SECTION 2 STRUCTURE AND FUNCTION

Group
Group
Group
Group
Group
Group

1
2
3
4
5
6

Pump Device
Main Control Valve
Swing Device
Travel Device
RCV Lever
RCV Pedal

2-1
2-21
2-46
2-58
2-69
2-76

SECTION 2 STRUCTURE AND FUNCTION

GROUP 1 PUMP DEVICE
1. STRUCTURE
The pump device consists of main pump, regulator and gear pump.
Pi1

Pm1

Qmax adjusting screw

Dr

A3

B3
Psv
Pm2

Pi2

a4
Qmin adjusting screw
Regulator

Regulator

Pi1

Qmin adjusting screw

Pi2
Pm2

Pm1

a4

Psv
B3
Dr
B1
a3
a2

a1
Port block

Front pump

Port

A1 Psv a4 A2
a2

a1

Pm1
Pi1

Pm2
Pi2

a3

Dr
B1

Rear pump

B3

A3

2-1

Port name

Gear pump
Port size

A1,2

Delivery port

SAE6000psi 3/4"

B1

Suction port

SAE2500psi 2 1/2"

Dr

Drain port

PF 3/4 - 20

Pi1,i2

Pilot port

PF 1/4 - 15

Pm1,m2 Qmax cut port

Psv

PF 1/4 - 15

Servo assist port

PF 1/4 - 15

a1,2,4

Gauge port

PF 1/4 - 15

a3

Gauge port

PF 1/4-14

A3

Gear pump delivery port

PF 1/2 - 19

B3

Gear pump suction port

PF 3/4 - 20

1) MAIN PUMP(1/2)
The main pump consists of two piston pumps(front & rear) and valve block.

702
789, 732 532 214 548 531 724 792 534 901 808 954 717 151 152 211 113
535
806
953
886
717
406
261
774

04

111
824
127
710
123
251
212

04
111
113
114
123
124
127
141
151
152
153
156
157
158
211
212
214

490

153

Gear pump
Drive shaft(F)
Drive shaft(R)
Spline coupling
Roller bearing
Needle bearing
Bearing spacer
Cylinder block
Piston
Shoe
Set plate
Bushing
Cylinder spring
Spacer
Shoe plate
Swash plate
Bushing

156 158 157 468 313 124 312 114 466

728
725

251
261
271
312
313
314
401
406
466
468
490
531
532
534
535
548
702

Support
Seal cover(F)
Pump casing
Valve block
Valve plate(R)
Valve plate(L)
Hexagon socket bolt
Hexagon socket bolt
VP Plug
VP Plug
Plug
Tilting pin
Servo piston
Stopper(L)
Stopper(S)
Pin
O-ring

2-2

885

314

141

710
717
724
725
728
732
774
789
792
806
808
824
885
886
901
953
954

271

401

O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
Oil seal
Back up ring
Back up ring
Hexagon head nut
Hexagon head nut
Snap ring
Pin
Spring pin
Eye bolt
Set screw
Set screw

MAIN PUMP(2/2)

544

543
545
541

079

VIEW A

79
541

Proportional reducing valve

Seat

543
544

2-3

Stopper 1
Stopper 2

545

Steel ball

2) REGULATOR(1/2)

412

875

874

755
A

897

858

614

612

615
613
A

611

647

KR3G-9C32

648
P2
Pf

723
642

438
801

801

Pm
Pi

924
641

730

643

708

644

645

646

728

SECTION B-B

413

438

656

438
735
722

496

724

725

436

VIEW C

2-4

Port

Port name

port size

Delivery port

3/4"

Suction port

2 1/2"

Pi

Pilot port

PF 1/4-15

Pm

Qmax cut port

PF 1/4-15

REGULATOR(2/2)
734

653

654

836

651 652

601

624

629

630

628

655

641

801
C
925

814
898
631

627

732

733

732

622

621

623

625

626

887

763

756

730
732
733
734
735
755
756
763
801
814
836
858
874
875
887
897
898
924
925

O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring
Nut
Snap ring
Snap ring
Snap ring
Pin
Pin
Pin
Pin
Pin
Set screw
Adjust screw(QI)

SECTION A-A

412
413
436
438
496
601
611
612
613
614
615
621
622
623
624
625
626
627
628
629
630

Hexagon socket screw

Hexagon socket screw
Hexagon socket screw
Hexagon socket screw
Plug
Casing
Feed back lever
Lever(1)
Lever(2)
Fulcrum plug
Adjust plug
Compensator piston
Piston case
Compensator rod
Spring seat(C)
Outer spring
Inner spring
Adjust stem(C)
Adjust screw(C)
Cover(C)
Lock nut

631
641
642
643
644
645
646
647
648
651
652
653
654
655
656
708
722
723
724
725
728

Sleeve, pf
Pilot cover
Pilot cover(QMC)
Pilot piston
Spring seat(Q)
Adjust stem(Q)
Pilot spring
Stopper
Piston(QMC)
Sleeve
Spool
Spring seat
Return spring
Set spring
Block cover
O-ring
O-ring
O-ring
O-ring
O-ring
O-ring

2-5

3) GEAR PUMP

700

354

351

433

B3

850
355

434
A3

311
312
a3
710

307
308
309
310
311
312
351

435

Poppet
Seat
Spring seat
Spring
Screw
Nut
Gear case

361

353

732

353
354
355
361
433
434
435

309

Drive gear
Driven gear
Filter
Front case
Flange socket
Flange socket
Flange socket

2-6

307

310

308

466
700
710
725
732
850

434

466, 725

Plug
Ring
O-ring
O-ring
O-ring
Snap ring

2. FUNCTION
1) MAIN PUMP
The pumps may classified roughly into the rotary group performing a rotary motion and working as
the major part of the whole pump function: the swash plate group that varies the delivery rates: and
the valve cover group that changes over oil suction and discharge.
(1) Rotary group
The rotary group consists of drive shaft
(F)(111), cylinder block(141), piston
shoes(151,152), set plate(153), spherical
bush(156), spacer(158) and cylinder
spring(157). The drive shaft is supported
by bearing(123,124) at its both ends.
The shoe is caulked to the piston to from
a spherical coupling. It has a pocket to
relieve thrust force generated by loading
pressure and the take hydraulic balance
so that it slides lightly over the shoe
plate(211). The sub group composed by
a piston and a shoe is pressed against
the shoe plate by the action of the
cylinder spring via a retainer and a
spherical bush.
Similarly, the cylinder block is pressed
against valve plate(313) by the action of
the cylinder spring.

141
151
152

313

124

158
156
153

111

157

123
211

531
548

(2) Swash plate group

The swash plate group consists of swash
plate(212), shoe plate(211), swash plate
support(251), tilting bush(214), tilting
pin(531) and servo piston(532).
The swash plate is a cylindrical part
formed on the opposite side of the sliding
surface of the shoe and is supported by
the swash support.
If the servo piston moves to the right and
left as hydraulic force controlled by the
regulator is admitted to hydraulic
chamber located on both sides of the
servo piston, the swash plate slides over
the swash plate support via the spherical
part of the tilting pin to change the tilting
angle()

214
212
251

211

532

2-7

(3) Valve block group

The valve block group consists of valve
block(312), valve plate(313) and valve
plate pin(885).
The valve plate having two melonshaped ports is fixed to the valve block
and feeds and collects oil to and from the
cylinder block.
The oil changed over by the valve plate is
connected to an external pipeline by way
of the valve block.
Now, if the drive shaft is driven by a prime
mover(electric motor, engine, etc), it
rotates the cylinder block via a spline
linkage at the same time. If the swash
plate is tilted as in Fig(previous page) the
pistons arranged in the cylinder block
make a reciprocating motion with respect
to the cylinder block, while they revolve
with the cylinder block.
If you pay attention to a single piston, it
performs a motion away from the valve
plate(oil sucking process) within 180
degrees, and makes a motion towards
the valve plate(or oil discharging process)
in the rest of 180 degrees. When the
swash plate has a tilting angle of zero,
the piston makes no stroke and
discharges no oil.

312
313

2-8

885

2) REGULATOR
Regulator consists of the negative flow control, total horse power control and power shift control
function.

Delivery flow, Q

(1) Negative flow control

By changing the pilot pressure Pi, the
pump tilting angle(delivery flow) is
regulated arbitrarily, as shown in the
figure.
This regulator is of the negative flow
control in which the delivery flow Q
decreases as the pilot pressure Pi rises.
With this mechanism, when the pilot
pressure corresponding to the flow
required for the work is commanded, the
pump discharges the required flow only,
and so it does not consume the power
uselessly.

Pilot pressure, Pi

2-9

 Flow reducing function

643

654

651

P1

652

613

CL

646

B(E)
874
897
C
A

875
611
Large diameter
chamber

Servo piston

548

Small diameter
chamber

531

As the pilot pressure Pi rises, the pilot piston(643) moves to the right to a position where the
force of the pilot spring(646) balances with the hydraulic force.
The groove(A) in the pilot piston is fitted with the pin(875) that is fixed to lever 2(613). Therefore,
when the pilot piston moves, lever 2 rotates around the fulcrum of point B [fixed by the fulcrum
plug(614) and pin(875)]. Since the large hole section(C) of lever 2 contains a protruding
pin(897) fixed to the feedback lever(611), the pin(897) moves to the right as lever 2 rotates.
Since the opposing-flat section(D) of the feedback lever is fitted with the pin(548) fixed by the
tilting pin(531) that swings the swash plate, the feedback lever rotates around the fulcrum of
point D, as the pin(897) moves.
Since the feedback lever is connected with the spool(652) via the pin(874), the spool moves to
the right.
The movement of the spool causes the delivery pressure P1 to connect to port CL through the
spool and to be admitted to the large diameter section of the servo piston. The delivery
pressure P1 that is constantly admitted to the small diameter section of the servo piston moves
the servo piston to the right due to the area difference, resulting in decrease of the tilting angle.
When the servo piston moves to the right, point D also moves to the right. The spool is fitted
with the return spring(654) and is tensioned to the left at all times, and so the pin(897) is pressed
against the large hole section(C) of lever 2.
Therefore, as point D moves, the feedback lever rotates around the fulcrum of point C, and the
spool is shifted to the left. This causes the opening between the sleeve(651) and spool(652) to
close slowly, and the servo piston comes to a complete stop when it closes completely.

2-10

 Flow increasing function

643

654

651

P1

652

613

CL

646

B(E)
874
897
C

875
611
Large diameter
chamber

Servo piston

548

Small diameter
chamber

531

As the pilot pressure Pi decreases, the pilot piston(643) moves to the left by the action of the
pilot spring(646) and causes lever 2(613) to rotate around the fulcrum of point B. Since the
pin(897) is pressed against the large hole section(C) of lever 2 by the action of the return
spring(654) via the spool(652), pin(874), and feedback lever(611), the feedback lever rotates
around the fulcrum of point D as lever 2 rotates, and shifts the spool to the left. Port CL opens
a way to the tank port as the spool moves. This deprives the large diameter section of the
servo piston of pressure, and shifts the servo piston to the left by the discharge pressure P1 in
the small diameter section, resulting in an increase in the flow rate.
As the servo piston moves, point D also moves to the left, the feedback lever rotates around the
fulcrum of point C, and the spool moves to the right till the opening between the spool and
sleeve is closed.

2-11

 Adjustment of flow control characteristic

The flow control characteristic can be
adjusted with the adjusting screw.
Adjust it by loosening the hexagon
nut(801) and by tightening(or loosening)
the hexagonal socket head screw(924).
Tightening the screw shifts the control
chart to the right as shown in the figure.

801
924

Adjusting values are shown in table.

Tightening
amount of
adjusting
screw(924)

Flow control Flow change

starting
amount
pressure
change
amount

(min -1)

(Turn)

(kgf/cm2)

(/min)

2100

+1/4

+1.5

+13.6

Delivery flow, Q

Speed

Adjustment of flow control

characteristic

Pilot pressure, Pi

2-12

(2) Total horsepower control

Delivery flow, Q

The regulator decreases the pump tilting

angle(delivery flow) automatically to limit
the input torque within a certain value
with a rise in the delivery pressure P1 of
the self pump and the delivery pressure
P2 of the companion pump.
(The input horsepower is constant when
the speed is constant.)
Since the regulator is of the simultaneous
total horsepower type that operates by
the sum of load pressures of the two
pumps in the tandem double-pump
system, the prime mover is automatically
prevented from being overloaded,
irrespective of the load condition of the
two pumps, when horsepower control is
under way.
Since this regulator is of the simultaneous
total horsepower type, it controls the
tilting angles(displacement volumes) of
the two pumps to the same value as
represented by the following equation :
Tin = P1q/2 + P2q/2
= (P1+P2)q/2
The horsepower control function is the
same as the flow control function and is
summarized in the following.(For detailed
behaviors of respective parts, refer to the
section of flow control).

Delivery pressure, (P1+P2)

2-13

 Overload preventive function

621

651

652

623

P1

612

601

625

626

CL
B(E)
897
F

P2

P1
875
611

Large diameter
chamber

Servo piston
D

Small diameter
chamber

When the self pump delivery pressure P1 or the companion pump delivery pressure P2 rises, it
acts on the stepped part of the compensating piston(621). It presses the compensating
rod(623) to the right till the force of the outer spring(625) and inner spring(626) balances with
the hydraulic force. The movement of the compensating rod is transmitted to lever 1(612) via
pin(875).
Lever 1 rotates around the pin(875) (E) fixed to the casing(601).
Since the large hole section(F) of lever 1 contains a protruding pin(897) fixed to the feedback
lever(611), the feedback lever rotates around the fulcrum of point D as lever 1 rotates, and then
the spool(652) is shifted to the right. As the spool moves, the delivery pressure P1 is admitted
to the large diameter section of the servo piston via port CL, causes the servo piston move to
the right, reduces the pump delivery, flow rate, and prevents the prime mover from being
overloaded.
The movement of the servo piston is transmitted to the feedback lever via point D. Then the
feedback lever rotates around the fulcrum of point F and the spool is shifted to the left. The
spool moves till the opening between the spool(652) and sleeve(651) is closed.

2-14

 Flow reset function

621

651

623

652

P1

612

601

625

626

CL
B(E)
897
F

P2

P1

875
Large diameter
chamber

Servo piston

Small diameter
chamber

As the self pump delivery pressure P1 or the companion pump delivery pressure P2 decreases,
the compensating rod(623) is pushed back by the action of the springs(625 & 626) to rotate
lever 1(612) around point E. Rotating of lever 1 causes the feedback lever(611) to rotate
around the fulcrum of point D and then the spool(652) to move to the left. As a result, port CL
opens a way to the tank port.
This causes the servo piston to move to the left and the pump's delivery rate to increase.
The movement of the servo piston is transmitted to the spool by the action of the feedback
mechanism to move it till the opening between the spool and sleeve is closed.

2-15

 Low tilting angle(Low flow) command preferential function

As mentioned above, flow control and horsepower control tilting angle commands are
transmitted to the feedback lever and spool via the large-hole sections(C & F) of levers 1 and 2.
However, since sections C and F have the pins(4) protruding from the large hole(8), only the
lever lessening the tilting angle contacts the pin(897) ; the hole(8) in the lever of a larger tilting
angle command is freed without contacting the pin(897). Such a mechanical selection method
permits preference of the lower tilting angle command of the flow control and horsepower control.
Adjustment of input horsepower
Since the regulator is of total cumulative horsepower type, adjust the adjusting screws of both
the front and rear pumps, when changing the horsepower set values. The pressure change
values by adjustment are based on two pumps pressurized at the same time, and the values will
be doubled when only one pump is loaded.
a. Adjustment of outer spring
Adjust it by loosening the hexagon
nut(630) and by tightening(or
loosening) the adjusting screw C(628).
Tightening the screw shifts the control
chart to the right and increases the
input horsepower as shown in the
figure. Since turning the adjusting
screw C by N turns changes the setting
of the inner spring(626), return the
adjusting screw QI(925) by NA turns
at first.(A=2.2)

625

626

925

Adjustment of outer spring

Speed

(Turn)

(kgf/cm2)

(kgfm)

2100

+1/4

+15.9

+4.2

Delivery flow, Q

Compens- Input torque

ating control
change
starting
amount
pressure
change
amount

(min -1)

628

801

Adjusting values are shown in table

Tightening
amount of
adjusting
screw(C)
(924)

630

Delivery pressure, (P1+P2)

2-16

b. Adjustment of inner spring

Adjust it by loosening the hexagon nut
(801) and by tightening(or loosening)
the adjusting screw QI(925).
Tightening the screw increases the flow
and then the input horsepower as
shown in the figure.

626

801
925

Adjusting valves are shown in table

Adjustment of inner spring
Speed
Compens- Input torque
ating control
change
starting
amount
pressure
change
amount

(min -1)

(Turn)

(kgf/cm2)

(kgfm)

2100

+1/4

+27.3

+4.1

Delivery flow, Q

Tightening
amount of
adjusting
screw(QI)
(925)

Delivery pressure, (P1+P2)

2-17

(3) Power shift control

621

651

652

623

P1

898

612

625

626

CL
B(E)
897
F

Pf
P2

P1
875
611

Large diameter
chamber

Servo piston

Small diameter
chamber

Delivery flow, Q

The set horsepower valve is shifted by

varying the command current level of
the proportional pressure reducing valve
attached to the pump.
Only one proportional pressure reducing
Pf=
MIN
valve is provided.
.
Pf=
MA
However, the secondary pressure Pf
X.
(power shift pressure) is admitted to the
horsepower control section of each
Delivery pressure, (P1+P2)
pump regulator through the pump's
internal path to shift it to the same set
horsepower level.
This function permits arbitrary setting of the pump output power, thereby providing the optimum
power level according to the operating condition.
The power shift pressure Pf controls the set horsepower of the pump to a desired level, as
shown in the figure.
As the power shift pressure Pf rises, the compensating rod(623) moves to the right via the
pin(898) and compensating piston(621).
This decreases the pump tilting angle and then the set horsepower in the same way as
explained in the overload preventive function of the horsepower control.
On the contrary, the
set horsepower rises as the power shift pressure Pf falls.

2-18

(4) Adjustment of maximum and minimum flows

Adjust it by loosening the hexagon
nut(808) and by tightening(or loosening)
the set screw(954).
The maximum flow only is adjusted
without changing other control
characteristics.

954

Adjustment of max flow

Tightening
amount of
adjusting screw
(954)

Flow change
amount

(min -1)

(Turn)

(/min)

2100
*1950

+1/4

+4.8
*-5.6

2-19(1)

Delivery flow, Q

Speed

808

* : Tier ll

Delivery pressure, Pi

Adjustment of minimum flow

Adjust it by loosening the hexagon
nut(808) and by tightening(or loosening)
the hexagonal socket head set screw
(953). Similarly to the adjustment of the
maximum flow, other characteristics are
not changed.
However, remember that, if tightened too
much, the required horsepower during
the maximum delivery pressure(or during
relieving) may increase.

953

2-19(2)

Delivery flow, Q

Speed

806

Adjustment of min flow

Tightening
amount of
adjusting screw
(953)

Flow change
amount

(min -1)

(Turn)

(/min)

2100
*1950

+1/4

+4.8
*+4.5

Delivery pressure, Pi

* : Tier ll

2-19

(5) Qmax cut control

The regulator regulates
the maximum delivery flow
by inputting the pilot
pressure Pm. Since this is
a 2-position control method,
the maximum delivery flow
may be switched in two
steps by turning on/off the
pilot pressure Pm.(The
maximum control flow
cannot be controlled in
intermediate level.)

647
648
723
642

438
801

801
924
641

730

708

Delivery flow, Q

Functional explanation
As shown in the figure, the pilot pressure
Pm switches the maximum flow in two
steps.
When the pilot pressure Pm is given, it is
admitted to the lefthand side of the
piston QMC(648). The piston QMC
moves the stopper(647) and pilot
piston(643) to the right, overcoming the
force of the pilot spring(646), thereby
reducing the delivery flow of the pump.
Since the adjusting screw QMC(642) is
provided with a flange, the piston QMC
stops upon contact with the flange, and
the position of the pilot piston at this time
determines the maximum flow of the
pump.

643

644

645

646

Pm

Pilot pressure, Pi

Delivery flow, Q

Adjustment of Qmax cut flow

Adjust it by loosening the hexagon
nut(801) and by tightening(or loosening)
the adjusting screw QMC(642).
Tightening the screw decreases the
Qmax cut flow as shown in the figure.

Pilot pressure, Pi

2-20

728