SECTION 3

COMPONENT OPERATION

—CONTENTS—
Group 1 Pump Device Group 4 Pilot Valve
Outline .....................................................T3-1-1 Outline .....................................................T3-4-1
Main Pump ...............................................T3-1-2 Operation .................................................T3-4-2
Regulator .................................................T3-1-4
Pilot Pump................................................T3-1-6 Group 5 Travel Device
N Sensor (Engine Speed Sensor) .............T3-1-6 Outline .....................................................T3-5-1
P Sensor Travel Reduction Gear..............................T3-5-2
(Pump Delivery Pressure Sensor) ...........T3-1-6 Travel Motor .............................................T3-5-3
A Sensor Travel Brake Valve ...................................T3-5-5
(Pump Displacement Angle Sensor) ......T3-1-6 Travel Motor Displacement
Angle Shift ..............................................T3-5-7
Group 2 Swing Device Parking Brake...........................................T3-5-9
Outline .....................................................T3-2-1
Swing Motor .............................................T3-2-2 Group 6 Others (Upperstructure)
Valve Unit .................................................T3-2-4 Pilot Shut-Off Valve ..................................T3-6-1
Swing Parking Brake ................................T3-2-6 Shockless Valve .......................................T3-6-2
Swing Reduction Gear..............................T3-2-7 Solenoid Valve Unit ..................................T3-6-3
Accumulator .............................................T3-6-4
Group 3 Control Valve
Outline .....................................................T3-3-1 Group 7 Others (Undercarriage)
Hydraulic Circuit .......................................T3-3-6 Swing Bearing ..........................................T3-7-1
Flow Combiner Valve................................T3-3-8 Center Joint..............................................T3-7-2
Pump Control Valve..................................T3-3-9 Track Adjuster ..........................................T3-7-3
Main Relief Valve.................................... T3-3-11
Overload Relief Valve .............................T3-3-12
Make-Up Valve .......................................T3-3-12
Holding Valve .........................................T3-3-13
Arm Regenerative Valve ......................... T3-3-14

167T-3-1
(Blank)

167T-3-2
 COMPONENT OPERATION / Pump Device
OUTLINE
The pump device consists of a transmission, two main The pilot pump is a gear pump which supplies pres-
pumps, and a pilot pump. sure oil to the pilot circuit.
According to the gear ratio of each power train, the
transmission distributes engine power to the output
shafts, driving the pumps. The gear ratio of the engine
to the main pump is 1:0.849. The gear ratio of the en-
gine to the pilot pump is 1:1. In addition, the transmis-
sion is lubricated by engine oil.
The two main pumps, which are variable displacement,
bent axis type axial plunger pumps, supply high pres-
sure oil to the hydraulic cylinders and motors via the
main circuit. Each main pump is equipped with a regu-
lator controlling the delivery rate .

Main Pump 1
Pilot Pump

Transmission
Regulator Main Pump 2

Regulator
T167-01-02-003

T3-1-1
 COMPONENT OPERATION / Pump Device
MAIN PUMP
The main pumps supply high pressure oil to operate
the main hydraulic components such as the hydraulic
cylinders and motors.
The main pump shaft is connected to the cylinder
block through seven plungers. As the shaft rotates, the
cylinder block rotates, reciprocating the plungers to
draw and discharge hydraulic oil.

Engine power is transmitted to the shaft and seven

plungers, rotating the cylinder block. Consequently, the
cylinder block end slides along the surface of the valve
plate.
The plungers reciprocate in the bores of the cylinder
block, drawing and discharging hydraulic oil.

Cylinder Block

Plunger

Shaft

Valve Plate
Regulator

T116-02-03-002

T3-1-2
 COMPONENT OPERATION / Pump Device
Increasing And Decreasing Main Pump Oil Flow
Rate

When the displacement angle of cylinder block (3) is When servo piston (6) is moved up or down, valve
changed, the stroke length of plunger (2) changes. plate (4) moves too, changing the displacement angle
Thus, oil flow rate of the main pump is controlled by of cylinder block (3); cylinder block (3) is kept in con-
changing the displacement angle of cylinder block tact with the surface of valve plate (4) and slides along
(3). Servo piston (6) is jointed to valve plate (4) with it.
pin (5).

Maximum displacement angle

2
2

3 T105-02-03-021
5
3
Minimum displacement angle 4
T116-02-03-003

T105-02-03-022

2 - Plunger 4 - Valve Plate 5 - Pin 6 - Servo Piston

3 - Cylinder Block

T3-1-3
 COMPONENT OPERATION / Pump Device
REGULATORS
Each main pump is equipped with a regulator to con- When the pilot pressure acting on servo spool (2)
trol pump oil flow rate so as not to exceed engine overcomes spring KS (3), servo spool (2) moves up-
horsepower. wards. As a result, Iarge chamber (6) is connected to
Each regulator is equipped with pump control pro- the hydraulic oil tank line, decreasing the pressure in
portional solenoid valve (1). The pump flow control large chamber (6).
pressure varies in proportion to an electrical current Consequently, servo piston (4) is moved downwards by
value supplied from the controller (PVC) to pump the pressure in small chamber (7), increasing the
control proportional solenoid valve (1). Subsequently, pump displacement angle, thus increasing pump flow
the regulator changes the pump displacement. rate. As servo piston (4) moves downwards, compres-
sion of control spring KL (5) decreases, decreasing the
When the electrical current supplied to pump spring force acting on servo spool (2).
control proportional solenoid valve (1) is in- The position of servo piston (4) is determined by the
creased (Flow rate increase operation): balancing of the secondary pilot pressure from pump
control proportional solenoid valve (1), control spring
The pilot pressure from pump control proportional KL (5), and spring KS (3).
solenoid valve (1), which is acting on servo spool (2),
increases.
1 2
3

Pilot Pressure

Increasing Pump
Displacement Angle
Pump Flow Rate
7

T116-02-03-004

1 - Pump Control 3 - Spring KS 5 - Control Spring KL 7 - Small Chamber

Proportional Solenoid
Valve
2 - Servo Spool 4 - Servo Piston 6 - Large Chamber

T3-1-4
 COMPONENT OPERATION / Pump Device
When the electrical current supplied to pump
control proportional solenoid valve (1) is de-
creased (Flow rate decrease operation):

The pilot pressure from pump control proportional so- However, servo piston (4) moves upwards due to the
lenoid valve (1), which is acting on servo spool (2), difference in pressure receiving areas between the
decreases. Consequently, spring KS (3) moves servo large and small chambers, decreasing the pump dis-
spool (2) downwards. The pump delivery oil or the pilot placement angle. Consequently, control spring KL (5)
pressure is led to both large and small chambers. is compressed, increasing the force acting on servo
spool (2). The position of servo piston (4) is deter-
mined by the balancing of the secondary pilot pressure
from pump control proportional solenoid valve (1), con-
trol spring KL (5), and spring KS (3).
1 2
3

Pilot Pressure

Decreasing Pump
Displacement Angle
Pump Flow Rate
7

T116-02-03-005
1 - Pump Control 3 - Spring KS 5 - Control Spring KL 7 - Small Chamber
Proportional Solenoid
Valve
2 - Servo Spool 4 - Servo Piston 6 - Large Chamber

Pump Displacement Angle Detection Function

The regulator is equipped with a displacement angle

sensor (A sensor). The displacement angle sensor (A
sensor) detects the pump displacement angle and
sends it as a signal to the controller (PVC).

T3-1-5
 COMPONENT OPERATION / Pump Device
PILOT PUMP
2 1
Drive gear (1) is rotated by the transmission, rotating
driven gear (2).

1 - Drive Gear 2 - Driven Gear

T137-02-03-005
N SENSOR (ENGINE SPEED SENSOR) 3

The N sensor detects engine speed. (This engine

speed data is used for various controls.)
The N sensor is installed close to the tips of the
flywheel gear teeth, detecting the number of gear teeth
passing under the N sensor tip. The detected number 4
is converted to electrical signals.

3 - N Sensor 4 - Gear (Teeth)

T162-03-01-009
P SENSOR (PUMP DELIVERY PRESSURE
SENSOR)
The P sensor detects pump delivery pressure. (This
data is used for various controls.)
Pump delivery pressure is exerted on diaphragm (8).
Electrical signals proportional to the extent of
diaphragm deformation are sent the controller.

5 - Ground Terminal 7 - Power Source (5 V) 5 6 7 8

6 - Output Terminal 8 - Pressure Receiving Area
(Diaphragm) T157-02-03-010

A SENSOR (PUMP DISPLACEMENT

ANGLE SENSOR)
9
The pump displacement angle is transmitted to A
sensor (9) via lever (10). The A sensor detects
displacement angle changes as changes in electrical
resistance.
10
9 - A Sensor (Pump
Displacement Angle Sensor)
10 - Lever

T162-03-01-010

T3-1-6
 COMPONENT OPERATION / Swing Device
OUTLINE
The swing device consists of the valve unit, swing The reduction gear functions to reduce the rotation
motor and reduction gear. speed of swing motor and to increase its torque before
The swing motor is driven by pressure oil from the transmitting the rotational force from swing motor to
pump and transmits rotational force to the reduction the pinion shaft.
gear. The valve unit functions to protect the swing circuit.

Valve Unit

Swing Motor

Reduction Gear

T111-02-04-001

T3-2-1
 COMPONENT OPERATION / Swing Device
SWING MOTOR
The swing motor is a swash-plate-type axial plunger The spherical end of plunger (8) is installed in shoe (4)
motor. by a ball-and-socket joint. The shaft part of plunger (8)
The swing motor consists of shaft (6), swash plate (5), is inserted into rotor (9). Rotor (9) is installed onto shaft
shoes (4), plungers (8), rotor (9), valve plate (1), hous- (6) with a spline coupling.
ing (7), and parking brake. The parking brake is a wet-type multiple disc brake,
consisting of friction plates (2) and plates (3).

9
2
3

8 4
5

T107-02-04-012
6

1 - Valve Plate 4 - Shoe 6 - Shaft 8 - Plunger

2 - Friction Plate 5 - Swash Plate 7 - Housing 9 - Rotor
3 - Plate

T3-2-2
 COMPONENT OPERATION / Swing Device
Operational Principle

Swing speed varies depending on the amount of oil The rotational force is then transmitted to the swing
delivered from the pump. reduction gear via the shaft. As the rotor is rotated,
When pressure oil is fed into the rotor bores via port the plungers are moved to port (B) side one by one,
(A), the plungers are pushed from the top to the returning oil to the hydraulic oil tank. When pressure
bottom causing the shoes to slide along the swash oil is fed via port (B), the motor rotates in the opposite
plate, developing rotational force. direction.

Plunger

Shoe

Shaft

T142-02-02-004

T3-2-3
 COMPONENT OPERATION / Swing Device
VALVE UNIT
The valve unit consists of the make-up valve and the
relief valve.

Make-Up Valve Drain Port

When swing is stopped, the upperstructure tends to Make-Up Valve
keep rotating due to swing inertia force, causing the
Port M
swing motor to continue rotating further, and to begin
Make-Up Port
drawing oil from the pump, developing cavitation the
motor.
Relief Valve
The make-up valve draws hydraulic oil through the
port M (Make-up port) to compensate for the lack of
oil, and prevent cavitation.
Control Valve

T166-03-02-001

Relief Valve

Port M
(Make-Up Port)

Make-Up Valve

T107-02-04-004

Control Valve

T3-2-4
 COMPONENT OPERATION / Swing Device
Relief Valve
When starting or stopping swing operation, oil
pressure in the swing circuit becomes high. The relief
valve prevents the circuit pressure from rising higher
than the specified pressure. Plunger is pushed to the
left by pressure Pp at port P and pressure-receiving
area A1.
However, plunger is also pushed back to the right by
spring force and pressure Pg at chamber (g) and
pressure-receiving area A2.
Chamber (g) is connected to port P through orifice
(m). When force acting to the left is higher than that Relief Valve
to the right, the relief valve operates.

Control Valve

T166-03-02-001

g (Pg) Spring Plunger

Port P (Pp)

T107-02-04-020
A2 m A1

T3-2-5
 COMPONENT OPERATION / Swing Device
SWING PARKING BRAKE Brake is released (OFF).

The swing parking brake is a wet-type multiple disc

brake. 1
Also, the swing parking brake is a negative type, i.e. 2
the brake is released when brake release pressure is
routed into brake-piston chamber (b). b
The brake release pressure is supplied from the pilot
Brake
pump via a solenoid valve when a swing or front Release
attachment control lever is operated. (Refer to the Pressure
Valve Control in the Control System group, the
SYSTEM section.)
In cases other than above, the brake release pressure 3
is returned to the hydraulic oil tank and the swing 4
parking brake is automatically applied by spring (1). 5
6
• When the parking brake is released. (When a
swing or front attachment control lever is
T111-02-04-020
operated.)
When a swing or front attachment control lever is
operated, the controller (PVC) actuates (shifts)
the solenoid valve. As the solenoid valve is shifted, Brake is applied (ON).
the brake release pressure from the pilot pump is
routed to the brake-piston chamber (b), acting on
1
brake piston (2). As a result, plates (3) and friction
plates (4) break contact, thus releasing the swing
2
parking brake.

• When the parking brake is applied. (When the b

swing or front attachment control levers are not
operated.)
When the swing or front attachment control levers
3
are not operated, the solenoid valve does not shift.
The brake release pressure is released to the
4
hydraulic oil tank port via the solenoid valve.
From the above, friction plates (4), which are 5
engaged with the outer circumference of rotor (6), 6
and plates (3), which in turn are engaged with the T111-02-04-021

inner wall of motor housing (5), are pushed by

spring (1), coming into tight contact with each
other. Consequently, rotor (6) is secured
immovable.

1 - Spring 4 - Friction Plate

2 - Brake Piston 5 - Motor Housing
3 - Plate 6 - Rotor

T3-2-6
 COMPONENT OPERATION / Swing Device
SWING REDUCTION GEAR
The swing reduction gear is a planetary-gear-type two The motor shaft rotates first stage sun gear (9). As the
stage reduction gear. first stage reduction takes place between first stage
Both first stage ring gear (2) and second stage ring planetary gears (1) and first stage carrier (8), second
gear (4) are immovable as they are fixed to the stage sun gear (7) is rotated. Then, the second stage
housing. reduction takes place between second stage planetary
gears (3) and second stage carrier (6), before the
rotational force is transmitted to shaft (5).

10
1
9 2
8

7 3
4

T107-02-04-021

1 - First Stage Planetary Gear 4 - Second Stage Ring Gear 7 - Second Stage Sun Gear 9 - First Stage Sun Gear
2 - First Stage Ring Gear 5 - Shaft 8 - First Stage Carrier 10 - Motor Output Shaft
3 - Second Stage Planetary Gear 6 - Second Stage Carrier

T3-2-7
 COMPONENT OPERATION / Swing Device
(Blank)

T3-2-8
 COMPONENT OPERATION / Control Valve
OUTLINE
The control valve regulates oil flow rate, oil flow Right (4-spool) block: Travel (R), Bucket, Boom 1, and
direction, and oil pressure in the hydraulic circuit. The Arm 2 sections, in that order viewed from the front
main control valve consists of two blocks: the right (4- side.
spool) block and the left (5-spool) block, connected. Left (5-spool) block: Travel (L), Aux., Boom 2, Arm 1,
The main control valve is a pilot-pressure operated and Swing sections, in that order viewed from the front
type. side.
The main control valve consists of main relief valve, The pump control valve is provided on each main
pump control valve, flow combiner valve, spools, arm control valve block downstream of each block’s neutral
regenerative valve, and holding valve. passage. These pump control valves send pressure
The spool sections of the main control valve are signals to the DP sensor to control the main pump
arranged as follows: delivery rate.
Travel (R)
Front
Side Bucket
Travel (L) Boom 1
Aux. Arm 2

Boom 2 Arm Regenerative Valve

Arm 1 DP Sensor
(4-Spool Block Side)
Swing Pump Control Valve
(4-Spool Block Side)
Overload Relief Valve

Make-Up Valve 4-Spool

Block

Tank Port T2
Holding Valve (Arm)

Overload Relief Valve Tank Port T1

5-Spool
Block T167-03-03-001

DP Sensor (5-Spool Block Side)

Pump Control Valve (5-Spool

Block Side)

5-Spool Block
Make-Up Valve

Overload Relief Valve

Front Side
Holding Valve (Boom)

Shuttle Valve Main Relief Valve

Flow Combiner
Valve
T162-05-02-012
Control Valve Layout

T3-3-1
 COMPONENT OPERATION / Control Valve
Left Travel Motor 1 2 3 4 5 6 7 8 9
Right Travel Motor

Travel (L)

41 10

11
40
12
Travel (R)
13
39
38
Bucket 14
37
Aux. 15
36
35 Bucket Cylinder

16
34
Boom 2
17

Am cylinder Arm 2
Arm 1 18

Boom Cylinder

Swing
Swing Motor
19

33 32 31 30 29 28 27 26 25 24 23 22 21 20
T167-01-02-008
1 - Pump Control Valve 12 - Check Valve (Aux. Parallel 22 - Pump Control Valve 32 - Holding Valve Shift Valve
(5-Spool Side) Circuit) (4-Spool Side) (Arm)
2 - Load Check Valve (Left 13 - Load Check Valve (Boom 1 23 - Load Check Valve 33 - Overload Relief Valve
Travel Parallel Circuit) Parallel Circuit) (Arm 2 Parallel Circuit) (Arm)
3 - Load Check Valve (Aux. 14 - Overload Relief Valve 24 - Check Valve (Arm Flow 34 - Holding Check Valve (Arm)
Parallel Circuit) (Bucket) Combining Circuit)
4 - Check Valve (Bucket Flow 15 - Check Valve (Boom Flow 25 - Check Valve (Aux. Flow 35 - Make-Up Valve (Boom 2)
Combining Circuit) Combining Circuit) Combining Circuit)
5 - Check Valve (Main Relief 16 - Overload Relief Valve 26 - Arm Regenerative Flow 36 - Load Check Valve
Pressure Combining Cir- (Boom) Control Valve (Boom 2 Tandem Circuit)
cuit)
6 - Flow Combiner Valve 17 - Holding Check Valve 27 - Check Valve (Arm 1 Paral- 37 - Load Check Valve
(Boom) lel Circuit) (Boom 2 Parallel Circuit)
7 - Check Valve (Travel Flow 18 - Make-Up Valve (Arm 2) 28 - Load Check Valve 38 - Load Check Valve (Aux.
Combining Circuit) (Arm 1 Parallel Circuit) Tandem Circuit)
8 - Check Valve 19 - DP Sensor 29 - Load Check Valve 39 - Overload Relief Valve
(4-Spool Side) (Swing Tandem Circuit) (Aux.)
9 - Shuttle Valve 20 - Holding Valve Shift Valve 30 - Arm Regenerative Valve 40 - Load Check Valve (Left
(Boom) Travel Tandem Circuit)
10 - Main Relief Valve 21 - Load Check Valve (Arm 2 31 - Load Check Valve 41 - DP Sensor (5-Spool Side)
Tandem Circuit) (Arm 1 Tandem Circuit)
11 - Load Check Valve
(Bucket Tandem Circuit)

T3-3-2
 COMPONENT OPERATION / Control Valve

Swing Arm 1
Boom 2 9 10 1 41

Aux.

Left Travel
Arm 2
Boom 1
Bucket
8
Right Travel

Front Side

T162-05-02-012
7 6 T162-05-02-009

43 14 46 12 47 39
42 28

Right Travel Left Travel Bucket Aux.

40 38

11 3

2 39

T166-01-02-004

14 49 25 4 48
T162-05-02-004
45 44
42 - Right Travel Forward Port 44 - Left Travel Reverse Port 46 - Bucket (Roll-Out) Port 48 - Aux. Port
43 - Left Travel Forward Port 45 - Right Travel Reverse Port 47 - Aux. Port 49 - Bucket (Roll-In) Port

T3-3-3
 COMPONENT OPERATION / Control Valve

Left Travel Motor 1 2 3 4 5 6 7 8 9

Right Travel Motor

Travel (L)

41 10

11
40
12
Travel (R)
13
39
38
Bucket 14
37
Aux. 15
36
35 Bucket Cylinder

16
34
Boom 2
17

Am cylinder Arm 2
Arm 1 18

Boom Cylinder

Swing
Swing Motor
19

33 32 31 30 29 28 27 26 25 24 23 22 21 20
T167-01-02-008
1 - Pump Control Valve 12 - Check Valve (Aux. Parallel 22 - Pump Control Valve 32 - Holding Valve Shift Valve
(5-Spool Side) Circuit) (4-Spool Side) (Arm)
2 - Load Check Valve (Left 13 - Load Check Valve (Boom 1 23 - Load Check Valve 33 - Overload Relief Valve
Travel Parallel Circuit) Parallel Circuit) (Arm 2 Parallel Circuit) (Arm)
3 - Load Check Valve (Aux. 14 - Overload Relief Valve 24 - Check Valve (Arm Flow 34 - Holding Check Valve (Arm)
Parallel Circuit) (Bucket) Combining Circuit)
4 - Check Valve (Bucket Flow 15 - Check Valve (Boom Flow 25 - Check Valve (Aux. Flow 35 - Make-Up Valve (Boom 2)
Combining Circuit) Combining Circuit) Combining Circuit)
5 - Check Valve (Main Relief 16 - Overload Relief Valve 26 - Arm Regenerative Flow 36 - Load Check Valve
Pressure Combining Cir- (Boom) Control Valve (Boom 2 Tandem Circuit)
cuit)
6 - Flow Combiner Valve 17 - Holding Check Valve 27 - Check Valve (Arm 1 Paral- 37 - Load Check Valve
(Boom) lel Circuit) (Boom 2 Parallel Circuit)
7 - Check Valve (Travel Flow 18 - Make-Up Valve (Arm 2) 28 - Load Check Valve 38 - Load Check Valve (Aux.
Combining Circuit) (Arm 1 Parallel Circuit) Tandem Circuit)
8 - Check Valve 19 - DP Sensor 29 - Load Check Valve 39 - Overload Relief Valve
(4-Spool Side) (Swing Tandem Circuit) (Aux.)
9 - Shuttle Valve 20 - Holding Valve Shift Valve 30 - Arm Regenerative Valve 40 - Load Check Valve (Left
(Boom) Travel Tandem Circuit)
10 - Main Relief Valve 21 - Load Check Valve (Arm 2 31 - Load Check Valve 41 - DP Sensor (5-Spool Side)
Tandem Circuit) (Arm 1 Tandem Circuit)
11 - Load Check Valve
(Bucket Tandem Circuit)

T3-3-4
 COMPONENT OPERATION / Control Valve

46 24 47
42 43
Arm 2 Arm 1
Boom 1 Boom 2 26
35
18 34 32
39
27

36 21
36
20 31

37
23 28

33

17 45 15 44 T166-01-02-002
16 50 49 T167-01-02-009

19 22 50

Swing

33

52
29

T167-01-02-010 T167-01-02-011
18 51

42 - Boom 1 (Lower) Port 45 - Boom 1 (Raise ) Port 48 - Arm 1 (Roll-In) Port 51 - Swing (Right) Port
43 - Boom 2 (Lower) Port 46 - Arm 2 (Roll-Out) Port 49 - Arm 2 (Roll-In) Port 52 - Center Bypass Valve
44 - Boom 2 (Raise) Port 47 - Arm 1 (Roll-Out) Port 50 - Swing (Left) Port

T3-3-5
 COMPONENT OPERATION / Control Valve
HYDRAULIC CIRCUITS
Main Circuit Pilot Signal Circuit
Oil flow from the main pumps is routed to the 4-spool Pressure oil from the pilot pump flows through the
block and 5-spool block of the control valve. A control valve blocks, acting as pilot signals.
parallel passage is provided on both control valve When the front attachment cylinders or swing motor
blocks, making combined operations possible. are operated, the pilot pressure in the front att. pilot
The main relief valve is provided in the main circuit to signal circuit in the main control valve increases,
set the main circuit pressure to a certain level. In shifting the flow combiner valve.
addition, an overload relief valve is provided in the
boom, arm, bucket, and aux. circuits.
A pump control valve is provided downstream of
each control valve block's neutral passage.

T3-3-6
 COMPONENT OPERATION / Control Valve

Pump Control Valve

(5-Spool Block Side)

Main Relief
Valve
Travel Pilot
Signal Circuit

Overload
Relief Valve Overload Relief
Valve

Front
Att.
Pilot
Signal

5-Spool Block
Side
4-Spool
Block Pump Control Valve
Side Main Main (4-Spool Block Side)
Pump 1 T167-03-03-002
Pump 2

T3-3-7
 COMPONENT OPERATION / Control Valve
FLOW COMBINER VALVE
When a control lever, other than the travel levers, is If the travel control levers are operated with the above
operated, the front att. pilot signal circuit is restricted by mentioned control lever operated, oil flow from main
the movement of the main control valve spool, pump 2 is routed to both Travel (R) and Travel (L)
increasing the pilot pressure and shifting the flow spools, securing straight travelability in travel combines
combiner valve. operations.

Left Travel Motor Right Travel Motor

Flow Combiner
Valve

Travel (L) Travel (R)

Boom 2 Boom 1

Boom Cylinder

Front Att.
Pilot
Signal
Circuit

5-Spool Block Side

4-Spool Block Side

Main Pump 2 Main Pump 1

T167-03-03-003

T3-3-8
 COMPONENT OPERATION / Control Valve
PUMP CONTROL VALVE
A pump control valve is provided on the farthest
downstream part of the neutral passage in each 4-
spool and 5-spool control valve block.
The pump control valve routes pressures of neutral
passage before and after the pump control valve’s
orifice to the DP sensor as pump flow control signals. If
the pressure difference is large, the pump flow rate is
decreased. If it is small, the pump flow rate is
increased.

Pump Control Valve (5-Spool Block Side) 4-Spool

Block Side

Pressure Difference
Sensor (DP Sensor)
(5-Spool Block side)

Neutral
Passage

Pressure Difference
Sensor (DP Sensor)
(4-Spool Block side)
Neutral
Passage

5-Spool Block Side

Pump Control Valve (4-Spool Block Side)

Main Pump 2 Main Pump 1

T167-03-03-004

T3-3-9
 COMPONENT OPERATION / Control Valve
Pump control valve operation when control valve Pump control valve operation when control levers
spools are in neutral. are operated.

When the control valve spools are in neutral, all oil When a control lever is operated, a control valve
flowing from the main control valve goes through the spool is shifted to route oil flow to an actuator,
orifice before it is returned to the hydraulic oil tank. reducing the oil flow rate in the neutral passage. As a
The pressure difference between before and after the result, the pressure difference between before and
orifice becomes large, reducing the main pump flow after the orifice becomes small, increasing the main
rate to the minimum. pump flow rate.

DP Sensor

To the controller.

Orifice

Neutral Passage (fp)

(rp)
Poppet Spring

T111-02-05-016
Return Line

Pump Control Valve Operation as a Relief Valve

Normally the pump control valve does not act as a

relief valve. However, if oil flow in the neutral passage
becomes excessive, a poppet opens to provide an
extra passage to the return line, in addition to the
orifice passage, to release excessive pressure.
Orifice Poppet

Neutral Passage

T111-02-05-017
Return Line

T3-3-10
 COMPONENT OPERATION / Control Valve
MAIN RELIEF VALVE
Main relief valve set pressure can be shifted in two
stages using the pilot pressure from main relief
pressure shift solenoid valve (SA).
When traveling or when operating in the precision
mode, the main relief pressure is set in the high stage
(high relief pressure). In other cases, the main relief
pressure is set in the low stage (low relief pressure).

Main Relief Valve Operation in Low Main Relief

Pressure Setting
When the travel pressure switch is OFF or when the the main relief valve piston is not pushed to the left,
work mode is set in other than the precision mode, keeping the pilot poppet setting relatively low.
the main relief valve shift solenoid valve is not excited When pressure at port Hp rises to the set pressure,
and, as a result, no pilot pressure exerts on the the pilot poppet opens, routing oil at port Hp to port Lp
shuttle valve port pF2. At the same time, port pF1 is via passage A.
open to the hydraulic oil tank line. For this reason, The pressure in spring A chamber decreases as the
pilot poppet opens, causing the main poppet to open.
As a result, pressure oil at port Hp is directly routed to
port Lp.

Main Poppet Pilot Poppet Spring Piston

Lp

Hp

Lp

pF1 pF2 Shuttle Valve

Passage A
Spring A Chamber
Main Relief Valve Shift Solenoid Valve

T111-02-05-014

Main Relief Valve Operation in High Main Relief

Pressure Setting
When the travel pressure switch is ON, when the The valve operation is the same as the one in the low
work mode is set in the precision mode or when the main relief pressure setting.
power boost switch is ON, the main relief valve shift
solenoid valve is excited and, as a result, a pilot
pressure is routed to the shuttle valve port pF2. This
pilot pressure acts on the piston, pushing it to the left.
As a result, the spring is compressed, increasing the
pilot poppet setting force. In other words, the main
relief pressure setting is shifted to the high stage.

T3-3-11
 COMPONENT OPERATION / Control Valve
OVERLOAD RELIEF VALVE
(With Make-Up Function)
1 2 3 4
An overload relief valve is provided on each of boom,
arm, and bucket actuator port, preventing excessive
HP
pressure from arising in each actuator circuit if each
actuator should be forcibly moved by an external force.
When the pressure at port HP overcomes spring (4),
piIot poppet (3) opens, decreasing the pressure in
chamber (a). As a result, piston (1) is moved to the
right, opening main poppet (2), thus routing pressure LP
oil at port HP directly to port LP.
T111-02-05-019
Make-Up Function
In addition, the overload relief valve draws oil from
the hydraulic oil tank line to prevent cavitation from
occurring if the actuator circuit pressure becomes 2 a
negative.
HP

1 - Piston 3 - Pilot Poppet

2 - Main Poppet 4 - Spring
LP

T111-02-05-021
MAKE-UP VALVE
d2 d1
1 2
A make-up valve is provided on the cylinder port of
boom 2 and arm 2 sections, reinforcing the overload
relief valve’s make-up function.
Poppet (5) is closed when the pressure at port HP is HP
higher than the pressure at port LP due to the
difference in pressure receiving areas of poppet ends
d1 and d2.
If the pressure at port HP becomes lower than the
pressure at port LP, port LP pressure for the area
difference between d1 and d2 is applied to poppet (5),
opening it. LP
b

T111-02-05-023

HP

5 - Poppet 6 - Spring

LP

T111-02-05-024

T3-3-12
 COMPONENT OPERATION / Control Valve
HOLDING VALVE
A holding valve is provided on the boom raise side and
arm roll-out side cylinder ports, preventing the boom
and arm cylinders from retracting when the control
levers are in neutral.

• Holding valve operation when the control

levers are in neutral.
The cylinder holding pressure at cylinder port C Because of the difference in the sizes of pressure
acts on chamber (a) via orifice (b) in check valve receiving areas d1 and d2, check valve (2) is
(2). securely seated on cylinder port C, closing the
cylinder port.

1 External Force

g
2 a
a
d1
b Holding Pressure
g
c 3
b
d2
d
c 3

Pi
f

f d e
T111-02-05-025
• Holding valve operation when the boom lower
or arm roll-in control lever is operated.
Pilot pressure Pi acts on poppet (1), connecting As the pressure in chamber (a) decreases, check
chamber (a) and the hydraulic oil tank line. valve (2) opens. At the same time, spool (3) is
moved to form a circuit ( (c) → (d) → (f) ) so that the
actuating cylinder (boom or arm) can move.

a
a
2

d c 3

Pi
f

f d
T111-02-05-026
1 - Poppet 2 - Check Valve 3 - Spool

T3-3-13
 COMPONENT OPERATION / Control Valve
ARM REGENERATIVE VALVE 1

The arm regenerative valve is provided to help smooth PB

arm operation and to prevent arm hesitation from PR
occurring. i
8
Return oil from cylinder rod side is restricted in two 3
stages at orifice (A) in spool (2) and at orifice (B) in arm 2
regenerative valve (7), increasing cylinder rod side h
pressure PR. A
When rod side pressure PR becomes larger than
bottom side pressure PB, check valve (3) opens,
C
routing the return oil from the rod side to supplement e
the pump oil flow to the bottom side. 7

9 b 6

a d B

1
T111-02-05-035

PR PB

8 9

A
h

f e a i d
e

7 B
d
c

6 5 4 T111-02-05-028

1 - Arm Cylinder 4 - Piston 6 - Spring 8 - Holding Valve

2 - Spool 5 - Spool 7 - Arm Regenerative Valve 9 - Load Check Valve
3 - Check Valve

T3-3-14
 COMPONENT OPERATION / Control Valve
When bottom side pressure PB is higher than rod side 1
pressure PR, check valve (3) closes. Moreover, bottom
side pressure PB acts on piston (4) in arm regenerative PB
valve (7) via passage (b). As a result, spool (5) is PR
moved to the left, widening orifice (B), thus returning i
rod side oil faster to hydraulic oil tank passage (d). 8
3
2
h
A

C
e
7

9 b 6

a d B

T111-02-05-035
1

PR PB

8 9

A
h

f e a i d
e

7 B
d
c

6 5 4 T111-02-05-029

1 - Arm Cylinder 4 - Piston 6 - Spring 8 - Holding Valve

2 - Spool 5 - Spool 7 - Arm Regenerative Valve 9 - Load Check Valve
3 - Check Valve

T3-3-15
 COMPONENT OPERATION / Control Valve
(Blank)

T3-3-16
 COMPONENT OPERATION / Pilot Valve
OUTLINE
The pilot valve functions to control the pilot pressure oil, The machine is equipped with the front attachment
causing the control valve spools to move. When a /swing pilot valve and the travel pilot valve.
control lever is operated, the pilot valve sends a pilot Construction and operation of both pilot valves are
pressure, in proportion to the lever stroke, to the almost identical.
control valve to move the respective control valve
spool.

Front Attachment / Swing Pilot Valve Travel Pilot Valve

9 10
11

7 2

3
6

5 4
14 13 12
T142-02-04-003
T142-02-04-004

1 - Left Pilot Valve 5 - Right Swing Port 9 - Left Travel Forward Port 12 - Right Travel Reverse Port
(Right Pilot Valve) (Boom Lower Port)
2 - Left Swing Port 6 - Port T 10 - Port P 13 - Port T
(Boom Raise Port)
3 - Port P 7 - Arm Roll-Out Port 11 - Left Travel Reverse Port 14 - Right Travel Forward Port
(Bucket Roll-In Port)
4 - Arm Roll-In Port 8 - Travel Pilot Valve
(Bucket Roll-Out Port)

NOTE: Ports in parentheses are the ones on the

right pilot valve.

T3-4-1
 COMPONENT OPERATION / Pilot Valve
OPERATION
Spool (7) is held upward by return spring (6) via spring
guide (4). Spring guide (4) cannot be lifted further as it
is held by the lower neck of spacer (3) that is making
contact with bushing (2) which is immovable.
With spool (7) in this position, the output port is
connected to port T via a notch on spool (7).

In neutral Full Stroke Operation

(Pusher stroke: A to B in the output diagram) (Pusher stroke: E to F in the output diagram)
When the control lever is in the neutral position, spool When the control lever is moved further to the stroke
(7) completely blocks pressure oil from port P. Since end, pusher (1) is lowered until spring guide (4)
the output port is open to port T pressure at the comes in contact with the stepped part of the valve
output port equals that of the hydraulic oil tank. housing.
When the control lever is slightly moved, pusher (1), At the stroke point “D(E)”, pusher (1) comes in direct
spacer (3), and spring guide (4) move downward as a contact with spool (7) so that the lower notch does not
unit against return spring (6) and balance spring (5). close from this point on to the stroke end.
As the neck of spool (7) is pulled downward and held For this reason, the pressure at the output port rises
against spring guide (4) by balance spring (5), spool until it reaches port P pressure, and stays there.
(7) is also moved downward together with the above-
mentioned unit until clearance (A) of the spool notch
becomes zero.

Operation Corresponding to the control lever

stroke
(Pusher stroke: C to D in the output diagram)
As the control lever is moved further, the lower notch
on spool (7) reaches port P, routing pressure oil from E F
Output Port Pressure
port P to the output port, thus increasing pressure at (Pilot Pressure)
the output port. A part of the pressure oil at the output D
port is routed inside spool (7) via a passage on spool
(7), acting against spool (7) from the inside, pushing it
upward, and also acting against piston (8). As long as
the force of balance spring (5) is larger than this
upward pressure, the output port pressure rises C
continuously.
When the output port pressure overcomes balance
spring (5) force, spool (7) is moved upward,
compressing balance spring (5). As a result, the A B Pusher Stroke
lower notch is closed to block pressure oil from port P
to the output port, stopping pressure rise at the output Output Diagram
port.
If the control lever is further moved, spool (7) is
pushed downward again, opening the notch and
increasing the output port pressure. At this time,
balance spring (5) is compressed for the amount
equivalent to the movement of spool (7). For this
reason, the output pressure rises further until the
output pressure (pressure force to push spool (7)
upward) balances against balance spring (5) force.

T3-4-2
 COMPONENT OPERATION / Pilot Valve
Pusher Stroke : A to B

1
2

4
5
Notched Part

7
Port T

Output Port

Port P

T142-02-04-006 T142-02-04-007

Pusher Stroke : C to D Pusher Stroke : E to F

Notched Part

5 4

7
7

Notched Part Output Port

Passage Notched Part
Output Port
Port P
Port P

8
T142-02-04-009
T142-02-04-008

1 - Pusher 3 - Spacer 5 - Balance Spring 7 - Spool

2 - Bushing 4 - Spring Guide 6 - Return Spring 8 - Piston

T3-4-3
 COMPONENT OPERATION / Pilot Valve
(Blank)

T3-4-4
 COMPONENT OPERATION / Travel Device
OUTLINE
The travel device consists of travel motor (1), the travel
reduction gear [parts (3) to (15)], and sprocket (2).

8 15

6 10 14

5
13

12

11

T116-03-02-001

1 - Travel Motor 5 - Third Stage Carrier 9 - First Stage Planetary 13 - Shaft

Gear
2 - Sprocket 6 - Third Stage Sun Gear 10 - First Stage Carrier 14 - Ring Gear
3 - Housing 7 - Second Stage Carrier 11 - Third Stage Planetary 15 - Cover
Gear
4 - Drum 8 - Second Stage Sun Gear 12 - Second Stage Planetary
Gear

T3-5-1
 COMPONENT OPERATION / Travel Device
TRAVEL REDUCTION GEAR
The travel reduction gear is a three stage planetary As third stage carrier (2) is spline-connected to motor
gear type. housing (12), it does not rotate. As sprocket (11) is
The travel motor rotates shaft (7), transmitting this bolted to drum (13), they rotate together.
rotational force to third stage carrier (2) and ring gear
(1) via first stage planetary gears (8), first stage carrier
(6), second stage sun gear (5), second stage planetary
gears (9), second stage carrier (4), third stage sun
gear (3) and third stage planetary gears (10).
11

12 13 2 3 4

6
7

Third Second First

Stage Stage Stage

T111-03-04-011
10 9 1

T116-03-02-002

1 - Ring Gear 5 - Second Stage Sun Gear 8 - First Stage Planetary Gear 11 - Sprocket
2 - Third Stage Carrier 6 - First Stage Carrier 9 - Second Stage Planetary 12 - Housing (Travel Motor)
Gear
3 - Third Stage Sun gear 7 - Shaft 10 - Third Stage Planetary Gear 13 - Drum
4 - Second Stage Carrier

T3-5-2
 COMPONENT OPERATION / Travel Device
TRAVEL MOTOR
The travel motor is a swash-plate-type axial plunger Tilt pistons (12) (4 provided) changes the displacement
motor, with a built-in hydraulically-released, wet-type angle of swash place (6); swash plate (6) is moved
multiple disc parking brake (3). (the angle is changed), having the contact point with
The travel motor consists of swash plate (6), rotor (17), ball (8) as the supporting point.
plungers (15) with shoes, valve plate (1), output shaft Rotor (17) is in tight contact with valve plate (1) by
(10), tilt pistons (12), and casing (7). spring (5).

1 2 3 4 5 6 7

10

18

11
17

16 14 13 12
15

T111-03-04-003

1- Valve Plate 6- Swash Plate 11 - Spring 15 - Plunger

2- Spring 7- Casing 12 - Tilt Piston 16 - Brake Piston
3- Parking Brake 8- Ball 13 - Ball 17 - Rotor
4- Retainer Plate 9- Roller Bearing 14 - Holder 18 - Valve Cover
5- Spring 10 - Output Shaft

T3-5-3
 COMPONENT OPERATION / Travel Device
Pressure oil from the pump flows to port A of valve As output shaft (6) rotates, rotor (2) also rotates. Then,
plate (1), and enters into one-sided bores in rotor (2) when plungers (3) reach port B, oil is routed to the
located just behind the right-side crescent-shaped oil hydraulic oil tank.
port (port A side) of valve plate (1). Whether pressure oil from the pump is supplied to port
Then, plungers (3) in the right half side of rotor (2) are A or port B determines travel direction.
pushed out toward swash plate (5), and slide on the
swash plate to rotate rotor (2) and output shaft (6).

Port B Port A
Port B
Port A

2 1

4
Valve
6 5 Plate
T111-03-04-004

1 - Valve Plate 3 - Plunger 5 - Swash Plate 6 - Output Shaft

2 - Rotor 4 - Shoe

T3-5-4
 COMPONENT OPERATION / Travel Device
TRAVEL BRAKE VALVE
The travel brake valve is located on the travel motor
head and consists of the following valves:

Counterbalance Valve: Check Valve:

ensures smooth starts and stops and prevents ensures smooth starts and stops, and prevents
overrunning when traveling down slopes. cavitation from occurring in the motor circuit by
functioning together with counterbalance valve.
Overload Relief Valve:
prevents overloads and surge pressure in the Travel Motor Displacement Angle Shift Valve:
motor circuit. controls the tilt pistons when travel mode switch
is operated.

Check Valve

Counterbalance Valve

Overload Relief Valve

Travel Motor Displacement Angle Shift Valve

T111-03-04-009

T3-5-5
 COMPONENT OPERATION / Travel Device
Travel Operation Descending Operation

When supply oil from the control valve is routed to When the machine travels down a slope, the travel
port BV, supply oil flows around spool CB, opens motors are forcibly driven by the machine weight so
check valve BC and is led to motor port BM. However, that the motor sucks oil like a pump. When the motor
return oil from motor port AM is blocked by check sucks oil, oil pressure at port BV and chamber G
valve AC and spool CB. decreases, causing spool CB to move to the right.
As supply oil pressure at port BV increases, supply oil Then, the return oil flow from the motor is restricted
is routed to chamber G through orifice F in spool CB, by the spool, increasing pressure at port AM.
moving spool CB to the left against spring force. The increased pressure at port AM brakes the motor.
Consequently, return oil from motor port AM starts to Thus, the restricted return oil flow increases the
flow into port AV through notch H in spool CB, pressure at port BV again, moving spool CB back to
allowing the travel motor to rotate. the left. This repeat movement of the spool (hydraulic
brake action) prevents the machine from overrunning.
When the travel levers are returned to the neutral
position, the oil in both ports AV and BV are routed to Circuit Protectors
the hydraulic oil tank through the control valve. Thus,
oil pressure in chamber G decreases, and spool CB If pressure in the circuit increases over the setting
is moved back to the original position by spring force. pressure of overload relief valve, this valve opens to
Then, the oil flow circuit is blocked, causing the travel relieve peak pressure to the lower pressure side to
motors to stop rotating. protect the motor from overloading. This valve also
functions to release shock pressure caused by inertia
force developing when the motor stops.
When the motor draws oil because of pumping
operation, check valve BC opens to make up vacuum,
so that cavitation will not develop in the circuit.

Spool CB H Check Valve AC

Overload Relief Valve F

AV
AM
BV

Check Valve BC

BM

T111-03-04-010

T3-5-6
 COMPONENT OPERATION / Travel Device
TRAVEL MOTOR DISPLACEMENT ANGLE
SHIFT
Travel speed mode shifts as the displacement angle of
swash plate (4) is changed by tilt pistons (5).

• Slow Speed Travel

(Maximum Displacement Angle)
With the travel mode switch is in the slow speed With the above, the displacement angle of swash
position, the controller (PVC) does not shift the plate (4) is held at the maximum angle, having the
travel speed mode shift solenoid valve SB so that maximum plunger (6) stroke. Accordingly the
pilot pressure (3) is not supplied to travel motor amount of oil required to rotate the travel motor
displacement angle shift valve (1) from the travel (per turn) becomes the maximum, resulting in
speed mode shift solenoid valve SB. Spool (7) in slow speed travel motor operation. (Refer to the
travel motor displacement angle shift valve (1) is Control System group in the SYSTEM section for
held in neutral by spring (2), blocking pressure oil the control circuit.)
from the control valve. At the same time, the line
to tilt pistons (5) is open to the hydraulic oil tank
line.
5 6

To the hydraulic 2 7 8 9 7 1
oil tank

10

10

From the control valve

T142-03-01-003
1 - Travel Motor Displacement 4 - Swash Plate 7 - Spool 9 - Spool
Angle Shift Valve
2 - Spring 5 - Tilt Piston 8 - Chamber A 10 - Ball
3 - Pilot Pressure (To the travel 6 - Plunger
motor displacement angle shift
solenoid valve SB)

T3-5-7
 COMPONENT OPERATION / Travel Device
• Fast Speed Travel
(Minimum Displacement Angle)
When the travel mode switch is turned to the fast Consequently, tilt pistons (5) push swash plate (4),
speed position, the controller (PVC) shifts the changing the displacement angle to the minimum. As a
travel speed mode shift solenoid valve SB so that result, the travel motor operates at fast speed. (Refer
pilot pressure (3) is supplied to chamber A (8) of to the Control System group in the SYSTEM section for
travel motor displacement angle shift valve (1), the control circuit.)
shifting spool (7), thus routing pressure oil from
the control valve to tilt pistons (5).

5 6

From the travel 9 1

motor
7 8
displacement angle

10 4

5
3

10

From the control valve.

T142-03-01-004

1 - Travel Motor Displacement 4 - Swash Plate 7 - Spool 9 - Spool

Angle Shift Valve
2 - Spring 5 - Tilt Piston 8 - Chamber A 10 - Ball
3 - Pilot Pressure (To the travel 6 - Plunger
motor displacement angle shift
solenoid valve SB)

T3-5-8
 COMPONENT OPERATION / Travel Device
PARKING BRAKE
The parking brake is a negative-type brake released Friction plates (4) are connected to rotor (6), and
when pressure oil from the control valve is applied to plates (3) to casing (5) via spline coupling respectively.
parking brake chamber M. Whenever the travel control When spring (1) pushes piston (2) to the right, friction
valve spools are in neutral, the parking brake is plates (4) come into contact with plates (3), applying
automatically applied. the parking brake.

M 2 3 4 5
1

6
T111-03-04-003

1 - Spring 3 - Plate 5 - Casing 6 - Rotor

2 - Piston 4 - Friction Plate

T3-5-9
 COMPONENT OPERATION / Travel Device
Brake ON
1
When the travel levers are in the neutral position,
friction plates (4) and plates (3) are pressed down by
spring (1) force, braking the motor. Pressure oil in
brake chamber M is released to the hydraulic oil tank.

5
6

T111-03-04-007

Brake OFF
1
When the travel levers are operated, pressure oil
from the control valve is led to brake chamber M and
pushes brake piston (2) against spring (1) force.
Consequently, friction plates (4) are separated from
plates (3), releasing the parking brake.
M

5
6
T111-03-04-008

1 - Spring 3 - Plate 5 - Casing 6 - Rotor

2 - Piston 4 - Friction Plate

T3-5-10
 COMPONENT OPERATION / Others (Upperstructure)
PILOT SHUT-OFF VALVE To Pilot Valve

The pilot control shut-off valve is a manually operated

switch valve. The valve spool is rotated when the pilot
control shut-off lever is operated, switching ON and
OFF the pilot pressure oil to the pilot valve.

From Pilot
Valve
To Hydraulic
Oil Tank

From Pilot
Valve

From Pilot
Pump

From Control
Valve T166-03-06-001

• Operation with Pilot Control Shut-Off Lever in

LOCK Position
When the pilot control shut-off lever is in the
LOCK position, the pilot shut-off valve is set in From Pilot Valve
neutral (OFF), blocking the pilot pressure oil from
the pilot pump to the pilot valve. The pilot pressure
oil in the pilot valve side is routed to the hydraulic
oil tank. As a result, the pilot valves become
inoperable with the control levers.

From Pilot Pump To Hydraulic Oil Tank

T162-03-06-002

• Operation with Pilot Control Shut-Off Lever in

UNLOCK Position To Pilot Valve
When the pilot control shut-off lever is moved to
the UNLOCK position, the pilot shut-off valve is
turned to the ON position, blocking the line to the
hydraulic oil tank and, at the same time, routing
the pilot pressure oil from the pilot pump to the
pilot valves. Thus, the pilot valves become
operable with the control levers.

From Pilot
Pump T162-03-06-003

T3-6-1
 COMPONENT OPERATION / Others (Upperstructure)
SHOCKLESS VALVE 5

The shockless valve regulates the pilot oil flow

between the pilot valve and control valve spools.

Shockless Valve (for Boom and Arm Functions) 2

The shockless valve consists of orifices (2) and (6),
1
check valve (3), restriction release shift valve (4),
heat circuit check valve (1) (used in the heating
circuit), and shuttle valve (5).
3

• When the boom raise control lever is operated,

the pilot valve is actuated, sending pilot pressure 4
oil to port A1. At the same time, port A2 is
connected to the hydraulic oil tank line. T105-02-09-001
At the start of pilot valve operation, pressure oil
from port A1 goes through orifice (2) only. The 5
1
pressure oil is regulated as it goes through orifice
(2), acting on the control valve spool from port B1 A1 A2 A3
side. As the pressure at port A1 rises, check valve
T1
(3) opens.

• Return oil from port B2 also goes through orifice

(6) only before it returns to the hydraulic oil tank in B1 B2 B3
the beginning of the pilot valve operation. As the T111-02-07-005
pressure at port A1 rises, restriction releasing shift
valve (4) is actuated, regulating the return oil in 2 3 4 6
proportional to the pressure value.
From Port A1 Side
4

B2
Heat Circuit A2
Hydraulic oil relieved from the pilot relief valve enters
port T1. Then, it flows to the pilot valve from each port
A via heat circuit check valve (1). 2 3 T105-02-09-005

Shuttle Valve 5 A4
A2
The shuttle valve outputs pilot pressures from port A2
(boom lower) and port A3 (arm roll-out) to port P2
(Pressure switch: Others).

To T1
1 - Heat Circuit Check Valve To P2
1 - Orifice 2 - Shuttle Valve
Restriction
2 - Check Valve Releasing 3 - Orifice
Shift Valve

A1 1 A3 T105-02-09-004

T3-6-2
 COMPONENT OPERATION / Others (Upperstructure)
SOLENOID VALVE
Solenoid Valve Unit
The solenoid valve unit (three solenoid valves used),
pump control proportional solenoid valve, swing Swing Parking Travel Mode Main Relief
preference circuit shift solenoid valve are provided on Brake Release Shift Solenoid Pressure Shift
Solenoid Valve Valve Solenoid Valve
the machine.

• Solenoid Valve Unit

The solenoid valve unit consists of three solenoid
valves SA, SB, and SC and pilot relief valve.
SA: Main Relief Pressure Shift Solenoid Valve. Pilot Relief Vaive
The solenoid valve SA functions to raise the SC SB SA
main relief valve setting upon receiving a
signal from the controller (PVC).

SB: Travel Mode Shift Solenoid Valve

The solenoid valve SB functions to shift the
travel motor displacement angle when the
travel mode switch is operated.

SC: Swing Parking Brake Release Solenoid

Valve
The solenoid valve SC functions to release
the swing parking brake when a swing or
front attachment function is operated upon
receiving signals from the cotroller (PVC).
(Refer to the heading “Pilot Circuit” in T111-02-07-002
“Hydraulic System” Group, “SYSTEM”
Section.)

• Swing Preference Circuit Shift Solenoid Valve

The swing preference circuit shift solenoid valve
regulates the control valve upon receiving signals
from the controller (PVC). (Refer to the “Hydraulic Spring Spool Solenoid
System” Group in “SYSTEM” Section.)

• Pump Control Proportional Solenoid Valve

The pump control proportional solenoid valve
regulates the pump flow rate upon receiving
signals from the controller (PVC). (Refer to the
heading “Regulator” in “Pump Device” Group,
“COMPONENT OPERATION” Section.)

Solenoid Valve Operation T111-02-07-003

• In Neutral: The spool is pushed to the right

by the spring. Pilot pressure P is P Output T2
blocked. Port Tank Port
• When Excited: The spool is pushed to the left by
the excited solenoid valve. Pilot
pressure P is routed to the output Spool Spring
port.

Pilot Relief Valve

The pilot relief valve functions to set the pilot pressure
delivered to port P to a certain level. Relief port T1 is
connected to the heat circuit in the shockless valve.

T111-02-07-004
P
T1

T3-6-3
 COMPONENT OPERATION / Others (Upperstructure)
ACCUMULATOR
The accumulator is provided in the pilot circuit to buffer
fluctuations in oil pressure, and to maintain the pilot
pressure for a short time period after the engine is
stopped. 6
The accumulator mainly consists of body (5), holder 1
(4), bladder (2), which encloses nitrogen gas (N2), and
poppet (1).
5 Nitrogen Gas
(N2 ) 2
• Pressure oil from the pilot pump enters into the
4
accumulator via port A. Pilot pressure com-
presses the nitrogen gas in bladder (2) until they
balance against each other.
Pilot Pressure Oil
• When pressure supply is stopped due to engine 3
stall or any other reasons, bladder (2) starts
expanding, supplying accumulated oil into the pilot
circuit via port A.

A
T105-02-10-003

1 - Poppet 4 - Holder
2 - Bladder 5 - Body
3 - Oil Port 6 - Gas Plug

T3-6-4
 COMPONENT OPERATION / Others (Undercarriage)
SWING BEARING
The swing bearing supports the upperstructure weight Outer race (1) is bolted to the upperstructure and inner
and functions to rotate the upperstructure smoothly. race (8) is bolted to the undercarriage. The internal
This bearing is a single-row shear ball-type bearing, gear of inner race (8) engages with the output shaft of
consisting of outer race (1), inner race (8), balls (5), the swing reduction gear.
supports (6), (7), seals (3)(9), and turn buckles (10). Seal (9) is securely tightened to inner race (8) by the
assembly of rods (11) and turn buckles (10).

4
3

8 5

10

11
W111-03-01-008

1 - Outer Race 4 - Bolt 7 - Support 10 - Turn Buckle

2 - Grease Fitting 5 - Ball 8 - Inner Race 11 - Rod
3 - Seal 6 - Support 9 - Seal

T3-7-1
 COMPONENT OPERATION / Others (Undercarriage)
CENTER JOINT
The center joint is a 360° rotating joint. The center joint Hydraulic oil flows to the right and left travel motors via
functions to allow hydraulic oil to flow smoothly to and the spindle and the oil ports of the body. Seals prevent
from the travel motors without twisting hoses while the oil leaks between the spindle and body into adjacent
upperstructure is rotated. passages.
The spindle is attached to the main frame, and the
body is bolted to the swing center of the undercarriage.

Spindle

Body

Seal

W142-03-03-001

T3-7-2
 COMPONENT OPERATION / Others (Undercarriage)
TRACK ADJUSTER
The track adjuster located on the side frame is
composed of spring (5) and adjuster cylinder (6).
Spring (5) absorbs loads applied to the front idler.
Adjuster cylinder (6) adjusts track sag.

• Grease is applied through grease fitting into

chamber a of adjuster cylinder (6) as illustrated
below. The pressure of the grease pushes piston 1
rod (8) out and decreases track sag.
• To increase track sag, loosen valve (1) 1 to 1.5 Grease Fitting
turns counterclockwise to release grease from the
track adjuster cylinder through the grease
discharge hole.

CAUTION: The adjusting cylinder is highly

pressurized. Loosening valve (1) quickly
and/or excessively may cause valve (1) to fly
off and the highly pressurized grease to
spout out, possibly resulting in personal Grease Discharge Hole
injury.
Be sure to loosen valve (1) slowly and M104-07-119
gradually, keeping face and body parts away
from valve (1). In addition, never attempt to
loosen the grease fitting.

1 2 3 4 a 5 6 7 8

T111-03-05-001
1 - Valve 3 - Washer 5 - Spring 7 - Flange
2 - Nut 4 - Spacer 6 - Adjuster Cylinder 8 - Piston Rod

T3-7-3