Hydraulic Equipment

SUMITOMO (S.H.I.) CONSTRUCTION MACHINERY CO., LTD.

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I. Hydraulic Pump ................................................................................................................... 3
1. Structure and operation of the main unit ........................................................................ 3
2. Regulator ........................................................................................................................ 5
3. P-Q diagram................................................................................................................... 11
4. Cavitation ...................................................................................................................... 13
5. Volume efficiency .......................................................................................................... 13
II. Control Valve .................................................................................................................... 15
1. Structure of the main unit .............................................................................................. 15
2. Spool ............................................................................................................................. 16
3. Flow force ..................................................................................................................... 18
4. Heat shock .................................................................................................................... 19
5. Main relief valve ............................................................................................................ 19
6. Over load relief valve .................................................................................................... 21
7. Load hold valve ............................................................................................................. 23
8. Negative control relief ................................................................................................... 25
III. Swing motor..................................................................................................................... 27
1. Structure and operation of the main unit ...................................................................... 27
2. Relief valve ................................................................................................................... 28
3. Reversal prevention valve ............................................................................................ 29
4. Rotational speed ........................................................................................................... 30
IV. Travel motor..................................................................................................................... 32
1. Structure and operation of the main unit of the motor .................................................. 32
2. Counter balance valve .................................................................................................. 34
3. Relief valve ................................................................................................................... 35
4. Speed switching ............................................................................................................ 37
5. Travel reduction gear .................................................................................................... 41
V. Cylinder ............................................................................................................................ 43
1. Structure of the main unit .............................................................................................. 43
2. Cushioning function ...................................................................................................... 45
3. Cylinder thrust ............................................................................................................... 46
VI. Small hydraulic devices .................................................................................................. 47
1. Remote control valve .................................................................................................... 47
2. Cushion valve ............................................................................................................... 49
3. Solenoid valve............................................................................................................... 52

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I. Hydraulic Pump
1. Structure and operation of the main unit
1) Structure
The shaft (01) and the cylinder block (11) are connected with the spline. The piston
(06) is inserted in the cylinder block (11) and it is connected to the piston shoe (04)
with a ball joint. The piston (06) and the piston shoe (04) have a hole at their center,
and the holes are connected to the groove (pocket) on the sliding surface of the shoe
(04).
The holder plate (14) pushes the piston shoe (04) against the shoe plate (15) via the
spherical bush (13) with the force of a spring (12).
The valve plate (10) separates the suction side and the discharge side of the cylinder
block (11), and it is secured onto the body with a pin. On both sides of the opening
are notches to reduce cavitation and noise.
The tilting pin (05) attached to the servo piston (03) supports the swash plate (16)
and maintains the swash plate angle. The self-pump discharge pressure applies to
the small diameter side of the servo piston (03), and the pressure controlled with the
regulator applies to the large diameter side. To restrict the stroke of the servo piston
(03), there are stopper bolts (02 & 07) on both sides.

01: Shaft 07: Maximum flow stopper 13: Spherical bush

02: Minimum flow stopper 08: Gear 14: Holder plate

03: Servo piston 09: Bearing 15: Shoe plate

04: Piston shoe 10: Valve plate 16: Swash plate

05: Tilting pin 11: Cylinder block 17: Bearing

06: Piston 12: Cylinder spring

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2) Operation
A. Suction and discharge
When the shaft (01) turns by engine power, the cylinder block (11) turns as well.
The piston (06), which is in the upper part of the figure, goes down along the
rotation of the cylinder block (11). The piston (06) moves while being pulled from
the cylinder block (11) with the holder plate (14). Oil is sucked into the cylinder
block (11) at this time. When the shaft further rotates, the piston (06) moves
upward. At this time, the shoe plate (15) pushes the piston (06) into the cylinder
block (11) and the oil is discharged. This means that the oil between the position at
which the piston is pulled out most and the position at which the piston is pushed in
most (stroke) is to be discharged.
When oil is discharged, it is supplied to the groove (pocket) on the sliding surface
of the piston shoe (04) through the hole on the piston (06) and the hole on the
piston shoe (04). The oil provides lubrication for the shoe plate(15), and it also
reduces the surface pressure (pushing force) between the piston shoe (04) and the
shoe plate (15) with hydraulic pressure.

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 B. Flow control
To change the discharge flow while running at a constant speed, the piston stroke
should be changed. Since the servo piston (03) holds the swash plate, the swash
plate (16) angle is changed if the servo piston (03) is moved. When the angle is
changed, the piston stroke changes, and the discharge flow changes as well.
Pressure applies to both sides of the servo piston (03) and the balanced pressure
moves the piston. The controlled pressure from the regulator applies to the large
diameter side to control the position of the servo piston.

2. Regulator
The regulator is a device which controls flow by moving the servo piston according to
the pressure generated from the load with the operation of hydraulic motors and
cylinders. The regulator conducts the negative control, which reduces the pump load
when the operation levers are in neutral (non-operation), and the horsepower control,
which changes the discharge flow according to the generated hydraulic pressure.

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 01: Pin 13: Spring

02: Spool 14: Sleeve

03: Pin 15: Compensation rod

04: Pin 16: Pin

05: Fulcrum plug 17: Lever 1

06: Lever 2 18: Pin

07: Feedback lever 19: Compensation piston

08: Pilot piston 20: Pin

09: Pin 21: Spring

10: Pin 22: Spring seat

11: Servo piston 23: Spring

12: Spring seat

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1) Negative control
A. Structure
The feedback lever (07) is connected to the servo piston (11) on the pump main
unit via the pin (10). The pin (01) is connected to the feedback lever (07) and is
inserted in the pin hole on the lever (06). In addition, the feedback lever (07) is
connected to the spool (02) with a pin (03). The pin (09) is connected to the lever
(06) and is secured to the boss (05) with a pin (04). The pilot piston (08) has been
machined to have a stepped section. The pin (09), which is secured to the lever
(06), is inserted into that stepped section.

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B. Operation
The pump discharge pressure directly applies to the small diameter side of the
servo piston (11), and the pressure (controlled pressure) controlled with the spool
(02) applies to the large diameter side.
When the negative control pressure applies to the end surface of the pilot piston
(08), the piston moves to the right to the point where the reactive force of the spring
(13) balances. The lever (06) rotates counter-clockwise (to the right in the figure)
with the pin (04) as its center, as the pin (09) inserted in the stepped section of the
pilot piston (08) moves. Since the pin (01) inserted in the hole on the lever (06) is
pushed to the right, the feedback lever (07) rotates clockwise with the pin (10) as
its center. Thus, the spool (02) connected to the feedback lever (07) is pulled (to
the right).

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 When the spool moves to the right, the control pressure increases and the servo
piston (11) moves toward the small diameter side. The discharge flow decreases
as the swash plate angle changes. When the servo piston (11) moves to the right,
the feedback lever (07) rotates counter-clockwise with the pin (01) as its center.
The spool (02) connected to the feedback lever (07) is pushed in (to the left). The
control pressure is shut off, and the movement of the servo piston (11) is stopped.

2) Horsepower control
A. Structure
The feedback lever (07) is connected to the servo piston (11) on the pump main
unit via the pin (10). The pin (01) is connected to the feedback lever (07) and is
inserted in the pin hole on the lever (17). In addition, the feedback lever (07) is
connected to the spool (02) with a pin (03).
The pin (16) is connected to the lever (17) and is secured to the body with a pin
(18).
The compensation rod (15) has been machined to have a stepped section. The pin
(16), which is secured to the lever (17), is inserted into that stepped section.
The compensation piston (19) has been machined to have a stepped section. The
self generated pressure applies to the cross sections of the large and intermediate
diameters through the body path, and the another pump generated pressure
applies to the cross sections of the intermediate and small diameters. Both cross
sections have the same area. The horsepower control proportional valve discharge
pressure (secondary pressure) applies to the left end of the pin (20).

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B. Operation
When load applies and the pressure on one side or on both sides increases the
compensation piston (19) is pushed to the right. The compensation piston (19)
pushes the compensation rod (15), and moves to the point where the reactive
force of the spring (23) balances.
The lever (17) rotates counter-clockwise (to the right in the figure) with the pin (18)
as its center, as the pin (16) inserted in the stepped section of the compensation
rod (15) moves. Since the pin (01) inserted in the hole on the lever (17) is pushed
to the right, the feedback lever (07) rotates clockwise with the pin (10) as its center.
Thus, the spool (02) connected to the feedback lever (07) is pulled (to the right).
When the spool (02) moves to the right, the control pressure increases and the
servo piston (11) moves toward the small diameter side.

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 The discharge flow decreases as the swash plate angle changes. When the servo
piston (11) moves to the right, the feedback lever (07) rotates counter-clockwise
with the pin (01) as its center. The spool (02) connected to the feedback lever (07)
is pushed in (to the left). The control pressure is shut off, and the movement of the
servo piston (11) is stopped.

When the current is low for the horsepower control proportional valve, the
secondary pressure (discharge pressure) will be higher, while the secondary
pressure will be lower when the current is high. The secondary pressure applies to
the left side of the pin (20). When the current is low (the secondary pressure high),
the pin (20) pushes the compensation piston (19) and the flow will decrease in the
same fashion.

3. P-Q diagram
The P-Q diagram indicates the relationship between the pressure generated with the
load such as an actuator (pump and cylinder) and the hydraulic pump discharge flow.
The higher the pressure or the greater the flow, the more engine horsepower required
to drive the hydraulic pump. When the hydraulic pump drive force exceeds the engine
output, an engine stall will occur. To prevent this from happening, the discharge flow will
be decreased when the pressure rises.

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The figure shows a sample of the P-Q diagram.
In this diagram, the horizontal axis indicates the pressure and the vertical axis indicates
the flow. For some other hydraulic pump manufactures, these two axes may be
switched. The number of polygonal lines may differ depending on the representing
conditions. The diagram may also vary according to the engine speed and horsepower
control proportional valve current.
The flow at the point at which the total pressure (simple addition) of the P1 side
pressure and the P2 side pressure meets the polygonal line indicates the discharge per
pump.
The P-Q diagram in the figure is for the engine speed 1800 min-1, and the polygonal
lines for 600 mA, 565 mA, and 548 mA of the horsepower control proportional valve
currents are shown.
For example, when the proportional valve current is 600 mA, the P1 side pressure 32
MPa, and the P2 side pressure 32 MPa, the total pressure is 64 MPa. The flow at the
point where 64 MPa meets the 600 mA polygonal line indicates 85 L/min for one side.
For both sides, it will be twice of this, which is 170 L/min.
Since the servo piston's stroke is restricted with the stopper bolts, the maximum flow in
the low pressure region is nearly constant.

The figure below shows the diagram in which the pressure axis and the flow axis are
switched.
This pump has an extra pump (P3 pump) in addition to the two main pumps and the one
pilot pump. There are two polygonal lines in the diagram. "P3 = 1 MPa" indicates the
relationship when there is hardly any pressure from the P3 pump, and "P3 = 22.6 MPa"
indicates the relationship when the P3 pump generates its maximum pressure.
For example, when P1 = 20 MPa, P2 = 20 MPa, and P3 = 22.6 MPa, then the sum will
be 40 MPa. The flow at the point where 40 MPa meets the "P3=22.6MPa" polygonal
line indicates 24 L/min.

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 Torque T (N•m)

Leak flow diagram

Pressure ΣP = P1 + P2 (MPa)

P3 shift pressure (MPa)

Flow Q1, Q2 (L/min)

4. Cavitation
If the pressure of the liquid drops due to the suction by the hydraulic pump or due to the
shape of the path, the pressure may locally become negative or below the saturated
vapor pressure (the pressure at which the liquid state and the gaseous state reaches a
balance in the sealed container), and part of the liquid is vaporized generating bubbles
in the liquid. This is called cavitation. If a bubble goes to a high pressure section and is
destroyed, an impact wave, as well as noise, is generated. This impact wave may lead
to a failure eroding the material in the hydraulic equipment. Erosion occurs where a
bubble is destroyed and not where it is generated.
The hydraulic oil tank may be pressurized to prevent the pressure from becoming
negative due to suction by the hydraulic pump. The swing motor may have a make-up
check valve to prevent the pressure from becoming negative during the swing stop.
These measures are to prevent cavitation.

5. Volume efficiency
When oil is discharged from the hydraulic pump, there is always a leak from a gap
between the component parts (internal leak). This leak provides lubrication for the

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components. The volume efficiency indicates the extent of the leak of a hydraulic pump.

Volume efficiency = Actual discharge / Theoretical discharge x 100 (%)

Generally, when the pressure rises, the leak increases, and efficiency drops.

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II. Control Valve
1. Structure of the main unit
The control valve has a body in which a complicated oil path is formed. The spool that
switches the oil paths, the relief valve that protects the equipment from an abnormal
high pressure, the negative control relief valve that generates the negative control
pressure, the load hold valve that reduces the natural drop of the booms and arms, and
the check valve for backflow prevention are installed onto the body.
The oil discharged from the hydraulic pump goes through the central paths (A) and (F)
of the control valve and through the paths (A) and (F) of the upper section and all the
sections back to the tank.
The parallel path (B) goes paralleled to the central path. This is filled with oil but the
circuit is closed with a spool when the machine is not operated. When the spool moves,
the central path is closed and the parallel path and the path (D) to the actuators will be
opened. At the same time, the return path from the actuators and the tank path will be
opened. Oil from the pump goes to the actuators and the return oil goes back to the
tank, which operates the actuators.

1: Spool

2: Load check valve

3: Check valve

4: Spring

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2. Spool
1) Operation
The spool moves in the axial direction inside the control valve due to the pilot
pressure, and switches the oil paths. It is at the neutral position by the spring when it
is not operated. When the pilot pressure applies to an end of the spool, it moves to
the direction opposite to the end where the pressure applies. As it moves, the path
that was closed with the large-diameter section becomes connected through the
small-diameter section allowing oil to flow.
Since the spool (A) moves in the axial direction in the body (B), a gap is required.
Thus, there is oil leak (internal leak) however minute. If the gap is small, the amount
of leak is small, but the possibility of the spool getting stuck due to dirt or thermal
expansion may increase.

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2) Circumferential groove
A groove is machined into the circumference of the large diameter side of the spool.
In addition, there is a notch on the large-diameter end.
Pressurized oil in the gap between the spool and the body may push the spool
against the body preventing the spool from moving smoothly. The circumferential
groove allows hydraulic pressure to apply all around the spool preventing the spool
from being pushed against the body.

3) Notch
When the spool is moved in the thrust direction (axial direction), the path that has
been closed with the spool and the body opens. If the path opens abruptly, hydraulic
oil flows at once causing the hydraulic equipment to operate suddenly. The notch
reduces the abrupt flow of hydraulic oil and improves inching capability (minute
operability).
When the circuit is closed (operation of the hydraulic equipment is stopped), it
reduces the shock which might result due to the abrupt closure of the circuit.

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3. Flow force
Flowing liquid has the force to wash away an object in it. This is called flow force (fluid
force). The greater the flow, the greater the flow force.

1) Greater effect
In the following circuit, the spool tries to move in the direction that closes the circuit
(to the left). As there is a large quantity of return oil from the motor flowing, a large
force applies to the spool to push it to the right. If the operator tries to slowly switch
back to neutral position, the spool cannot move back smoothly because of the
resistance (flow force), resulting in an abrupt switching.

2) Smaller effect
If the circuit is of the form in the figure below, the return oil from the motor flows in the
direction to close the spool. There is no reactive force in the direction of the neutral
position of the spool, and the spool can move back smoothly.
When the spool is opened, it moves to the right. The quantity of the return oil from the
motor at startup is small and hence, the force to push the spool to the left is small as
well. Thus, the spool can move smoothly.

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4. Heat shock
If the spool is moved without warm-up when the temperature is low, the spool may
thermally expand locally to get stuck. This is called local heat shock. Normally, this can
be prevented by warming up the equipment.
At the moment when the main path is just opened as the spool moves due to the pilot
pressure, the path where oil flows is narrow and the temperature of the oil that goes
through it becomes hot. Due to this heat, the spool locally expands (the diameter
increases). The body has a large volume and it does not expand right away. There is a
gap between the spool and the body, but if the diameter of the expanded spool exceeds
that of the body, the spool may temporarily get stuck so that the actuator does not stop.

5. Main relief valve

1) Structure
The main poppet (1) and the plug (6) are inserted in the sleeve (2).
At the center of the main poppet (1) and the plug (6) is the throttling path. Oil on the
high pressure side (HP) is sealed with a pilot poppet (3) pushed by a spring.

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 1: Main poppet

2: Sleeve

3: Pilot poppet

4: Spring

5: Piston

6: Plug

2) Operation
The HP side pressure applies to chamber E through the throttling path of the main
poppet (1). The sleeve (2) securely seals the body with the difference in area
between cross sections A and B. The main poppet (1) securely seals the sleeve with
the difference in area between cross sections C and D.

When the pressure at the HP port rises and exceeds the force to close the pilot
poppet (3), the pilot poppet (3) is opened and oil flows through paths F and G to the
low pressure side (LP).

When oil flows, a pressure difference occurs due to the throttling path in the main
poppet (1), and the pressure of chamber E drops. The main poppet (1) is pushed
open and the oil on the high pressure side (HP port) flows directly into the low
pressure side (LP port).

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 3) Boosting the pressure
When the pilot pressure applies to port I, the piston (5) moves the distance of H. This
strengthens the spring force that closes the pilot poppet, and the relief pressure is
raised.

6. Over load relief valve

1) Structure
The main poppet (2) is inserted in the sleeve (3), and the piston (1) is inserted in the
main poppet (2). The HP port and the LP port are shut off with the pilot poppet (4).

1: Piston

2: Main poppet

3: Sleeve

4: Pilot poppet

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2) Operation
The HP port side pressure applies to chamber F through path E in the piston (1). The
high pressure side (HP port) and the low pressure side (LP port) are sealed off with
the pilot poppet (4). The sleeve (3) securely seals the body with the difference in area
between cross sections A and B. The main poppet (2) securely seals the sleeve (3)
with the difference in area between cross sections C and D.

When the pressure at the HP port rises and pushes the pilot poppet (4), the oil in
chamber F flows through paths G and H to the low pressure side (LP).

The throttling path E of the piston (1) generates a pressure difference, and the
pressure in chamber F drops. Thus, the piston (1) is pushed and moves, and the pilot
poppet (4) closes path E of the piston (1).

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 When the outlet of path E of the piston (1) is closed, the oil in path E flows through
path I and then paths G and H. Thus, the pressure difference between the high
pressure side (HP port) and chamber F further increases. The main poppet (2) is
pushed open and the oil in the high pressure side (HP port) flows directly to the low
pressure side (LP port).

3) Suction
If the pressure of the HP port becomes lower than that of the LP port due to cavitation,
for instance, the sleeve (3) is pushed to the right due to the difference in area of the
cross sections B and J, and the oil in the LP port directly flows into the HP port.

7. Load hold valve

1) Structure
The spool (3) and the poppet (5) are inserted in the sleeve (4). When the piston (2)
pushes the spool (3), the poppet (5) is also pushed and moves, and it shuts off the
path in the sleeve (4). At the same time, the paths in the spool (3) and the sleeve (4)
are connected.

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 1: Poppet
2: Piston
3: Spool
4: Sleeve
5: Poppet

2) Operation
The cylinder hold pressure applies to port A through path B. At the same time, it
applies to chamber E through paths C and D. The cylinder hold pressure of port A
tries to push the poppet (1) open, but because the same pressure applies to chamber
E, the poppet (1) seals the body due to the difference in area where pressure applies.
On the other hand, when the pressure from port M pushes the poppet (1), the oil in
chamber E can flow through paths D and C to path B. Thus, the poppet (1) can be
opened.

If the pilot pressure for canceling the load hold valve applies to port F, the piston (2)
pushes the spool (3) and the poppet (5). Since the relative position between the
sleeve (4) and the poppet (5) changes, paths C and D are shut off from each other. At
the same time, path D becomes connected to paths G and H of the spool (3), and
further more to path L, which is a tank line, through paths J and K. When the oil in
chamber E is connected to the tank line and its pressure decreases, the oil in port A
pushes the poppet (1) open and flows into port M.

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8. Negative control relief
1) Structure
The piston (2) moves to the right with the pilot pressure. Then, the reactive force to
push the poppet (1) open becomes great. The sleeve (3) has small holes as orifices.

1: Poppet

2: Piston
3: Sleeve

2) Generating signal pressure

When the pilot pressure applies to port S, the force to push the poppet (1) increases.
Oil from the pump comes to path P through the control valve. The oil further flows
through orifice A to tank line T. Throttling the flow generates pressure in path P, and
the pressure acts on the negative control port of the pump through port N.

3) Relief operation
When the flow further increases, the throttling further increases the pressure. The
poppet valve (1) gets opened and prevents excessive pressure from happening.

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When the pilot pressure of port S is shut off, the spring force that pushes the poppet
(1) decreases and the poppet (1) opens at an extreme low pressure, which makes
the generated pressure at path P extremely low.

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III. Swing motor
1. Structure and operation of the main unit
1) Structure
The piston (6) is inserted in the cylinder (1) and it is connected to the piston shoe (2)
with a ball joint. The piston (6) and the piston shoe (2) have a hole at their centers,
and the holes are connected to the groove (pocket) on the sliding surface of the shoe
(2).
The return plate (5) pushes the piston shoe (2) against the cam plate (4) with the
force of the hold spring (3).
The balance plate (14) separates the suction side and the discharge side of the
cylinder (1), and is secured onto the body with a pin. On both sides of the opening are
notches to reduce cavitation and noise. The balance plate (14) is pushed against the
cylinder (1) via the bush (13) with the spring force of the cross wave (12). The
balance plate (14) has small holes and the pistons (11) are inserted in them.
The brake liners (7) are interlocked to the cylinder (1) with a spline, and they rotate
with the cylinder (1). The brake plates (8) are interlocked to the body with a spline.
The brake liners (7) and the brake plates (8) are stacked alternately. Brake functions
as the brake piston (9) pushes them with the force of the spring (10). When the pilot
pressure applies to port A, the piston (9) moves up, releasing the brake.

1. Cylinder 7: Brake liner 13: Bush

2: Piston shoe 8: Brake plate 14: Balance plate

3: Hold spring 9: Brake piston 15: Relief valve

4: Cam plate 10: Spring 16: Reversal prevention valve

5: Return plate 11: Piston 17: Check valve

6: Piston 12: Cross wave 18: Spring

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 2) Operation
If oil is supplied to the left port of the cylinder (1), the piston (6) is pushed out. Then,
the piston (6) moves to the right along the cam plate (4). Thus, the cylinder (1)
rotates.
The pressing force of the cross wave presses the cylinder (1) and the balance plate
(14) together. Yet, the force of the cross wave (12) is not sufficient when hydraulic oil
acts. Thus, the oil that goes through the path in the balance plate (14) acts on the
piston (11) and pushes the balance plate.
The oil that has flowed through the path in the piston (6) and the piston shoe (2) is
supplied to the surface of the cam plate (4). With the help of the groove (pocket) at
the bottom of the shoe, lubrication and reduction of the pressing force (surface
pressure) are attained.
When swing is stopped, the swing motor is forced to run due to the inertia of the
swing body to act as a pump. The pressure on the discharge side is released to the
tank line through the relief valve (15). Yet, since the circuit is closed, negative
pressure is generated on the suction side. Then, the check valve (17) opens to suck
in oil from the return line to prevent cavitaion.

2. Relief valve
1) Structure
The poppet (1) has a path at its center. The path is throttled in the middle and
reaches to the end. The poppet piston (3) also has a throttling hole.

1: Poppet

2: Sleeve

3: Poppet piston

2) Operation
The pressure in path A tries to open the poppet. Yet, the pressure goes through the
path in the poppet (1) and applies to chamber C to become the force that closes the
poppet (1). This force and the spring force combine to seal the poppet (1) securely.
When the pressure in path A rises, the pressure in chamber D also rises and the

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 poppet piston (3) moves to the left. While the piston is moving, the pressure in
chamber C drops and the force to close the poppet (1) decreases. The poppet (1)
opens and oil flows from path A to path B.
When the poppet piston (3) stops moving, the pressure in chamber C rises. The force
to close the poppet (1) increases and paths A and B are closed. Because of the
higher pressure, the poppet (1) opens again. In this fashion, by relieving pressure
once at a pressure lower than the setting, shocks at swing starts and stops are
reduced.

3. Reversal prevention valve

1) Structure
The valve is symmetrically constructed with the same components for the right and
left of the center line. The check (1) and the poppet (3) are inserted in the sleeve (2).
The sleeve (2) has orifices on its side. The poppet (3) also has orifices on the side
and at the center.

1: Poppet

2: Sleeve
3: Poppet Piston

2) Operation
If a lever is moved from Swing to Neutral while pressure applies to the port B side,
the swing motor generates pressure on the port A side because of the pumping
action due to the inertia of the swing body. The pressure applies to chamber E
through paths C and D, and presses the poppet (1) to the left.

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 When the swing body stops, the accumulated pressure turns the swing motor in the
opposite direction.
When reverse rotation starts, the pressure at port A decreases and the pressure at
port B starts to increase. Along with this, the poppet (1) is pushed to the right. As oil in
chamber E goes through paths D and C, the flow is throttled and the poppet (1)
slowly moves to the right. During this time, ports A and B are linked with path F,
quickly becoming the same pressure, and reverse rotation stops.

4. Rotational speed
Rotational speed can be calculated from the discharge flow of the pump and the
absorption and reduction ratio of the motor.
1) Reduction ratio
To decrease the motor speed and to increase the torque, a reducer is employed. The
reduction ratio indicates the ratio of output speed against input speed.

Reduction ratio = Driven gear teeth / Drive gear teeth

Sample 1) Driven gear 40 teeth

Drive gear 20 teeth
Reduction ratio = 40 / 20 = 2
For one rotation of the output shaft, the input shaft should turn twice.

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 Sample 2) A: 20 teeth
B: 30 teeth
C: 15 teeth
D: 30 teeth
Reduction ratio = (B / A) x (D / C) = (30 / 20) x (30 / 15) = 3
For one rotation of gear D, gear A should turn three times.

M: Motor

G: Reducer

A: Gear A

B: Gear B

C: Gear C

D: Gear D

2) Rotational speed
The motor speed including the reducer can be obtained with the following expression.

Output shaft speed = Pump discharge / Motor absorption / Reduction ratio

Sample) Pump discharge 200 L/min

(discharge flow for one minute per pump)
Motor absorption 150 cm3/rev
(150 cm3 required for one rotation of the motor)
Reduction ratio 15
(when the motor turns 15 times, the output shaft of the
reducer turns once)
Output shaft speed = 200 x 1000 / 150 / 15
= 88.9 min-1 (88.9 rotations per minute)
* To adjust the unit, it is multiplied by 1000.
1 L = 1000 cm³

31
IV. Travel motor
1. Structure and operation of the main unit of the motor
1) Structure
The cylinder block (10) and the shaft (03) are connected with the spline. The piston
(11) is inserted in the cylinder block (10) and it is connected to the piston shoe (16)
with a ball joint. The piston (11) and the piston shoe (16) have a hole, and the holes
are linked to the groove (pocket) on the sliding surface of the piston shoe (16). The
pin (17) pushes the retainer holder (12) with the force of the spring (09). The retainer
plate (13) pushed by the retainer holder (12) pushes the piston shoe (16) against the
swash plate (02).
The valve plate (18) separates the suction side and the discharge side of the cylinder
block (10), and it is secured onto the body with a pin. On both sides of the opening
are notches to reduce cavitation and noise.
The friction plates (06) are interlocked to the cylinder block (10) with a spline, and
they rotate with the cylinder block (10). The disc plates (05) are interlocked to the
body with a spline. The disc plates (05) and the friction plates (06) are stacked
alternately. Brake functions as the brake piston (07) pushes them with the force of the
spring (08). When the travel drive pressure applies to port A, the brake piston (07)
moves up to release the brake.
The swash plate (02) is supported with the steel balls (01) and the pistons (14). The
pilot pressure from the travel 2-speed switching solenoid valve switches the 2-speed
switching spool, and the pistons (14) are switched with the travel drive pressure.

32
01: Steel ball 07: Brake piston 13: Retainer plate

02: Swash plate 08: Spring 14: Piston

03: Shaft 09: Spring 15: Spring

04: Flange 10: Cylinder block 16: Piston shoe

05: Disc plate 11: Piston 17: Pin

06: Friction plate 12: Retainer holder 18: Valve plate

33
 2) Operation
If oil is supplied to the lower port of the cylinder block (10), the piston (11) is pushed
out. Then, the piston (11) moves upward along the swash plate (02). Thus, the
cylinder block (10) rotates.
The oil that has flowed through the path in the piston (11) and the piston shoe (16) is
supplied to the surface of the swash plate (02). With the help of the groove (pocket)
at the bottom of the shoe, lubrication and reduction of the pressing force (surface
pressure) are attained.
When switched to the travel 2nd speed, the 2nd speed switching piston (14) is
pushed out with the pilot pressure from the solenoid valve. The swash plate (02)
changes its angle with the steel ball (01) as the fulcrum. Thus, the stroke of the piston
(11) decreases, and the amount of oil required for one rotation decreases. Thus, with
the same flow, the rotational speed increases and the travel speed becomes faster.

2. Counter balance valve

When the travel lever is operated, oil flows to the P1 port and pushes the check (2)
open. It further flows into the cylinder block (M1 port). However, the return oil from the
motor (M2 port) is blocked with the counter balance valve. Thus, oil does not flow and
the motor will not turn.
When the pressure in the P1 port further rises, the pressure of chamber B at the end of
the counter balance valve increases through the orifice (6) and the check (4) from the
P1 port. The counter balance valve (1) moves to the right. Then, the return oil from the
motor (M2 port) flows through path E to the P2 port, opening the travel circuit. At the
same time, the drive pressure applies to the parking brake piston to release the brake,
and the travel motor turns.
On the downhill, the motor is turned because of the weight of the machine (external
force). Then, the pressure in the P1 port drops and the counter balance valve (1)
returns to the neutral position with spring force. Since the oil which acts on the end of
the counter balance valve (1) should go through the orifice, the counter balance valve
slowly returns. When it returns to the neutral position, path E is closed and the motor
tries to stop its rotation. Yet, since the travel lever is at "Travel," the P1 pressure
increases and the counter balance valve (1) moves to the right again, turning the motor.
In this fashion, even if the motor is turned with external force, the rotational speed does
not exceed a certain speed, and excursion is prevented.

34
3. Relief valve
1) Structure
The poppet (1) has a path with an orifice at its center. Port A and chamber C are
connected. The free piston (2) can move right and left on the circumference of the
sleeve (3). Chamber E formed with the sleeve (3) and the free piston (2) is connected
to chamber C via path D.

35
2) Operation
The pressure in port A acts on area F and tries to push the poppet (1) open. Yet, the
pressure of chamber C, which goes through the path, acts on area G, and with the
spring force, the poppet (1) stays closed.
When the pressure in port A rises, the oil lead to chamber C acts on chamber E via
path D, and the free piston (2) is moved to the left. Oil flow occurs in chamber C and
the pressure drops. Since the pressure in chamber C becomes lower than that of port
A, the force to close the poppet (1) decreases, and the poppet (1) is opened with a
lower pressure.

When the free piston (2) moves to the end of its stroke, the pressure in chamber C
becomes identical to that of port A, and the force to close the poppet (1) increases.
Thus, the poppet (1) will be opened when the pressure rises to the set pressure. In
this manner, by relieving the pressure once at a lower pressure and then at the set
pressure, the shocks of the motor start/stop are reduced.

36
4. Speed switching
1) Low speed
The oil in chamber N at the back of the 2nd speed switching pistons (1 & 8) is
connected to the tank line through paths D and E and the path inside the 2nd speed
switching spool. Thus, the 2nd speed switching pistons (1 & 8) are pushed back and
the swash plate (3) is on the low-speed side.

37
2) High speed
When the 2nd speed switching solenoid valve (7) is switched, the pilot pressure
applies to chamber K through paths H and J. The pilot pressure that applies in
chamber K pushes the spool (4) to the right. Although the travel drive pressure
applies to chamber M, the spool (4) is switched because the cross section of
chamber K is larger. Thus, the tank line is shut off, and the motor internal pressure (A
& B) applies to chamber N through paths D and E on the back of the 2nd speed
switching piston, and the 2nd speed switching pistons (1 & 8) are pushed out.
Because of the 2nd speed switching pistons, the swash plate changes its angle with
the steel ball (2) as its fulcrum, and the piston stroke decreases. Thus, the rotational
speed becomes faster.

38
3) High speed (Automatic switching)
If the drive pressure increases due to uphill during high-speed travel, the pressure in
chamber M increases. When the force generated with the travel drive pressure in
chamber M increases, the spool (4) is moved back to the left due to the force
generated with the pilot pressure in chamber K. Paths D & E are shut off from the
motor internal pressure (A & B) to the 2nd speed switching pistons (1 & 8), and the
swash plate moves to the low-speed side.

39
4) 2nd speed switching piston
This travel motor has two 2nd speed switching pistons, but some have one. This
motor has two pistons for the following reasons.
Depending on the rotational direction of the motor, the drive pressure (high pressure)
applies to half of the motor. If the drive pressure applies to the right half of the valve
plate (9), the center of the force that pushes the swash plate is at position A. The
swash plate is supported with two steel balls (2) and two 2nd speed switching pistons
(1 & 8). If the motor has only one 2nd speed switching piston, the swash plate would
be stable when the center of the force is within the range of triangle C. However, if it
is outside of the range of the triangle, a force will push up the left part of the swash
plate to make it unstable. Since the center of the force always comes within the
triangle formed with two steel balls (2) and the 2nd speed switching piston (1), the
swash plate stays stable.

1: 2nd speed switching piston (high-pressure side)

8: 2nd speed switching piston (low-pressure side)

2: Steel ball

9: Valve plate

A: Center of action

B: Stable range when the piston 1 is a fulcrum

C: Stable range when the piston is at the center

40
5. Travel reduction gear
1) Structure
The motor output shaft is connected to the drive gear (5).
Planetary gear B (6) is inserted on the shaft of holder B (10) of the first stage.
Planetary gear B (6) is meshed with the drive gear (5) and the ring gear of the
housing (2). Sun gear C (11) is connected to holder B (10) and it rotates with it.
Holder C (15) of the second stage is secured onto the flange (1), and the planetary
gear (12) is inserted on its shaft. Planetary gear C (12) is meshed with sun gear C
(11) and the ring gear of the housing (2).

1: Flange 7: Needle bearing 13: Needle bearing

2: Housing 8: Inner race 14: Inner race

3: Cover 9: Thrust plate 15: Holder C (2nd stage)

4: Thrust plate 10: Holder B (1st stage) 16: Thrust plate

5: Drive gear (shaft) 11: Sun gear C

6: Planetary gear B (1st stage) 12: Planetary gear C (2nd stage)

41
2) Operation
When the drive gear (5) rotates clockwise, planetary gear B (6) rotates
counter-clockwise. Then, planetary gear B (6) revolves clockwise since it is meshed
with the gear of the housing (2). Thus, holder B (10) rotates clockwise. Sun gear C
(11), which is connected to holder B (10), also rotates clockwise.
Due to the rotation of sun gear C (11), planetary gear C (12) rotates
counter-clockwise. Since the holder C (15) is fixed, the housing (2) rotates
counter-clockwise due to the rotation of planetary gear C (12).

42
V. Cylinder
1. Structure of the main unit
1) Whole unit
The cylinder tube (4) and the cylinder head (3) are secured with bolts, and the inside
of the cylinder tube (4) is sealed. Inside the cylinder tube (4), the piston rod (1) and
the piston (2) are secured with a nut. The piston (2) divides the inside of the cylinder
tube (4) into two chambers.
If oil is supplied to port A, the cylinder shortens, and if oil is supplied to port B, the
cylinder expands.

1: Piston rod 3: Cylinder head A: Head-side port

2: Piston 4: Cylinder tube B: Bottom-side port

2) Cylinder head section

The wiper ring (5) removes foreign objects stuck on the piston rod (1). The bush (9)
holds the piston rod (1) so that it will not directly contact the cylinder head (3). The
buffer ring (8) and the U ring (7) seal the cylinder tube (4) so that the oil inside it will
not leak out.

5. Wiper ring 7: U ring 9: Bush

6. Backup ring 8. Buffer ring

43
3) Piston section
The seal ring (12) separates the expansion side chamber and the contraction side
chamber. The slide ring (14) holds the piston (2) so that it will not directly contact the
cylinder tube (4). The slide ring (15) traps and embeds the foreign object attached to
the inside wall of the cylinder tube (4) to prevent scratching the seal ring (12). The
cushion rings (10 & 21) mitigate the impact at the cylinder stroke ends.
The narrower the gap between the cushion rings (10 & 21) and the cylinder tube (4),
the better the cushioning properties (cushion is more effective). However, since the
piston (2) is held with the slide ring (14), the center of the cushion rings (10 & 21)
tends to get misaligned with the center of the tube hole. If the gap is made narrow,
there will be a greater possibility of the cushion rings (10 & 21) interfering with the
hole.
For the floating type (cushion rings are floating against the piston rod) as in the figure,
when the cushion rings (10 & 21) come close to the tube hole, a phenomenon occurs
in which the center of the ring and the tube hole gets aligned due to the pressure
generated around the rings (automatic centering). Thus, the gap between the
cushion rings (10 & 21) and the tube hole can be lessened, and the cushioning
properties will improve.

2: Piston 14: Slide ring 19: Ball

10: Cushion ring 15: Slide ring 20: Cushion seal

11: Seal cushion 16: Shim 21: Cushion ring

12: Seal ring 17: Piston nut

13. Backup ring 18: Screw

44
2. Cushioning function
Cushioning function is provided to reduce the impact on the cylinder stroke ends.
When the piston is moving in the middle of the stroke, the return oil goes back to the
control valve through a wide path. On the contrary, the cushioning rings shut off the
wide path close to the stroke ends, and the return oil goes through a narrow path. Thus,
the return oil flow is throttled down, and the cylinder speed decreases, reducing the
shock.

45
3. Cylinder thrust
The cylinder thrust is a force P generated in the cylinder as the hydraulic pressure acts
on the cylinder. The thrust is obtained by multiplying the acting pressure by the
receiving area. If there is a pressure (back pressure) generated on the return side, this
force should be subtracted.

Sample) Piston rod outer diameter = 95mm

Cylinder tube inner diameter = 135 mm
Pressure = 32 MPa
Back pressure = 1 MPa
1 MPa = 10.2 kgf/cm²
The thrust in this sample is calculated.
Cylinder rod area = 70.8 cm²
Cylinder tube area = 143.1 cm²
Pushing force = (Receiving area) x (Pressure)
= 70.8 × (32 × 10.2)
= 46708 kg
Reactive force = (Receiving area) x (Pressure)
= (143.1 – 70.8) × (1 × 10.2)
= 737 kg

Thrust = 46708 -737

= 45,971 kg

46
VI. Small hydraulic devices
1. Remote control valve
1) Structure
The operation lever is connected to the adjusting nut (5). The hydraulic pressure from
the pilot pump applies to the port P. The port T is connected to the tank line. The
discharge ports such as A and B are connected to the control valve spool switching
port.
The discharge port can be opened or closed to the port P or the port T with the spool
(13). The return spring (14) pushed up the spring seat (11), and the pressure setting
spring (12) pushes down the spool (13).
When the operation lever is pushed forward, the force is transmitted to the plate (6),
push rod (8), and spring seat (11) in this order.

1. Casing

2. Washer

3. Plate

4. Boot

5. Adjusting nut

6. Round plate (plate)

7. Joint

8. Push rod

9. Seal

Ｔ 10. Plug

11. Spring seat

12. Pressure setting spring

Ｐ
13. Spool

14. Return spring

Ａ Ｂ

47
2) Operation
When the operation lever is in neutral, the discharge port and the port T are
connected, and the control valve spool remains neutral.
When the operation lever is pushed to the left, the push rod (8) pushes the spring
seat (11). This causes the pressure setting spring (12) to be pushed making the spool
(13) move down. Therefore, the flow of the pressurized oil from the port P to the port
A is restricted at the gap between the casing (1) and the spool (13), moving the
control valve spool. At this time, because of the pressure at the port A, the spool (13)
is pushed up and is maintained at the point where it balances with the force of the
pressure setting spring (12), which results in the discharge port pressure (secondary
pressure) being kept constant in accordance with the stroke of the push rod (8).

Ａ Ｂ

48
2. Cushion valve
1) Structure
The ports A and C are connected to the remote control valve while the ports B and D
are connected to the control valve.
The pressure at the port A applies to the side of the spool (2). Oil flows from A to B
pushing up the check valve (5), but for the opposite direction, it flows through the
restricting section of the check valve. The situation is the same for the ports C and D.

1. Body

2. Spool

3. Spring

4. Plug

5. Check valve

6. Check valve

7. Spring
8. Screw cap

49
2) Operation
A. When the remote control valve is operated
The oil from the remote control valve acts on the port A to push up the check valve
(5). It then makes the spool of the control valve move via the port B. At this time,
the spool (2) moves to the right, and the oil pushed out of the control valve spool
flows through the port D to the port T.

B. When the remote control valve is returned to the neutral position

The oil pushed out of the control valve spool as the remote control valve is in
neutral flows through the port B to the port A. As the oil flows through the restricting
section of the check valve, the return speed of the control valve spool is
suppressed to reduce the shock when the cylinder stops.

50
C. When the remote control valve is operated in reverse
When the operation lever is switched in reverse (from the direction in which the
cylinder extends to the direction in which the cylinder contracts), the cushioning
function is disabled with no response delay.
When the remote control valve is switched to switch the pressurized oil from the
port A to the port C, the spool moves to the left because of the pressure at the port
C. The oil pushed out of the control valve spool directly returns from the port B to
the tank line without flowing through the restricting section of the check valve.

51
3. Solenoid valve
1) Structure

A. Normal-close type
There are three ports: the port B to which the pilot pressure applies, the port T
which is connected to the tank line, and the port C which is connected to the
actuator.
When the solenoid is deactivated, the ports B and C are shut off while the ports C
and T are connected. When it is activated, the spool (2) moves to the right
connecting the ports B and C and shutting off the ports C and T.

1. Solenoid

2. Spool

3. Body

4. Spring

5. Snap ring
6. Adapter

52
B. Normal-open type
There are three ports: the port B to which the pilot pressure applies, the port T
which is connected to the tank line, and the port C2 which is connected to the
actuator.
When the solenoid is deactivated, the ports B and C2 are connected while the
ports C2 and T are shut off. When it is activated, the spool (2) moves to the right
shutting off the ports B and C2 and connecting the ports C2 and T.

C. Four port type

There are four ports: the port P to which the pilot pressure applies, the port T which
is connected to the tank line, and the ports C4 and C5 which are connected to the
actuator.
When the solenoid is deactivated, the ports P and C4 are connected and the ports
C5 and T are connected. When it is activated, the spool (2) moves to the right
shutting off the ports P and C4 and the ports C5 and T while connecting the ports P
and C5.

53
2) Operation
When the solenoid (1) is activated, the pin inside the solenoid is pushed out due to
the electromagnetic force to push the spool (2) in turn, which switches the passage.

[ Solenoid OFF ]

[ Solenoid ON ]

54