Technical Manual

(Operational Principle)

EX120- 5E
Export Version

Excavator

KM-155E-02
T0155E-02
HITACHI
 INTRODUCTION
TO THE READER

• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using ″Service Manual
Revision Request Form″ at the end of this man-
• Be sure to thoroughly read this manual for correct ual.
product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-298-32-7173
FAX: 81-298-31-1162

ADDITIONAL REFERENCES

• Please refer to the materials listed below in addition • Operation Manual of the Engine
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog

MANUAL COMPOSITION

• This manual consists of three portions: the Techni- • Information included in the Technical Manual
cal Manual (Operational Principle), the Technical (Troubleshooting):
Manual (Troubleshooting) and the Workshop Man- technical information needed for operational per-
ual. formance tests, and troubleshooting procedures.

• Information included in the Technical Manual • Information included in the Workshop Manual:
(Operational Principle): technical information needed for maintenance
technical information needed for redeliver and and repair of the machine, tools and devices
delivery, operation and activation of all devices needed for maintenance and repair, maintenance
and systems. standards, and removal/installation and assem-
ble/disassemble procedures.

PAGE NUMBER

• Each page has a number, located on the center

lower part of the page, and each number contains
the following information:

Example : T 1-3-5

Consecutive Page Number for Each Group

Group Number
Section Number
T: Technical Manual W: Workshop Manual

IN-01
 INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS

In this manual, the following safety alert symbol and • CAUTION:

signal words are used to alert the reader to the Indicated potentially hazardous situation which
potential for personal injury of machine damage. could, if not avoided, result in personal injury or
death.
This is the safety alert symbol. When you see this
symbol, be alert to the potential for personal injury. • IMPORTANT:
Never fail to follow the safety instructions prescribed Indicates a situation which, if not conformed to the
along with the safety alert symbol. instructions, could result in damage to the machine.
The safety alert symbol is also used to draw attention
to component/part weights.
To avoid injury and damage, be sure to use appropri- • NOTE:
ate lifting techniques and equipment when lifting heavy Indicates supplementary technical information or
parts. know-how.

UNITS USED

• SI Units (International System of Units) are used in 2

Example : 24.5 MPa (250 kgf/cm , 3560 psi)
this manual.
MKS system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.

Quantity To Convert Into Multiply By Quantity To Convert Into Multiply By

From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
°C °F °C×1.8+32
3 3
m yd 1.308 Temperature
Weight kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375

IN-02
 SECTION 1
GENERAL

—CONTENTS—
Group 1 Specification
Specifications .......................................... T1-1-1
Working Ranges and Machine Dimensions for
Transportation ....................................... T1-1-2
Component Specification ......................... T1-1-3

Group 2 Component Layout

Main Components.................................... T1-2-1
Electrical System (Overall System) .......... T1-2-2
Electrical System (Relays) ....................... T1-2-3
Electrical System
(Monitor and Switch Panels) .................. T1-2-4
Pump and Related Parts .......................... T1-2-5
Other Components .................................. T1-2-6

155T-1-1
(Blank)

155T-1-2
 GENERAL / Specifications
Specifications

Model Std.
EX120-5 Hydraulic Excavator
Type of Front-End Attachment 2.52 m (8 ft 3 in) Arm
3 3 3 3 3
Bucket Capacity (Heaped) m (yd ) PCSA 0.55 m (0.72 yd ), CECE 0.45 m
Operating Weight kg (Ib) 11 800 (26 000)
Basic Machine Weight kg (Ib) 9 300 (20 500)
-1
Engine ISUZU A 4BG1T, 63kW (85 PS)/2 100 min (rpm)
∗ 66 kW (90 PS)/2 200 min (rpm)
-1

A : Overall Width
(Excluding Rearview Mirrors) mm (ft⋅in) 2 500 (8’2”)
B : Cab Height mm (ft⋅in) 2 720 (8’11”)
C : Rear End Swing Radius mm (ft⋅in) 2 130 (7’0”)
D : Minimum Ground Clearance mm (ft⋅in) ∗∗ 440 (1’5”)
E : Counterweight Clearance mm (ft⋅in) ∗∗ 890 (2’11”)
F : Engine Cover Height mm (ft⋅in) 1 920 (6’4”)
G : Overall Width of Upperstructure mm (ft⋅in) 2 460 (8’1”)
H : Undercarriage Length mm (ft⋅in) 3 580 (11’9”)
I : Undercarriage Width mm (ft⋅in) 2 490 (8’2”)
J : Sprocket Center to Idle Center mm (ft⋅in) 2 880 (9’5”)
K : Track Shoe Width mm (ft⋅in) 500 (20”)
(Grouser Shoe)
2
Ground Pressure kPa (kgf/cm ) (psi) 37 (0.38) (5.4)
-1
Swing Speed min (rpm) 12.7 (12.7)
Travel Speed (fast/slow) km/h 5.5/3.2
(mph) (3.4/2.0)
Gradeability degree (%) 35 (70)

NOTE: * H/P mode.

** The dimensions do not include the height
of the shoe lug.

M155-11-001

T1-1-1
 GENERAL / Specifications
Working Ranges and Machine
Dimensions for Transportation

M155-11-004
M155-11-003

Category 2.10 m (6’11”) Arm 2.52 m (8’3”) Arm 3.01 m (9’11”) Arm
Item Backhoe Shovel Backhoe Shovel Backhoe Shovel
A: Maximum Digging Reach mm 7 900 8 050 8 270 8 410 8 740 8 880
(ft⋅in) (25’11”) (26’5”) (27’2”) (27’7”) (28’8”) (29’2”)
∗B: Maximum Digging Depth mm 5 160 5 300 5 570 5 720 6 060 6 210
(ft⋅in) (16’11”) (17’5”) (18’3”) (18’9”) (19’11”) (20’5”)
∗C: Maximum Cutting Height mm 8 350 8 540 8 550 8 750 8 880 9 070
(ft⋅in) (27’5”) (28’0”) (28’1”) (28’9”) (29’2”) (29’9”)
∗D: Maximum Dumping Height mm 5 940 6 020 6 140 6 220 6 470 6 530
(ft⋅in) (19’6”) (19’9”) (20’2”) (20’5”) (21’3”) (21’5”)
E: Transport Height mm 2 720 2 720 2 720 2 720 ∗∗2 720 ∗∗2 720
(ft⋅in) (8’11”) (8’11”) (8’11”) (8’11”) (8’11”) (8’11”)
F: Overall Transport Length mm 7 570 7 570 7 580 7 580 ∗∗2 590 ∗∗7 590
(ft⋅in) (24’10”) (24’10”) (24’10”) (24’10”) (24’11”) (24’11”)
G: Minimum Swing Radius mm 2 310 2 310 2 330 2 330 2 590 2 590
(ft⋅in) (7’7”) (7’7”) (7’8”) (7’8”) (8’6”) (8’6”)

NOTE: * The dimensions do not include the height

of the shoe lug.
**For trasport pin position.

T1-1-2
 GENERAL / Specifications
COMPONENT SPECIFICATIONS

Engine

MAIN SPECIFICATIONS
Manufacturer ....................................................ISUZU
Model ................................................................A-4BG1T
Type ..................................................................Diesel, 4 cycle, vertical, 4-cylinder inline, water-cooled,
direct injection type
Cyl. No.-bore × stroke.......................................4-105 mm×12 mm (4.13 in×4.92 in)
3 3
Piston displacement .........................................4 329 cm (264 in )
-1
Rated output .....................................................62.5 kW/2 100 min (85 PS/2 100 rpm)
-1
HP Mode: 66.2 kW/2 200 min (90 PS/2 200 rpm)
Compression ratio ............................................17.0
Dry weight.........................................................361 kg (796 lb)
Firing order .......................................................1-3-4-2
Rotation direction..............................................Clockwise (view from fan side)

COOLING SYSTEM
Cooling fan .......................................................Dia. 540 mm, 7 blades, draw-in type
Fan pulley ratio .................................................Engine rpm×1.01
Thermostat .......................................................Cracking temp. : 82 °C (180 °F)
(under atmospheric pressure) .........................Full open (Stroke: 10 mm or larger) temp. : 95 °C (203 °F)
Water pump ......................................................Centrifugal type, belt driven

LUBRICATION SYSTEM
Lubrication pump type ......................................Gear pump
Oil filter .............................................................Full-flow paper element type with bypass function
Oil cooler ..........................................................Water-cooled, built-in

STARTING SYSTEM
Motor ................................................................Magnetic pinion shift system, reduction type
(with starter relay)
Voltage⋅Output ..................................................24 V⋅4.5 kW

PRE-HEAT SYSTEM
Heating method ................................................Glow plug

ENGINE STOP SYSTEM

Stop method .....................................................Fuel cut

ALTERNATOR
Type ..................................................................AC type (with regulator)
Voltage ⋅ Output ................................................24 V⋅40 A (Brush-less type)

SUPERCHARGING SYSTEM
Type ..................................................................Exhaust-gas-turbo type TD04H

FUEL SYSTEM
Injection pump model .......................................Bosch A type
Governor...........................................................Centrifugal all speed control RSV
Injection nozzle ................................................Multihole nozzle

T1-1-3
 GENERAL / Specifications
PERFORMANCE
Lubrication oil consumption ..............................Less than 50 mL/h (New engine, at rated horsepower)
-1
Fuel consumption ratio .....................................Less than 241 g/kW⋅h (177 g/PS⋅h) @62.5 kW/2 100 min
-1
Less than 243 g/kW⋅h (179 g/PS⋅h) @66.2 kW/2 200 min
Injection timing..................................................12 before T.D.C.
-1
Max. output torque............................................314 N⋅m (32 kg⋅m, 231 lbf⋅ft) or more at 1 600 min
2
Injection pressure .............................................18.1 MPa (185 kgf/cm , 2 631 psi)
2
Cylinder compression .......................................3.04 Mpa (31 kgf/cm , 441 psi)
Valve clearance (inlet/exhaust).........................0.4/0.4 mm (when cool)
-1
No load speed ..................................................Min. : 950 min
-1
Max. : 2 300±50 min
-1
HP Mode: Max. : 2 400±25 min

T1-1-4
 GENERAL / Specifications
Engine Performance Curve (A-4BG1T)

Test Conditions: 1. In conformity with JIS D1005

(Performance test method for
diesel engines used for
construction machinery), under
standard atmospheric pressure.
2. With fan and generator.

T155-01-01-009

T1-1-5
 GENERAL / Specifications
Engine Accessories

RADIATOR ASSEMBLY
Type ..................................................................Radiator/Oil cooler tandem type assembly
Weight ..............................................................67 kg (148 lb)

Radiator Oil cooler

Capacity............................................................5.8 L (1.5 US gal) 4.4 L (1.2 US gal)
Air-tight testing pressure...................................88.3 kPa 981 kPa
2 2
(0.9 kgf/cm , 13 psi) (10 kgf/cm , 142 psi)
Cap opening pressure ......................................49 kPa −
2
(0.5 kgf/cm , 7 psi)

BATTERY
Capacity............................................................55 Ah (5 hours)
Voltage..............................................................12 V
Weight ..............................................................19 kg (42 lb)×2

Hydraulic Devices

MAIN PUMP
Model ................................................................HPV050FW
Type ..................................................................Variable displacement plunger pump: regulator attached type
Max. flow (Theoritical value).............................94.5 L/min (24.9 US gpm)×2

PILOT PUMP
Model ................................................................HY/ZFS 11/16.8
Type ..................................................................Fixed displacement type gear pump
Max. flow (Theoritical value).............................30.7 L/min (8.10 US gpm)
HP Mode: 32.2 L/min (8.50 US gpm)

CONTROL VALVE
Type ..................................................................Pilot pressure operated type (4-spool+5-spool)
2
Main relief pressure ..........................................34.3 MPa (350 kgf/cm , 4 977 psi)
@80 L/min (21 US gpm)
2
Overload relief pressure ..................................37.3 MPa (380 kgf/cm , 5 404 psi)
@50 L/min (13.2 US gpm)
(Boom raise/lower, Arm roll-in, Bucket roll-in)
2
39.2 MPa (400 kgf/cm , 5 688 psi)
@50 L/min (13 US gpm)
(Arm roll-out, Bucket roll-out)

SWING DEVICE
Type ..................................................................Two-stage planetary reduction type

SWING MOTOR
Model ................................................................AP5S72
Type ..................................................................Swash-plate type, fixed-displacement plunger motor

T1-1-6
 GENERAL / Specifications
SWING BRAKE VALVE
Type .............................................................Non counter balance valve type
2
Relief pressure ............................................31.4 MPa (320 kgf/cm , 4 550 psi)
@94.5 L/min (24.9 US gpm)

SWING PARKING BRAKE

Type .............................................................Multiple-wet-plate negative type
2
Cracking pressure for release .....................1.96 to 2.94 MPa (20 to 30 kgf/cm , 284 to 427 psi)

TRAVEL DEVICE
Type .............................................................Two-stage planetary reduction gear

TRAVEL MOTOR
Model ...........................................................HMV075CF-18A
Type .............................................................Bent-axis type, variable displacement plunger motor

TRAVEL BRAKE VALVE

Type .............................................................Counter balance valve type
2
Relief pressure ............................................34.8 MPa (355 kgf/cm , 5 048 psi)

TRAVEL PARKING BRAKE

Type .............................................................Multiple-wet-plate negative type
2
Cracking pressure for release .....................0.89 MPa (9.1 kgf/cm , 129 psi )

CYLINDER
Boom ...........................................................Arm Bucket Bucket
Rod Dia........................................................70 mm (2.76”) 80 mm (3.15”) 65 mm ( 2.56”)
Cylinder Bore ...............................................105 mm (4.13”) 110 mm (4.33”) 95 mm (3.74”)
Stroke ..........................................................940 mm (3’1”) 1 135 mm (3’9”) 875 mm (2’ 10”)
Fully retracted length ...................................1 447 mm (4’9”) 1 650 mm (5’5”) 1 590 mm ( 5’ 3”)
Plating thickness..........................................30 µm (1.18 µin) 30 µm (1.18 µin) 30 µm (1.18 µin)
or more or more or more

FRONT ATTACHMENT PILOT VALVE

Model ...........................................................HVP04F-040-101

TRAVEL PILOT VALVE

Model ...........................................................HVP04E-040-101

SOLENOID VALVE UNIT

Functions .....................................................⋅SC : Arm regenerative control
⋅SI : Travel motor swash angle control

OIL COOLER BYPASS CHECK VALVE

2
Cracking pressure .......................................392 kPa (4 kgf/cm , 57 psi) at 5 L/min (1.3 US gpm)

T1-1-7
 GENERAL / Specifications
Electrical Equipment

BATTERY RELAY
Voltage⋅Current............................................24 V⋅100 A

GLOW RELAY
Voltage.........................................................24 V

HORN
Specifications ..............................................24 V⋅1.5 A, 113 dB (A)

LIGHT
Specifications ..............................................Work lights : halogen 24 V⋅70 W⋅60 W
Dome light : 24 V⋅10 W

AIR CONDITIONER
Refrigerant...................................................134a
Cooler capacity............................................19.3 MJ/h (4 600 kcal/h)
3 3
Cooler air flow..............................................550 m /h (720 yd /h) or more
Heater capacity............................................19.8 MJ/h (4 725 kcal/h) or more
Temperature control ....................................Electronic control

T1-1-8
 GENERAL / Component Layout
MAIN COMPONENTS

1
3

4
5
6
7

19

10

11

12
18 13
14
17

16 15 T155-01-01-010

1- Bucket Cylinder 6- Swing Device 11 - Engine 16 - Shockless Valve

2- Arm Cylinder 7- Fuel Tank 12 - Radiator 17 - Pilot Shut-Off Valve
3- Boom Cylinder 8- Hydraulic Oil Tank 13 - Oil Cooler 18 - Travel Pilot Valve
4- Center Joint 9- Control Valve 14 - Battery 19 - Front/Swing Pilot Valve
5- Swing Bearing 10 - Pump Device 15 - Travel Device

T1-2-1
 GENERAL / Component Layout
ELECTRICAL SYSTEM
(Overall System)
1 2 3 4

5
6

8
27
9

10

11
26

25

24

23 12
13

14

22

21

T155-01-01-011

20 19 18 17 16 15
1 - Wiper Motor 8 - Pressure Switch (Front) 15 - Engine Oil Pressure Switch 22 - Battery
2 - Monitor Panel 9 - Pressure Switch (Travel) 16 - Engine Oil Level Switch 23 - Pressure Switch and
Sensor
3 - Relays 10 - Hydraulic Oil Level Switch 17 - Alternator 24 - Windshield Washer Tank
4 - Work Light 11 - Solenoid Valve Unit 18 - Overheat Switch 25 - MC (Main Controller)
5 - Fuel Sensor 12 - EC Sensor 19 - Coolant Temperature 26 - Fuse Box
Sensor
6 - Low Fuel Level Switch 13 - EC Motor 20 - Battery Relay 27 - PC Pressure Sensor
(5-Spool Side)
7 - PC Pressure Sensor 14 - Pump Delivery Pressure 21 - Coolant Level Switch
(4-Spool Side) Sensor

T1-2-2
 GENERAL / Component Layout
ELECTRICAL SYSTEM (Relays)

1
2
3
4
5
6
7
8
9

13

14

10
11
12 16 15 T155-01-01-007

T157-01-01-007

1- Wiper Relay (R14) 5- Horn Relay (R5) 9- Load Dump Relay (R1) 13 - Fusible Link
2- Wiper Relay (R8) 6- Work Light Relay (R4) 10 - Air Conditioner Relay (R10) 14 - Battery Relay
3- Wiper Relay (R7) 7- Work Light Relay (R3) 11 - Air Conditioner Relay (R12) 15 - Fusible Link
4- Wiper Relay (R6) 8- Windshield Washer Relay 12 - Air Conditioner Relay (R11) 16 - Glow Plug Relay
(R2)

T1-2-3
 GENERAL / Component Layout
ELECTRICAL SYSTEM
(Monitor and Switch Panels)

10
24 11
1
12

2 13
23
14
22
21 15
3 20 16
19 17
18

T157-07-02-001

5
25

4 6
7

8 32
26

27
31

28

30

T157-01-01-041 29 T157-01-01-018

1 - * Solar Radiation Sensor 9 - Air Conditioner Panel 17 - Fuel Level Indicator 25 - Work Light Switch
2 - Monitor Panel 10 - Warm Up Complete 18 - Overheat Indicator 26 - Wiper Switch
Indicator
3 - Switch Panel 11 - Fuel Gauge 19 - Alternator Indicator 27 - Travel Mode Switch
4 - Key Switch 12 - E Mode Indicator 20 - Engine Oil Pressure 28 - Work Mode Select Switch
Indicator
5 - Cigar Lighter 13 - Auto-Idle Indicator 21 - Engine Oil Level Indicator 29 - Buzzer Stop Switch
6 - HP Mode Switch 14 - Hydraulic Oil Level 22 - Coolant Level Indicator 30 - Auto-Idle Switch
Indicator
7 - E Mode Switch 15 - Preheat Indicator 23 - HP Mode Indicator 31 - Washer Switch
8 - Engine Control Dial 16 - Air Filter Restriction 24 - Coolant Temperature 32 - Level Check Switch
Indicator Gauge

NOTE: * Machines produced from beginning

Aug.’98.

T1-2-4
 GENERAL / Component Layout
PUMP AND RELATED PARTS

1 2 3 4 5

T154-01-01-003

11 10 9 8

1 - Pilot Pump 4 - EC Motor 7 - Pilot Filter 10 - Pump Delivery Pressure

Sensor (Pump 2)
2 - Regulator (Pump 2) 5 - EC Sensor 8 - Pump Delivery Pressure 11 - Pump 2
Sensor (Pump 1)
3 - Regulator (Pump 1) 6 - Pilot Relief Valve 9 - Pump 1

T1-2-5
 GENERAL / Component Layout
OTHER COMPONENTS

Swing Device 1 Shockless Valve

4
5

9
6
7
8 T157-07-03-018

T155-01-01-005 Solenoid Valve Unit

Travel Device

10
2 3 11

T155-01-01-006
W155-02-11-004

1 - Swing Relief Valve 4 - Shockless Valve 7 - Shockless Valve 10 - Solenoid Valve Unit (SC)
2 - Counterbalance Valve 5 - Pressure Switch 8 - Check Valve 11 - Solenoid Valve Unit (SI)
(Boom Raise)
3 - Travel Relief Valve 6 - Check Valve 9 - Pressure Sensor
(Arm Roll-In)

T1-2-6
 SECTION 2
SYSTEM

—CONTENTS—
Group 1 Control System
Outline..................................................... T2-1-1
Engine Control......................................... T2-1-2
Valve Control ........................................... T2-1-8
Other Control Function ...........................T2-1-11

Group 2 Hydraulic System

Main Circuit ............................................. T2-2-1
Pilot Circuit .............................................. T2-2-2
Neutral Circuit.......................................... T2-2-3
Single Actuator Operation ........................ T2-2-3
Combined Operation................................ T2-2-4

Group 3 Electrical System

Outline..................................................... T2-3-1
Electric Power Circuit .............................. T2-3-2
Bulb Check Circuit ................................... T2-3-3
Preheat Circuit......................................... T2-3-4
Starting Circuit......................................... T2-3-6
Charging Circuit....................................... T2-3-8
Surge Voltage Prevention Circuit ............T2-3-11
Accessory Circuit................................... T2-3-12
Engine Stop Circuit ................................ T2-3-13

155T-2-1
(Blank)

155T-2-2
 SYSTEM / Control System
OUTLINE

Micromputer built-in main controller (MC) is provided After processing the sensing signals in the logic
to control machine operation. Electronic sensing circuits, the MC sends out the control signals to the
signals from the engine control dial, various sensors EC motor, and solenoid valve unit to control the engine
and switches are sent to the MC. and valve operations.

Sensing Signals (Input Signals) Control Signals (Output Signals)

• EC Sensor → → EC Motor Normal Control

• Engine Control Dial → : Engine Control HP Mo+de Control
• Pump Control Pressure Sensor → E Mode Control
• Pump Delivery Pressure Sensor → Auto-Idle Control
• Pressure Switches (Travel and Front) → Engine Learning Control
• Pilot Pressure Sensor (Arm Roll-In) →
• Pilot Pressure Switch (Boom Raise) → → Solenoid Valve Arm Regenerative Control
• Auto-Idle Switch → (SC, SI) Travel Motor Swash Angle
• Learning Switch → : Valve Control Control
• HP Mode Switch →
• Travel Mode Switch → → Work Mode Control
• Work Mode Switch →
• Key Switch →

T2-1-1
 SYSTEM / Control System
ENGINE CONTROL

The engine control system has the following control

functions:

• Normal Control
• HP Mode Control
• E Mode Control
• Auto-Idle Control
• Engine Learning Control

Layout of Engine Control System

T157-04-04-027

T2-1-2
 SYSTEM / Control System
Normal Control

Purpose: To control engine speed in response to

the operation angle of the engine control
dial on the switch panel.

Operation:In response to the operation angle of the

engine control dial, the MC drives the EC
motor, causing the governor lever to
move to control engine speed.

NOTE: Normally, the governor lever does not

come into contact with the full side stopper
even if the engine control dial is turned to
the full speed position. (Refer to HP Mode
Control)

T157-04-04-028

T2-1-3
 SYSTEM / Control System
HP Mode Control

Purpose: To instantaneously increase the engine

speed only when a little more hydraulic
power is required for arm roll-in
operation. For example, to increase the
arm roll-in power while conducting a deep
ditching work.

Operation:Only when the following conditions are

satisfied, the MC drives the EC motor to
operate the engine faster than normal
operation.

• Engine Control Dial Setting: 1500 min-1 or faster

• HP Mode Switch: ON
• Operation: Arm Roll-In
• Average Delivery Pressures of Pump 1 and 2:
Higher Range
NOTE: The engine governor stopper position is
adjusted in accordance with the HP mode
operation. Therefore, the governor lever
does not come into contact with the T157-04-03-002
stopper in the Normal Control mode.

T157-04-04-030

T2-1-4
 SYSTEM / Control System
E Mode Control

Purpose: To decrease the engine speed at a fixed

rate.

Operation:When the E mode switch is ON, the MC

instructs the EC motor to run the engine
in the speed range slower than normal
operation in proportion to the engine
control dial set angle.

T157-04-03-001

T157-04-04-030

T2-1-5
 SYSTEM / Control System
Auto-Idle Control

Purpose: To slow the engine speed when all control

levers are in neutral to reduce fuel
consumption and noise.

Operation:When the auto-idle switch is ON and all

control levers are kept in neutral (the
pressure switches for travel and front
operations are off) for more than four
seconds, the MC instructs the EC motor
to reduce the engine speed to the auto-
idle speed.

T157-04-04-031

T2-1-6
 SYSTEM / Control System
Engine Learning Control

Purpose: To check the governor lever stopper

positions to run the engine at full-speed
or to stop as engine control standard
data.

Operation:When the learning switch in the rear

console is turned to the engine learning
side, the EC motor is driven by the signal
from the MC. Then, the EC motor moves
the governor lever to the Idle, FULL, and
STOP positions in order. Thereby, the EC
sensor checks the stopper positions for
the FULL and STOP operation. The
signals corresponding to each stopper
position are sent to the MC from the EC
sensor, and the MC stores the data.

IMPORTANT: Be sure to operate the engine

learning control system after
replacing the engine, engine control
cable, EC motor, or MC.
T157-07-04-001

NOTE: The replacement of batteries does not

require operation of the engine learning
control system.

T157-04-04-032

T2-1-7
 SYSTEM / Control System
VALVE CONTROL

The valve control consists of the arm regenerative

control, and travel motor swash angle control.

T155-04-04-005

T2-1-8
 SYSTEM / Control System
Arm Regenerative Control

Purpose: To increase arm roll-in speed and prevent Operation Conditions:

the arm roll-in hesitation. Pump Delivery Pressure Sensor (Pump 2): Delivery
pressure from pump 2 is low (requiring less arm
Operation:When the signals to the MC from the operating force).
pump delivery pressure sensor (pump 2), Pilot Pressure Sensor (Arm Roll-In): Output is large
pilot pressure sensor (arm roll-in), and (operating the arm control lever with a great stroke).
pressure switch (boom raise) fall into the Pressure Switch (Boom Raise): ON
following conditions, the MC magnetizes
the solenoid valve unit (SC). Then, the
solenoid valve (SC) starts to deliver the
pilot pressure to actuate the arm
regenerative valve, closing the return
circuit to the hydraulic oil tank from the
arm cylinder rod side.
Thereby, the return oil from the arm
cylinder rod side is combined with the
pump delivery oil and supplied to the arm
cylinder bottom side, increasing the arm
roll-in speed and preventing arm roll-in
hesitation.

T155-04-04-006

T2-1-9
 SYSTEM / Control System
Travel Motor Swash Angle Control

Purpose: To change high/low travel speed. Operation Conditions:

Pressure Switch (Travel): ON
Operation:When the travel mode switch is in Pressure Switch (Front): OFF
position, the travel motor swash angle is Pump Delivery Pressure Sensors (Pump 1 and 2):
held at a large angle, causing the Pump delivery pressure is low.
machine to travel at a slow speed. Pump Displacement Target Angle (controlled by the
MC according to signals from sensors and
When the travel mode switch is in
switches): Large
position and the signals to the MC from
the pressure switch (travel), pump
delivery pressure sensors (pump 1 and 2) NOTE: Even if the track is revolved with the track
fall into the following conditions, the MC raised, one side pump displacement target
magnetizes solenoid valve (SI), allowing angle remains small so that the travel
pilot oil pressure to change the travel motor speed does not increase.
motor swash angle control valve port. The pump displacement target angle is
Thereby, the travel motor swash angle is different from the travel motor
reduced to cause the machine to travel at displacement target angle.
a fast speed.

T155-04-04-007

T2-1-10
 SYSTEM / Control System
OTHER CONTROL FUNCTION

Work Mode Control

The work mode includes the four modes of

GENERAL PURPOSE, GRADING, PRECISION,
and ATTACHMENT, which can be selected by the
work mode switch.

General Purpose Mode:

Normal control is applied.

Grading Mode:
To decrease the arm leveling speed, the arm
regenerative control is deactivated.
(Refer to T2-1-9)

Precision Mode:
Engine speed is reduced to 70 % of the full speed
to be set when the engine control dial is placed in
the full position.

NOTE: Operating speed is reduced but operating

force is unchanged.

Attachment Mode:
Only when the attachment option kit is installed,
this function works. In proportion to the auxiliary
pilot valve lever stroke, the engine speed is
controlled by the MC so as to meet the installed
attachment operation. The engine speed setting
for the attachment mode is made by the Dr.EX.

NOTE: On the machines with MC version 0300

and after, the attachment mode functions
when the HP mode switch is ON.

T2-1-11
 SYSTEM / Control System
(Blank)

T2-1-12
 SYSTEM / Hydraulic System
MAIN CIRCUIT

The main pumps (pump 1 and pump 2) draw hydraulic Return oil from the motors and cylinders flows back to
oil from the hydraulic oil tank. Pump 1 delivers oil to the hydraulic oil tank via the control valves and the oil
the 4-spool control valve while pump 2 delivers oil to cooler. When oil temperature is low (viscosity is high),
the 5-spool control valve. return oil flowing through the oil cooler will be
Pressure oil from the main pumps are routed to the hampered because of the increased flow resistance in
motors and cylinders in response to respective control the oil cooler. If that happens, the bypass check valve
valve spool shifts. opens, allowing the return oil to directly flow back to
the hydraulic oil tank.

T157-04-03-003

T2-2-1
 SYSTEM / Hydraulic System
PILOT CIRCUIT

Pressure oil from the pilot pump acts as working

pressure in pilot operating circuit, in the pump/valve
control circuit, and in the swing parking brake release
line.

T2-2-2
 SYSTEM / Hydraulic System
NEUTRAL CIRCUIT SINGLE ACTUATOR OPERATION

When the control levers are in neutral, pressure oil Pressure oil from pump 1 flows to the spools (Travel
from the main pumps returns to the hydraulic oil tank (R), Bucket, Boom 1, and Arm 2) in the 4-spool side
via the control valves. (Refer to the Control Valve section in the control valve. Pressure oil from pump 2
Group in the COMPORNENT OPERATION.) flows to the spools (Swing, Arm 1, Boom 2 , Aux., and
Travel (L))in the 5-spool control valve.
When arm or boom is operated, pressure oil from both
pumps is combined and flows together into the
respective cylinder.

T155-04-03-007

T2-2-3
 SYSTEM / Hydraulic System
COMBINED OPERATION

Swing and Boom Raise Operation

When swing and boom raise operations are The detoured oil flow is combined with the oil flow
performed at the same time, pilot pressure shifts the from pump 1 after flowing through the parallel passage
swing, boom 1, and boom 2 spools in the control and boom 2 spool in the 5-spool control valve. The
valves. boom is raised by combined oil flow from pump 1 and
Then, pressure oil from pump 1 flows into the boom pump 2.
cylinder via the parallel passage in the 4-spool side
section in the control valve to raise the boom.
Pressure oil from pump 2 flows into the swing motor
to swing the upperstructure. A portion of the
pressure oil from pump 2 is detoured to the boom
cylinder.

T155-04-03-008

T2-2-4
 SYSTEM / Hydraulic System
Travel and Arm Roll-In Operation

When travel and arm roll-in operations are A portion of the pressure oil from pump 1 is detoured
performed at the same time, pilot pressure shifts the to the left travel motor via the flow combiner valve and
travel, arm 1, and arm 2 spools. Pressure in the travel (L) spool, actuating it. For this reason, the
front att. signal pilot pressure circuit rises due to machine can travel straight even when the arm roll-in
arm spool movement, shifting flow combiner valve. operation is performed at the same time, blocking oil
Then, pressure oil from pump 1 flows into the right flow from pump 2 to the left travel motor.
travel motor via the travel (R) spool, actuating it. Pressure oil from pump 2 flows into the arm cylinder
via the arm 1 spool, actuating it.

T155-04-03-006

T2-2-5
 SYSTEM / Hydraulic System
(Blank)

T2-2-6
 SYSTEM / Electrical System
OUTLINE

The electrical system is classified into the main circuit,

control circuit, and monitor circuit.

• Main circuit operates the engine and accessories.

• Control circuit functions to control operations of the

engine, hydraulic pump, and valves (including
actuators such as solenoid valves, MC (Main
Controller), switch box, sensors, and pressure
switches).

• Monitor circuit operates the monitor devices

consisting of the monitors, sensors, and switches.

In this group, the functions and construction of the

main circuit are introduced.

• Electric Power Circuit:

Supplies electric power to all electric system on this
machine.
(Key Switch, Batteries, Fuses (Fuse Box and
Fusible Links), Battery Relay)

• Bulb Check Circuit:

Checks for blown indicator bulbs.
(Key Switch, Battery Relay, Fuses, Monitor)

• Preheat Circuit:
Helps start the engine in cold weather.
(Key Switch, Glow Plug Relay, Glow Plug)

• Starting Circuit:
starts the engine.
(Key Switch, Starter, Starter Relay)

• Charging Circuit:
Recharges batteries and supplies consumption
electricity.
(Alternator, (Regulator) )

• Surge Voltage Prevention Circuit:

Prevents surge voltage from occurring when the
engine is suddenly stopped.
(Load Dump Relay)

• Accessory Circuit:
Works with the key switch placed in the ACC
position.
(Key Switch, Battery, Fuses)

• Engine Stop Circuit:

Stops the engine with the EC motor.
(MC, EC Motor)

T2-3-1
 SYSTEM / Electrical System
ELECTRIC POWER CIRCUIT
(KEY SWITCH: OFF)

The battery negative terminal is grounded to the

vehicle. Current from the positive terminal flows as
follows with the key switch OFF.

→ Glow Plug Relay (Power Source)

Battery → Fusible Link → Key Switch B Terminal No.1 → Backup Power Source
→ Load Dump Relay Terminal No.2 → MC (Power Source)
→ Fuse Box Terminal No.3 → MC (EC Motor)
Terminal No.9 → Optional
Terminal No.14 → Air Conditioner

T157-04-02-001

T2-3-2
 SYSTEM / Electrical System
BULB CHECK CIRCUIT
(KEY SWITCH: ON)

When the key switch is turned to the ON position, key At the same time, the battery power via the fuse box is
switch terminal B connects with key switch terminals supplied as power source to the work lights, wiper,
M and ACC. heater, MC (solenoid valve power source), and
The current from terminal M excites the battery relay. optional circuits.
Then, the battery power is routed to the fuse box,
turning the indicators on (for bulb check)

T157-04-02-010

T2-3-3
 SYSTEM / Electrical System
PREHEAT CIRCUIT
(KEY SWITCH: HEAT)

When the key switch is turned to the Preheat position, Current from the batteries flows to the glow plugs via
the key switch terminal B is connected to terminal G1 the glow plug relay. Approx. 20 seconds passes after
in the switch. After flowing through the fuse box, the preheat is started, the monitor timer turns the preheat
current from terminal G1 magnetizes the glow plug indicator OFF, informing that engine preheating has
relays, operates the monitor, and lights the preheat been completed.
indicator.

T157-04-02-002

T2-3-4
 SYSTEM / Electrical System
(Blank)

T2-3-5
 SYSTEM / Electrical System
STARTING CIRCUIT
(KEY SWITCH: START)

When the key switch is turned to the START position, Starter Relay Operation
terminal B on the key switch is connected to terminals
G2, M, and ST in the switch. The current from terminal • When the key switch is turned to the START
M magnetizes the battery relay, leading the battery position, key switch terminal B and terminal ST
current to terminals B on the starter and starter relay have continuity in the key switch. Then, the
via the battery relay. current flows to the base of transistor (Q2) via
Terminal ST of the key switch is connected to terminal resistance R4 in the starter relay, switching
S on the starter relay so that the battery current flows transistor (Q2) ON. Thereby, the current flows
through the coil in the starter relay, allowing the relay through coil (L), closing the circuit between starter
to close the circuit. Then, the battery current can flow terminals B and C. Then, the starter begins to
to terminal C on the starter, closing the inner starter rotate.
relay. Thereby, the starter begins to rotate. • Once the engine is started, the alternator begins
Terminal G2 has continuity with terminal G1 by wiring. to charge the batteries so that the voltage at
Therefore, the battery current flows to the preheat starter relay terminal R rises. When the voltage at
circuit when the key switch is positioned at START, terminal R reaches 21 to 22 V, zener diode (Z)
leading the current to the glow plugs. becomes ON. Accordingly, transistor (Q1) is
The current from terminal M flows to the MC, switched ON so that the base current to transistor
instructing that the key switch is positioned at ON or (Q2) is cut, switching transistor (Q2) OFF. At this
START. When this signal arrives at the MC, the MC time, continuity between starter terminal B and C
actuates the EC motor which moves the governor is opened. Then, the starter is switched OFF.
lever.
Capacitor C1 shown in the figure is used to stabilize
the operating voltage. Diode D4 protects the circuit
from damage when the batteries are inversely
connected.

T107-04-04-003

T2-3-6
SYSTEM / Electrical System

T157-04-02-003

T2-3-7
 SYSTEM / Electrical System
CHARGING CIRCUIT (KEY SWITCH: ON)

After the engine starts and the key switch is released, In addition, this current is supplied through the fuse
the key switch is returned to the ON position. With the box as a power source to the solenoid valve, switch
key switch kept ON, key switch terminal B is box, hour meter, work lights, wiper, and heater.
connected to terminals ACC and M. Current from terminal L flows to the monitor to turn off
After the engine starts, the alternator begins to the alternator indicator.
recharge the batteries. Current from terminal B on the
alternator flows to the batteries through the battery
relay recharging the batteries.

T157-04-02-011

T2-3-8
 SYSTEM / Electrical System
Power Generation

The alternator consists of field coil FC, stator coil When the key switch is turned ON, the battery voltage
SC, and diodes D. is applied to base B for transistor T1 in the regulator,
The regulator consists of transistors T1 and T2, allowing current to flow from collector C to emitter E.
zener diode ZD, and resistors R1 and R2. Accordingly, field coil FC is grounded through
transistor T1. Then, when the rotor starts to rotate,
Alternator terminal B is connected to: alternating voltage is generated in stator coil SC due
to residual magnetism in the rotor.
(R)→R1→Base B for Transistor T1 Thereby, the current starts to flow through field coil
B→R→RF FC, magnetizing the rotor further and increasing
FC→(F)→Collector C for Transistor generating voltage.
T1 As generating voltage increases, the flowing current
through field coil FC is increased further, causing the
generating voltage to increase more. Thus, the
batteries are recharged.

T157-04-02-008

T2-3-9
 SYSTEM / Electrical System
Regulator Operation

When the generating voltage increases higher than Then, when the voltage to be applied to zener diode
the set voltage of zener diode ZD, the current from ZD becomes lower than the set voltage of zener diode
the alternator flows through the zener diode to base ZD, transistor T2 is turned OFF, turning transistor T1
B for transistor T2, connecting collector C to emitter ON again. Thus, the current is allowed to flow through
E. Accordingly, the current flowing through base B field coil FC to increase the generating voltage by
for transistor T1 is cut so that transistor T1 is turned stator coil SC. As this operation is repeated, the
OFF. Thereby, the current flowing through field coil alternator generating voltage is maintained at the
FC is cut, causing the SC generating voltage to specified level.
decrease.

T157-04-02-009

T2-3-10
 SYSTEM / Electrical System
SURGE VOLTAGE PREVENTION CIRCUIT

The surge voltage prevention circuit protects the Thereby, the battery current is supplied to the
electrical parts and components in the controller from magnetizing circuit for the load dump relay to close the
being damaged by the alternator generating surge load dump relay. Accordingly, even if the key switch is
current developed when the engine is suddenly turned OFF while the engine is running, the battery
stopped. current can be supplied through the load dump relay to
While the batteries are being recharged, the magnetize the battery relay, holding the battery relay
generating current from terminal L on the alternator is ON until the alternator stops generating.
led to terminal 42 on the monitor, turning the transistor
ON for terminal 18 on the monitor.

T157-04-02-005

T2-3-11
 SYSTEM / Electrical System
ACCESSORY CIRCUIT
(KEY SWITCH: ACC)

When the key switch is turned to the ACC position,

terminal ACC is connected to terminal B in the key
switch.
Then, the battery current flows through the fuse box to
each accessory circuit such as the horn, radio, cigar
lighter, dome light, and to the auxiliary circuit to
operate them.

T157-04-02-006

T2-3-12
 SYSTEM / Electrical System
ENGINE STOP CIRCUIT
(KEY SWITCH: OFF)

When the key switch is turned from the ON position to

the OFF position, the signal instructing the MC that the
key switch is ON is cut.
Then, the MC moves the EC motor to the stop
position, causing the engine to stop.

T157-04-02-007

T2-3-13
 SYSTEM / Electrical System
(Blank)

T2-3-14
 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................................................. T3-1-5
Pilot Pump ............................................. T3-1-12 Group 5 Travel Device
Pump Delivery Pressure Sensor ............ T3-1-12 Outline ..................................................... T3-5-1
Travel Reduction Gear ............................. T3-5-2
Group 2 Swing Device Travel Motor ............................................ T3-5-3
Outline..................................................... T3-2-1 Travel Brake Valve................................. T3-5-10
Swing Motor ............................................ T3-2-2 Parking Brake ........................................ T3-5-14
Brake Valve ............................................. T3-2-4
Swing Parking Brake ............................... T3-2-6 Group 6 Others (Upperstructure)
Swing Reduction Gear ............................. T3-2-7 Pilot Shut-Off Valve.................................. T3-6-1
Shockless Valve....................................... T3-6-2
Group 3 Control Valve Solenoid Valve Unit.................................. T3-6-4
Outline..................................................... T3-3-1 Pilot Relief Valve...................................... T3-6-6
Hydraulic Circuit ...................................... T3-3-6 EC Motor ................................................. T3-6-6
Flow Combiner Valve ............................... T3-3-8
Pump Control Valve ................................. T3-3-9 Group 7 Others (Undercarriage)
Main Relief Valve ....................................T3-3-11 Swing Bearing.......................................... T3-7-1
Overload Relief Valve Center Joint ............................................. T3-7-2
(With Make-Up Function) .......................T3-3-11 Track Adjuster ......................................... T3-7-3
Arm Regenerative Valve ........................ T3-3-12
Boom Anti-Drift Valve,
Arm Anti-Drift Valve .............................. T3-3-14
Bucket Flow Control Valve ..................... T3-3-14
Travel Flow Control Valve ...................... T3-3-16
Travel / Boom Lower
Selector Valve....................................... T3-3-16
Boom Regenerative Valve...................... T3-3-18

155T-3-1
(Blank)

155T-3-2
 COMPONENT OPERATION / Pump Device
OUTLINE

The pump device consists of a transmission, main The main pumps are variable displacement, bent-axis
pump, and pilot pump. The transmission receives plunger-type pumps equipped with the pump delivery
engine power via coupling, then divides and transmits pressure sensors for controlling of the valves.
the power to the pump 1, the pump 2 and the pilot These main pumps are incorporated into a single
pump via gears. Gear ratios on the main pump drive housing.
side is 1, the pilot pump side is 0.871. Pilot pump is a gear-type pump.
The transmission is lubricated with gear oil.

W155-02-04-030

Pilot Pump Pump 2 Pump 1 Transmission

T154-02-01-001

Pump Delivery W155-02-04-029

Pressure Sensor

T3-1-1
 COMPONENT OPERATION / Pump Device
MAIN PUMP

Main pump consists of pump 1 and pump 2, and Therefore, the rotation of the shaft is transferred to the
supplies hydraulic oil to actuate main components cylinder block, causing the plungers to reciprocate in
such as motors and/or cylinders. the cylinder bores, thus discharging hydraulic oil to the
The pump shaft is connected to the cylinder block via hydraulic circuits.
seven plungers.

W157-02-04-010

2
6

W155-02-04-032
4

W155-02-04-001

1 - Regulator 3 - Shaft 5 - Valve Plate 6 - Cylinder Block

2 - Housing 4 - Plunger

T3-1-2
 COMPONENT OPERATION / Pump Device
Engine torque is transferred to seven plungers via the
shaft, causing cylinder block to slide along the surface
of the valve plate; The plungers move in and out of
their bores in the cylinder block to alternatively suck
and deliver hydraulic oil.

Plunger

Valve Plate

Shaft

Cylinder Block

T105-02-03-002

T3-1-3
 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
changing the displacement angle of cylinder block contact with the surface of valve plate (4) and slides
(3). Servo piston (6) is jointed to valve plate (4) with along it.
pin (5).

Maximum displacement angle;

3
2

α
5

6
W155-02-04-032
4 2
3
T105-02-03-021

Minimum displacement angle;

T105-02-03-022

2 - Plunger 4 - Valve Plate 6 - Servo Piston

3 - Cylinder Block 5 - Pin

T3-1-4
 COMPONENT OPERATION / Pump Device
REGULATOR

Regulator Construction

Both main pumps (1 and 2) are equipped with a The pump control pressure is routed to section 1
regulator. Upon receiving various signal pressures, and the applicable main pump pressure and the
the regulator controls main pump oil flow rate not to other main pump pressure are routed to the section
exceed the engine horsepower. 2 of the regulator. (Note that, viewed from a
Regulator mainly consists of spring (1), sleeve B (2), regulator, two main pumps are said to be the
spool B (3), piston (4), load piston (5), spool A (6), applicable main pump and the other main pump.)
sleeve A (7), outer spring (8), and inner spring (9). Upon receiving the signal pressures stated above,
the regulator outputs a pilot pressure to servo piston
(10) to change the displacement angle of cylinder
block (11), thus controlling the pump oil flow rate.

1 2 3 4

Section 1

Section 2

W155-02-04-003
5 6 7 8 9

12
11

10

W155-02-04-032
1 - Spring 4 - Piston 7 - Sleeve A 10 - Servo Piston
2 - Sleeve B 5 - Load Piston 8 - Outer Spring 11 - Cylinder Block
3 - Spool B 6 - Spool A 9 - Inner Spring 12 - Link

T3-1-5
 COMPONENT OPERATION / Pump Device
Regulator Functions

The regulator functions to control pump oil flow rate

as follows:

• Control by Pump Control Pressure

The pump control valve attached on the control
valve regulates the pump control pressure. Upon Q
receiving the pump control pressure from the
pump control valve, the regulator increases or Flow
decreases the pump flow rate accordingly. Rate
When the control valve spool is moved to in-
crease the pump control pressure, the regulator
increases the pump flow rate.
When the control valve spool is returned to neu-
tral, the pump control pressure decreases.
Accordingly, the regulator reduces the pump flow
rate to the minimum flow. (Refer to the Control 0 Pump Control Pressure Pi
Valve Group.)

• Summation Control (Control by monitoring both

main pump pressures)
If the delivery oil pressure of either of two main Q
Pressure Increase
pumps increases so that the average pressure of Flow
two main pumps exceeds the values set by the P- Rate Flow Rate Decrease
Q line, the regulator functions to reduce pump oil
flow rate of both main pumps to match the P-Q
value to the one on the set P-Q line, preventing
engine overloading.
Since the P-Q line is set using the average pres-
sure of two main pump pressures, delivery rates
of both pumps are approximately equal to each 0
Pressure P
other.
For this reason, a larger load is applied to the
pump delivering high pressure oil while a smaller
load is applied to the pump delivering low pres-
sure oil, keeping the total load applied to the
pumps equal with the engine horsepower output,
(Total Horsepower Control)

T3-1-6
 COMPONENT OPERATION / Pump Device
Regulator Operation 3 6 2 1

12
10

9
11
13
Pd1 Pd2

7 4 5 T157-02-03-012

3 2 6 1

Pi

Pd1
11, 12

Pd2

9 13 10

7 4 8 T157-02-03-013

1- Piston 5 - Link 8 - Small Chamber 11 - Inner Spring

2- Spool B 6 - Sleeve B 9 - Load Piston 12 - Outer Spring
3- Spring 7 - Large Chamber 10 - Spool A 13 - Sleeve A
4- Servo Piston

T3-1-7
 COMPONENT OPERATION / Pump Device
• Flow Rate Control by Pump Control Pressure

Flow Rate Increase:

1. Pump control pressure Pi increases when a 6. The movement of servo piston (4) is transmitted
control valve spool is moved. to sleeve B (6) via link (5), moving sleeve B (6) in
2. Piston (1) pushes spool B (2) and spring (3) to the direction that spool B (2) has moved. When
move spool B (2) to the direction indicated by the sleeve B (6) moves for the same distance spool B
arrow. (2) has moved, large chamber (7) is closed to the
3. Large chamber (7) at the end of servo piston (4) hydraulic oil tank line, stopping the servo piston
is connected to the hydraulic oil tank line. movement, thus stopping the increase of pump
4. As a result, servo piston (4) moves to the flow rate at that point.
direction indicated by the arrow.
5. The displacement angle of the cylinder block is
changed by the movement of the servo piston,
increasing the pump flow rate.
3 6 2 1

Pressure
Pi IIncrease

Flow
Rate

Pd1 Pd2

0 Pump Control Pi
Pressure 8

T157-02-03-003
7 4 5

1 - Piston 3 - Spring 5 - Link 7 - Large Chamber

2 - Spool B 4 - Servo Piston 6 - Sleeve B 8 - Small Chamber

T3-1-8
 COMPONENT OPERATION / Pump Device
Flow Rate Decrease:

1. When the control valve spool is returned to 6. The movement of servo piston (4) is transmitted
neutral, the pump control pressure Pi decreases. to sleeve B (6) via link (5), moving sleeve B (6) in
2. Spring (3) pushes back piston (1) and spool B (2), the direction that spool B (2) has moved. When
returning spool B (2) to the direction indicated by sleeve B (6) moves for the same distance spool B
the arrow. (2) has moved, large chamber (7) is closed to the
3. As a result, the servo pressure acting on small hydraulic oil tank line, stopping the servo piston
chamber (8) is also routed to large chamber (7). movement, thus stopping the decrease of pump
4. Servo piston (4) moves in the direction indicated flow rate at that point.
by the arrow, due to the size difference of the
pressure receiving area between both chambers.
5. The displacement angle of the pump decreases.
3 6 2 1

Pressure
Pi Decrease

Flow
Rate

Pd1 Pd2

0 8
Pi

T157-02-03-004
7 4 5

1 - Piston 3 - Spring 5 - Link 7 - Large Chamber

2 - Spool B 4 - Servo Piston 6 - Sleeve B 8 - Small Chamber

T3-1-9
 COMPONENT OPERATION / Pump Device
• Summation Control (Flow Rate Control by
Monitoring Both Main Pump Pressures)

Flow Rate Increase:

(Note that, viewed from a regulator, two main pumps 5. As the servo piston moves, the displacement
are said to be the applicable main pump and the angle of the cylinder block changes, increasing
other main pump.) the pump flow rate.
6. The movement of servo piston (4) is transmitted
1. The pressure from the applicable main pump to sleeve A (13) via link (5), moving sleeve A (13)
(Pressure Pd1) or from the other main pump in the direction spool A (10) has moved. When
(Pressure Pd2) decreases. sleeve A (13) moves for the same distance spool
2. Inner spring (11) and outer spring (12) pushes A (10) has moved, large chamber (7) is closed to
load piston (9) and spool A (10), moving them in the hydraulic oil tank line, stopping the servo
the direction indicated by the arrow. piston movement, thus stopping the increase of
3. Large chamber (7) at the end of servo piston (4) pump flow rate at that point.
is connected to the hydraulic oil tank line.
4. As a result, servo piston (4) moves in the
direction indicated by the arrow.

9 13 10

Pi

11

Flow 12
Rate
Pd1 Pd2
Pressure
Decrease

8
0 (Summation of Two Pd
Main Pump Pressures)

T157-02-03-003
7 4 5

4 - Servo Piston 8 - Small Chamber 10 - Spool A 12 - Outer Spring

5 - Link 9 - Load Piston 11 - Inner Spring 13 - Sleeve A
7 - Large Chamber

T3-1-10
 COMPONENT OPERATION / Pump Device
Flow Rate Decrease:

1. The pressure from the applicable main pump 5. The displacement angle of the pump decreases.
(Pressure Pd1) or from the other main pump 6. When sleeve A (13) moves for the same distance
(Pressure Pd2) increases. spool A (10) has moved, servo pressure routed to
2. Load piston (9) pushes spool A (10), inner spring large chamber (7) is shut out, stopping the servo
(11), and outer spring (12), moving spool A (10) in piston movement, thus stopping the decrease of
the direction indicated by the arrow. pump flow rate at that point.
3. As a result, the servo pressure acting on small
chamber (8) is also routed to large chamber (7).
4. Servo piston (4) moves in the direction indicated
by the arrow, due to the size difference of the
pressure receiving area between both chambers.

9 13 10 11

Pi

Flow
Rate
12

Pd1 Pd2
Pressure
IIncrease

0 (Summation of Two Pd 8
Main Pump Pressures)

T157-02-03-005
4 7

4 - Servo Piston 8 - Small Chamber 10 - Spool A 12 - Outer Spring

5 - Link 9 - Load Piston 11 - Inner Spring 13 - Sleeve A
7 - Large Chamber

T3-1-11
 COMPONENT OPERATION / Pump Device
PILOT PUMP
Suction Port
The drive gear is rotated via the transmission to drive Driven Gear Drive Gear
the driven gear.

Delivery Port

T137-02-03-005

PUMP DELEVERY PRESSURE SENSOR

The pump delivery pressure sensor detects the pump

delivery pressure which is required for various con-
trols.
Oil pressure is received by diaphragm (4).
Depending on the extent of diaphragm deformation, oil
pressure is detected as an electrical signal.

1 - Grounding Terminal 3 - Power Source (5V)

2 - Output Terminal 4 - Pressure Receiving T157-02-03-010
Section (Diaphragm)
1 2 3 4

T3-1-12
 COMPONENT OPERATION / Swing Device
OUTLINE

The swing device consists of the valve unit, the swing

motor unit, and the swing reduction gear unit.

Valve Unit

Swing Motor

Swing Reduction Gear

Unit

T105-02-04-017

T3-2-1
 COMPONENT OPERATION / Swing Device
SWING MOTOR

The swing motor is a swash-plate-type axial plunger

motor.
The major parts of the motor are: fixed-type swash
plate (5), rotor (9), plungers (8), valve plate (3), motor
housing (6), and the parking brake. 3
The parking brake is a wet-type multiple disc brake,
consisting of plates (1) and friction plates (2). 1
Shoes (4) are caulked to each plunger (8) and nine
2
plungers with shoes are provided in rotor (9).
Rotor (9) is installed onto shaft (7) with a spline
coupling. 4
9
5
8

7
T105-02-04-020
1 - Center Plate 4 - Shoe 6 - Motor Housing 8 - Plunger
2 - Friction Prate 5 - Fixed-Type Swash Plate 7 - Shaft 9 - Rotor
3 - Valve Plate

T3-2-2
 COMPONENT OPERATION / Swing Device
Swing speed varies depending on the amount of oil
delivered from the pump. From port A, high pressure
oil is fed so that plunger (3) is moved upward from the
bottom dead center to the top dead center.
Shoe (4) then slides along swash plate (5), developing
turning force.
Turning force is transmitted to the swing reduction
gear unit via shaft (6). The return oil flows to outlet
port B and returns to the hydraulic oil tank.
When pressure oil is fed to port B, the motor rotates in
the opposite direction.

4
5

6
T107-02-04-002
1 - Valve Plate 3 - Plunger 5 - Swash Plate 6 - Shaft
2 - Rotor 4 - Shoe

T3-2-3
 COMPONENT OPERATION / Swing Device
VALVE UNIT •

The valve unit consists of the relief valve and the

make-up valve.

Relief Valve
When swinging starts or stops, oil pressure in the
swing circuit increased. The relief valve prevents the
circuit pressure from rising higher than the set pres-
sure.

• When the swing control lever is operated, the • As long an the swing control lever is neutral,
system pressure is led to the shockless spring equal pressure oil from the control valve is routed
chamber via port A (or port B) and passage A (or to the both sides of the shockless valve via pas-
passage B), moving the shockless spool to the sages A and B, holding the shockless spool in the
right (or left). Then, oil pressure in the relief valve neutral position.
spring chamber decreases.
• Unit the shockless spool reaches the stroke end,
relief pressure stays lower. When the spool
reaches the stroke end, oil pressure increases,
causing a two stage relief valve operation. As a
result, shock load is reduced when stopping Shockless Spool
swing operation. Shockless Spring Shockless Spring

Passage A
Passage B

Spring Chamber Relief Relief

in Relief Valve Valve Valve
Two Stage Relief Operation
High Pressure Relief
Operation

Pressure Make-Up
Low Pressure Relief Valve
Operation

Time T105-02-04-003

Make-Up
Valve

Port A Port B

T155-02-02-002

T3-2-4
 COMPONENT OPERATION / Swing Device
Make-Up Valve

When swing is stopped, if the upperstructure tends

to keep rotating due to swing inertia force, causing
the swing motor to continue rotating further, and to
begin sucking oil from the pump, developing
cavitation in the motor.
To alleviate this, the make-up valve sucks hydraulic
oil through the return circuit (port C) to compensate
for the lack of oil, and prevent cavitation.

D C E

Return Line

A B

Make-Up Valve
D C E

Return Line

Control Valve

T135-02-04-001

T3-2-5
 COMPONENT OPERATION / Swing Device
SWING PARKING BRAKE
1
The parking brake is a wet-type multiple disc brake. 2
The brake is released only when brake release b
pressure enters into brake piston chamber (b), Brake
(negative type brake). When swing and/or front Release
Pressure
attachment operation is made brake release pressure 3
is supplied from the pilot pump.
4
During operations other than swing and/or front, or
while the engine is stopped, brake release pressure is 5
routed to the hydraulic oil tank and the parking brake
6
is automatically applied by spring (1).

T155-02-02-001

• When the swing and/or front function is operated,

the brake is released: When the brake is released (OFF):
Oil Pressure
When the swing and/or front control lever is Timer
operated, the control valve spool for swing and/or Brake Release
front function is moved from the neutral position, Pressure
closing the spool passage for the signal pilot Signal
pressure circuit. Then, the pilot oil pressure Pilot OFF
increases, and the increased pressure pilot oil is Pressure
Circuit
sent to the pilot port of the switch valve in the brake
release circuit. Therefore, the switch valve is
opened, allowing the brake release pilot oil pressure
from the pilot pump to act on brake piston (2) via the Swing
oil pressure timer check valve. Accordingly, brake Motor
Switch Valve
piston (2) is moved up against spring (1), breaking Spool
contact between friction plates (4) and plates (3).
T157-02-04-005
Then, the brake is released.

When the brake is applied (ON): Oil Pressure

Timer
• When the swing and/or front function is not Brake Release
operated, the brake is applied: Pressure
When the swing and/or front control lever is not
operated, the control valve spool for swing and/or ON
front function is in the neutral position, holding the
spool passage for the signal pilot pressure circuit Signal Pilot
open. Then, the pilot oil pressure does not increase. Pressure
Therefore, the switch valve in the brake circuit is Circuit
kept closed, allowing the brake release pilot oil Swing
pressure on brake piston (2) to flow out to the Motor Switch Valve
hydraulic oil tank via the oil pressure timer orifice.
Accordingly, brake piston (2) is moved down by Spool
spring (1) force so that friction plates (4) come into
T157-02-04-004
contact with plates (3). As friction plates (4) engage
the inner circumference of motor housing (5) and
plates (3) engage the outer circumference of rotor
(6), is braked by friction force developed between
plates (3) and friction plates (4).

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 two-stage planetary Then, rotary power is transmitted to second stage sun
gear type. Ring gears (2 and 4) in the first and second gear (7) via first stage planetary gear (1) and first
stages are provided on the inside of the housing. stage carrier (8). Second stage sun gear (7) rotates
The housing is bolted to the main frame so that ring shaft (5) via second stage planetary gear (3) and
gears (2 and 4) are held stationary. carrier (6).
The motor output shaft of the swing motor drives first As shaft (5) meshes with the internal gear of the swing
stage sun gear (9). bearing bolted to the undercarriage, the
upperstructure is rotated.

8
1
9

W155-02-06-003

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

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

T3-2-8
 COMPONENT OPERATION / Control Valve
OUTLINE

The control valve controls oil pressure, flow rate, and In the 4-spool section, the Right Travel, Bucket, Boom
flow direction in the hydraulic circuit. A 4-spool side 1, and Arm 2 spool sections are arranged in that order
section and a 5-spool side section are bolted together. as viewed from the machine front.
The control valve is a pilot-pressure-operated type In the 5-spool side section, the Left Travel, Auxiliary,
which mainly consists of the main relief valve, pump Boom 2, Arm 1, and Swing spool sections are
control valves, flow combiner valve, and main spools. arranged in that order as viewed from the machine
front.

Swing
Machine Rear Arm 1
Boom 2
Auxiliary
Left Travel
Arm 2
Boom 1
Bucket

Right Travel
5-Spool Side Section

T155-01-01-003
Machine Front

4-Spool Side Section

T3-3-1
 COMPONENT OPERATION / Control Valve
Layout

Left Travel Motor Right Travel Motor

1 2 3 4 5 6 7 8 9 10 11

12

13
14
15

40 16

39
38
Bucket Cylinder
37
36
35
Boom Cylinder
33
34
17
Arm Cylinder

18
32

31

19
30
29 20

21
22

23
Swing Motor Pump 2 Pump 1
28 27 26 25 24 T155-04-03-005
1 - Hydraulic Timer 11 - Bucket Flow Control Valve 21 - Boom Regenerative Valve 31 - Arm Regenerative Valve
(Switch Valve B)
2 - Travel Flow Control Valve 12 - Bucket Flow Control Valve 22 - Check Valve (Arm Roll-In 32 - Overload Relief Valve
(Poppet Valve) Flow Combining) (Arm)
3 - Load Check Valve 13 - Load Check valve 23 - Pump Control Valve 33 - Overload Relief Valve
(Travel Parallel Circuit) (Boom 1 Parallel Circuit) (4-Spool Side) (Arm)
4 - Check Valve 14 - Load Check Valve 24 - Check Valve 34 - Arm Anti-Drift Valve
(Main Relief Circuit) (Boom 1 Tandem Circuit) (Check Valve)
5 - Main Relief Valve 15 - Overload Relief Valve 25 - Restriction (4-Spool Side 35 - Arm Anti-Drift Valve
(Bucket) Parallel Circuit) (Switch Valve)
6 - Check Valve 16 - Overload Relief Valve 26 - Load Check Valve 36 - Load Check Valve (Boom 2
(Main Relief Circuit) (Bucket) (Arm Parallel Circuit) Parallel Circuit)
7 - Check Valve (Flow Com- 17 - Overload Relief Valve 27 - Restriction (Arm 1 Parallel 37 - Travel/Boom Lower Se-
biner Valve Circuit) (Boom) Circuit) lector Valve
8 - Flow Combiner Valve 18 - Overload Relief Valve 28 - Load Check Valve (Swing) 38 - Load Check Valve (Aux.)
(Boom)
9 - Load Check Valve 19 - Boom Anti-Drift Valve 29 - Load Check Valve (Arm 39 - Load Check Valve
(Bucket) (Check Valve) Tandem Circuit) (Travel Tandem Circuit)
10 - Bucket Flow Control Valve 20 - Boom Anti-Drift Valve 30 - Check Valve (Arm Roll-Out 40 - Pump Control Valve
(Switch Valve A) (Switch Valve) Flow Combining) (5-Spool Side)

T3-3-2
 COMPONENT OPERATION / Control Valve

F
E Machine Front
D
C
B
A
33
Machine Front

15
2

17

11 10
T155-01-01-004
T155-01-01-003

Section A Section B

R. Travel L. Travel

8
7 40

3 2

39 1
6 5
W155-02-05-006

W155-02-05-005

T3-3-3
 COMPONENT OPERATION / Control Valve

Left Travel Motor Right Travel Motor

1 2 3 4 5 6 7 8 9 10 11

12

13
14
15

40 16

39
38
Bucket Cylinder
37
36
35
Boom Cylinder
33
34
17
Arm Cylinder

18
32

31

19
30
29 20

21
22

23
Swing Motor Pump 2 Pump 1
28 27 26 25 24 T155-04-03-005

1 - Hydraulic Timer 11 - Bucket Flow Control Valve 21 - Boom Regenerative Valve 31 - Arm Regenerative Valve
(Switch Valve B)
2 - Travel Flow Control Valve 12 - Bucket Flow Control Valve 22 - Check Valve (Arm Roll-In 32 - Overload Relief Valve
(Poppet Valve) Flow Combining) (Arm)
3 - Load Check Valve 13 - Load Check valve 23 - Pump Control Valve 33 - Overload Relief Valve
(Travel Parallel Circuit) (Boom 1 Parallel Circuit) (4-Spool Side) (Arm)
4 - Check Valve 14 - Load Check Valve 24 - Check Valve 34 - Arm Anti-Drift Valve
(Main Relief Circuit) (Boom 1 Tandem Circuit) (Check Valve)
5 - Main Relief Valve 15 - Overload Relief Valve 25 - Restriction (4-Spool Side 35 - Arm Anti-Drift Valve
(Bucket) Parallel Circuit) (Switch Valve)
6 - Check Valve 16 - Overload Relief Valve 26 - Load Check Valve 36 - Load Check Valve (Boom 2
(Main Relief Circuit) (Bucket) (Arm Parallel Circuit) Parallel Circuit)
7 - Check Valve (Flow Com- 17 - Overload Relief Valve 27 - Restriction (Arm 1 Parallel 37 - Travel/Boom Lower Se-
biner Valve Circuit) (Boom) Circuit) lector Valve
8 - Flow Combiner Valve 18 - Overload Relief Valve 28 - Load Check Valve (Swing) 38 - Load Check Valve (Aux.)
(Boom)
9 - Load Check Valve 19 - Boom Anti-Drift Valve 29 - Load Check Valve (Arm 39 - Load Check Valve
(Bucket) (Check Valve) Tandem Circuit) (Travel Tandem Circuit)
10 - Bucket Flow Control Valve 20 - Boom Anti-Drift Valve 30 - Check Valve (Arm Roll-Out 40 - Pump Control Valve
(Switch Valve A) (Switch Valve) Flow Combining) (5-Spool Side)

T3-3-4
 COMPONENT OPERATION / Control Valve

Section C Section D Boom 1

Bucket Auxiliary Boom 2

37
15
33
20
38 19

11
36
10

13

12 14

18

21
16 9 W155-02-05-046
W155-02-05-003

Section E Section F

Arm 2 Arm 1
Swing

30 35

17 34
31

28
26
24
27

25 23

22 29

32
W155-02-05-001

T155-02-03-001

T3-3-5
 COMPONENT OPERATION / Control Valve
HYDRAULIC CIRCUIT

Main Circuit Signal Pilot Pressure Circuit

Pressure oil from pump 1 and from pump 2 is The pilot pressure from the pilot pump flows through
routed to the 4-spool side section in the control the control valve.
valve and to the 5-spool side section in the control When the travel levers are operated, the movement
valve, respectively. A parallel passage is provided in of the travel spool causes the travel signal pilot cir-
both right and left main circuits, making combined cuit to be restricted, increasing the pilot pressure,
operations possible. thus turning on the pressure switch (travel) and
The main circuit pressure is restricted by the main shifting the travel/boom lower selector valve.
relief valve. Moreover, two overload relief valves are When a control lever other than the travel levers is
provided in each of boom, arm, and bucket circuits. operated, the pilot pressure in the front att. signal
Also, a pump control valve is provided at the most pilot passage increases, thus turning on the pres-
downstream position of each of right and left neutral sure switch (front) and shifting the flow combiner
passages. valve, travel flow control valve, and swing parking
brake shift valve.
Swing Parking Brake Pressure Switch Pressure Switch Flow Combiner
Shift valve (Front) (Travel) Valve Neutral Passage

Main Relief Valve

Signal Pilot
Pressure Circuit
Left Travel Motor

Pump Control Valves

(5-Spool Side)
Right Travel Motor
Auxiliary
Overload Relief
Valves

Bucket
Travel Flow
Control Valve

Travel/Boom Lower
Selector Valves
Boom
Arm
Overload Relief
Valves

Overload Relief Valves

Pump Control Valve
(4-Spool Side)
Swing
Parallel Passages
Main Circuits

5-Spool Side
4-Spool Side

Neutral Passages
Pump Pump Pilot Pump

T155-02-05-008

T3-3-6
 COMPONENT OPERATION / Control Valve
Pilot Valve Guided Pilot Pressure Circuit •
Pilot pressure via the pilot valve exerts on the • When the boom lower lever is operated, the pilot
control valve spools, shifting them. At the same pressure exerts on the boom anti-drift valve
time, it also exerts on switch valves. (switch valve), shifting it.
(Arm anti-drift valve, Boom anti-drift valve, Bucket
flow control valve) In addition, an air bleed circuit is provided in the top
Besides shifting of control valve spools (when part of the control valve, automatically bleeding air
control levers are operated), the pilot valve guided trapped in the circuit.
pilot pressure functions as follows:
• When the arm roll-in lever is operated, the pilot Solenoid Valve Guided Pilot Pressure Circuit
pressure via the pilot valve exerts on the bucket The pilot pressure guided via the solenoid valve unit
flow control valve and the anti-drift valve (switch (SC) shifts the arm regenerative valve. (Refer to the
valve), shifting them. Control System Group in the System Section.)
• When the boom raise lever is operated, the pilot
pressure exerts on the bucket flow control valve
as the valve shift pressure.
Main Relief Valve Bucket Flow Control Valve

1 2
11 12

8
5

3 4 14
13

5
Arm Anti-Drift 5
Valve

Arm Regenerative
Valve
7 8
From the Solenoid Valve 8 7
Unit (SC)
Boom Anti-Drift Valve

9 10
Air Bleed Circuit

Pump 2 Pump 1

T155-02-05-009
1- Left Travel Forward 5- Boom Raise 9 - Swing Left 12 - Right Travel Forward
2- Left Travel Reverse 6- Boom Lower 10 - Swing Right 13 - Bucket Roll-In
3- Auxiliary 7- Arm Roll-Out 11 - Right Travel Reverse 14 - Bucket Roll-Out
4- Auxiliary 8- Arm Roll-In

T3-3-7
 COMPONENT OPERATION / Control Valve
FLOW COMBINER VALVE

When a control lever other than the travel levers is As a result, the pressure oil from the pump 1 is routed
operated, the movement of the control valve spool to both right and left travel spools, securing straight
restricts the pilot pressure in the front att. singal pilot travel in trabel combined operations.
circuit, increasing the pilot pressure to shift the flow
combiner valve.

Left Travel Motor Right Travel Motor

Flow Combiner Front Att. Signal

Valve Pilot Pump Pilot Circuit

Arm
Cylinder

Pump 2 Pump 1
T155-04-03-006

T3-3-8
 COMPONENT OPERATION / Control Valve
PUMP CONTROL VALVE

A pump control valve is provided on the most down- In addition, the pump control pressure sensor detects
stream part of the neutral passage in each of the 4- the pump control pressure, sending signals to MC for
spool and 5-spool side sections. travel motor displacement angle control. (Refer to the
The pump control pressure altered by the pump con- Control System Group in the SYSTEM Section.)
trol valve exerts on the regulator, changing the pump
displacement angle. (Refer to the Pump Device group
in this section.)

To the Pump 2 Regula- Pump Control Valve

tor (5-Spool Side) Neutral Passage
and to Pump Control
P S

Pump Control Valve

(4-Spool Side)

Neutral Passage
To the Pump 2 Regulator
and to Pump Control
5-Spool Side Pressure Sensor

4-Spool Side

T155-02-05-009

T3-3-9
 COMPONENT OPERATION / Control Valve
Operation with Control Valve Spool Activated
When a control valve spool is shifted, oil flowing This increased pump control pressure exerts on the
through the neutral passage and through the pump regulator and, in return, the regulator increases the
control valve decreases. pump displacement angle, increasing the pump
As oil flowing through the pump control valve delivery oil flow.
decreases, the pump control valve spool shifts to
the left, increasing the relief valve set pressure, thus
raising the pump control pressure.

From the Pilot Pump

Pump Control Pressure Passage

Hydraulic Oil Tank

Pump Control Pressure Sensor

Pressure
Increase
Pump Control Valve

To the Regulator

Neutral Passage

Small Oil Flow

T157-04-04-039

Operation with Control Valve Spools in Neutral

Position
When control valve spools are returned ton the As the pump control pressure decreases to a mini-
neutral position, the neutral passage is fully opened mum, the regulator decreases the pump displace-
and all pump oil flow goes through the neutral pas- ment angle to have the minimum pump delivery
sage and the pump control valve so that the pump flow, contributing to fuel efficiency.
control valve spool moves to the right, decreasing
the relief valve set pressure so as to have the low-
est pump control pressure.

From the Pilot Pump

Pump Control Pressure Passage

Hydraulic Oil Tank

Pump Control Pressure Sensor

Pressure
Decrease
Pump Control Valve

To the Regulator

Neutral Passage

Large Oil Flow

T157-04-04-038

T3-3-10
 COMPONENT OPERATION / Control Valve
MAIN RELIEF VALVE

The main relief valve regulates main circuit pressure. As the pilot poppet opens, the pressure in the spring-A
When pressure Hp increases to the pressure set by chamber decreases, opening the main poppet, thus
the spring (B), the pilot poppet opens, routing the oil at routing the pressure oil at port Hp directly to port Lp.
port Hp to the port Lp via passage (A).
Main Poppet Pilot Poppet Spring B

Hp

Lp
Spring A Passage A
Chamber

T155-02-05-004

OVERLOAD RELIEF VALVE

(With Make-Up Function)

Overload relief valves are provided in each port of the Moreover, these relief valves function to suction oil
boom, bucket, and arm cylinders, and regulate oil from the return (hydraulic oil tank) line to prevent the
pressure in the cylinder circuits to protect them from occurrence of cavitation if negative oil pressure arises
damage due to excessive high pressure that might in a cylinder (the make-up function).
develop if a cylinder is moved by excessive external
force.

Make-Up Valve Main Poppet Pilot Poppet

Actuator Side

Spring-A Passage A Spring B

Chamber

Hydraulic Oil Tank

T155-02-05-005

T3-3-11
 COMPONENT OPERATION / Control Valve
ARM REGENERATIVE VALVE

The arm regenerative valve is shifted by the pilot Then, the return oil is combined with the pump delivery
pressure guided via the solenoid valve unit (SC). oil to be supplied to the cylinder bottom side,
When the arm regenerative valve is shifted, the return increasing the arm roll-in speed, improving the arm
oil line from the cylinder rod side is closed. controllability in general, and preventing arm
movement hesitation from occurring in arm roll-in
operations. (Refer to the Control System Group in
SYSTEM Section.)

Arm Cylinder

From Solenoid Valve Unit (SC)

Arm Regenerative Valve

T157-02-05-019

T3-3-12
 COMPONENT OPERATION / Control Valve

Arm
Regenerative
Valve

Arm 1
From the
Solenoid
valve Unit
(SC)

Swing

Pump 2 Pump 1 T155-02-05-009

T3-3-13
 COMPONENT OPERATION / Control Valve
BOOM ANTI-DRIFT VALVE, ARM ANTI-
DRIFT VALVE

An anti-drift valve is provided on the bottom side of the When the arm roll-in or boom lower is operated, the
boom cylinder and on the rod side of the arm cylinder pilot pressure via the pilot valve shifts the switch valve
so as to reduce cylinder drift. of the anti-drift valve. The oil pressure exerted on the
When the control valve spool is in neutral, the switch check valve is returned to the hydraulic oil tank via the
valve part of the anti-drift valve is not shifted and the restriction in the switch valve.
pressure in the boom cylinder bottom side (the arm (The check valve is designed to close by a signal
cylinder rod side) exerts on the check valve of the anti- pressure, which arises when the switch valve is
drift valve via the switch valve, closing the check closed, and to open when the signal pressure is not
valve. exerted (when the switch valve is open.))

Boom Cylinders

Boom Lower
Pilot Pressure Boom 1

Anti-Drift Valve (Check Valve)

Anti-Drift Valve (Switch Valve)

T157-02-05-007

BUCKET FLOW CONTROL VALVE

The bucket flow control valve restricts the bucket Thus, the back pressure exerting on the poppet valve
circuit in the combined operations of the bucket, arm rises, applying a force to close the poppet valve, thus
roll-in, and boom raise, so as to raise the boom restricting oil flow through the poppet valve. For this
sufficiently. reason, the oil flow to the bucket is restricted,
When the arm is rolledin, the arm rollin pilot pressure supplying an oil flow to the higher-load-applied boom
shifts switch valve (A) of the bucket flow control valve. raise side.
If the boom is raised at the same time, the boom raise
pilot pressure is routed through the switch valve (A),
shifting the switch valve (B) of the bucket flow control
valve.

Arm Roll-In
Pilot Pressure
Poppet Valve
Switch Valve A

Boom Raise Pilot Pres-

Bucket

Switch Valve B Bucket Pilot

Pressure
Bucket Cylinder

T157-02-05-008

T3-3-14
 COMPONENT OPERATION / Control Valve

Bucket Flow Control Valve

Arm
Anti-Drift
Valve

Boom
Anti-Drift
Valve

Pump 2 Pump 1 T155-02-05-009

T3-3-15
 COMPONENT OPERATION / Control Valve
TRAVEL FLOW CONTROL VALVE

When the front attachment or swing is operated while As the parallel circuit is gradually restricted, shock
traveling, the front att. signal pilot pressure exerts on loads, occurring due to the front attachment operation,
the travel flow control valve, which is located in the are reduced.
parallel circuit, after flowing through the hydraulic
timer, so as to gradually restrict the parallel circuit.
Hydraulic Timer

To the Travel Motor

Left Travel Front Att. Signal Pilot

Spool P

Travel Flow
Control
Valve

Front or Swing Spool

Travel Parallel Circuit

T157-02-05-009

TRAVEL/BOOM LOWER SELECTOR

VALVE

The boom lower operation is actuated by the oil flow To prevent this from occurring, in travel-combined
via the boom 1 section. However, in travel-combined boom lower operations, the boom 2 spool is shifted to
operations, the oil flow from pump 1 does not flow in route the oil flow from pump 2 to the boom lower
the downstream boom 1 spool as it goes to the section so that the boom lowers to sufficiently perform
upstream travel spool. If the boom is positioned up in the machine jack-up operation.
the air at the moment, the boom would be lowered by When the travel spool is shifted, the travel signal pilot
its own weight. However, if the travel-combined boom pressure shifts the travel/boom lower selector valve,
lower operation is performed with the base machine allowing the boom lower pilot pressure to exert on the
raised off the ground, the boom does not lower. boom 2 spool. Thus, the boom lower operation is
sufficiently performed in travel-combined operations.

Right Travel Spool

Boom 2
Boom 1

To the Boom Cylinder

Travel/Boom Lower
Selector Valve

Pump 2
T157-02-05-010

T3-3-16
 COMPONENT OPERATION / Control Valve

Signal Pilot
Travel Flow Pressure
Control Valve Circuit

Left Travel
Motor
Hydraulic
Timer
Right Travel
Motor

Bucket
Travel/Boom
Lower
Selector
Valve

Boom

Parallel Passage

Pilot

Pump 2 Pump 1
T155-02-05-008

T3-3-17
 COMPONENT OPERATION / Control Valve
BOOM REGENERATIVE VALVE

In boom lower operations, the return oil from the

cylinder bottom side is combined with the oil flow from
the pump, supplying an additional oil flow to the
cylinder rod side, via the check valve in the boom
spool.
By this boom regenerative valve operation, the boom
lower operation is improved and cavitation is
prevented from occurring.

Boom Regenerative Boom Cylinders

Valve

Boom Lower Boom 1

Pilot Pressure

T157-02-05-012

T3-3-18
 COMPONENT OPERATION / Pilot Valve
OUTLINE

The pilot valve controls pilot pressure oil to move the

control valve spools. There are two types of pilot
valves. One is for front operation / swing operation; the
other is for travel operation. Both have four standard
oil ports.
An optional two-oil-port type is available.

• Right and left pilot valves

(Front attachment / Swing)
Port No. Hitach Std. ISO Std.
1 Bucket roll-out ←
Right 2 Boom lower ←
Valve 3 Bucket roll-in ←
4 Boom raise ←
1 Arm roll-in Swing right
Left 2 Swing right Arm roll-out
Valve 3 Arm roll-out Swing left
4 Swing left Arm roll-in

P T

1 3 2 4
T105-02-07-020
T107-02-06-032

• Travel pilot valve

Port No. Hitachi standard/ISO standard

1 Left travel forward
2 Left travel reverse
3 Right travel reverse T
4 Right travel forward
P

P T

4 1

1 3 2 4
3 2
T105-02-07-020

T154-02-04-001

T3-4-1
 COMPONENT OPERATION / Pilot Valve
OPERATION

• Front and Swing Pilot Valve In neutral

(Corresponding to A to B in the output diagram) :

The lower face of spool (8) head is suspended by the When control lever (1) is in the neutral position (no
upper face of spacer (4); they are kept in contact by pusher stroke), spool (8) completely blocks pressure
setting force of balance spring (6). Spacer (4) is oil from entering port P. Since the delivery port is open
installed between pusher (3) and spring guide (5) and to port T, pressure at the delivery port equals that in
supported by return spring (7). Piston (9) is located the hydraulic oil tank.
inside spool (8). The lower end of piston (9) makes When control lever (1) is slightly moved, cam (2)
contact with the plate, preventing the piston from moves together, pressing down on pusher (3).
moving further downward. Then, pusher (3), spacer (4), and spring guide (5)
Above piston (9), a chamber is provided and it is led to move downward as a unit, compressing return spring
the outside of spool (8) through holes provided in (7).
spool (8). The lower face of spool (8) is kept in contact with the
upper face of spacer (4) by setting force of balance
spring (6) and moves downward together with spacer
(4).
However, even if control lever (1) is moved further,
until clearance (A) at section (a) reaches zero, the
delivery port remains open to port T, keeping pressure
at the delivery port equal to that in the hydraulic oil
tank.

Delivery Port
Pressure
(Pilot Pressure)

Pusher Stroke

OUTPUT DIAGRAM

Section (a)

Port T

Delivery Port

Port P

T158-03-04-001
1 - Control Lever 4 - Spacer 6 - Balance Spring 8 - Spool
2 - Cam 5 - Spring Guide 7 - Return Spring 9 - Piston
3 - Pusher

T3-4-2
 COMPONENT OPERATION / Pilot Valve
Ready to start operation
(Corresponding to B to C section in the output
diagram) :

When control lever (1) is tilted slightly further from the Once spool (8) moves upward, upper clearance at
position where clearance (A) in section (a) reaches section (a) is opened and lower notch section at
zero, and pusher (3) is pushed downward, spool (8) is section at (b) is closed, leading oil pressure at the
moved downward, opening notched section (b) to delivery port to port T, and decreasing oil pressure at
allow pressure oil at the port P to flow into the delivery the delivery port.
port. When oil pressure at the delivery port decreases, the
This oil pressure is also led to the inside of spool (8) force to push up spool (8) is reduced so that balance
via orifice (10), and acts to push spool (8) upward. spring (6) stretches to move spool (8) downward,
Until this oil pressure force reaches the setting force of closing both the clearance and the notch at sections (a
balance spring (6), will not be compressed so that and b).
spool (8) is not moved upward, closing the clearance Thus, original position of spool (8) is kept resumed.
at section (a), keeping the notch at section (b) opened, The oil pressure will continue to increase until it is
and letting the oil pressure to increase at the delivery equal to setting force of balance spring (6) (shown by
port. the point C in the output diagram).
If the oil pressure at the delivery port increases, and
the upward-pushing force of spool (8) slightly exceeds
the setting force of balance spring (6), spool (8)
moves upward against setting force of balance spring
(6).

Delivery Port
Pressure
(Pilot Pressure)

Pusher Stroke

OUTPUT DIAGRAM

Section (a)

Port T
Clearance (A) Reaches Zero
Delivery Port Section (b)

Port P

T110-02-07-003
1 - Control Lever 6 - Balance Spring 9 - Piston 10 - Orifice
3 - Pusher 8 - Spool

T3-4-3
 COMPONENT OPERATION / Pilot Valve
Operation corresponding to the control lever stroke
(Corresponding to C to D in the output diagram) :

As control lever (1) is moved further to push pusher Accordingly, when compressed by pusher (3), spring
(3) downward, spool (8) is pushed down to open the force of balance spring (6) increases in proportion to
notch at section (b), increasing oil pressure at the the pusher stroke, Then, oil pressure increases to
delivery port. counteract against this spring force.
As pressure increases, the force to push up spool (8)
increases. Then, when force to push up spool (8)
exceeds the setting force of balance spring (6), spool
(8) starts to move upward, compressing balance
spring (6).
When spool (8) moves upward until the clearance at
section (a) opens, the delivery port is opened to port T,
stopping oil pressure increase at the delivery port and
stopping movement of spool (8).

Delivery Port
Pressure
(Pilot Pressure)

Pusher Stroke

OUTPUT DIAGRAM

Section (a)

Port T

Delivery Port
Section (b)
Port P

T110-02-07-004

1 - Control Lever 3 - Pusher 6 - Balance Spring 8 - Spool

T3-4-4
 COMPONENT OPERATION / Pilot Valve
Operation close to pusher stroke end
(Corresponding to D to E in the output diagram) :

As pusher (3) is pressed down, balance spring (6) is Then, oil pressure at the delivery port increases until it
compressed, reducing clearance (B) between pusher reaches port P pressure.
(3) and the top of spool (8) (shown at section (c) ),
finally to zero.
After that, pusher (3) directly pushes spool (8).
Even if oil pressure at the delivery port increases,
spool (8) cannot move upward, closing the oil passage
from the delivery port to port T, and opening the oil
passage from the delivery port to port P.

Delivery Port
Pressure
(Pilot Pressure)

Pusher Stroke

OUTPUT DIAGRAM

Section (c)

Clearance (B) Reaches Zero

Port T

Delivery Port

Port P

T110-02-07-005

3 - Pusher 6 - Balance Spring 8 - Spool

T3-4-5
 COMPONENT OPERATION / Pilot Valve
Full stroke operation
(Corresponding to E to F section in the output
diagram) :

Even if the control lever is tilted further to push down This process corresponds with E to F section in the
pusher (3), spool (8) moves downward along with output diagram.
pusher (3), only widening the notch at lower section The total stroke of the control lever is decided by
(b) of spool (8). dimension C.

Thus, oil pressure at the delivery port is kept same as

at port P. Pusher (3) can be pressed down until spring
guide (5) comes into contact with the shoulder (section
(d)) of the casing.
This position is the stroke end of pusher (3)
(corresponding to F position in the output diagram).

Delivery Port
Pressure
(Pilot Pressure)

Pusher Stroke

OUTPUT DIAGRAM

Section (d)

Port T

Delivery Port
Section (b)
Port P

T110-02-07-006
3 - Pusher 5 - Spring Guide 8 - Spool

T3-4-6
 COMPONENT OPERATION / Pilot Valve
(Blank)

T3-4-7
 COMPONENT OPERATION / Pilot Valve
• Travel Pilot Valve

In neutral
(Corresponding to A to B in the output diagram) : Full stroke operation:
Lever - In Neutral (Pusher Stroke : A to B) Lever - Full Stroke (Pusher Stroke)

In neutral, spool (6) closes port P (the input port) and When the control lever is moved full stroke, pusher (2)
tank port T is connected to delivery port. Through is moved down until spring guide (3) comes into
clearance (A). Thus, the pressure at delivery port is contact with the shoulder of the valve casing (Lever
the same as that at tank port T. Stroke End), opening the notch (B) further to port P.
When the control lever is moved slightly from A to B, The output pressure (pilot pressure to the control
pusher (2) and spring guide (3) together move down valve) remains at the pilot system pressure (the port P
against return spring (5) and balance spring (4). At this pressure).
time, as both oil pressures above and below spool (6) Dimension (C) in the figure right shows the control
are the same as the tank pressure, spool (6) moves lever full stroke.
down together with spring guide (3) until clearance (A)
becomes zero.

Operation corresponding to the control lever stroke

(Corresponding to C to D in the output diagram) :
Lever - Operated
(Pusher Stroke : C to D --- Metering)

When the control lever is moved further to push

pusher (2) down, port P, is connected to delivery port
through notch (B) and passage in spool (6), routing
Delivery Port
pilot pump pressure. However, when the pressure Pressure
applied into spool (6) overcomes the balance spring (Pilot Pressure) D
forse, spool (6) moves up, closing port P. When
pusher (2) is moved further down, compressing return
spring (5) and balance spring (4), the larger the
balance spring force; thus, the output pressure C
increases in proportion to the increase in the balance
spring force.
A B Pusher Stroke

OUTPUT DIAGRAM T523-02-05-001

T3-4-8
 COMPONENT OPERATION / Pilot Valve
Pusher Stroke: A to B
1

4
5

Port T
(Clearance A:
(A)

Port P

T154-02-04-003
Delivery Port
T154-02-04-002

Pusher Stroke: C to D Pusher Stroke: Full Stroke

2
2

4
5 (C)

(B)
Port T
Port T
6 3
Port P
Port P

Delivery Port T154-02-04-004

Delivery Port T154-02-04-005

1 - Cam 3 - Spring Guide 5 - Return Spring 6 - Spool

2 - Pusher 4 - Balance Spring

T3-4-9
 COMPONENT OPERATION / Pilot Valve
(Blank)

T3-4-10
 COMPONENT OPERATION / Travel Device
OUTLINE

The travel device consists of travel motor (1),

planetary reduction gears (2) to (10), and sprocket
(11).

8
10

5
3
4

11

T155-03-02-007

1 - Travel Motor 4 - Second Stage Sun Gear 7 - First Stage Planetary Gear 10 - Ring Gear
2 - Drum 5 - First Stage Carrier 8 - Second Stage Planetary Gear 11 - Sprocket
3 - Hub 6 - Shaft 9 - Second Stage Carrier

T3-5-1
 COMPONENT OPERATION / Travel Device
TRAVEL REDUCTION GEARS

The travel reduction gear is second stage planetary Second stage carrier (2) is held stationary by housing
gear type. (10) of the travel motor and hub (9).
The travel motor rotates shaft (5) and this driving force As ring gear (1) and sprocket (8) are bolted to drum
is transmitted to second stage carrier (2) and ring gear (11), they all rotate together.
(1) through first stage planetary gear (6), first stage
carrier (4), second stage sun gear (3) and second
stage planetary gear (7).

1 2 3 4

1 2 3 4
6

10
5

9
6
10 11 9 7

8 8 7 Second First
Stage Stage
T135-03-04-002

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

T3-5-2
 COMPONENT OPERATION / Travel Device
TRAVEL MOTOR

The travel motor is a variable-displacement swash Rotor (18) is splined to shaft (11) and friction plate (3).
plate-type motor which includes parking brake (Wet- Each plungers (17) is fitted to a shoe (6) by a ball
multi-disc negative type). socket joint.
The main parts of the motor are valve plate (1), rotor Shoe (6) moves, sliding along swash plate (7).
(18), plungers (17), shaft (11), swash plate (7), piston
(13), brake piston (19), friction plate (3) and plate (4).

1 2 3 4 6 7

12

11

10

19 18 17 5 15 16 14 13

W155-03-02-005
1- Valve Plate 6- Shoe 11 - Shaft 16 - Retainer
2- Disk Spring 7- Swash Plate 12 - Pin 17 - Plunger
3- Friction Plate 8- Housing 13 - Piston 18 - Rotor
4- Plate 9- Roller Bearing 14 - Plate 19 - Brake Piston
5- Spring 10 - Dowel Pin 15 - Bushing

T3-5-3
 COMPONENT OPERATION / Travel Device
Pressure oil routed to port AM (2) of valve plate (8) As rotor (3) rotates, plungers (7) move to port BM (1)
acts on plungers (7) in one half of rotor (3), pushing side one by one, returning oil to the hydraulic oil tank
them against swash plate (4). As the swash plate via port BM (1).
surface is slanted against the plungers, shoes (6) slide Travel direction (forward or reverse) is determined by
along swash plate (4), rotating rotor (3) and shaft (5). which of the valve plate ports (port AM or BM) the
pressure oil from the pump is supplied to.

1 2 3 4

8 7 6

T135-03-04-004
1 - Port BM 3 - Rotor 5 - Shaft 7 - Plunger
2 - Port AM 4 - Swash Plate 6 - Shoe 8 - Valve Plate

T3-5-4
 COMPONENT OPERATION / Travel Device
(Blank)

T3-5-5
 COMPONENT OPERATION / Travel Device
Travel Speed Selection

Pistons (9) and (11) are installed on swash plate (8).

The travel speed mode is changed by changing the
angle of swash plate (8). The angle of swash plate
(8) is changed by extending and retracting pistons
(9) and (11).

• Slow Speed
When the slow speed travel mode is selected,
the pilot pressure is not supplied to pilot port (1)
as MC (Main Controller) does not send an
electrical control signal to the solenoid valve unit
(SI). At this point, spool (2) is held upward by
spring (4).
The oil pressure in high-pressure motor port AM
or BM is led through piston-operating shuttle
valve (5) to slow-speed piston (11).
Slow-speed piston (11) then pushes swashplate
(8) to increase swash angle.
As a result, the stroke of plunger (7) is increased
and motor speed is slowed.

T3-5-6
 COMPONENT OPERATION / Travel Device

4 5 2

T155-03-02-001

6
7

9
11

10

T155-03-02-002
1 - Pilot Port 4 - Spring 7 - Plunger 10 - Shaft
2 - Spool 5 - Piston Operating Shuttle 8 - Swash Plate 11 - Slow-Speed Piston
Valve
3 - To Slow-Speed Piston 6 - Rotor 9 - Fast-Speed Piston

T3-5-7
 COMPONENT OPERATION / Travel Device

• Fast Speed
When the fast speed travel mode is selected, the
main controller (MC) send out an electronic control
signal to the solenoid valve unit (SI), when traveling
under light loads. Therefore, the pilot pressure is
routed from pilot port (1) moving spool (2) leftward.
Pressure oil from fast-pressure motor port AM or
BM flows through fast-speed orifice (12) to fast-
speed piston (9).
Fast-speed piston (9) pushes swash plate (8) to
reduce swash angle.
As the result, the stroke of plunger (7) is shortened
and motor speed is increased.

T3-5-8
 COMPONENT OPERATION / Travel Device

4 5 2 1

12

T155-03-02-008

6
7

8
9

11

T155-03-02-003
10

1 - Pilot Port 4 - Spring 7 - Plunger 10 - Shaft

2 - Spool 5 - Piston Operating Shuttle 8 - Swash Plate 11 - Slow-Speed Piston
Valve
3 - To Slow-Speed Piston 6 - Rotor 9 - Fast-Speed Piston 12 - Fast-Speed Orifice

T3-5-9
 COMPONENT OPERATION / Travel Device
TRAVEL BRAKE VALVE

The travel brake valve is located on the motor head of

each travel motor.
The travel brake valve consists of the following valves:

COUNTERBALANCE VALVE (1):

ensures smooth starts and stops, and prevents
overrunning when traveling down slopes.

CHECK VALVE (5):

ensures smooth starts and stops, and prevents
cavitation from occurring in the motor circuit by
functioning together with counterbalance valve (1).

OVERLOAD RELIEF VALVE (4):

prevents overload and surge pressure in the motor
circuit.

PARKING BRAKE RELEASE SHUTTLE VALVE (3):

leads divided hydraulic oil flow for travel motor
operation to the piston.

TRAVEL MOTOR SWASH ANGLE CONTROL VALVE

(2):
leads pressure oil supplied through the piston
operating shuttle valve to the slow-speed or fast-
speed piston.

FAST-SPEED ORIFICES (6):

function to change the speed (change the angle of
the swashplate) smoothly.

T3-5-10
 COMPONENT OPERATION / Travel Device

1 5

W155-03-02-006
3 4

1 - Counterbalance Valve 3 - Parking Brake Release 5 - Check Valve 6 - Fast-Speed Orifice

Shuttle Valve
2 - Travel motor Swash Angle 4 - Overload Relief Valve
Control Valve

T3-5-11
 COMPONENT OPERATION / Travel Device
Travel Operation
When supply oil from the control valve is routed to
port BV (8), supply oil flows around spool (9), opens
check valve BC (7) and is led to motor port BM (6).
However, return oil from motor port AM (4) is
blocked by check valve AC (3) and spool (9).
As supply oil pressure at port BV (8) increases,
supply oil is routed to chamber B (10) through orifice
“f” in spool CB (7), moving spool (9) to the right
against spring force.
Consequently, return oil from motor port AM (4)
starts to flow into port AV (1) through notch (h) in
spool (9), allowing the travel motor to rotate.

When the travel levers are returned to the neutral

position, the oil in both ports AV (1) and BV (8) are
routed to the hydraulic oil tank through the control
valve. Thus, oil pressure in chamber B (10)
decreases, and spool (9) is moved back to the
original position by spring force. Then, the oil flow
circuit is blocked, causing the travel motors to stop
rotating.

Descending Operation
When the machine travels down a slope, the travel
motors are forcibly driven by the machine weight so
that the motor sucks oil like a pump. When the
motor sucks oil, oil pressure at port BV (8) and
chamber B (10) decreases, causing spool (9) to
move to the left.
Then, the return oil flow from the motor is restricted
by the spool, increasing pressure at port .
The increased pressure at motor port AM (4) brakes
the motor. Thus, the restricted return oil flow
increases the pressure at port BV (8) again, moving
spool (9) back to the right. This repeat movement of
the spool (hydraulic brake action) prevents the
machine from overrunning.

Circuit Protectors
If pressure in the circuit increases over the setting
pressure of overload relief valve (5), this valve
opens to relieve peak pressure to the lower
pressure side to 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 sucks oil because of pumping
operation, check valve BC (7) opens so that
cavitation will not develop in the circuit.

T3-5-12
 COMPONENT OPERATION / Travel Device

10 8 9 1 2

BV AV

h
f

7 4

T155-03-02-004

5
1 - Port AV 4 - Motor Port AM 7 - Check Valve BC 9 - Spool (Counterbalance
Valve)
2 - Chamber A 5 - Overload Relief Valve 8 - Port BV 10 - Chamber B
3 - Check Valve AC 6 - Motor Port BM

T3-5-13
 COMPONENT OPERATION / Travel Device
PARKING BRAKE

The parking brake is a negative-type brake released When the machine starts traveling:
when oil pressure “k” is applied to parking brake Pressure oil from port AV or BV is routed through
chamber “m”. The parking brake is always applied notch “n” in spool (10) to parking brake chamber
except when traveling in which the parking brake is “m” when spool (10) moves rightward or leftward.
automatically released. Then, pressure oil pushes brake piston (5) to the
Friction plates (2) and plates (3) are connected to rotor left. As friction plates (2) and plates (3) are
(8) and to travel motor housing (7), respectively, via separated, the parking brake is released.
spline coupling. The parking brake is applied as disc
spring (1) pushes brake piston (5) so that friction When the machine stops traveling:
plates (2) and plates (3) came tightly into contact with When the travel motor stops rotating, spool (10) is
each other. retuned to the neutral position. Parking brake
chamber “m” is led to drain circuit (12) through
notch “P”. Brake piston (5) is gradually forced to the
right by disc spring (1), making friction plates (2)
come into contact with plates (3).

9 10 11

BV AV

T155-03-02-006

12 p h

9 - Port BV 10 - Spool 11 - To Parking Brake 12 - Drain

(Counterbalance Valve)

T3-5-14
 COMPONENT OPERATION / Travel Device

1 2 3
Brake On Brake Off

m m

6 5 4

T155-03-02-009
1 - Disc Spring 3 - Plate 5 - Brake Piston 7 - Housing (Travel Motor)
2 - Friction Plate 4 - Seal 6 - Seal 8 - Rotor

T3-5-15
 COMPONENT OPERATION / Travel Device

(Blank)

T3-5-16
 COMPONENT OPERATION / Others (Upperstructure)
PILOT SHUT-OFF VALVE
To Pilot Valve

The pilot shut-off valve is a manual-operated switch

valve. The spool in the pilot shut-off valve is rotated by To Hydraulic
moving the pilot control shut-off lever to turn on or off Oil Tank
the pilot oil flow to the pilot valves.

From Pilot
Pump

To Shockless Valve
W157-02-08-001
From Pilot Valve

• Valve Operation with Pilot Control Shut-Off Lever in From Pilot Valve
To Shockless Valve
LOCK Position
The pilot shut-off valve is set in the neutral position.
Pressure oil from the pilot pump does not flow into
the pilot valves, but it is routed to the shockless
valve. Pilot oil on the pilot valve side is routed to the
hydraulic tank as drain passages in the pilot shut-off
valve open.

To Hydraulic From Pilot

Oil Tank Pump T157-02-07-003

• Valve Operation with Pilot Control Shut-Off Lever in To Pilot Valve

UNLOCK Position
The pilot shut-off valve is set in the operating
position, allowing pressure oil from the pilot pump to
flow into the pilot valves. The pilot pressure can be
and will be routed to the control valve to operate the
respective hydraulic cylinders and/or motors as the
pilot valves are operated, in other words, as the
control levers are operated.

From Pilot
Pump T157-02-07-004

T3-6-1
 COMPONENT OPERATION / Others (Upperstructure)
SHOCKLESS VALVE 1 2

Check valves, pilot pressure sensor (for arm roll-in),

and pilot pressure switch (for boom raise) are built into
the shockless valve block in addition to the shockless
valves.
The shockless valves regulate secondary pilot
pressure (pilot pressure between the pilot valves and
the control valve spools) for the arm roll-out and for
boom raise functions, preventing abrupt and rapid
movement of the respective control valve spools.

6
5 3 T157-07-03-018
4

• When the arm roll-out or the boom raise is

operated, secondary pilot pressure from the pilot To Control A B From Pilot
valve is routed to the side B of the shockless valve. Valve Spool Valve
Immediately after operating the control lever, the
secondary pilot pressure routed to the side B flows
to the control valve spool via orifice (9). As the
secondary pilot pressure increases, check valve (7) 9 8
opens.
T157-02-07-005

• Return oil from the control valve spool flows back to

the hydraulic oil tank via orifice (9). As the pressure
at the side A increases, spool (8) moves in
proportion to the pressure increase, regulating the
From Control A B
return oil flow. Valve Spool
To Hydraulic
Oil Tank via
Pilot Valve
1 - Shockless Valve 6 - Pilot Pressure Sensor
(Arm Roll-In) 9 8
2 - Pilot Pressure Switch 7 - Check Valve
(Boom Raise)
T157-02-07-006
3 - Check Valve 8 - Spool
4 - Check Valve 9 - Orifice
5 - Shockless Valve

T3-6-2
 COMPONENT OPERATION / Others (Upperstructure)
Warm-Up Circuit

When the pilot shut-off valve is in the LOCK

position, pilot oil via the pilot shut-off valve flows into
the shockless valve. The oil is heated as it flows
through the restriction located at the inlet of the
shockless valve.
For this reason, the pilot circuit is warmed as this
heated oil flows into the shockless valve and into the
pilot valves.

To Pilot Valve To Control Valve

To Pilot Valve To Control Valve

To Pilot Valve To Control Valve

To Pilot Valve To Control Valve

Shockless Valve

Pilot Shut-Off Valve

From Pilot Pump

T157-02-05-013

T3-6-3
 COMPONENT OPERATION / Others (Upperstructure)
SOLENOID VALVE UNIT

The solenoid valve unit functions to control the pump

regulator, control valve and travel motor swash angle Front
control valve upon receiving signals from the main
controller (MC).
The solenoid valve unit consists of two solenoid valves
(SC), and (SI). (Refer to the Control System Group in
the SYSTEM Section.)

SC: Controls the arm regenerative valve located in the

control valve.
SI : Controls the travel motor swash angle control
SC
pistons.
SI

W155-02-11-004

T3-6-4
 COMPONENT OPERATION / Others (Upperstructure)
Proportional Solenoid Valve

Upon receiving an electric current signal from the

MC, the proportion solenoid valve outputs hydraulic
pressure proportional to the degree of the electric
current.

• When not energized (In neutral): (See detail “a.”) Because of the pressure receiving
The spring pushes the spool to the right, area difference between the two walls, the pressure at
connecting the output port S to the tank port T. port S acts as a force to push the spool to the right. As
the pressure at port S increases, the force to push the
• When energized: spool to the right also increases. When this force
The solenoid pushes the spool to the left for a overcomes the force to push the spool to the left by
distance proportional to the electric current solenoid, the spool moves back to the right side,
flowing through the solenoid. Pilot oil from port P closing the passage between output port S and port P.
flows into output port S, increasing the pressure As a result, pressure increase at port S stops.
at output port S. The pressure at port S acts on
the two banks of walls on the spool .

Spool Spring Solenoid

T S P

a
T107-02-07-005

T3-6-5
 COMPONENT OPERATION / Others (Upperstructure)
PILOT RELIEF VALVE

The pilot relief valve has a pilot filter incorporated.

Pilot relief valve functions to regulate the pilot pump
pressure oil routed to port P to a set constant
pressure.

Pilot Relief Valve

P T157-05-04-007

Output Gear Output Shaft Worm Gear

EC MOTOR

The EC motor is used to control engine speed. A

worm gear is incorporated into the EC motor to
prevent a loss of synchronism from occurring. The EC
sensor is provided to detect the degrees of the EC
motor rotation to calculate the governor lever position.
(Refer to the Control System Group in SYSTEM
Section.)

Motor

T157-02-05-018
Sensor EC Worm
Gear Sensor Wheel

T3-6-6
 COMPONENT OPERATION / Others (Undercarriage)
SWING BEARING

This bearing is a single-row shear ball-type bearing,

comprising outer race (1), inner race (3), balls (6),
supports (5), and seals (2), (4). Outer race (1) is
bolted to the upperstructure and inner race (3) is
bolted to the undercarriage.
The internal gear of inner race (3) engages with the
output shaft of the swing reduction gear.

T135-03-02-001

1 - Outer Race 3 - Inner Race 5 - Support 6 - Ball

2 - Seal 4 - Seal

T3-7-1
 COMPONENT OPERATION / Others (Undercarriage)
CENTER JOINT

The center joint is a 360ß rotating joint. When the

upperstructure is rotated, the center joint avoids
twisting of hoses and allows hydraulic oil to flow
smoothly to or from the travel motors. Spindle (1) is
attached to the main frame, and body (2) is bolted to
the swing center of the undercarriage.
Hydraulic oil flows to the right and left travel motors via
spindle (1) and the oil ports of body (2). Seals (3)
prevent oil leaks between spindle (1) and body (2) into
adjacent passages.

To Left Travel To Right Travel To Left Travel To Right Travel

Motor (Reverse) Motor (Forward) Motor (Forward) Motor (Forward)

To Left Travel To Left Travel To Right Travel

To Right Travel
Motor (Forward) Motor (Reverse) Motor (Reverse)
Motor (Reverse)
1

Pilot Pressure
for Travel Pilot Pressure
Drain
Speed for Travel
Speed
2

Drain

3
Drain

Drain

Forward
Reverse
Pilot Pressure for
Travel Speed Selection

T157-03-02-004

1 - Spindle 2 - Body 3 - Seal

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

CAUTION: Do not loosen valve (1) quickly or

loosen it too much as high-pressure grease
in the adjusting cylinder may spout out. Grease Discharge Hole
Loosen carefully, keeping body parts and
M104-07-119
face away from valve (1).
Never loosen grease fitting.

1 2 3 4 a 5 6 7 8

T135-03-05-001

1 - Valve 3 - Washer 5 - Spring 7 - Flange

2 - Nut 4 - Spacer 6 - Adjuster Cylinder 8 - Piston Rod

T3-7-3
 COMPONENT OPERATION / Others (Undercarriage)
(Blank)

T3-7-4