Hydraulic Tank

Section 2.2 OLSS Pumps

 DCV Construction

There are various types of DCV, in the mobile hydraulics, the spool valve
type is most common.

Spool Valve
It provides good control, metering and cushioning by notches and
Open Centre Load Sensing.
Open Centre is when the spools are in the neutral position the flow of
oil from the pump is directed back to tank at low pressure.
Section 2.2 OLSS Pumps
 Directional Control Valve - CLSS

Closed centre Load Sensing System.

(CLSS)
When all the spools are in the neutral
position, the oil pumped to the control valve
doesn’t return to tank.
The CLSS will normally have a variable
displacement pump in the system, so the
pump de-strokes in neutral and increases the
flow of oil when a hydraulic circuit is in use.

Section 2.2 OLSS Pumps

E-OLSS Hydraulic Pump.

Section 3.2

OLSS Pumps
 E-OLSS Hydraulic Pump
Introduction.
The E-OLSS (Electronic – Open centre Load Sensing System) is an energy saving
system to reduce fuel consumption by means of controlling the swash plate angle.
A Variable-displacement swash plate piston pump is used with an OLSS control valve.
For this combination to work, there is a series of valves mounted on the pump to
sense the different machine operating demands

Section 2.2 OLSS Pumps

 E-OLSS Hydraulic Pump
Effective Use of Engine
Servo valve
Horsepower
For optimum out-put of the machine, it is
important for the engine to maintain a
set speed. CO, NC Valve
As the load in the hydraulic system
changes, the discharge amount from
the pump needs to be adjusted.
The valves mounted on the hydraulic
pump that sense the change in
working conditions are:
1. Servo Valve.
2. CO valve (Cut-Off control)
3. NC valve (Neutral control).
4. TVC valve (Torque Variable Control)
TVC Valve
All the pump control valves and
servo piston are operated by Servo piston

charge pump pressure.

Section 2.2 OLSS Pumps
 E-OLSS Hydraulic Pump

Servo valve

Servo piston

CO, NC Valve

TVC Valve

Section 2.2 OLSS Pumps

 E-OLSS Hydraulic Pump

Servo Valve.
The Servo Valve controls the pump output (oil amount) from the signals
received from TVC, CO and NC valves.
The arm is connected into the servo piston and senses the servo piston
position, this will allow the pump to discharge the oil volume amount
corresponding to signal pressure.

Guide Spool

Control Piston
Arm

Section 2.2 OLSS Pumps

 Servo Valve.
Increase Pump Discharge.
As signal pressure of NC valve
(pecn) increases, it pushes
Control Piston (8) to left by Hyd.
Pressure in chamber c. Control
Piston stops where it balances
with force of springs (4) and
(4A).
At the same time arm (6) uses
servo piston (19) as a fulcrum,
pushing Guide Spool (13) to the
Left.
The movement of Guide Spool
will open charge pressure
supply Port (a) to port (h),
pushing servo piston (19) to
increase pump discharge.
At the same time servo piston
chamber (f) port is connected to
drain port through port (d).
Because of servo piston
movement, the arm (6) will move
the Guide Spool (13) to the right
closing off Port (a) to (h).
Matching Pump output to pecn
signal
Section 2.2 OLSS Pumps
 Servo Valve

Decrease Pump Discharge.

When signal pressure

(pecn) drops, springs (4) &
(4A) push control piston (8)
right. control piston stops
where spring force and
signal are balanced with
each other.
At the same time, arm (6)
uses servo piston as a
fulcrum, pushing guide
spool to the right.
The movement of guide
spool will close charge
pressure supply port (a) to
port (h), opening servo
piston (j) chamber to drain
through guide spool (13).
At the same time, servo
piston chamber (f) and port
(d) are connected to
charge pump pressure port
(a), decreasing pump
discharge.
Section 2.2 OLSS Pumps
 TVC Valve

TVC Valve.
TVC (Torque Variable Control) Valve ensures that pump absorption
torque doesn’t exceed the engine output by monitoring the output
of all HPV pumps. It also changes the working mode depending on
the signal from the monitor panel (DH,H & G) to the TVC solenoid.

Section 2.2 OLSS Pumps

 TVC Valve
Load is Small.
The TVC valve senses the
pressure in all the pumps. when
pressure or load increases, the
pump discharge is reduced by
reducing the charge pressure
(Pe) to the servo valve.
The command current from the
TVC solenoid pushes pin (9), and
pressure from all pumps act on
the underside of the two TVC
spools.
At this moment, the pumps
pressures combined with
solenoid pressure are not strong
enough to overcome spring (1).
As a result port (a) and ports (b)
is completely open, allowing a
good flow of signal pressure to
the servo valve.
In this position, the pump
discharge becomes maximum.

Section 2.2 OLSS Pumps

 TVC Valve

Load is Large.
As pump pressure (load) increases,
this pushes against spring (1).
Moving TVC spool up until it
balances with force of spring (1),
closing the flow from port (Psv) to
port (Pe).
As a result, the flow of oil to the
servo piston is throttled.
Main pump discharge is decreased.
The TVC valve maintains a constant
pump absorption torque. So TVC out
put pressure (Pe) is controlled by
pump discharge pressure.

Section 2.2 OLSS Pumps

 CO and NC Valve

CO (Cut Off) valve, when the load

becomes large during
operation and the main pump
discharge pressure raises to a
point close to relief pressure,
the Cut Off valve acts to reduce
pump discharge in order to
reduce relief loss.
CO Valve
NC (Neutral Control): Reduces
pump output during fine
control or when all levers are in NC Valve
neutral. The signal is received
from the jet sensors.

Section 2.2 OLSS Pumps

 CO Valve

Load is Small
Currently the pump
output pressure is not
close to main relief
pressure.
So spring (3) is able to
push CO spool (4) fully
open allowing signal
(Pec) to flow to servo
valve via NC valve and
maximum pump
discharge occur.

Section 2.2 OLSS Pumps

 CO Valve

Mains Pressure
Close to Relief
If the load (pressure)
3 increases and main
pump discharge
pressure comes close to
main relief
pressure,There is
enough force in chamber
(5) to push CO spool (4)
up against spring (3).
This will throttle port
(Pe) to port (Pec) and
port (c) is opened,
allowing signal pressure
to drain to tank.
Pump discharge amount
becomes minimum.

Section 2.2 OLSS Pumps

 CO Valve

Cut Off Cancel.

When the heavy lift
solenoid is activated, this
will direct charge pressure
to port (Pc).
Pushing down on piston (2),
stopping the pump
pressure from closing off
(Pec) signal when pump
discharge pressure goes up
to main relief pressure.
As a result the pump
discharge remains at a
maximum at relief pressure.

Section 2.2 OLSS Pumps

 CO Valve.

Cut Off Cancel Function.

With a combination of Two Stage relief and CO cancel function ON this will increase the
boom lifting power by approximately 10 %.

Section 2.2 OLSS Pumps

 NC Valve
Levers in Neutral
The NC valve controls the
main pump discharge
amount according to the
amount that the control
valve spool is operated.
This flow control function
reduces the neutral loss and
fine control.
The Jet Sensor picks up the
flow of oil returning to the
tank through the control
valve.
When levers are in neutral,
the differential pressure in
the Jet Sensor becomes
maximum.
(Pt) pressure pushing on
piston (10) becomes larger
than spring tension (12).
As a result closing off port
(Pec) to port (Pecn)

Section 2.2 OLSS Pumps

 NC Valve

Control Levers are

Operated.
When the control valve is
moved, the Jet Sensor
differential pressure goes
down in accordance with
movement of the control
valve.
The pressure (Pt) is no
longer strong enough to
push down on NC spool (11)
and on the spring.
Therefore, NC spool (11)
moves up by spring force
and opens port (Pec) to port
(Pecn).
As a result, the servo piston
receives the signal to
increase pump discharge.

Section 2.2 OLSS Pumps

 E-OLSS Hydraulic Pump

End of
E - OLSS

Section 2.2 OLSS Pumps

E-OLSS: Control Valve.

Section 3.3

OLSS Pumps
 E-OLSS Control Valve

Control Valve.
The valve is a Open centre Load
Sensing System with the jet sensors
installed into the control valve.
Jet Sensors detect the flow of return
oil passing through the control valve
and returning to tank. The two
pressures Pt and Pd are sent to the
NC valve.
The main relief valve maintains
maximum work pressure.
Built into the control valves are the
straight travel, arm throttle and swing
priority valves.

Section 2.2 OLSS Pumps

 E-OLSS Control Valve

1
2

10 9

Section 2.2 OLSS Pumps

 E-OLSS Control Valve

Section 2.2 OLSS Pumps

 E-OLSS Control Valve
Jet Sensors: Levers in Neutral
Oil carry over from the control valve flow through the jet sensors.
When levers are in the neutral position, there is a small flow from the pump returning to
tank.
The jet stream coming out of the Jet Sensor Orifice is uninterrupted filling Pt sense line
back to NC valve.

Jet Sensor Out-put

Pressure Pt Jet Sensor Out-put
Pressure Pd

Jet Stream

Orifice

Section 2.2 OLSS Pumps

 E-OLSS Control Valve
Jet Sensors: Levers Operated.
As the machine starts to operate, the oil flow in the control valve increases.
When the differential pressure
Pt – Pd reaches 15 Kg/cm2 (at 40 l/min) the relief valve opens.
Now almost all the carry over oil (Qc) is being discharged through the relief valve.
A small amount is passing through Jet Sensor Orifice.
Pt (Jet Sensor
output pressure)

Pt
Pd (Back pressure)

Pd

Pump
pressure Qc

Section 2.2 OLSS Pumps

 E-OLSS Control Valve

Straight Travel Valve

The straight travel valve is installed into
the control valve.
It acts to prevent travel deviation in the
direction of travel if the boom, arm, or
bucket are operated when the machine is
traveling.

Section 2.2 OLSS Pumps

 E-OLSS Control Valve

Straight Travel Valve

Travel operating
Independently
The straight travel solenoid is de-
energized, so no pilot pressure is
flowing to the spool (6) .
Ports P1 (Right travel circuit) and P2
(Left travel circuit) are not connected.
So each circuit remains independent.

Section 2.2 OLSS Pumps

 E-OLSS Control Valve

Straight Travel Valve

When travel and work

equipment are operated
together.
The straight travel solenoid is
excited and pilot pressure is flowing
to RH of spool (6), pushing it across
to the left.
Ports P1 and P2 are now
interconnected so the same amount
of oil is delivered to both travel
motors evenly.
This prevents travel deviation.

Section 2.2 OLSS Pumps

 E-OLSS Control Valve

Section 2.2 OLSS Pumps

 E-OLSS

End of
E - OLSS

Section 2.2 OLSS Pumps

E-OLSS: Swing Motor.

OLSS Pumps
 Swing Motor

Swing Motor

Section 2.2 OLSS Pumps

 Swing Motor

Swing Motor

Section 2.2 OLSS Pumps

 Swing Motor

Swing Motor
Operation of swing brake

-When swing brake solenoid

Valve is de-energized.
SWING
LOCKED

Solenoid
Deactivated

Section 2.2 OLSS Pumps

 Swing Motor

Swing Motor
Operation of swing brake

-When swing brake solenoid

Valve is energized.

SWING LOCK
RELEASED

Solenoid
Activated

Section 2.2 OLSS Pumps

 Swing Motor

Section 2.2 OLSS Pumps

 Swing Motor

Section 2.2 OLSS Pumps

 Swing Motor

Reverse
Prevention
valve

Section 2.2 OLSS Pumps

 Swing Motor

Reverse
Prevention
valve

Section 2.2 OLSS Pumps

 END of
E-OLSS: Swing Motor.

OLSS Pumps
E-OLSS: Travel motor.

OLSS Pumps
 Travel Motor

Section 2.2 OLSS Pumps

 Travel Motor

Section 2.2 OLSS Pumps

 Travel Motor

Relief Valve

Section 2.2 OLSS Pumps

 Travel Motor

Travel speed
selector Valve

Section 2.2 OLSS Pumps

 Travel Motor

Travel motor
internal parts

Section 2.2 OLSS Pumps

 Travel Motor

Parking Brake

Section 2.2 OLSS Pumps

 Travel Motor

Parking Brake

Section 2.2 OLSS Pumps

 Travel Motor

Parking Brake

Brake release
Tank port
line

Section 2.2 OLSS Pumps

 Travel Motor

Parking Brake

FORWARD traveling

To
To Travel Release
Motor Brake

Section 2.2 OLSS Pumps

 Travel Motor

Parking Brake REVERSE traveling

To Travel To
Motor Release
Brake

Section 2.2 OLSS Pumps

 Travel Motor

Counter-Balance
valve

Section 2.2 OLSS Pumps

 Travel Motor

Location
Operation
-On travel
1- When Suction Counterbalance
safety valve valve
pressure oil Motor
is supplied

Section 2.2 OLSS Pumps

 Travel Motor

Descending Downhill or stopping

Section 2.2 OLSS Pumps

 Travel Motor

Operation
2- When
descending
downhill or
stopping

Section 2.2 OLSS Pumps

 Travel Motor

Section 2.2 OLSS Pumps

 Travel Motor

Section 2.2 OLSS Pumps

 Travel Motor

Section 2.2 OLSS Pumps

 END of
E-OLSS: Travel motor.

OLSS Pumps
 E-OLSS:
PPC
& SOLENOIDS

OLSS Pumps
 WORK EQUIPMENT PPC

Section 2.2 OLSS Pumps

 WORK EQUIPMENT PPC

PPC CIRCUIT IN HYDRAULIC CIRCUIT DIAGRAM B ,C,D & E

Parts and ports

1 3 F
4
T

Section 2.2 OLSS Pumps

 WORK EQUIPMENT PPC

PPC ACCUMULATOR

Section 2.2 OLSS Pumps

 WORK EQUIPMENT PPC

VALVE CONTROL

Section 2.2 OLSS Pumps

 WORK EQUIPMENT PPC

WORK EQUIPMENT, SWING PPC

VALVE

Section 2.2 OLSS Pumps

 WORK EQUIPMENT PPC

PPC OPERATION:
1) At Neutral

Section 2.2 OLSS Pumps

 WORK EQUIPMENT PPC

PPC OPERATION:
2) Fine control
(Partial movement)

Section 2.2 OLSS Pumps

 WORK EQUIPMENT PPC

PPC OPERATION:
3) Fine control
(Full stroke)

Section 2.2 OLSS Pumps

 Travel PPC

Section 2.2 OLSS Pumps

 Travel PPC

Section 2.2 OLSS Pumps

 Travel PPC

Section 2.2 OLSS Pumps

 SOLENOIDS

Section 2.2 OLSS Pumps

 SOLENOIDS

Section 2.2 OLSS Pumps

 SOLENOIDS

Section 2.2 OLSS Pumps

 END of
E-OLSS:
PPC
& SOLENOIDS

OLSS Pumps
E-OLSS: Electronic Control

OLSS Pumps
 E-OLSS: Electronic Control

Pump Controller.
The controller receives the input signals, processed these internally and sends
output signals to the TVC solenoid and ON/OFF solenoids.

Electrical Connector
Blocks

Section 2.2 OLSS Pumps

 E-OLSS: Electronic Control

Input and Output Signals

Section 2.2 OLSS Pumps

 E-OLSS: Electronic Control

Electronic – OLSS
(Pump Control System)
When load on the pump rises and the
pressure rises, the pump
discharge amount is reduced and
the engine speed is controlled so
that it becomes close to the rated
speed.

Inputs
1. Monitor panel.
2. Speed sensor.
3. Fuel throttle.
4. PPC pressure switches.
5. Engine controller

Outputs

1. TVC solenoid

Section 2.2 OLSS Pumps

 E-OLSS: Electronic Control

Working Mode Selection

The combination of the 4 level working mode
and 3 level power set makes it possible to
choose a pump absorption torque
corresponding to the nature of the work, so it
is possible to use the engine more effectively
while also reducing fuel consumption

Section 2.2 OLSS Pumps

 E-OLSS: Electronic Control

PEMC System
(Pump and Engine Mutual
Control System)
The PEMC system has total
control over the pump and
engine outputs.
To give a higher level of both
power and fuel economy.

Section 2.2 OLSS Pumps

 E-OLSS: Electronic Control

TVC and Swing Lock Prolix

Switches
If there is a failure in the pump
controller, the Prolix Switches can
be switch on to by-pass the
controller. They can be activated
individually.
When the prolix switch to the TVC
solenoid is on, a current is
supplied through a resistor, the
signal becomes constant so the
force pushing the TVC valve is
constant. There is no pump
sensing.
The swing lock solenoid will
receive a constant current, this will
release the swing brake all the
time.

Section 2.2 OLSS Pumps

 E-OLSS: Electronic Control

Prolix Switch ON
If there is a failure in the
pump controller, the Prolix
Switch can be switched ON
to switch to the resistor side,
by passing the controller.

When this is done, the pump

absorption becomes
constant.
The TVC output is controlled
by the (Pe) pressure.
There is no pump sensing.

Section 2.2 OLSS Pumps

 E-OLSS: Electronic Control

Travel Speed Selector

Function.
To maintain the draw bar pull when
traveling the Cut Off is canceled and main
relief is raised .
Travel speed is selected on the monitor
panel. When high speed is selected the
controller will energize the Travel Speed
Solenoid Valve.

Section 2.2 OLSS Pumps

 E-OLSS: Electronic Control

Swing Control
Function.
Swing lock brake is applied
when not swinging. this
prevents drift.
When the swing lever is
operated, the PPC pressure
switch sends a signal to the
controller that swing is in use.
Controller will release the
swing brake by sending a
current to the Swing Parking
Brake Solenoid valve.
Hydraulic power will release
the park brake actuator.
If an abnormality should occur
in the controller, the swing
brake can be released by the
Swing Lock Prolix switch.
When the Swing Lock Prolix
switch is ON, the swing brake
is not canceled.

Section 2.2 OLSS Pumps

 E-OLSS: Electronic Control
Text

Section 2.2 OLSS Pumps

 E-OLSS: Electronic Control

End of
E – OLSS:
Electronic Control

Section 2.2 OLSS Pumps

 TVC Valve

Flow (L/min) X pressure (bar)

Pump horsepower absorption HP=
448
4 piston pumps Pilot pump PTO Lub. pump
490 x 320 x 2 136 x 30 16 x 30
HP =
450
+ + 707 > 454
450 450

Section 2.2 OLSS Pumps