is lighter
than the other one ,the other pump can automatically absorb the surplus power from this
pump,so that the power output by engine can be utilized to its utmost.
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Autologous Circuit Pressure Regulating:

as the red line in the next diagram shows. the discharged oil by
the front pump flows through the checkvalve and enters into small
end of servo piston,and the same stream of flow will reach to left
side of compensator spool, as pressure increases, once it's strong
enough to get over spring force of the servo spool,the servo spool
will move right, and let the pressurized oilfrom pump in itself enter
into big end of the servo piston, and push the servo piston to the
right slowly, and the swashplate of the pump will be driven
clockwisely, and pump displacement will decrease,

once the pressure from pump in itself start to drop, the spring force will push the servo spool to the left
gradually, oil in the big chamber of servo piston will return to tank, and the pressure in small chamber will push
servo piston to the left, and inclination of swashplate will increase. if the force generated by the pressure is
equal to compensator spring force, the servo spool will stay at neutral position, and pump displacement will
not change.
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Opposite pump pressure control : as the pink line shows in the picture below.

The autologous pump pressure and opposite pump pressure work together, and form a
constant power control.
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The Kawasaki K3V Series Hydraulic Pump equipped Constant Power Control Strategy
with a synchronized constant power type regulator,
its displacement is regulated according to the total
load of front pump and rear pump, so during the
power regulating process, the engine can avoid from
overload, and no need to care about load of either
single pump. and it's also because of this regulator is
a synchronized constant power type,it will keep the
swashplate inclination of both pump always the same
when the two pumps work at the same time. .
this constant power control strategy will let the implements work fast with light load, and slow
with heavy load, and take full advantage of power output by engine, but will not overload.
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Constant Power Control Strategy

When the engine speed is constant, the power of the

hydraulic pump is also constant. as output pressure P1 of
autologous pump or output pressure P2 of the opposite
pump increases, the pump regulator will automatically
reduce the inclination of the swash plate, that is, the
displacement of the pump is reduced, so that the power of
the hydraulic pump can maintained at a constant range.
When the work load of the excavator is small, the machine
can work with high flow to ensure a fast work speed without exceeding power output by engine, When the power of
the hydraulic pump tends to exceed output power of the engine, the displacement of the piston pump must decrease..
The regulating principle just as shown in the firgure on the left.
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Constant Power Control Strategy

Constant power control is performed by the compensating spool. there are
two ring steps on the compensator spool, and pressure from both front pump
and rear pump will apply on these two steps respectively, As the load on the
two pumps increases, When the sum of pressures (P l + P2) acted on the
compensation spool reaches the setted value of the power spring, it will
overcome the spring force to shift the servo spool to the right and let it work
in its left position.The pressure oil CD connected to the servo valve enters the
big end of the servo piston, due to the cross-section area difference of the
two ends, the pressurized oil will push the servo piston moves to the right,
and the swashplate will be pulled to rotate clockwise synchronously by servo
piston , and then the pump displacement will reduce, and keep power of 1. Compensator Spool; 2. Power Spring,
3. Spring Retainer 4. Servo spool 5. Feedback lever,
6.Servo Piston, 7.Negative Control Spring,
pump constant. thereby preventing the engine from being overloaded. 8. Negative Control Plunger
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Constant Power Control Strategy

At the same time when the displacement is reduced, the
servo piston simultaneously drives the feedback lever to
rotate counterclockwise. The feedback lever drives the
servo spool to move to the left to close the servo valve.
The oil inlet passage of the servo piston large chamber is
then closed. and the whole displacement regulating
process finished..
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● The pump regulator is a type of hydraulic servo mechanism.

On the K3V main pump regulator, two springs are used to
form two straight line ,and these two straight lines form an
approximate constant power curve on the pressure-flow
diagram.

● By adjusting the pre-compression of the spring to change the

pump pressure starting point, the absorbed power of pump
can be adjusted therefore.

The pump outlet pressure is directly proportional to the

spring force, and the spring force is inversely proportional to
the pump displacement.

Shifting pressure p0 = spring precompression force ÷ oil pressure acting area

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Constant Power Control Strategy

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Constant Power Control Strategy

The purpose of constant power control strategy is to adequately absorb power output from engine,
and keep engine speed constant, so it can be called constant torque control strategy as well.

Priciple：
P = T·n／9550 P=p x V (p and V are inversely related)
T= p x v / ( 2 xπ) T=Constant

P: engine power output

n: Engine speed
T: Engine output torque
p: Pump pressure
V:Pump displacement
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The Regulator adjust pump

displacement according to external Power Control Flow Control
feedbacks in real-time, and realized
the following functions:
●Flow Control （Negative Flow Control ）

●Power Control：

1.Constant Power Control

（Crossed mutual control）

2.Powershift Control
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Power Adjusting
• ● It’s forbidden to adjusting all these screws

• ● loosen(anti-clockwise)

• Min. displacement screw, pump displacement

Negative oil adjusting will decrease

• ● loosen(outer direction) Max.

Min. displacement Displacement bolt, pump displacement
adjusting screw

Pilot relief
increased
pressure adjusting
• ● loosen(outer direction) the other adjusting
bolts, the concerned parameters decreased
Max. displacement
adjusting screw
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Pilot Pump
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SERVO PISTON
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Compensator Spool
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SERVO SPOOL
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● Function: Used to set the absorbed power

of pump in real time

● The input current of Psv is inversely

correlated with outlet oil pressure, and
positive correlated with absorbed power
(that is, the larger the current value is, the
lower outlet pressure and the greater
absorbed power will be.)

● Poor toleration with impurities.

● When wire connector disconnected, the pf

pressure is: 3.66MPa
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SWING MOTOR-KPM M5X180CHB 山河智能
SWING MOTOR-KPM M5X180CHB 山河智能
SWING MOTOR-KPM M5X180CHB 山河智能
SWING MOTOR-KPM M5X180CHB 山河智能
SWING MOTOR-KPM M5X180CHB 山河智能
 山河智能
SWING RELIEF VALE
REBOUND DAMPING VALVE 山河智能
REBOUND DAMPING VALVE 山河智能
REBOUND DAMPING VALVE 山河智能
REBOUND DAMPING VALVE 山河智能
SWING CHECK VALVE 山河智能
BRAKE TIME DELAY VALVE 山河智能
BRAKE VALVE 山河智能
TRAVEL MOTOR-KYB MAG-170VP 山河智能

PA
PS

DR

PB
COUNTER BALANCE VALVE 山河智能
COUNTER BALANCE VALVE 山河智能
COUNTER BALANCE VALVE SPOOL 山河智能
COUNTER BALANCE VALVE 山河智能
RELIEF VALVE 山河智能
RELIEF VALVE 山河智能
DOUBLE SPEED VALVE 山河智能
DOUBLE SPEED SPOOL 山河智能
BREAK CYLINDER 山河智能
BREAK CYLINDER 山河智能
BREAK PLATE 山河智能
DOUBLE SPEED PIN-AGAINST SWASH PLATE 山河智能
PISTON/SWASH PLATE 山河智能
Travel Motor Working 山河智能
AUTO-REDUCED SPEED OF DOWN SLOPE 山河智能

AUTO-REDUCED SPEED OF DOWN SLOPE

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Speed control: Anti-overrun (especial down slope)
Function: High-Low Speed 山河智能

Low Speed High Speed

Automatic change back single speed(especial while climbing) 山河智能
 HYDRAULIC MAIN CONTROL VALVE 山河智能

Arm regeneration
disable valve
Negative Flow Vale
Arm Flow Bypass cut-off
valve Negative flow valve
Limit Valve
Arm Rod
Chamber Relief
Valve
Arm rodless Bucket flow Arm holding valve
chamber relief valve limit valve
Arm
2 Arm 1
Boom Holding Valve
Boom rodless
chmb relief valve

Boom
1
Bk Rod Chmb Boom 2
Relief Valve

Bucket
Boom rod swing
chamber Strt Tr Pilot
relief valve Control Valve

Swing flow
limit valve
Optiona
RH travel l
LH Travel
Strt Tr Valve

Bucket Rodless
Chmb relief valve Main Relief valve
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arm(1) arm(2)

boom(2) boom(1)

swing bucket

hammer Right travel

Left travel straight

P70
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4
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Oil flow-Neutral position 山河智能
Oil flow-boom up 山河智能

P1,p2 conflux
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Oil flow-boom down

Return oil
regeneration
Oil flow-arm curl 山河智能

P1,p2 conflux
regeneration
Oil flow-arm in(p1,p2 increased) 山河智能

P1,p2 conflux
Non-regeneration
Oil flow-bucket curl 山河智能

regeneration
Oil flow-swing 山河智能

p1
Oil flow-singe travel 山河智能

P1/ p2
Oil flow-boom up & swing 山河智能

P1 priority to boom
P2 totally to boom
Oil flow-arm curl & bucket curl 山河智能

P1 priority to arm
P2 totally to arm
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Oil flow-boom up & arm curl

P1 priority to boom
P2 to boom and arm
ARM Curl CONFLUX AND REGENERATION 山河智能
BOOM UP CONFLUX 山河智能
STRAIGHT VALVE 山河智能
HOLDING VALVE 山河智能
Holding VALVE 山河智能
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Front view Rear view

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Left view Right view

Diagram-main spool 山河智能
Front view-spool 山河智能
spool 山河智能
relief valve 山河智能
Secondary relief valve 山河智能
Secondary relief valve 山河智能

● Relief pressure when cylinders

overload

● Cylinder Anti-cavitation

● Pilot operated cartridge valve

Adjusting is generally prohibited.

Secondary relief valve 山河智能

Secondary Relief Valve（Relief）

Closed

溢流状态

先导开启状态
Main relief valve 山河智能

• ●boost function

• 31.4Map(normal)
• 34.3Mpa(boost）
• It’s forbidden to
adjust this valve.
Main relief valve 山河智能

1 2 3 4
Main relief valve 山河智能

Relief status
Closed status

Pilot for boost coming Power Boosting

Secondary relief valve 山河智能
Oil flow limited relief valve(rear view) 山河智能

1. Arm flow limit valve

2. Swing flow limit valve

3. Bucket flow limit valve

2 3
Oil flow restrict valve (Left/right view) 山河智能

Swing Flow Restrict valve

Flow Restrict valve 山河智能
Flow restrict valve 山河智能
Diagram-Holding valve 山河智能
 Holding valve-front view 山河智能

Arm(piston
side)

Boom(non-
piston side)
Holding valve 山河智能
Anti-drift valve 山河智能
Straight travel valve 山河智能
Straight travel valve-pilot 山河智能
Straight valve-pilot 山河智能
diagram-relief valve 山河智能
Diagram-check valve 山河智能
SPOOLS 山河智能

L（1）ARM 2、
R（1）ARM 1、 L（2）BOOM 1
R（2）BOOM 2、 L（3）BUCKET、
R（3）SWING、 L（4）RIGHT TRAVEL、
R（4）HAMMER、 L（5）STRAIGHT。
R（5）LEFT TRAVEL。
SAFETY VALVE-IN CASE HOSE BROKEN 山河智能
SAFETY VALVE-IN CASE HOSE BROKEN 山河智能
PILOT OIL BLOCK 山河智能

1：ACCULATOR
2：PILOT SOLENOID
3：STAND BY SOLENOID
4：BOOST SOLENOID
5：TWO SPEED SOLENOID
FP:PILOT OIL INPUT
FT:TO TANK
F1:BOOST OIL OUT
F2:TWO SPEED OUT
F3:JOYSTICK OUT
PILOT OIL BLOCK 山河智能
TESTING&PERFORMANCE-SWE230B 山河智能

PILOT RELIEF VALVE）

2 a1
1 3
4

a2
a3

MAIN RELIEF VALVE）

TESTING&PERFORMANCE-SWE230B 山河智能

1 2

1 2

SECONDARY RELIEF VALVE）

1 2

TREAD MOTOR RELIEF VALVE

SWING MOTOR RELIEF VALVE

CYLINDER SPEED TEST 山河智能

AV/3 TIMES OPERATION STANDARD

BOOM CYLINDER RAISE 3.5±0.3 (S)

LOWER 3.5±0.3 (S)

ARM CYLINDER ROLL-IN 3.4±0.3 (S)

ROLL -OUT 3.2±0.3 (S)

BUCKET CYLINDER ROLL-IN 3.4±0.3 (S)

ROLL -OUT 3.1±0.3 (S)

TESTING&PERFORMANCE 山河智能

AV/3 TIMES WITHOUT LOAD RATED LOAD

BOOM Less than 5 mm Less than 20 mm

CYLINDER

ARM Less than 15 mm Less than 20 mm

CYLINDER

BUCKET Less than 10 mm Less than 20 mm

CYLINDER
SWING SPEED 山河智能

AV/3 TIMES THREE STANDARD

ROTATIONS
SWING SPEED LEFT 11.5±1 (S)
RIGHT 11.5±1 (S)
TESTING & PERFORMANCE 山河智能

Standard
Travel of coasting Less than 900 mm
TESTING&PERFORMANCE 山河智能

Standard
Coasting amount Less than 900 mm
TESTING&PERFORMANCE 山河智能

20 Meter distance Standard(S)

LOW speed 23.2±2(S)
TWO-Speed 15.5±1 (S)
TESTING&PERFORMANCE 山河智能
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