Hydraulic Circuit Outline

ES04-01-0085.0R0S

1 Overall Circuit
9

0.39 to 1.47MPa
(56.6 to 213.2psi)

10
10

PS.12

SOL.20 T

SOL.21 T

B A
R.D. L

B A
F.D. L

B.H.

SOL.29 T

B A
3.D./4.D.
L

57

FRONT
BRAKE
SOL.7

10

B A

10

PS.13

B4
B4

R.D.

6 0.39 to 0.78MPa

PS.4

B B BB BB
1 2 3 4 5 6

T1

(56.6 to 113.1psi)
A1

F.D.

R.D. H
X

P
T

3.D./
4.D.

A3

10

L.H
SWING

PS.6
8
R.H 0.39 to 0.78MPa
(56.6 to 113.1psi)

10

A3

A3

R.D.I

a3

b3
L

1.47 MPa
(213.2psi)

B.H.

23.5MPa
(psi)

0.39 to 0.78MPa
(56.6 to 113.1psi)

A2

10

A9

10
0.39 to 1.47MPa
(56.6 to 213.2psi)

A10

11

3/4.D. H

F
L.T.

b2

B1
R.T.

A1

b1

4th. BRAKE
SOL.13
P

L.T.

A1

a1

a1

PS3

52

29.4 MPa
(4264psi)

P1

P1'

P2'

52

P2

29.4 MPa
(4264psi)

X
0.7MPa
(101.5psi)

B B B B B B
12 1110 9 8 7

X
X

AV

0.7MPa
(101.5psi)
X
Dr 35

BV

AV

BV

9
X
28.4MPa
(4119psi)

36

17

A
SOL.14

PILOT
PRESS CUT

28.4MPa
(4119psi)

36

58
40

B A

X
Dr

19

54

X
a1

X
b
4.5
MPa
(653
psi)

34.3 MPa
(4975psi)

34

T
SOL.34

55

22.5MPa
(3263psi)
Dr

39

38

37

DR

21

B2
A2

0.05MPa
(7.3psi)
4th.
DRUM

AM
FRONT DRUM
(MAIN HOIST)

B1
A1
PB

DR

SOL.12

1.76MPa
(255.3psi)

Dr

Dr

DR

16

X
X 0.7 MPa
(101.5psi)
Av
Bv

12

DR

BM

BV

AV

PS.20

43

4th. CLUTCH
P

5.9 to 6.5MPa
(856 to 943psi)
PS10

PS.21

51

PS4

35
9

10

b1

A11

0.39 to 0.78MPa
(56.6 to 113.1psi)

X
0.10MPa
(14.5psi)

A B AB
2 2 1 1

13

A12

52

DRUM
SELECTION

18

SOL.3

X
T2

PP

P2

SOL.1

B A

15

3.D/4.D.

a2

B A

P1

b2

a2

F.D. H

A8
F
R.T.

P2

17
17

27.4MPa
(3974psi)

1.47 MPa
(213.2psi)
A7

SOL.17
T

10

TRAVEL
(HIGH SPEED)

A6

10

A SOL.11 B A
AUX.
EMERGENCY
BRAKE

B A

b3
L

PS.6

SOL.4

B A

B2

B1

0.39 to 2.94MPa
(56.6 to 426.4psi)

SOL.19
T

R.D.II

14

A2

A5

T
P

53
14

a3

B2
PS2

B A

16

SOL.5
B.H. H

A4

0.39 to 1.47MPa
(56.6 to 213.2psi)

B A

SOL.9
T

b4
H

B3

14
P1

B.H.

PS.5

a4

SOL.2

10

0.39 to 0.78MPa
(56.6 to 113.1psi)

b4
L

H
B3

PS.2

A4

14

56

REAR
CLUTCH

SOL.6

27.4MPa
(3974psi)

F.D.I

27.4MPa
(3974psi)

F.D.II

a4

PS1

A2

PS.1

A4

0.39 to 2.74
MPa
(56.6 to 397.4
psi)

SOL.8 B
MAIN
EMERGENCY
BRAKE

P
B A

B A

PS.3
T

FRONT
CLUTCH

BOOM HOIST SWING

BRAKE
BRAKE
SOL.15
SOL.18

REAR
BRAKE
SOL.10

PB
PA

SWING
R.H

SWING
L.H

Description
Remote Control Valve
Orifice
Remote Control Valve
Remote Control Valve
Pressure Guage
Pressure Switch
Pressure Switch
Pressure Switch
Pressure Switch
Solenoid Valve
Orifice
Check Block
Control Valve
Flow Control Valve
Control Valve
Solenoid Valve
Throttle Check Valve
Return Filter
Accumlator
Relief Valve
Check Valve
Line Filter
Control Valve
Flow Control Valve
Hyd. Cylinder
Check Valve
Oil Tank
Travel Motor
Gear Pump
Combination Pump
Check Valve
Oil Cooler
Nipple
Hoist Motor (B/H)
Counter Bal. Valve
Hoist Motor (Main & Aux.)
Clutch Ass'y
Rotary Joint
Brake Cylinder
Pressure Switch

No.
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58

Description
Check Valve
Control Valve
Swing Motor
Rotary Joint
Retract Cylinder
Take-Up Cylinder
Check Valve
Shuttle Valve
Shut-off Valve
Reducing Valve
Flow Control Valve
Plug
Control Valve
Counter Bal. Valve
Hoist Motor
Remote Control Valve
Pressure Switch
Solenoid Valve

B.H.: Boom Hoist

R.D.: Rear Drum
F.D. : Front Drum
3.D. : Third Drum
4.D. : Fourth Drum
R.T. : Right Travel
L.T. : Left Travel
I
: 1-Speed
II : 2-Speed
H : Hoisting
L : Lowering
F : Forward
B : Backward
R.H.: Right Hand
L.H. : Left Hand

20

3RD. DRUM
LBCE SUPPLY
BOOM
HOIST

37
P

20.6 MPa
(2988psi)

REAR DRUM
(AUX. HOIST)

No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40

41

38

37

39

40

7.85MPa
(1139psi)

39

39

40

20.6 MPa
(2988psi)

22

23

PS.9

PS.8

42

38

5.9 to 6.5MPa
(856 to 943psi)

0.4MPa
(psi)
0.10MPa
(14.5psi)

44

24

X
F

C H

G A

25

45
P

RETRACT CYL.

49
26

A
2.94MPa
(426.4psi)

33
0.02MPa (2.9psi)

TAKE-UP CYL.

48

33
47

33
47

20.6 MPa (2988psi)

46

33

20.6 MPa (2988psi)

P3 A2
Psv

31

(FRONT)

a1 X

X a2

(REAR)

48

COUNTERWEIGHT REMOVAL CYLINDER

Pm1

Pm1

P2

P1

P1

P2

32
27
Pi1

R/G

R/G

FORWARD

28

0.2 MPa (29psi)

BACKWARD

BACKWARD

SOL.16
B XA

Pc2

Pc1

FORWARD

T P

ENGINE
P1

30

0504

COUNTERWEIGHT REMOVAL DEVICE

Pi2

28

Pm2
TRAVEL MOTOR(L.H)

25
49

0.02MPa
A1

46

0.3MPa
(43.5psi)

50

Ps

Ps

Pm2

Dr

P2

P3

P4

29

16

PUMP CONTROL

B1

CBJ2165Z-E 1

TRAVEL MOTOR(R.H)

1/14

Hydraulic Circuit Outline

ES04-01-0085.0R0S

2 Types And Driven Actuator Of Pumps

Pump Type

Pump No.

Variable Delivery
Pump (Tilting Plate)

P1

R.H. Travel, Boom Hoist, Rear Low 1-Speed, Front High 2-Speed

P2

L.H. Travel, 3rd/4th Drum, Rear High 2-Speed, Front Low 1-Speed

P3

Swing, Retract, Pump Regulator Control

P4

Pilot Line, Clutch Line, Brake Lline, Pump Control,

Counterweight Removal Line, Travel High Speed Line

Fixed Delivery Gear

Pump

Driven Actuator

3 Explanation Of Control Circuit

3.1 Control circuit of pump
In each delivery pump (P1,P2), the amount of delivery can be changed depending upon the loads
applied. The flow-rate is controlled by means of detecting the pressure between the pumps, to restrain a
maximum load in the system. The functions for front drum, rear drum hoist and travel operations can be
performed at the same time. A maximum load is totally controlled in this system by means of detecting
the pressure of pumps (P1,P2) though the pilot line.
Pump P3 is used for swing motion (including retracting motion) only. The horsepower of the pump is
totally controlled, thus the engine can be run without stopping when an overload is applied, as the flowrate at P1 and P2 is cotrolled by swing load pressure.
Pump control
When the pump control switch located on the rear drum control lever is turned on, the discharge amount
of the P1 and P2 pumps are controlled to a minimum.
It can be used to fine-control the hoisting and lowering of the hook. This switch also allows slowing the
front, rear, third, fourth drum, boom hoist, and travel operations.
To Control Device
(Pilot, Clutch, Brake Line)
Gate Lock
Accumulator
Hydraulically Operated
Electrically Operated

From Pilot Line

(R.H. Travel, Boom Hoist,
Rear Low 1-Speed,
Front High 2-Speed)

Front High 2-Speed

Front Low 1-Speed
Rear High 2-Speed
Rear Low 1-Speed
3rd/4th Drum
Boom Hoist
R.H. Travel
L.H. Travel
4-Series Control Valve

From Pilot Line

(L.H. Travel, 3rd/4th Drum,
Rear High 2-Speed,
Front Low 1-Speed)
Counterweight
Cylinder Line

Swing And Retract

Oil Cooler

Sump Tank

Engine

P4
P1

Pump Control

P2 P3
CB04-001

0504

2/14

Hydraulic Circuit Outline

3.2 Pilot circuit

ES04-01-0085.0R0S

L.H. Travel
Control Lever

R.H. Travel
Control Lever

Swing
Control Lever

3rd/4th Drum
Control Lever

Rear Drum
Control Lever

Front Drum
Control Lever

Boom Hoist
Control Lever

To
Tank

To P2 Pump
Regulator

Control Valve

To P2 Pump
Regulator

To P1 Pump
Regulator

To P2 Pump
Regulator

1 Speed

1 Speed

Control Valve

To P1 Pump
Regulator

To P1 Pump
Regulator

2 Speed

Lever

To P2 Pump
Regulator

2 Speed

To P1 Pump
Regulator

"Stop" Side
"Operation"
Side

R.H.
Swing
Accumulator

L.H.
Swing

Motor

Motor

Motor
Motor

Motor
Front Drum

Poilot Pressure
Cut

Rear Drum

4th Drum
Swing Device

Relief Valve
7.84MPa
(1137psi)

Boom Hoist Drum

Hydraulically Operated
Electrically Operated

CB04-002

Counterweight Removal
Device
Engine P1 P2 P3 P4

Line Filter
Hydraulic Power
Source
3rd Drum (LBCE Supply)

The power source in the pilot circuit is pump P4. The pressure of pump P4 is also used for the brakes and clutches of the front, rear, 4th and boom hoist, the brakes in the swing mechanism, counterweight cylinders.
The circuit pressure is controlled at 7.84MPa (1137psi) by the relief valve.
[Hydraulic power source]
The hydraulic power source consists of an accumulator, relief valve and line filter. When the pressure reaches 7.84MPa (1137psi), a relief valve opens to return this hydraulic pressure to a tank.
Even if the engine is stopped, the pressure will not drop suddenly since the reverse of pressurized hydraulic oil is prevented with a check valve. Still, the pressure drop may not be perfectly prevented due to some internal leakage in remote
control (pilot) valves and solenoid valves. In fact, the accumulator is necessary to maintain the circuit pressure constant for a while, by supplying the pressure into the circuit since the circuit pressure will drop to zero instantaneously when
leaking occurs in any part of the circuit as the hydraulic oil is incompressible.
The pressure, however, will gradually drop and finally fall to zero. The accumulator is filled with nitrogen gas (N2) under 4.5MPa (653psi) and the circuit pressure from 7.84MPa (1137psi) to 4.5MPa (653psi) drops gradually but once the
pressure becomes lower than 4.5MPa (653psi), it will drop sharply.
[Pilot pressure cut]
When the lever located at an entrance of the operators cab is pushed forward, pressurized oil is returned to the tank and all the functions are stopped.
It prevents the accident due to forgetting returning the control levers or wrong operations.
0504

3/14
2/14

Hydraulic Circuit Outline

ES04-01-0085.0R0S

3.3 Front and rear drum circuit

Basically the front drum and rear drum circuits are independent of each other. As mentioned before,
pumps P1 and P2 are of the variable delivery type. The P1 and P2 are designed to ensure efficient
functions by restraining a maximum load. In addition, the line speed can be changed from low to high
speed and vice versa with a control valve. In the 2-speed circuit in the high-speed (2-speed) mode, the
front and rear drum are driven with the pressurized hydraulic oil delivered from both P1 and P2 pumps.
The pilot pressure functions the control valve. As this line is explained in 3.2, description will be made
only of the pressure line here. Since the front and rear drums have the same circuits, the front drum is
explained herein.
When the front drum control lever is set to the hoisting position (pulled toward), the pressurized
hydraulic oil of the P2 pump will flow in the direction of the arrow ( ) from the control valve. The oil is
directed to a winch motor through the check valve to rotate the motor and then its pressure will decrease.
The oil will return to the sump tank again through the control valve.
Front Drum Control Lever
Lowering Hoisting
0.39 to 2.74MPa
(56.6 to 397psi)

Rear Drum Control Lever

Lowering Hoisting
0.39 to 2.74MPa
(56.6 to 397psi)

HSOL

LSOL

P4

To Tank

HSOL

LSOL
To P2 Pump
Regulator

To P1 Pump
Regulator

S/C

To P1 Pump
Regulator

To P2 Pump
Regulator

S/C

P2
Control Valve
2-Speed

Control Valve
2-Speed

1-Speed

1-Speed

P1

BSOL

CSOL

BSOL

CSOL

ESOL

Motor

.7MPa
(102psi)

Front Drum

ESOL

Motor

.7MPa
(102psi)

28.4MPa
(4119psi)

28.4MPa
(4119psi)

Rear Drum

Brake Cylinder

Brake Cylinder

Clutch

Clutch

Limit Switch
S/C
Safety
Controller

Overhoist Limit Switch

(Normally Switched ON
When The Weight Is
Applied.)

Front Drum Lock

Toggle Switch

Control Panel
Buzzer

Switch(Front)
Switch(Rear)

Front Drum
Lock Mode

Lock Pawl
Motor

0504

HSOL: Hoisting Stop Solenoid Valve

LSOL: Lowering Stop Solenoid Valve
BSOL: Brake Solenoid Valve
CSOL: Clutch Solenoid Valve
ESOL: Emergency Solenoid Valve

4/14

Auto-Brake Mode
Free Mode
R.H. Control Panel
Hydraulically Operated
Electrically Operated
CB04-003

Hydraulic Circuit Outline

ES04-01-0085.0R0S

When the lever is returned to the neutral position, the hoist side of the control valve is a blocked circuit,
thus the motor will not reverse. Of course, the reverse current of oil can be prevented with a check valve
within the counterbalancing valve. Eventually, a double reverse current preventing system is available
as the control valve with neutral block position also function as a check valve preventing the reverse
current. The control valve alone does not give an effective sealing so, the counterbalancing valve mainly
functions to block the oil flow.
A relief valve set to 28.4MPa (4119psi) is provided in the counterbalancing valve. In normal operation,
this relief valve does not function. If any overloads or problems are produced in the circuit, the main relief
valve 29.4MPa (4264psi) will function prior to this relief valve to protect the circuit. If the pressure is
released instantaneously, the relief valve in the counterbalancing valve may function in some cases. But
the counterbalancing valves will never function to release the pressure unless the main relief valve is out
of order as the latter is set to the lower pressure limit.
When the control lever is set to the lowering position (pushed forward), the pressurized hydraulic oil will
flow in the direction of the arrow (
) from the control valve.
But as the circuit is closed while the pressure is low, the oil does not flow in the circuit. The pilot
pressure exceeds the spring force only when the pressure reaches .7MPa (102psi), and the bypass
circuit is then opened to reverse the motor.
In the case of front drum operation, pump P1 and P2 will run and the motor speed is doubled for the
high speed operation with the control lever shifted at high speed stage. The combined operation of the
front drum high speed and rear drum low speed cannot be got in this circuit, the rear drum operation is
stopped.
[Anti-two block]
When the hook is raised too high (to the head sheave anti-two block switch), the limit switch activates
to send a signal to the solenoid valve HSOL7, so that the pilot line for hoisting is changed over to the tank
port.This will make the control valve return to the neutral position. The motor stops and an audio/visual
alarm Two-block Limit.
[Front and rear drum pawl lock]
The drum pawl lock is provided as a device to prevent the hook or the suspended load from falling.
When the toggle switch is turned to the lock side, the electric motor of the pawl lock is activated and the
pawl is engaged with the drum at the same time a signal is sent to the solenoid valve LSOL 5. The valve
will connect the load lowering pilot line to the tank port. This will return the control valve to the neutral
position. When the toggle switch is on the lock side, pressurized oil from P5 flows to the tank port without
operation even if the control lever is turned to the lowering side. This produces a safety circuit, which
does not damage the machine at all.
[Lever lock]
The function of control lever stops when lever lock switch on the control panel is turned to the lock side.
When lever lock switch is turned to the lock side, a signal is sent to the solenoid valve LSOL5 and
HSOL7. Even if the control lever is set to hoisting/lowering position, the pilot pressure is connected to
tank port, the drum dose not rotate.

0504

5/14

Hydraulic Circuit Outline

ES04-01-0085.0R0S

[Explanation of brake function]

No foot braking is required since the brake is automatically applied when the control lever is placed in
neutral position. But the automatic brake can not be applied when the brake mode is placed at the free
mode (bucket mode) side.
The brake has two systems. One is the automatic brake system and the other is the foot brake (free fall)
system. These two systems can be changed over by the manual select switch on the control panel and
the safety switch on the brake pedal for prevention of accidental changing.
[Automatic brake system]
The automatic brake is activated by a spring force and is released hydraulically. No pilot pressure will
be charged with the front and rear drum control levers placed in neutral position. The BSOL2 and ESOL4
in the automatic brake line activates by the signal sent from the pressure switch 1 which detects the pilot
pressure, to flow out the oil from the release cylinder, to apply brake by a spring force. On the other hand,
on the clutch side, the signal from the pressure switch 1 operates the CSOL6 to continuously guide the
pressurized oil in order to activate the clutch. When the front and rear drum control levers are positioned
to Hoisting (or Lowering), pilot pressure is charged and the BSOL 2 is activated. Pressure oil goes
through BSOL 2 and is blocked briefly by ESOL 4 until 4 is activated, so the brake is not released yet. On
the other hand, when the clutch line reaches 6.5MPa (943psi) the pressure switch 3 is activated and
activates the emergency brake ESOL 4. The brake pressurized oil flows through BSOL 2 and ESOL4,
flowing into the brake release cylinder, releasing the brake.
[Foot brake system]
The free fall (bucket mode) operation is made by selecting the switch of the front and rear drum control
lever at the same time, pushing the brake pedal lightly. With the free fall conditions, the pressurized oil is
directed to the release cylinder of the automatic brake device, and the automatic brake is released. The
braking operation can be made by the foot brake. The brake will be applied through the link mechanism
by pressing the foot pedal.
For safety reasons, if the engine stops for reason or clutch pressure goes below 5.9MPa (856psi), the
ESOL4 is activated by the pressure switch 3 to apply the brake automatically. At the same time, the
lowering stop LSOL5 is also activated to prevent suspended load from falling.

0504

6/14

Hydraulic Circuit Outline

ES04-01-0085.0R0S

3.4 Fourth drum circuit

The fourth drum is driven with the variable capacity pump P2 .
The control lever is common to the third and fourth drum and change the switch on the control panel for the purpose
of use.
The hydraulic circuit for the fourth drum is the same as the front and the rear drum.
However this circuit has not "High speed (2nd speed)".

3rd/4th Drum Control Lever

Lowering Hoisting
.39 to 1.47MPa
(56.6 to 213psi)
P4

HSOL

LSOL
To P2 Pump
Regulator

5
S/C

P2

.7MPa
(102psi)

BSOL

CSOL

ESOL
34.3 MPa
(4975psi)
Clutch

Brake Cylinder

Fourth Drum

Limit Switch

3RD/4TH Drum Lock

Toggle Switch

S/C
Safety
Controller

Overhoist Limit Switch

(Normally Switched ON
When The Weight Is
Applied.)

Control Panel
Buzzer

Fourth Drum

3RD
Switch ( 4TH )

Switch (3RD/4TH SELECT)

Lock Mode
Third Drum : Illustrated By LBCE

HSOL: Hoisting Stop Solenoid Valve

Lock Pawl LSOL: Lowering Stop Solenoid Valve
BSOL: Brake Solenoid Valve
CSOL: Clutch Solenoid Valve
Motor
ESOL: Emergency Solenoid Valve

0504

7/14

Auto-Brake Mode
Free Mode
R.H. Control Panel
Hydraulically Operated
Electrically Operated
CB04-004

Hydraulic Circuit Outline

ES04-01-0085.0R0S

3.5 Boom hoist circuit

This circuit is basically the same as those of front and rear drum winches with the exception that the 2speed control system is not provided.
The pressure for the boom hoist is produced by pump P1. When the control lever is moved to the
hoisting position, (pulled toward the operator), the pressurized hydraulic oil will flow in the arrow ( )
direction as the pilot pressure moves the spool of the control valve.

Boom Hoist Lever

Lowering

Hoisting
.39 to 1.47MPa
(56.6 to 213psi)

P4
Brake/Drum Lock Solenoid Valve

4
Pressure
Switch

3
Drum Lock

22.5MPa (3263psi)

Check Block

Brake

To P1 Pump
Regulator

Control Valve

Drum

1.76MPa (255 psi)

S/C
Safety
Controller

P1

Buzzer

Boom

Overhoist
Limit
Switch

Hydraulically Operated
Electrically Operated
CB04-005

0504

8/14

Hydraulic Circuit Outline

ES04-01-0085.0R0S

The oil passes through a check valve in the counterbalancing valve to rotate the motor, and then returns
to the control valve under low pressure from the motor, and to the sump tank. On the other hand, the
same pilot pressure is detected with a pressure switch and the solenoid valve in the brake line and drum
lock circuit are energized. Thus, the pressure in the pilot line (P4) is directed to the brake cylinder and
drum lock cylinder to release the brake and drum lock before the motor rotates.
When the control lever is returned to the neutral position, the pilot pressure will become low and the
pressure switch will cut off the electric current to the solenoid. Then the spool is changed over and the
pressure in the brake line and drum lock is cut off returning the oil to the tank port. The disk will be applied
again by means of a force produced by a spring of the brake cylinder to lock the drum with secure stop of
the motor. In addition, boom lowering is prevented by the drum lock.
Although a counterbalancing valve is incorporated into this circuit like the front and rear drum circuits,
the disk brake is also used to secure sufficient motor locking. The select switch of free mode is not
provided is the difference from the front and rear drum brake mechanism.
When the control lever is moved to the lowering position (pushed forward), the oil flow direction will be
reversed, flowing in the direction of the arrow (
).The motor can not be reversed since a check valve in
the counterbalancing valve is provided in the return circuit.
The oil is returned to the control valve by opening the bypass circuit with pilot pressure produced from
the self-pressure. With this function, the motor will rotate and the boom can be lowered by rotating the
drum. The pilot pressure can be applied smoothly with a throttle valve provided in the pilot line, thus the
boom can be lowered smoothly. The pilot pressure is 1.76MPa (255 psi). and changes over the functions
of valve as the bypass circuit.
[Boom over hoist limiting device]
When the boom reaches raising limit, the limit switch activates to send signal to the solenoid valve 1, so
that the pilot line for hoisting is changed over to the tank port. This will make the control valve return to the
neutral position. The motor stops, and the buzzer sounds.

0504

9/14

Hydraulic Circuit Outline

ES04-01-0085.0R0S

3.6 Swing circuit

The swings are independent from each other.
The circuit is same as the R.H. swing and L.H. swing.

Retract Cylinder

Swing/Retract Control Valve

Rotating Joint

Brake
Release
Cylinder

Swing Brake
Release Switch

20.6 MPa
(2988 psi)

R.H.

L.H.

Swing
Control Lever

Accumlator
Swing
Motor

L.H. R.H.

.39 to 1.47Mpa
(56.6 to 213psi)

Engine

Relief Valve
P4

Swing Device

Line Filter

P3
P2

P1

Swing Brake Solenoid

Hydraulically Operated
Sump Tank

Electrically Operated

CB04-006

3.6.1 Swing circuit

When the swing lever is pushed forward, (L.H. swing) the oil pressurized by pump P3 will flow in the
direction of the arrow ( ) from the control valve. The pressurized hydraulic oil actuates the swing motor
and returns to the control valve under low pressure and then to the sump tank (
). If the rotation of the
motor is stopped by any external pressure applied, the oil will be bypassed through a relief circuit
(20.6MPa(2988psi)) of the control valve to protect the circuit since the highly pressurized oil is deadlocked in the circuit.
The swing brake release switch on the swing lever is used for parking temporarily after the swing is
stopped, and should not be put into function during swinging. If actuated in swinging, accidents may
occur. There is a method to stop the swing at the required position, in which the swing is stopped by
shifting the control lever slightly in the reverse direction.
Normally, the swing speed is controlled by means of the control lever stroke.
3.6.2 Swing brake circuit
By placing the switch on the swing lever in ON, the pressurized oil is directed in the brake release
cylinder to release a wet-type multi-plate brake.
By placing the switch in OFF, the solenoid valve should be in OFF. The pressurized oil in the brake
release cylinder is drained and the wet-type multi-plate function to brake the swing by spring pressure.

0504

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Hydraulic Circuit Outline

ES04-01-0085.0R0S

3.7 Travel circuit

The travel motor receives the pressurized hydraulic oil from two pumps, which do not flow together.
The pumps P1 and P2 supply the pressurized oil to the R.H. motor and L.H. motor respectively. Discrepancy in discharge of P1 and P2 pumps may cause uneven travelling or unbalanced travelling which
may be increased by circuit resistance. To avoid this trouble, the pressure of both pumps must be
checked and then corrected to be equal in the regulator circuit in this system.

Travel
High Speed
Switch

Forward

P4

R.H. Travel Control Lever

.39 to 1.47Mpa (56.6 to 213psi)

L.H. Travel Control Lever

.39 to 1.47Mpa(56.6 to 213psi)

Backward Forward

Backward
To Tank
To P1 Pump Regulator

To P2 Pump Regulator

Control Valve
P2

Control Valve
P1

Control Panel

Hydraulically Operated

Travel High Speed

Select Solenoid Valve

Shoe Extension
Cylinder

C H

G A

Rotating Joint

.02MPa
(2.9psi)

Electrically Operated

.02MPa
(2.9psi)

20.6MPa
(2988psi)

20.6MPa
(2988psi)
Pm1

Pm1
Backward

Backward
P1

R/C

P2
P1

T
Forward

Pm2

R/C

P2

T
Forward

Ps

Ps Pm2

Travel Motor(L.H)

Right Travel Device

CB04-007

0504

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Hydraulic Circuit Outline

ES04-01-0085.0R0S

3.7.1 Travel circuit

When the travel control lever is pushed forward or backward, the oil pressurized by pump P1 will flow in
the direction of the arrow ( ) as the pilot pressure .39 to 1.47MPa (56.6 to 213psi) changes over the
control valve spool, and reaches the brake valve through a rotating joint. The brake valve opens the
pipeline,directing the pressurized oil to the motor. As the motor has a brake with it, the oil alone can not
rotate it. Therefore, a part of the pressurized oil must be directed to the brake cylinder to release the disk
brake to free the motor. Oil pressure from the motor will become low and the oil will return to the sump
tank under low pressure throuth the control valve along the return circuit.
With the control lever set to the neutral position, the brake valve blocks the oil circuit to stop the motor
and at the same time, the spring releases the oil in the brake release cylinder and the multi-plate brake
applies and the motor drive shaft is secured. This prevents the machine from traveling on a slope.
If any load greater than the rotating torque is applied on to the travel motor, the motor will stop and the
oil pipeline circuit will close resulting in breakage on instruments or piping as the pressure will rise too far.
A safety valve therefore, is necessary to prevent any breakage or damage in the circuit. The pressure is
released to the tank port by opening the bypass circuit with the main relief valve 29.4MPa (4264psi) in
the control valve.
A relief valve (set pressure: 32.4MPa (4699psi)) to release the overpressure is provided in the motor
unit.
3.7.2 High speed circuit
When the travel high speed switch on the control panel is placed in "ON" side, the travel high speed
select solenoid valve is changed over and the control hydraulic oil generated from pump P4 changes
over the speed select valve built in the travel motor through the solenoid valve and the rotating joint.
The regulator in the motor is activated by the pressurized oil and a tilting angle of the tilting plate becomes smaller.
Therefore, the travel operation can be made at high speed with motor speed increased. (The motor
displacement is decreased.)
3.7.3 Shoe extension cylinder circuit
When the travel control lever is placed forward or backward, the oil, as the above mentioned, will flow to
the shoe extension cylinder at the same time the travel motor is started, to give appropriate tension
(adjustment value) shoe extension cylinder automatically. The condition is maintained even if the lever is
placed in neutral.
The pressurized oil is maintained by the check valve, and unless the external pressure is applied, the
shoe does not contract. If the external pressure exceeds 20.6MPa (2988psi), the check valve will be
opened. The check valve releases the pressurized oil to prevent applying excessive force to the shoe
and the drive equiment.
Note: Refer to the operator's manual for tension adjustment value.
3.7.4 Travel brake circuit
When the travel motor is driven, the pressurized oil is directed in the brake release cylinder to release.
With the lever in neutral, the control valve is in neutral and the pressurized oil in the brake release
cylinder is directed to the tank. The brake is actuated by the spring force.

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Hydraulic Circuit Outline

ES04-01-0085.0R0S

3.8 Retract cylinder circuit

The retract cylinder, installed on side frames.
When the retract lever is placed in the Extend side, the pressurized oil with pump P3 will flow in the
direction of the arrow ( ).
When the retract lever is placed in the Retract side, the pressurized oil from pump P3 will flow in the
direction of the dotted arrow (
). If any external pressure is applied, the oil will be bypassed through a
relief circuit (20.6 Mpa (2988 psi)) of the control valve to protect the circuit since the highly pressurized oil
is deadlocked in the circuit.

Swing/Retract Control Valve

Extend

Retract

Rotating Joint

To Swing

P3

Engine

Retract Cylinder

20.6Mpa(2988 psi)

Sump Tank
CB04-008

0504

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Hydraulic Circuit Outline

ES04-01-0085.0R0S

3.9 Counterweight cylinder circuit

The counterweight removal/installation cylinder line is controlled by pump P4. The oil discharged from
the pump P4 usually flows to control devices such as the pilot line, clutch, brake line. The control valve is
used for counterweight removal/installation. When the lever is set to the Extend (lowering) side, the
pressurized oil from P4 pump flows in the direction of arrow ( ), passing through the line filter, control
valve and the cylinder. The oil on the Retract side in the cylinder flows in the direction of dotted line (
),
passing through the flow control valve, control valve and the sump tank. On the other hand, when the
lever is set to the Retract (lifting) side, the oil flows reversely.
When the oil is fed continuously by the P4 pump, its temperature rises causing damages of devices and
piping. A safety circuit for prevention of such damages is provided, where the main relief valve of the
control valve is activated at 20.6Mpa (2988psi) to lead the oil to the sump tank.
Other control devices cannot be used during operation of the counterweight removal/installation cylinder.

To Control Device
Accumulator

P
20.6MPa
(2988psi)

Relief Valve

Line Filter

Engine
Counterweight Removal Clyinder

P3 P4
P1 P2

Sump Tank

0504

CB04-009

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