Komatsu Hydraulics

Sales Presentation Kit
Construction Product Lines
Hydraulic Systems
Section 2
Basic Komatsu Construction Equipment

& Earthmoving Principles
KS900202
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Basic Komatsu Equipment
09/02
Characteristics of Pressure of Page 2-2
Static Fluid Pascals Law

Pressure is transmitted in static fluid
with the following characteristics:
Pressure acts at a right angle
to every surface.
Pressure at every point of fluid
acts in equal strength in every
direction.
Pressure applied to a certain
part of fluid in enclosed
container is transmitted to
every part of the fluid in the
original strength.
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Transmission of Power Pascals Law

09/02
Page 2-3
10kg x 10 = 100kg
The force of 10kg
Which means the force of 10 times is obtainable.
pushing Piston A
with the area of Pushing with the The force of 100kg
1cm becomes the force of 10kg is obtainable
hydraulic force of
10kg/cm, which
pushes up Piston B
Area 1 cm2 Area 10 cm2
in accordance with
Pascals law.
The piston B having Hydraulic
force
the area of 10cm
Hydraulic force
can produce the 10kg/cm2
force of 100kg/cm.
This is 10 times the Piston A Piston B
original force. (Cylinder) (Cylinder)

Transmission of Power Pascals Law

09/02
Page 2-4
(Cont)
10kg x 10 = 100kg
Which means the force of 10 times is obtainable.
The volume of oil
pushed out by Pushing with the The force of 100kg
small piston A is force of 10kg is obtainable
the same as that
is fed to large
piston B. Area 1 cm2 Area 10 cm2
The distance
Large
piston B moves Small
will be smaller Hydraulic

force
than that of Hydraulic force
piston A. 10kg/cm2
Piston A Piston B
(Cylinder) (Cylinder)

09/02
Hydraulic System Components Page 2-5
Using a hydraulic system to perform your work
Hydraulic system Controlled oil

consists of the High pressure oil Control
following 5 basic valve
elements:
1. Hydraulic pump Return
2. Control valve
Hydraulic cylinder
Hydraulic and motor
3. Hydraulic
pump
cylinder and
hydraulic motor
4. Hydraulic oil
Low pressure oil Hydraulic
tank
tank
5. Piping and other
accessories

09/02
Hydraulic Pumps Page 2-7
A hydraulic pump is the equipment with which mechanical

energy, from an engine, is converted to fluid energy.
It sucks hydraulic oil from tank to pushes it to discharge.
Here are three types of hydraulic pumps:
Gear Vane Piston

Pump Pump Pump

09/02
Rotation of a Gear Pump Page 2-8
In a gear pump oil

fills the space
between the gear
case and gears.
As the gears
rotate they
perform a
pumping action
that moves the oil
from the suction
to the discharge
side.

09/02
Hydraulic Piston Pump Page 2-9
Reciprocating Motion of Piston Pump

A piston pump performs
pumping action through
reciprocation of the
piston.
Being small in size and
in order to reduce
pulsation, it is necessary
to run at fast speed.
Multi-piston type is used
with an odd number of
pistons for prevention of
pulsation.

09/02
Two Types of Piston Pumps Page 2-10
There are 2 types of

piston pumps:
Axial piston pump
Radial piston
pump
In addition, there are
2 types of axial Swash plate
piston pumps type
Axial piston
Swash plate Piston pump
Angled axial
Angled axial pump type
Radial
piston pump

09/02
Axial Piston Pumps Page 2-11
While the working

principle is basically the
same, piston pumps
with the input shaft and
cylinder block on the
same axis, and with a
swash plate installed to
it, are called SWASH Swash Plate Type
PLATE TYPE.
Those which have the

input shaft and cylinder
block at an angle are
called ANGLED AXIAL
TYPE.
Angled Axial Type

09/02
Swash Plate Type Axial Piston Pump Page 2-12
The pistons are installed

to the swash plate.
The input shaft and Pistons move as
cylinder block are on the cylinder rotates
same axis. The cylinder
is installed on the input
Cylinder Input shaft
shaft.
Discharge
The inclination of the
swash plate causes the
piston to move back and
forth for repeated
suction and discharge of
oil, which results in a
pumping action. Suction Inclination of
swash plate

09/02
Hydraulic Control Valve Page 2-13
The hydraulic
control valve
controls the action
of various
hydraulic
equipment.
These valves are

combined and are
installed as a
combined valve
(Control Valve)

09/02
The hydraulic
control valve
controls the action
of various
hydraulic
equipment.
These valves are

combined and are
installed as a
combined valve
(Control Valve)

09/02
The hydraulic
control valve
controls the action
of various
hydraulic
equipment.
These valves are

combined and are
installed as a
combined valve
(Control Valve)

09/02
The hydraulic
control valve
controls the action
of various
hydraulic
equipment.
These valves are

combined and are
installed as a
combined valve
(Control Valve)

09/02
The hydraulic
control valve
controls the action
of various
hydraulic
equipment.
These valves are

combined and are
installed as a
combined valve
(Control Valve)

09/02
The hydraulic
control valve
controls the action
of various
hydraulic
equipment.
These valves are

combined and are
installed as a
combined valve
(Control Valve)

09/02
The hydraulic
control valve
controls the action
of various
hydraulic
equipment.
These valves are

combined and are
installed as a
combined valve
(Control Valve)

09/02
Relief Valve and Safety Valve Page 2-20
Controls the
pressure of oil.
A safety valve
releases circuit
pressure when it
reaches an
abnormal level.
(Installed between
control valve and
cylinder.)

09/02
Controls the
pressure of oil.
A safety valve
releases circuit
pressure when it
reaches an
abnormal level.
(Installed between
control valve and
cylinder.)

09/02
Controls the
pressure of oil.
If oil is sent
continuously, even
when cylinder is at
stroke end or if it
stops moving due
to excessive load,
pressure will keep
increasing until
hose ruptures.

09/02
Controls the
pressure of oil.
This is the valve

which releases the
oil totally or
partially to control
the pressure
under such
circumstances.
(Installed between
pump and control)

09/02
Hydraulic Cylinder Page 2-24
A hydraulic cylinder
converts hydraulic power
to linear motion.
A hydraulic cylinder is
comprised of a piston,
a rod, and a cylinder.
Piston Rod
The oil sent from the
Cylinder
pump into cylinder
pushes piston.
The rod is pushed
together to move the
work equipment.

09/02
Hydraulic Cylinder Page 2-25
A hydraulic cylinder
converts hydraulic power
to linear motion.
Entering oil alternately

to inlet and outlet for oil,
causes piston to
reciprocate. Oil sent
from pump

09/02
Hydraulic Motor Page 2-26
Converts hydraulic
oil to rotating motion.
It is the hydraulic
motor that receives
hydraulic pressure
from the pump and
performs rotational
motion.

09/02
Converts hydraulic
With the hydraulic

pressure sent from
the pump through Pressure
the port block, oil
rotational torque is
output from the
output shaft and
transmitted.

09/02
Converts hydraulic
Controlling the
swash plate Output shaft
inclination enables Piston Swash plate
variable motor
output (rotation and
torque)

09/02
Hydraulic Oil Tank Page 2-29
Duties of the
hydraulic tank:
Disperses heat
generated in the
hydraulic system
Replenishes oil
reduced by
leakage and
settling dust and
rust in worked oil.

09/02
Swivel Joint Page 2-30
The joint that is not

twisted if rotated.
The swivel joint

connects the piping
between swinging and
stationary parts, as
seen in the case of a
hydraulic excavator.

09/02
Swivel Joint Page 2-31
The joint that is not

twisted if rotated.
Rotor
The swivel joint

consists of a shaft and Oil from
rotor, either of which control
rotates together with valve
swinging side. Oil
returning
On the periphery of the to tank
Port
shaft, the grooves are
provided in a required
Shaft
number of connections
to be made in order for
oil to enter and exit. From undercarriage
To undercarriage

09/02
Types of Hydraulic Systems Page 2-32
OPEN CENTER
LOAD SENSING SYSTEM
CLOSED CENTER
LOAD SENSING SYSTEM

Electronic-Open Center Load

Sensing Hydraulic System
E-OLSS

KS900202
09/02
E-OLSS Hydraulic System Page 2-34
The PC600-6 and larger excavators uses the field proven E-OLSS (Electronic - Open
center Load Sensing System) hydraulic system. This system has proven itself to be
powerful, as well as fuel efficient, and provides the operator with the following features.
Working Modes
DH: High pressure and speed Hydraulic
H: High production S S
Electrical
G: Fuel efficient production Engine Hydraulic

pump
Control
valve
NC Control: Neutral loss control,
Hydraulic Control
for precise operation pump valve
CO Control: Relief loss control S S
CO Control Cancel: For faster NC NC

operations CO CO Cut-off cancel
Auto Deceleration TVC Pump absorption torque

Heavy Lift Mode valve control (delivery amount)
2-Stage Boom Push Force Monitor
Straight Travel Control lever

Working mode
Shockless Boom Control

Swing Priority
Automatic Hi-Lo Travel Speed
Mode setting
Shifting
09/02
Why OLSS and not CLSS Page 2-35
Large machines are mostly used for digging and loading, where emphasis
is placed on power and speed. Furthermore, fuel consumption is a major
concern for the large machine owner. As a result, OLSS is used because
it meets both the power/speed and efficiency needs. In addition, the
OLSS hydraulic system has a long history of dependability in this market.
Emphasis on
Speed and Fuel
Consumption
(Not Precise Control and

Compound Operations as
with small/medium
machines.)

09/02
How OLSS Works Page 2-36
OLSS works with five devices to

control oil loss while maintaining Jet Sensor Jet Sensor
maximum speed, power, and Control Valve
efficiency. As a result the
pumps are not overworked and
neutral flow loss is minimized. Front Rear
Pump Pump
The five devices used are:
SERVO VALVE - controls
Servo Valve Servo Valve
swash plate angle of the main
>
>
pump. NC Valve NC Valve
TVC VALVE - provides work
>
>
mode capabilities and prevents
pumps from stalling the engine. > CO Valve CO Valve <
CO VALVE - controls flow as < >
system nears relief pressure. TVC Valve
NC VALVE - controls neutral Charging
loss and flow during fine
Controller > < pump
control.
JET SENSOR - signals NC
valve.
09/02
2-Pump, 2-Valve System Page 2-37
The 3-pump, 3-valve (3P3V) system used on the PC650-5 has been
changed to a 2-pump, 2-valve (2P2V) system on the PC600-6.
PC600-6 PC650-5
2-PUMP 2-VALVE E-OLSS 3-PUMP 3-VALVE E-OLSS
M M
TRAVEL(R) SWING TRAVEL(R) SERVICE SWING
BOOM BOOM BOOM BOOM

BUCKET ARM BUCKET ARM
ARM BUCKET ARM BUCKET
TRAVEL(L) TRAVEL(L)
BOOM CYLINDER BOOM CYLINDER
ARM CYLINDER ARM CYLINDER
BUCKET CYLINDER BUCKET CYLINDER

TRAVEL TRAVEL SWING TRAVEL TRAVEL SWING
MOTOR MOTOR MOTOR MOTOR MOTOR MOTOR
(R) (L) (R) (L)

09/02
Why Use 2P2V System Page 2-38
Emphasis on Speed and Reliability

The PC600-6 was designed to provide greater production
and efficiency. The technically advanced 2P2V system
provides superior swing performance over the 3P3V
(independent swing) system.
In addition, with the 2P2V system the swing pump can

back-up the work equipment when the swing circuit is not
being used. This gives the PC600-6 its increased speed
and force during the digging cycle. Furthermore, the
hydraulic system has been simplified, thereby lowering the
opportunities for oil leaks and pressure loss.

09/02
Filtration Page 2-39
An ultra clean hydraulic

system is used to reduce
down-time. The High
Pressure, In-Line Filter is
used to guard against debris
in the unlikely event of a
major hydraulic failure.
Komatsu is the only
manufacturer to provide 3
levels of protection as
standard equipment.
Other filters such as the
suction strainer, a Hybrid 8
micron return filter, and PPC
A 100 micron screen
filter are used to ensure a
clean running hydraulic
system.

09/02
Machines with E-OLSS Hydraulic Page 2-40
Systems
PC600LC-6
PC1250LC-7
Closed Center Load Sensing

Hydraulic System
CLSS

KS900202
09/02
Basics of Hydraulics Page 2-42
Hydraulics can be broken down into three main principles:

FLOW - determines the speed of the work equipment.
The speed of work equipment is determined by the amount of pump flow.
The greater the pump flow the greater the speed.
Lesser pump flow creates slower speeds.
Pump flow rate is determined by the pump swash plate angle and engine/pump
rpm.
PRESSURE - determines the amount of force the work equipment can exert on an
object.
Pressure is determined by resistance up until maximum relief pressure is reached.
Resistance can come in two forms
Flow rate and size of port the oil must travel through (restriction).
Amount of resistance the work equipment meets.
When maximum relief pressure is reached the machine cannot exert any more
force and the work equipment stops in order to prevent system damage.
POWER - combination of FLOW and PRESSURE.
09/02
Basic Principle of HydrauMind Page 2-43
1. Speed = Stroke
Pump delivery is proportional to lever
stroke giving the operator control over the
speed of the equipment.
2. Consistent Compound Operations

Equipment speed is consistent even if the
load changes in one actuator circuit.

09/02
Speed = Stroke Page 2-44
Pump delivers oil in proportion to lever stroke due to the LS Valve (Load Sensing).
The LS Valve is designed to keep a +20 kg/cm2 pressure differential on the pump
side of the control valve. In this way the operator controls speed not the load.
Valve Stationary Valve Opened Valve Closed
With no movement of valve When the operator opens the When the operator closes
system stays balanced with valve more, the +20 kg/cm2 the valve more, the +20
+20 kg/cm2 on pump side. differential drops and the LS kg/cm2 differential increases
Valve increases pump flow to and the LS Valve decreases
increase the pressure pump flow to decrease the
differential. pressure differential.

09/02
Clean Hydraulic System Page 2-45
This is a representative drawing of a Komatsu Hydraulic system.

09/02
Benefits of Speed = Stroke Page 2-46
The benefits of Speed = Stroke Full power even during fine control operations
are: Smoothing operations are easy and consistent
The lever movement
provides direct and
consistent equipment speed.
The operator controls speed,
not the load.
There is less feathering of
controls during operations,
making work easier.
Attachment movements are smooth and powerful Pipes are moved with minimal sway and
greater control
09/02
Consistent Compound Operations Page 2-47
Pressure Compensating Valves are used to keep system pressure constant

when the load is uneven. As a result, one function does not over power the
other and the work equipment moves smoothly.
valve
When the loads are even the When the loads are uneven the Pressure
Pressure Comp. Valves are inactive Comp. Valves are activated and suppress
because system pressure is even. the flow on the lighter side.
09/02
Benefits of Pressure Compensation Valve Page 2-48
Automatically balances the system Equipment moves at consistent

speeds even with multi-function
flow when using several functions at
attachments
one time.
The operator does not
compensate for the machine,
rather the machine automatically
compensates itself.
Reduces operating effort and
operator fatigue thus increasing
productivity.
Buckets load easier and retain load longer

Greater control under full power for easier operation
Shaking reduced by eliminating overcompensation

09/02
Exclusively HydrauMind Page 2-50
This is a representative drawing of a Komatsu Hydraulic system. Pressure

Compensating Valve
Automatically adjusts
pressure between
circuits being used, to
control loads.
LS (Load Sensing)
Valve
Tells the pump when to
stroke and destroke to
maintain a constant
differential pressure
between pump side and
actuator side of the
control valve. Signals
servo valve to change
pump displacement.
LS EPC Valve Pump Merge/Divide LS Select Valve LS Bypass Valve

Enhances fuel efficiency Valve Increases ease of Improves dynamic
by receiving signals from Improves cycle time and operation when using stability during operation
the governor and pump fuel efficiently by merging swing with the work by relieving residual
controller and then or separating the 2 pump equipment. Prevents the pressure in the LS circuit.
sending a proportional flow. Divided for travel, fine high LS pressure of the
signal to the LS Valve. control, and boom up swing circuit from affecting
when swinging. other LS Circuits.

09/02
Machines with CLSS Hydraulic Page 2-51
Systems
PC200LC-7
PC300LC-6
KS900202
SEP 2002
Sales Basic Komatsu Construction Equipment &

Presentation Kit Earthmoving Principles
Components
Engines
TM & TC
Hydraulic Systems
Wheel Loaders END OF

Basics
Komatsu WL HYDRAULICS
Excavators
SECTION
Crawler Tractors
Motor Graders
Dump Trucks
Working Gear
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Sales Presentation Kit

Construction Product Lines

Basic Komatsu Construction Equipment

Characteristics of Pressure of Page 2-2

Static Fluid Pascals Law

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Transmission of Power Pascals Law

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Transmission of Power Pascals Law

will be smaller Hydraulic

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Hydraulic System Components Page 2-5

Using a hydraulic system to perform your work

Hydraulic system Controlled oil

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Hydraulic Pumps Page 2-7

A hydraulic pump is the equipment with which mechanical

Gear Vane Piston

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Rotation of a Gear Pump Page 2-8

In a gear pump oil

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Hydraulic Piston Pump Page 2-9

Reciprocating Motion of Piston Pump

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Two Types of Piston Pumps Page 2-10

There are 2 types of

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Axial Piston Pumps Page 2-11

While the working

Those which have the

Angled Axial Type

Swash Plate Type Axial Piston Pump Page 2-12

The pistons are installed

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Hydraulic Control Valve Page 2-13

These valves are

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Hydraulic Control Valve Page 2-14

These valves are

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Hydraulic Control Valve Page 2-15

These valves are

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Hydraulic Control Valve Page 2-16

These valves are

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Hydraulic Control Valve Page 2-17

These valves are

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Hydraulic Control Valve Page 2-18

These valves are

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Hydraulic Control Valve Page 2-19

These valves are

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Relief Valve and Safety Valve Page 2-20

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Relief Valve and Safety Valve Page 2-21

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Relief Valve and Safety Valve Page 2-22

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Relief Valve and Safety Valve Page 2-23