Component Operation: Section 3

SECTION 3
COMPONENT OPERATION
—CONTENTS—
Group 1 Pump Device Group 4 Pilot Valve
Outline .....................................................T3-1-1 Outline .....................................................T3-4-1
Main Pump ...............................................T3-1-2 Operation .................................................T3-4-2
Regulator .................................................T3-1-6
Solenoid Valve........................................T3-1-22 Group 5 Travel Device
Pilot Pump..............................................T3-1-24 Outline .....................................................T3-5-1
N Sensor (Engine Speed Sensor) ...........T3-1-24 Travel Reduction Gear..............................T3-5-2
Pump Delivery Pressure Sensor .............T3-1-24 Travel Motor .............................................T3-5-4
Pump Control Pressure Sensor ..............T3-1-24 Parking Brake...........................................T3-5-6
Travel Mode Change ................................T3-5-8
Group 2 Swing Device Travel Brake Valve .................................T3-5-14
Outline .....................................................T3-2-1
Swing Reduction Gear..............................T3-2-2 Group 6 Signal Control Valve
Swing Motor .............................................T3-2-4 Outline .....................................................T3-6-1
Swing Parking Brake ................................T3-2-6 Pilot Port ..................................................T3-6-2
Valve Unit .................................................T3-2-8 Shuttle Valve ............................................T3-6-4
Shockless Valve .......................................T3-6-6
Group 3 Control Valve Pump 1 and Pump 2 Flow Rate
Outline .....................................................T3-3-1 Control Valves ........................................T3-6-8
Hydraulic Circuit .....................................T3-3-10 Bucket Flow Rate Control Valve,
Flow Combiner Valve..............................T3-3-15 Flow Combiner Valve Control Spool,
Main Relief Valve....................................T3-3-16 Swing Parking Brake Release Spool .....T3-6-10
Overload Relief Valve .............................T3-3-18
Regenerative Valve ................................T3-3-20 Group 7 Others (Upperstructure)
Arm Regenerative Valve .........................T3-3-22 Pilot Shut-Off Valve ..................................T3-7-1
Anti-Drift Valve .......................................T3-3-24 Solenoid Valve Unit ..................................T3-7-2
Flow Rate Control Valve .........................T3-3-26 Pilot Relief Valve ......................................T3-7-6
Auxiliary Flow Combiner Valve and EC Motor ..................................................T3-7-6
Bypass Shut-Out Valve .........................T3-3-28
Group 8 Others (Undercarriage)
Swing Bearing ..........................................T3-8-1
Center Joint..............................................T3-8-2
Track Adjuster ..........................................T3-8-3
178T-3-1
(Blank)
178T-3-2
ANIMATION
COMPONENT OPERATION / Pump Device

OUTLINE
The pump device consists of transmission (11), main The main pump is a bent-axis type variable
pump[pump 1 (1) and pump 2 (2)] and pilot pump (3). displacement axial plunger pump. Pump 1 (1) and
The engine output is transmitted to transmission (11) pump 2 (2) are integrated as two units in one housing.
via coupling (12). After being distributed by the gear The pilot pump is a gear pump.
train in the transmission, the engine power drives Pump delivery pressure sensors (4 and 5), pump
pump 1 (1), pump 2 (2), and pilot pump (3). Both control pressure sensors (8 and 9), and N sensor
reduction gear ratios of the main pumps and pilot (engine speed sensor) (10) are provided to control
pump are 1:1. The transmission is lubricated with pump and valve operations.
engine oil.
6
7
8
10
3 2 1
11 T178-03-01-001
12
5 4 T178-03-01-003
T178-03-01-002
1 - Pump 1 4 - Pump 1 Delivery Pressure 7 - Torque Control Solenoid Valve 10 - N Sensor

Sensor
2 - Pump 2 5 - Pump 2 Delivery Pressure 8 - Pump 1 Control Pressure Sensor 11 - Transmission
Sensor
3 - Pilot Pump 6 - Pump 1 Flow Rate Control 9 - Pump 2 Control Pressure Sensor 12 - Coupling
Solenoid Valve
T3-1-1
COMPOMRNT OPERATION / Pump Device
MAIN PUMP
The main pump supplies pressure oil to actuate the

hydraulic components such as motors or cylinders.
The main pump consists of pump 1 and pump 2. Shaft
(3) is connected to each pump cylinder block (6) via
seven plungers (4) so that the shaft and cylinder block
rotate together. When cylinder block (6) is rotated,
plungers (4) oscillate in the cylinder block, suctioning
and delivering hydraulic oil. Each main pump is
equipped with a regulator which controls the flow rate.
1 2
4
T178-03-01-005
1 - Regulator 3 - Shaft 5 - Valve Plate 6 - Cylinder Block

2 - Housing 4 - Plunger
T3-1-2
Operational Principle
Engine torque is transferred to the shaft and the
seven plungers, causing the cylinder block to rotate
while sliding along the valve plate surface. The
plungers oscillate in the cylinder block bores to
alternately draw and deliver hydraulic oil.
Plunger
Valve Plate
Shaft
Cylinder Block
T105-02-03-002
T3-1-3
Increasing and Decreasing Flow Rate
Changing inclination of cylinder block (3), causes
plunger (2) stroke to increase or decrease depending
on the slant angle which in turn controls the main
pump flow rate. Up-down movement of servo piston
(6) changes inclination of cylinder block (3). Servo
piston (6) is interlocked with valve plate (4) via pin (5).
The one end of cylinder block (3) is kept in contact
with the surface of valve plate (4) and slides along it.
Maximum Displacement Angle:

2
T105-02-03-021
5
Minimum Displacement Angle (Operable Limit Angle):
6
T178-03-01-005
4 2
T105-02-03-022
2 - Plunger 4 - Valve Plate 5 - Pin 6 - Servo Piston

3 - Cylinder Block
T3-1-4
(Blank)
T3-1-5
REGULATOR
1 3 2 4
The regulator controls the main pump flow rate in
response to the various command signal pressures so Dr
that the pump driving power doesn’t exceed the engine
power. Pump 1 and pump 2 are provided with one
regulator each. The major parts of the regulator are
Pi
spring (1), sleeve A (2), sleeve B (7), spool A (3), spool
B (6), piston (4), load piston (5), outer spring (8), and Pd2 Air
inner spring (9). According to the various command Bleeding
Circuit
signal pressures, the regulator opens or closes the Pps
Dr
circuit to servo piston (10), causing the inclination of
cylinder block (11) to change, by which the pump flow Pd1
rate is controlled.
NOTE: Pilot oil pressure is constantly supplied in 5 7 6

the smaller side chamber of servo piston Pg
(10). 10 12 8, 9
Increase Decrease
T176-03-01-009
Cylinder Block Inclination
Pd1 -Pump 1 Delivery Pi - Pump Control Pressure

Pressure
Pd2 -Pump 2 Delivery Pps -Torque Control Pressure
Pressure
Dr - Returning to Hydraulic Pg - Primary Pilot Pressure
Oil Tank (From Pilot Pump)
T3-1-6
1 2 3 4
T178-03-01-006
5 6 7 8 9
12
11
10
T178-03-01-005
1 - Spring 4 - Piston 7 - Sleeve B 10 - Servo Piston

2 - Sleeve A 5 - Load Piston 8 - Outer Spring 11 - Cylinder Block
3 - Spool A 6 - Spool B 9 - Inner Spring 12 - Link
T3-1-7
Regulator Control Function
The regulator has the following four control
functions.
• Control by Pump Control Pressure

When a control lever is operated, the pump flow rate Flow
Rate (Q)
control valve in the signal control valve regulates
pump control pressure Pi in response to the lever
stroke. Then, when the regulator receives pump
control pressure Pi, the regulator controls the pump
flow rate in proportion to pump control pressure Pi.
When a control lever is operated, pump control
pressure Pi increases. Thereby, the regulator
increases the pump flow rate. When the control
lever is returned to neutral, pump control pressure Pi 0 Pump Control Pressure (Pi)
decreases, causing the regulator to reduce the
pump flow rate.
• Control by Own or Opponent Pump Delivery

Pressure
The regulator receives own pump delivery pressure
Pd1 and opponent pump delivery pressure Pd2 as Flow
Pressure Increase
control signal pressures. If the two average Rate (Q)
pressures increase over the set P-Q line, the Flow Rate Decrease
regulator reduces both pump flow rates by the
excess pressure from the P-Q line so that the total
pump output is returned to the set P-Q line. Thereby,
the engine is protected from being overloaded. The
P-Q line has been designated to jointly regulate both
pump operations. Therefore, both pump flow rates
are regulated almost equally to each other.
0 Pressure (P)
Accordingly, although the higher-pressure side pump
is loaded more than the lower-pressure side pump,
the total pump output matches with the engine
output. (Total Output Control)
• Control by Pilot Pressure from Torque Control

Solenoid Valve
The main controller (MC) operates based on both
the engine target speed input data and actual speed Flow
information signals and outputs signals to the torque Rate (Q)
control solenoid valve. In response to the signals
from the MC, the torque control solenoid valve
delivers torque control pilot pressure Pps to the
regulator. Upon receiving pilot pressure Pps, the
regulator reduces the pump flow rate. (Speed
Sensing Power Decrease Control: Slow Speed
Torque Increase Control)
(Refer to the CONTROL SYSTEM section.)
0 Pressure (P)
T3-1-8
• Control by Pilot Pressure from Flow Rate Control

Solenoid Valve
(Pump 2 Side Only) Flow
When the MC receives signals from the work mode Rate (Q)
switch, pressure sensor (optional) [auxiliary] or
attachment mode switch (optional), the MC send
signals to the maximum pump flow rate control
solenoid valve. Then, in response to the signals from
the MC, the maximum pump flow rate control
solenoid valve reduces pump control pressure Pi,
limiting the maximum pump flow rate. (Pump Flow
Rate Limit Control) 0 Pressure (P)
(Refer to the CONTROL SYSTEM section.)
Dr
Pi
Pd2 Air
Bleeding
Circuit
Pps
Dr
Pd1
Pg
Increase Decrease
Cylinder Block Inclination T176-03-01-009

Pressure
Pd2 - Pump 2 Delivery Pps -Torque Control Pressure
Pressure
T3-1-9
Control by Pump Control Pressure
• Increasing Flow Rate

1. When a control lever is operated, the flow rate
Flow
control valve in the signal control valve is shifted, Rate (Q)
increasing pump control pressure Pi.
2. Piston (4) pushes spool A (3) and spring (1) so
that spool A (3) is moved in the direction of the
arrow.
3. Then, the circuit from the large chamber of servo
piston (10) is opened to the hydraulic oil tank.
4. The pilot oil pressure is always routed into the
small chamber of servo piston (10). Thereby,
servo piston (10) is moved toward the direction of 0 Pump Control Pressure (Pi)
the arrow. Then, the cylinder block rotated in the
maximum inclination direction, increasing the 1 3 2 4
pump flow rate. Dr
5. The movement of the cylinder block is transmitted
to sleeve A (2) via link (12). Then, sleeve A (2) is
moved in the same direction as spool A (3).
6. When sleeve A (2) is moved by the same stroke Pi
as spool A (3), the circuit from the large chamber Pd2 Air
of servo piston (10) to the hydraulic oil tank is Bleeding
closed so that servo piston (10) is stopped, Pps
Circuit
completing flow rate increase operation. Dr
Pd1
Pg
10 12
Increase Decrease
1 - Spring 4 - Piston
2 - Sleeve A 10 - Servo Piston
3 - Spool A 12 - Link

Pressure
Pressure
T3-1-10
ANIMATION
To Hydraulic Primary Pilot Oil

1 Oil Tank Pressure 2 3 4 Pump Control
Pressure Pi
Torque
Control
Pressure
Pps
Pump 2
Delivery
Pressure
Pd2
Pump 1 12
Delivery
Pressure
Pd1
10
T178-03-01-008

Pressure Pi
Torque
Control
Pressure
Pps
Pump 2
Delivery
Pressure
Pd2
Pump 1 12
Delivery
Pressure
Pd1
10
T178-03-01-009
T3-1-11
• Decreasing Flow Rate

1. When a control lever is operated, the flow rate Flow
Rate (Q)
control valve in the signal control valve is returned,
decreasing pump control pressure Pi.
2. Piston (4) and spool A (3) is pushed by spring (1)
so that spool A (3) is moved in the direction of the
arrow.
3. Then, the pilot oil pressure is also routed onto the
large chamber of servo piston (10).
4. Due to the difference in diameter between the
large and small chambers, servo piston (10) is 0 Pump Control Pressure (Pi)
moved toward the direction of the arrow so that
the cylinder block is rotated in the minimum 1 3 2 4
inclination direction, decreasing the pump flow
Dr
rate.
to sleeve A (2) via link (12). Then, sleeve A (2) is
moved in the same direction as spool A (3). Pi
6. When sleeve A (2) is moved by the same stroke Air
as spool A (3), the pilot oil pressure circuit to Pd2
Bleeding
servo piston (10) through sleeve A (2) and spool A Circuit
(3) is closed so that servo piston (10) is stopped, Pps
Dr
completing flow rate decrease operation.
Pd1
Pg
10 12
Increase Decrease

Pressure
Pressure
T3-1-12
ANIMATION
To Hydraulic Primary Pilot

Pressure Pi
Torque
Control
Pressure
Pps
Pump 2
Delivery
Pressure
Pd2
Pump 1
12
Delivery
Pressure
Pd1
10
T178-03-01-010

Pressure Pi
Torque
Control
Pressure
Pps
Pump 2
Delivery
Pressure
Pd2
Pump 1 12
Delivery
Pressure
Pd1
10
T178-03-01-011
T3-1-13
Control by Own or Opponent Pump Delivery
Pressure

1. When the pump is loaded by operating any of the
control levers, either pump 1 delivery pressure Flow
Rate (Q)
Pd1 or pump 2 delivery pressure Pd2 increases.
(During operation, pump control pressure Pi is
increased.)
2. Load piston (5) moves spool B (6) and inner and
outer springs (8 and 9) toward the direction of the
arrow.
3. Due to the movement of spool B (6), the pilot oil
pressure is routed into the large chamber of servo
piston (10). 0 Pressure (P)
large and small chambers, servo piston (10) Dr
moved toward the direction of the arrow so that
the cylinder block is rotated in the minimum
inclination direction, decreasing the pump flow
rate. Pi
5. The movement of the cylinder block is transmitted Pd1 Air
to sleeve B (7) via link (12). Then, sleeve B (7) is Bleeding
moved in the same direction as spool B (6). Pps
Circuit
6. When sleeve B (7) is moved by the same stroke Dr
as spool B (6), the pilot oil pressure circuit to Pd2
servo piston (10) through sleeve B (7) and spool B
(6) is closed so that servo piston (10) is stopped,
completing flow rate decrease operation.
5 7 6 Pg
10 12 8, 9
Increase Decrease
5- Load Piston 9 - Outer Spring

6- Spool B 10 - Servo Piston
7- Sleeve B 12 - Link
8- Inner Spring
Pd1 - Pump 1 Delivery Pi - Pump Control Pressure

Pressure
Pressure
T3-1-14
ANIMATION

5 Oil Tank Pressure 6 7 Pump Control
Pressure Pi
Torque
Control
Pressure
Pps
Pump 2
Delivery 8 9
Pressure
Pd2
Pump 1 12
Delivery
Pressure
Pd1
10
T178-03-01-012
Pressure Pi
Torque
Control
Pressure
Pps
Pump 2
Delivery 8 9
Pressure
Pd2
Pump 1 12
Delivery
Pressure
Pd1
10
T178-03-01-013
T3-1-15
• Increasing Flow Rate

1. When the pump load is reduced, either pump 1
delivery pressure Pd1 or pump 2 delivery
pressure Pd2 decreases. (During operation, pump
control pressure Pi is kept increased.) Flow
Rate (Q)
2. Load piston (5) and spool B (6) are pushed by
inner and outer springs (8 and 9) toward the
direction of the arrow.
3. Due to the movement of spool B (6), the circuit
from the large chamber of servo piston (10) is
opened to the hydraulic oil tank.
4. Since the pilot oil pressure is constantly routed in
to the small chamber of servo piston (10), servo
piston (10) is moved toward the direction of the 0 Pressure (P)
arrow. Then, the cylinder block is rotated in the
maximum inclination direction, increasing the Dr
pump flow rate.
to sleeve B (7) via link (12). Then, sleeve B (7) is
moved in the same direction as spool B (6). Pi
6. When sleeve B (7) is moved by the same stroke Pd2 Air
as spool B (6), the pilot oil pressure circuit to Bleeding
Circuit
servo piston (10) through sleeve B (7) and spool B Pps
(6) is closed so that servo piston (10) is stopped, Dr
completing flow rate increase operation. Pd1
5 7 6 Pg
10 12 8, 9
Increase Decrease

8- Inner Spring

Pressure
Pressure
T3-1-16
ANIMATION

Pressure Pi
Torque
Control
Pressure
Pps
Pump 2
Delivery 8 9
Pressure
Pd2
Pump 1 12
Delivery
Pressure
Pd1
10
T178-03-01-014

Pressure Pi
Torque
Control
Pressure
Pps
Pump 2
Delivery 8 9
Pressure
Pd2
Pump 1 12
Delivery
Pressure
Pd1
10
T178-03-01-015
T3-1-17
Control by Pilot Pressure from Torque Control
Solenoid Valve

1. When the torque control solenoid valve is
activated by the signals from the MC, torque Flow
control pressure Pps increases. Rate (Q)
2. Torque control pressure Pps and either own pump
delivery pressure Pd1 or opponent pump delivery
pressure Pd2 are combined and applied to load
piston (5).
3. Load piston (5) pushes spool B (6) and inner and
outer springs (8 and 9) toward the direction of the
arrow.
4. Due to the movement of spool B (6), the pilot oil 0 Pressure (P)
pressure is routed into the large chamber of servo
piston (10). Dr
large and small chambers, servo piston (10) is
moved toward the direction of the arrow. Then, the
cylinder block is rotated in the minimum inclination Pi
direction, decreasing the pump flow rate. Pd2 Air
6. The movement of the cylinder block is transmitted Bleeding
to sleeve B (7) via link (12). Then, sleeve B (7) is Pps
Circuit
moved in the same direction as spool B (6). Dr
7. When sleeve B (7) is moved by the same stroke Pd1
as spool B (6), the pilot oil pressure circuit to the
large chamber of servo piston (10) through sleeve
B (7) and spool B (6) is closed so that servo piston
(10) is stopped, completing flow rate decrease 5 7 6 Pg
operation.
10 12 8, 9
Increase Decrease

8- Inner Spring

Pressure
Pressure
T3-1-18
ANIMATION

Pressure Pi
Torque
Control
Pressure
Pps
Pump 2
Delivery 8 9
Pressure
Pd2
Pump 1 12
Delivery
Pressure
Pd1
10
T178-03-01-016

Pressure Pi
Torque
Control
Pressure
Pps
Pump 2
Delivery 8 9
Pressure
Pd2
Pump 1 12
Delivery
Pressure
Pd1
10
T178-03-01-017
T3-1-19
Control by Pilot Pressure from Flow Rate Control
Solenoid Valve Flow
Rate (Q)
• Limiting Maximum Flow Rate (Pump 2 Only)
1. The maximum pump flow rate control solenoid
valve in the pump control pressure Pi circuit is
activated by the signals from the MC.
2. The maximum pump flow rate control solenoid
valve functions as a reducing valve, limiting pump
control pressure Pi.
3. Piston (4) pushes spool A (3) and spring (1)
0 Pressure (P)
toward the direction of the arrow.
4. Due to the movement of spool A (3), the circuit
from the large chamber of servo piston (10) is 1 3 2 4
opened to the hydraulic oil tank.
5. Since the pilot oil pressure is constantly routed Dr
into the small chamber of servo piston (10), servo
piston (10) is moved toward the direction of the
arrow so that the cylinder block is rotated in the
Pi
maximum inclination direction, increasing the
pump flow rate. Pd2 Air
Bleeding
6. The movement of the cylinder block is transmitted Circuit
to sleeve A (2) via link (12). Then, sleeve A (2) is Pps
Dr
moved in the same direction as spool A (3).
7. When sleeve A (2) is moved by the same stroke Pd1
as spool A (3), the pilot oil pressure circuit to the
large chamber of servo piston (10) is closed so
that servo piston (10) is stopped, completing flow
rate increase operation. Pg
8. As the pump control pressure is restricted, the 10 12
maximum flow rate is reduced more than normal. Increase Decrease
Pd1 - Pump 1 Delivery Pi - Pump Control Pressure

Pressure
Pressure
T3-1-20
ANIMATION

2 3 4 Pump Control
1 Oil Tank Pressure
Pressure Pi
Regulated by
Maximum Pump
Flow Rate Control
Solenoid Valve
Torque
Control
Pressure
Pps
Pump 2
Delivery
Pressure
Pd2
Pump 1 12
Delivery
Pressure
Pd1
10
T178-03-01-018

Oil Tank Pressure 2 3 4 Pump Control
1
Pressure Pi
Regulated by
Maximum Pump
Flow Rate Control
Solenoid Valve
Torque
Control
Pressure
Pps
Pump 2
Delivery
Pressure
Pd2
Pump 1 12
Delivery
Pressure
Pd1
10
T178-03-01-019
T3-1-21
SOLENOID VALVE
The torque control solenoid valve and the pump 2 flow

rate limit solenoid valve are provided on the pump 1
regulator. The torque control solenoid valve supplies
the torque control pressure Pps to both the pump 1
and pump 2 regulators to reduce the pump flow rate.
The pump 2 flow rate limit solenoid valve reduces the
pump control pressure to the pump 2 regulator so that
the maximum pump flow rate is limited.
Operation
1. When neutral, port P is connected to the output
port through the notch on the spool.
2. When the current flows to the solenoid from the
MC, the solenoid is magnetized, pushing spring 1.
3. Then, spring 1 pushes the spool so that the output
port is connected to port T through the notch on
the spool.
4. Thereby, pressure at the output port begins to
decrease.
5. Since the left side spool stap flange diameter (A)
is larger than the right side spool stap flange
diameter (B), the spool is returned to the left side.
T3-1-22
ANIMATION

When Neutral:
Solenoid Spring 1 Spring 2 Sleeve Spool
T176-03-01-030
A Port P Port T B
Output Port
When in Operation:
T176-03-01-031
A Port P Port T B
Output Port
T3-1-23
PILOT PUMP
1
Inlet Port
Drive gear (1) is driven by the engine via the
transmission which in turn rotates driven gear (2) as 2
they are meshed together.
1 - Drive Gear 2 - Driven Gear
Outlet Port
N SENSOR (ENGINE SPEED SENSOR) T137-02-03-005
The N sensor detects the engine speed, which is used

to control various operations. The N sensor is located
close to the transmission teeth so that the sensor
converts the number of teeth passing by the sensor
into pulse signals, effectively sensing the engine
4 5
speed.
3 - Tooth 5 - Output 3
4 - Output
T178-03-01-020
PUMP DELIVERY PRESSURE SENSOR
This sensor detects the pump delivery pressures,

which are used to control various operations. When oil
pressure is applied onto diaphragm (9), the diaphragm
is deformed. The deformation of the diaphragm is
detected as electrical signals.
T157-02-03-010
6 - Ground 8 - Power Source (5V) 7
6 8 9
7 - Output 9 - Pressure Receiving Area
(Diaphragm)
PUMP CONTROL PRESSURE SENSOR
This sensor detects the pump control pressures, which

are used to control various operations. When oil
pressure is applied onto diaphragm (10), the
diaphragm is deformed. The deformation of the
diaphragm is detected as electrical signals.
T176-03-01-023
10 - Pressure Receiving Area 12 - Output
10 11 12 13
(Diaphragm)
11 - Ground 13 - Power Source (5V)
T3-1-24
COMPONENT OPERATION / Swing Device
OUTLINE
The swing device consists of the valve unit, swing mo- The swing reduction gear converts the swing motor
tor, and swing reduction gear. The valve unit prevents output into slow large torque to rotate the shaft.
cavitation in the swing circuit from occurring and pro- Thereby, the upperstructure is rotated.
tects the circuit from being overloaded. The swing mo-
tor is a swash plate type axial plunger motor with a
built-in swing parking brake. The swing motor is driven
by pressure oil delivered from the pump, and drives the
swing reduction gear.
ZAXIS200,225USR,225US,230 ZAXIS270
Valve Unit
Valve Unit
Swing Motor
Swing Motor
Swing Reduction Swing Reduction

Gear Gear
T178-03-02-001
T1HG-03-02-003
T3-2-1
ANIMATION

SWING REDUCTION GEAR
The swing reduction gear is a two stage reduction The shaft meshes with the swing bearing internal gear
planetary gear type. The ring gear is formed on the secured to the undercarriage, causing the upperstruc-
internal surface of the housing so that they are inte- ture to rotate.
grated. As the housing is bolted on the upperstructure,
the ring gear doesn’t rotate. The swing motor shaft
rotates the first stage sun gear. Then, its torque is
transmitted to the second stage sun gear via the first
stage planetary gear and carrier. The second stage
sun gear rotates the shaft via the second stage plane-
tary gear and carrier.
ZAXIS200,225USR,225US,230
Swing Motor Shaft
First Stage Sun Gear

First Stage Planetary Gear
First Stage Carrier
Ring Gear
Second Stage Sun Gear
Second Stage Planetary Gear
Second Stage Carrier
Shaft
T178-03-02-006
T3-2-2
ZAXIS270
First Stage Sun Gear Swing Motor Shaft
First Stage Carrier First Stage Planetary Gear
First Stage Ring Gear
Second Stage Planetary

Second Stage Sun Gear
Second Stage Ring Gear
Second Stage Carrier
Shaft
T164-03-02-003
T3-2-3
SWING MOTOR
The swing motor consists of the swash plate, rotor, When pressure oil is supplied from the pump, the
plungers, valve plate, housing and swing parking brake pressure oil pushes the plungers. Since the swash
(springs, brake piston, plates, friction plates, and swing plate is inclined, the shoes on top of the plungers slide
parking brake switch valve). The rotor in which the along the swash plate, causing the rotor and shaft to
plungers are inserted is splined onto the shaft. rotate. The shaft tip end is splined into the first stage
sun gear in the swing reduction gear so that shaft rota-
tion is transmitted to the swing reduction gear.
Spring
Valve Plate
Brake Piston
Rotor Plate
Housing
Friction Plate
Shoe
Plunger
Retainer
Swash Plate
Shaft
T178-03-02-002
T3-2-4
ZAXIS270
Valve Plate
Rotor
Spring
Swing Parking
Brake Switch Valve
Brake Piston
Plate
Friction Plate
Plunger
Shoe Retainer
Swash Plate
Housing
Shaft
T1HH-03-02-002
T3-2-5
ANIMATION

SWING PARKING BRAKE
The swing parking brake is a wet-type multi-disc brake.

The brake is released when brake release pressure
enters into the brake piston chamber (negative brake
type). Brake release pressure is supplied from the pilot
pump only when a front attachment and/or swing op-
eration is made. During operations other than swing
and/or front attachment or while the engine is stopped,
brake release pressure is returned to the hydraulic oil
tank so that the brake is automatically applied by
spring.
Releasing Brake: Applying Brake:

1. When the swing and/or front attachment control 1. When the swing and/or front attachment control
levers are operated, the swing parking brake re- levers are released, the swing parking brake re-
lease spool in the signal pilot pressure control lease spool in the signal pilot pressure control
valve is shifted. Thereby, the pilot pressure oil valve is returned to neutral so that the pilot pres-
from the pilot pump is routed to port SH. sure routed to port SH is reduced.
2. Pilot pressure at port SH pushes to open the 2. Therefore, the check valve is closed, allowing
check valve and flows into the brake piston brake release pressure to flow into the swing mo-
chamber. tor housing through the orifice.
3. Then, the brake piston is raised, breaking contact 3. Consequently, spring force is applied to plates
between the plates and friction plates so that the and friction plates which are meshed with the
brake is released. outer diameter of the rotor and inner diameter of
the housing respectively via the brake piston.
Then, the rotor outer diameter is held with friction
force. While the engine is stopped, no pilot pres-
sure is routed to port SH, allowing the brake to be
automatically applied.
Spring
Brake Piston
Orifice
Friction Plate Check Valve

Port SH
(Brake Release
Pressure)
Plate
Brake Piston Chamber
T178-03-02-003
T3-2-6
ZAXIS270
Releasing Brake: Applying Brake:

1. When the swing and/or front attachment control 1. When the swing and/or front attachment control
levers are operated, the swing parking brake re- levers are released, the swing parking brake re-
lease spool in the signal pilot pressure control lease spool in the signal pilot pressure control
valve is shifted. Thereby, the pilot pressure oil valve is returned to neutral so that the pilot pres-
from the pilot pump is routed to port SH. sure routed to port SH is reduced.
2. The spool is shifted to the right side by the pilot 2. Thereby, the spool returns to the original position.
pressure supplied to port SH. The pilot pressure from port PG is blocked, open-
The pilot pressure supplied to port PG is routed to ing the check valve.
the brake piston chamber via the spool. 3. The pressure oil in the brake piston chamber is re-
3. At the same time, the pressure oil in port PG is leased to the swing motor housing through the ori-
routed to the check valve via the spool. The pres- fice of the check valve.
sure difference is developed between the front 4. Consequently spring 1 force is applied to plates
and the rear of the check valve caused by the ori- and friction plates which are meshed with the
fice, moving the check valve to the right when the outer diameter of the rotor and inner diameter of
pressure difference is increased more than the the housing respectively via the brake piston.
force of spring 2. Thereby, the drain circuit to the Then, the rotor outer diameter is held with friction
housing is blocked. force. While the engine is stopped, no pilot pres-
4. Then, the brake piston is raised, breaking contact sure is routed to port SH, allowing the brake to be
between the plates and friction plates so that the automatically applied.
brake is released.
Spring 1
Check Valve Spring 2 Brake Piston
Rotor
Port PG
(Brake Release Plate
Pressure)
Friction Plate
Spool
Port SH
(Brake Release
Pressure) T1HG-03-02-004
Orifice Brake Piston Chamber
T3-2-7
VALVE UNIT
The valve unit consists of the make-up valves and the

relief valves. The make-up valves prevents cavitaion in
the circuit. The relief valves prevent surge pressure Relief Valve
and overloads in the circuit.
Make-Up Valve
Make-Up Valve
During swing stop operation, the swing motor is
driven by inertia force of the upperstructure. The mo-
tor is rotated by inertia force more than by pressure
oil delivered from the pump, causing cavitation to de-
velop in the circuit. To prevent cavitation, when pres- Port C
sure in the swing circuit is reduced more than the re-
turn circuit (port C) pressure, the poppets are opened
Control Valve
so that hydraulic oil is drawn into the circuit from the
hydraulic oil tank to compensate for the lack of oil in
T107-02-04-013
the circuit.
Control Valve
Poppet
Make-Up Valve Make-Up Valve
Port C
T178-03-02-004
Relief Valve
T3-2-8
ZAXIS270
Control Valve
Poppet
Make-Up Valve
Make-Up Valve
Port C
T1HG-03-02-001
Relief Valve
T3-2-9
ANIMATION

Relief Valve
During starting or stopping swing operation, oil pres-
sure in the swing circuit becomes high. The relief
valve prevents the circuit pressure from rising higher
than the set-pressure.
Low Pressure Relief Operation (Shock Reducing Func- High Pressure Relief Operation (Overload Prevention):
tion): 1. After the piston is moved full stroke, the spring is
1. Pressure at port HP (swing circuit) is routed into compressed so that the circuit pressure is in-
oil chamber C through the poppet orifice. creased to the set-pressure.
2. Pressure oil in oil chamber C is further routed into 2. If pressure in port HP increases more than the
oil chambers A and B via passages A and B re- spring set-pressure, the poppet is unseated, caus-
spectively. ing pressure oil to flow to port LP from port HP.
3. The pressure receiving area in oil chamber B is 3. When pressure in port HP is reduced to the speci-
larger than oil chamber A so that the piston moves fied level, the poppet is seated by spring force.
to the left.
4. As long as the piston keeps moving, a pressure
difference is developed between the front and the
rear of the poppet. When this pressure difference
is increased more than spring force, the poppet is
unseated, allowing pressure oil to flow to port LP.
5. When the piston is moved full stroke, the pressure
difference between the front and the rear of the
poppet disappears, causing the poppet to be
seated.
Poppet Orifice Spring Passage A Passage B Piston
HP
LP
Oil Chamber C Oil Chamber B T178-03-02-005
Oil Chamber A
T3-2-10
ZAXIS270
Low Pressure Relief Operation (Shock Reducing Func- High Pressure Relief Operation (Overload Preven-
tion): tion):
1. Pressure at port HP (swing circuit) is routed into 1. After the piston is moved full stroke, so that the
oil chamber through the poppet orifice. circuit pressure is increased to the set-pressure.
2. When the pressure in the oil chamber is in- 2. If pressure in port HP increases more than the
creased more than the force of spring 2, the pis- spring 1 set-pressure, the poppet is unseated,
ton moves to the left side. causing pressure oil to flow to port LP from port
3. As long as the piston keeps moving, a pressure HP.
difference is developed between the front and the 3. When pressure in port HP is reduced to the speci-
rear of the poppet. When this pressure difference fied level, the poppet is seated by spring 1 force.
is increased more than spring force, the poppet is
unseated, allowing pressure oil to flow to port LP.
4. when the piston is moved full stroke, the pressure
difference between the front and the rear of the
poppet disappears, causing the poppet to be
seated.
Spring 2 Piston Spring 1 Plunger Poppet
Orifice
LP
HP
Oil Chamber
T157-02-04-006
T3-2-11
(Blank)
T3-2-12
COMPONENT OPERATION / Control Valve
OUTLINE
The control valve controls oil pressure, flow rate, and In the 4-spool section, the right travel, bucket, boom 1,
flow direction in the hydraulic circuit. The major parts of and arm 2 spool sections are arranged in that order as
the control valve are the main relief valve, overload viewed from the machine front (ZAXIS200,230,270)
relief valve, flow combiner valve, anti-drift valve, flow [as viewed from the machine right on ZAXIS225US
rate control valve, regenerative valve, auxiliary flow and ZAXIS225USR].
combiner valve, bypass shut-out valve, and spools. In the 5-spool section, the left travel, auxiliary, boom 2,
The spools are operated by pilot oil pressure. arm 1, and swing spool sections are arranged in that
order as viewed from the machine front
(ZAXIS200,230,270) [as viewed from the machine
right on ZAXIS225US, and ZAXIS225USR].
Front
ZAXIS200
ZAXIS230 Right Travel
ZAXIS270 Bucket
Boom 1
Left Travel Arm 2
Main Relief Valve

4-Spool Section
Auxiliary
Boom 2
Arm 1
Swing
5-Spool Section
Front M178-05-003
ZAXIS225US
ZAXIS225USR
T3-3-1
HYDRAULIC CIRCUIT
1 2 3 4 5 6 7 8 9 10
36
35
34
33
11
12
13
32 14
31 15
30
16
17
29
28
18
19
20
21
27 22
26
25 24 23
T178-03-03-016
1 - Load Check Valve (Travel 10 - Bucket Flow Rate Control 19 - Boom Anti-Drift Valve 28 - Overload Relief Valve
Parallel Circuit) Valve (Poppet Valve) (Switch Valve) (Arm: Bottom Side)
2 - Check Valve 11 - Bucket Regenerative Valve 20 - Load Check Valve (Arm 29 - Overload Relief Valve
(Main Relief Circuit) Tandem Circuit) (Arm: Rod Side)
3 - Main Relief Valve 12 - Overload Relief Valve 21 - Check Valve (Orifice) 30 - Arm Anti-Drift Valve (Check
(Bucket: Rod Side) (4-Spool Side Parallel Valve)
Circuit)
4 - Check Valve 13 - Overload Relief Valve 22 - Bypass Shut-Out Valve 31 - Arm Anti-Drift Valve
(Main Relief Circuit) (Bucket: Bottom Side) (Switch Valve)
5 - Check Valve 14 - Load Check Valve (Boom 1 23 - Arm Flow Rate Control 32 - Load Check Valve (Boom 2
(Flow Combiner Valve Parallel Circuit) Valve (Poppet Valve) Parallel Circuit)
Circuit)
6 - Flow Combiner Valve 15 - Boom Regenerative Valve 24 - Arm Flow Rate Control 33 - Auxiliary Flow Rate Control
Valve (Switch Valve) Valve (Switch Valve)
7 - Auxiliary Flow Combiner 16 - Overload Relief Valve 25 - Load Check Valve (Swing 34 - Auxiliary Flow Rate Control
Valve (Boom: Bottom Side) Circuit) Valve (Poppet Valve)
8 - Check Valve 17 - Overload Relief Valve 26 - Check Valve 35 - Load Check Valve (Travel
(Aux. Flow Combiner (Boom: Rod Side) (Arm Regenerative Circuit) Tandem Circuit)
Valve Circuit)
9 - Bucket Flow Rate Control 18 - Boom Anti-Drift Valve 27 - Arm Regenerative Valve 36 - Load Check Valve (Orifice)
Valve (Switch Valve) (Check Valve) (Bucket)
T3-3-2
19
Front
12 ZAXIS225US
ZAXIS225USR
29
3
18
35
22
20 2
14
4
9,10
36
W178-02-05-017
Front
ZAXIS200
Front ZAXIS230
ZAXIS225US ZAXIS270
ZAXIS225USR
25
31
16
30
23,24
32
33,34
26
28
Front 17 W178-02-05-018
ZAXIS200 13
6
ZAXIS230
ZAXIS270
T3-3-3
1 2 3 4 5 6 7 8 9 10
36
35
34
33
11
12
13
32 14
31 15
30
16
17
29
28
18
19
20
21
27 22
26
25 24 23
T178-03-03-016
Circuit)
Circuit)
Valve Circuit)
T3-3-4
H A Cross Section A
B
I C 3
D
E
F
View K
G
M178-05-003
7 6
T178-03-03-003
Cross Section C Cross Section a

Auxiliary Bucket 5
12
T178-03-03-047
1
Cross Section J
34 10
33 9
T178-03-03-044
11
13
T178-03-03-005
NOTE: There are only spools but no valves in

Cross Section B.
T3-3-5
1 2 3 4 5 6 7 8 9 10
36
35
34
33
11
12
13
32 14
31 15
30
16
17
29
28
18
19
20
21
27 22
26
25 24 23
T178-03-03-016
Circuit)
Circuit)
Valve Circuit)
T3-3-6
Cross Section D Cross Section F
Boom 2 Boom 1
Swing
19
16
18
27
32
14 25
15
26
17
T178-03-03-008
T178-03-03-006
Cross Section E Cross Section G

Arm 1 Arm 2
22
31 29
30
23
20
T178-03-03-009
24
28
T178-03-03-007
T3-3-7
1 2 3 4 5 6 7 8 9 10
36
35
34
33
11
12
13
32 14
31 15
30
16
17
29
28
18
19
20
21
27 22
26
25 24 23
T178-03-03-016
Circuit)
Circuit)
Valve Circuit)
T3-3-8
Cross Section H Cross Section I
21
4 2
T178-03-03-042 T178-03-03-041
View K Cross Section L

36
T178-03-03-045
M Cross Section M
35
T178-03-03-046
T178-03-03-048
T3-3-9
HYDRAULIC CIRCUIT
Main Circuit
Pressure oil from pump 1 and from pump 2 is routed
to the 4-spool section and to the 5-spool section of
the control valve respectively. A parallel circuit is
provided in both right and left main circuits, making
combined operations possible. An oil flow combiner
circuit is provided in both the boom and arm circuits
so that when a single operation is made, pressure oil
from both pumps 1 and 2 is supplied to the boom or
arm cylinders.
The main relief valve is located in the main circuit

(between the pump and actuators), preventing oil
pressure in the main circuit from increasing more
than the set-pressure while the control valve spool (s)
[the control lever (s)] is (are) operated. The overload
relief valves are located in the boom, arm, and
bucket actuator circuits (between the control valve
and actuators).The overload relief valve prevents
surge pressure from being developed by external
loads in the actuator circuit and prevents pressure in
the circuit from rising more than the set-pressure
when the control valve spool (s) [the control lever (s)]
is (are) in neutral.
T3-3-10
Left Travel Motor Main 4-Spool Section Right Travel Motor

Relief Valve Parallel Passage
5-Spool Section 4-Spool Section
Auxiliary
Bucket
Cylinder
Overload
Relief Valve
Arm
Cylinder Overload
Relief Valve
Swing Motor
Boom
Cylinder
Oil Flow
Combiner Circuit
5-Spool Section
Parallel Circuit
Pump 2 Pump 1
T178-02-02-001
T3-3-11
Pilot Control Circuit External Pilot Pressure Oil Circuit
Pilot pressure oil (indicated with numbers) from the • The main relief valve set-pressure is increased by
pilot valve exerts onto the spool ends in the control the pilot pressure oil delivered from solenoid valve
valve, shifting them. In the following operations, the unit (SG).
pilot pressure oil exerts on the switch valves while • The arm regenerative valve is shifted by the pilot
shifting the spools. pressure oil delivered from solenoid valve unit
• When the arm is rolled in, the pilot pressure oil (SC).
shifts the switch valve in the arm anti-drift valve • The arm flow rate control valve is shifted by the
while exerting onto the arm spool end. pilot pressure oil delivered from solenoid valve unit
• When the boom is lowered, the pilot pressure oil (SE).
shifts the switch valve in the boom anti-drift valve • The flow combiner valve is shifted by the pilot
while exerting onto the boom spool end. pressure oil delivered from the flow combiner valve
As the air bleed circuit is provided in the upper control spool in the signal control valve.
section of the control valve so that any air trapped in • The bucket flow rate control valve is shifted by the
the control valve will automatically be bled. pilot pressure oil delivered from the bucket flow
rate control valve spool in the signal control valve.
• The auxiliary flow combiner valve and the bypass
shut-out valve are shifted by the pilot pressure oil
from auxiliary pilot valve.
• The auxiliary flow rate control valve is shifted by
the pilot pressure oil from the auxiliary flow rate
control solenoid valve.
(Refer to the SYSTEM / Control System group.)
T3-3-12
Pilot Pressure from Flow Combiner Valve Control
Spool in Signal Control Valve
Pilot Pressure Pilot Pressure Oil from Aux. Pilot Valve
from Solenoid
Pilot Pressure from Bucket Flow Rate Control
Valve Unit (SG)
Valve Spool in Pilot pressure Signal Control Valve
Auxiliary Flow
Combiner
Valve
Main Relief
Valve
10
11
9
12
Bucket Flow
Flow Rate Control
Combiner Valve
Valve
Pilot Pressure 8
Oil from
Auxiliary Flow 7
Rate Control
Solenoid
Valve
Auxiliary Flow
Rate Control 2
1
Solenoid 1
Valve
Arm Anti-
Drift Valve
Boom Anti-
Pilot 4 Drift Valve
Pressure Oil 3
from 3
Solenoid
Valve Unit
Arm
Regenerative
Valve
Pilot Pressure
6 Air Bleeding Oil from Aux.
Pilot 5 Circuit Pilot Valve
Pressure Oil
from
Solenoid
Valve Unit
(SE)
Arm Flow Rate
Control Valve
Bypass Shut-Out Valve
T178-03-03-040
1 - Boom Raise 4 - Arm Roll-In 7 - Bucket Roll-In 10 - Left Travel Reverse
2 - Boom Lower 5 - Left Swing 8 - Bucket Roll-Out 11 - Right Travel Forward
3 - Arm Roll-Out 6 - Right Swing 9 - Left Travel Forward 12 - Right Travel Reverse
T3-3-13
(Blank)
T3-3-14
ANIMATION

FLOW COMBINER VALVE
To Hydraulic
1. When a combined operation of the front Oil Tank
attachment and travel functions is made, the flow
combiner control valve spool in the signal control
valve is shifted, causing pilot pressure oil to shift To Left Travel
Spool
the flow combiner valve spool.
2. When the flow combiner valve spool is shifted, Pressure Oil
from Pump 1
pressure oil from pump 1 flows to the left travel
spool.
3. Therefore, pressure oil from pump 1 is routed to Spool
both right and left travel spools. Then, pressure oil
from pump 2 is routed to the front attachment and
swing functions. Consequently, when a combined
operation of travel, front attachment, and swing is
made, the machine can travel straight.
T178-03-03-010
Pilot Pressure Oil from Flow

Combiner Valve Control Spool
Left Travel Motor Right Travel Motor
Flow Combiner Valve

Pilot Pressure Oil from Flow Combiner Valve Control
Spool in Signal Control Valve
Pump 1 T176-03-03-026
T3-3-15
MAIN RELIEF VALVE
The main relief valve prevents pressure in the main

circuit from increasing more than the set-pressure
during operations of actuators such as the motors and
the cylinders. Thereby, oil leaks from the joints of the
hoses and pipes and damage to the actuators are
prevented.
Relief Operation
1. Pressure in port HP (main circuit) exerts on the
pilot poppet via orifice A in the main poppet and
orifice B in the seat.
2. When pressure in port HP increases more than
set-force of spring B, the pilot poppet is unseated,
allowing pressure oil to flow to port LP (hydraulic
oil tank) through the passage and clearance
around the sleeve.
3. At this time a pressure difference arises between
port HP and the spring chamber due to orifice A.
4. If this pressure difference increases more than
set-force of spring A, the main poppet is unseated
so that pressure oil at port HP flows to port LP.
5. Thereby, the main circuit pressure decreases.
6. When the main circuit pressure decreases more
than the specified pressure, the main poppet is
seated by spring A.
Set-Pressure Increase Operation

1. The pilot pressure from solenoid valve unit (SG) is
delivered to port SG, the piston compresses
spring B.
2. Then, spring B force is increased.
3. Accordingly, pressure required to unseat the pilot
poppet is increased, causing the relief valve set-
pressure to increase.
T3-3-16
ANIMATION

During Normal Operation:
Main Poppet Orifice A Orifice B Seat Passage Spring B
HP SG
LP
Sleeve Spring Sprind A Pilot Poppet Piston T157-02-05-003

Chamber
During Relief Operation:

Main Poppet Orifice A Orifice B Seat Passage Spring B
HP
LP
Sleeve Spring Spring A Pilot Poppet T157-02-05-003

Chamber
During Set-Pressure Increase Operation:

Spring B
HP SG
LP
Pilot Poppet Piston T157-02-05-004
T3-3-17
OVERLOAD RELIEF VALVE (with Make-Up
Function)
The overload relief valves are provided in the boom,

arm, and bucket circuits. The overload relief valve
controls pressure in the actuator circuit not to
abnormally increase when the actuator (s) is (are)
moved by external loads. In addition, when pressure in
the actuator circuit is reduced, the overload relief valve
makes up the lack of oil from the hydraulic oil tank to
prevent cavitation.
Relief Operation
1. Pressure in port HP (actuator circuit) exerts on the
pilot poppet via an orifice in the piston.
set-force of spring B, the pilot poppet is unseated,
allowing pressure oil to flow to port LP (hydraulic
oil tank) through passage A and clearance around
the sleeve.
3. At this time a pressure difference arises between
port HP and the spring chamber due to the orifice.
4. If this pressure difference increases more than
set-force of spring A, the main poppet is unseated
so that pressure oil at port HP flows to port LP.
5. Thereby, the actuator circuit pressure decreases.
6. When the actuator circuit pressure decreases
more than the specified pressure, the main
poppet is seated by spring A.
Make-Up Operation
1. When pressure at port HP (actuator circuit) is
reduced more than port LP (hydraulic oil tank), the
sleeve is moved to the right.
2. Then, hydraulic oil flows in port HP from port LP,
preventing cavitation.
the specified pressure, the sleeve is closed by
spring C .
T3-3-18
ANIMATION

During Normal Operation:
Make-Up Valve Sleeve Spring A Passage A Spring B
Main Poppet
HP
LP
Orifice Piston Spring Pilot Spring C T107-02-05-019
Chamber Poppet
During Relief Operation:
Sleeve Spring A Passage A Spring B
Main Poppet
HP
LP
T178-03-03-049
Orifice Piston Spring Pilot
Chamber Poppet
During Make-Up Operation:
Sleeve
HP
LP
Spring C T178-03-03-050
T3-3-19
ANIMATION

REGENERATIVE VALVE
The regenerative valves are provided in the boom

lower, arm roll-in, and bucket roll-in circuits to increase
cylinder speeds and to prevent cylinder hesitation,
improving machine controllability.
Boom Regenerative Valve and Bucket Regener-

ative Valve
NOTE: Operational principle of the boom regen-

erative valve is identical to that of the
bucket regenerative valve. Therefore, the
bucket generative valve is explained as an Pressure Oil from Pump 1
example.
Operation
1. When the bucket is rolled in, the return oil from
the cylinder rod side (bottom side of the boom
cylinder) enters hole A in the spool and acts on Bucket
the check valve. Cylinder
2. At this time, if pressure in the cylinder bottom side
(rod side of the boom cylinder ) is lower than the
rod side, the check valve is opened.
3. Then, the return oil from the cylinder rod side
flows into the bottom side together with oil
delivered from the pump, increasing the cylinder Check Valve
speed.
4. When the cylinder is moved full stroke or the T176-03-03-027
digging load increases, pressure in the cylinder

bottom side circuit will increases more than the
rode side, causing the check valve to close and
stopping regenerative operation.
T3-3-20
Orifice
Return Oil from

Cylinder Rod
Hole A Side
Spool
Pressure Oil to
Cylinder Bottom
Check Side
Valve
T178-03-03-052
T3-3-21
ARM REGENERATIVE VALVE
Operation
1. Normally, during arm rolled-in operation, the
return oil from the cylinder rod side flows back to
the hydraulic oil tank through the hole (orifice) in
the arm regenerative valve spool.
2. When solenoid valve unit (SC) is activated by a
signal from the MC (main controller), pilot
pressure oil delivered from solenoid valve unit
(SC) shifts the arm regenerative valve spool,
blocking the return oil circuit from the cylinder rod
side. (Refer to the SYSTEM /Control System
group.)
3. Thereby, the return oil from the cylinder rod side
flows to the bottom side together with oil delivered
from the pump, increasing the cylinder speed.
T3-3-22
Arm Regenerative
Valve
Arm 1 Arm 2
Return Oil from Arm

Cylinder Rod Side To Arm
Regenerative Valve
Spool
Spool
To Hydraulic
Oil Tank Hole
From Arm 1
Spool
Pilot Pressure
Oil from
Solenoid Valve
Unit (SC)
T178-03-03-007
T178-03-03-018
T3-3-23
ANTI-DRIFT VALVE
The anti-drift valves are provided in the boom cylinder

bottom side circuit and the arm cylinder rod side circuit,
preventing the cylinders from drifting.
NOTE: Both the boom and arm anti-drift valves are

identical in construction.
Holding Operation
1. When the control lever is in the neutral position
(neutral spool position), the switch valve in the Boom Cylinder
anti-drift valve is not shifted.
2. Thus, pressure oil from the boom cylinder bottom
side (arm cylinder rod side) exerts on the check
valve (spring side) in the anti-drift valve though the
switch valve.
3. Consequently, the check valve is closed so that
the return circuit from the cylinder is blocked,
reducing cylinder drift.
Releasing Operation
1. When the arm is rolled in or the boom is lowered,
pilot pressure oil from the pilot valve pushes the
T176-03-03-028
piston in the anti-drift valve so that the switch Anti-Drift Valve Anti-Drift Valve
valve is shifted. (Switch Valve) (Check Valve)
2. Then, oil in the check valve spring chamber flows To
back to the hydraulic oil tank through the switch Pressure Oil Hydraulic
from Pump 1 Oil Tank Boom Cylinder
valve.
3. Thereby, the check valve is opened, allowing the
return oil from the boom cylinder bottom side (arm
cylinder rod side) to flow to the spool.
From Pilot
Valve
To
Hydraulic
Oil Tank
T176-03-03-029
Anti-Drift Valve Anti-Drift Valve
(Switch Valve) (Check Valve)
T3-3-24
Pilot Pressure Oil

Piston
from Pilot Valve
To Hydraulic Oil Tank

Switch Valve
To Main Spool
T178-03-03-051
Check Valve
Cylinder
Bottom Side
Circuit
T3-3-25
ANIMATION

FLOW RATE CONTROL VALVE
The flow rate control valves are provided in the arm,

bucket and auxiliary circuits to restrict oil flow rate in Arm
the circuit when a combined operation is made, giving Cylinder
priority to other actuators.
NOTE: Each flow rate control valve functions in To Hydraulic

Oil Tank
respective combined operation as shown
below. As an example, the arm flow rate
control valve operation is explained in this
section.
Flow Rate
Combined Operation
Control Valve
Switch
Arm Swing and Arm Roll-In Valve
Bucket Boom Raise and Arm Roll-In
Poppet
Auxiliary Front Attachment and Auxiliary Valve
Normal Operation
1. Pressure oil from pump 2 exerts on the check
valve in the poppet valve. Pressure Oil
2. Normally, the switch valve is kept opened. Then, from Pump 2
pressure oil from pump 2 opens the check valve
and flows to the main spool through the switch T178-03-03-030
valve. Arm
Cylinder
3. Thereby, the poppet valve is opened so that
pressure oil from pump 2 flows to the main spool.
To Hydraulic
Flow Rate Control Operation Oil Tank
1. Pilot pressure oil from solenoid valve unit (SE)
shifts the switch valve in the arm flow rate control
valve.
2. When the switch valve is shifted, oil pressure is
enclosed behind the poppet valve, limiting the
poppet valve to open.
3. Thereby, the poppet valve restricts the oil flow rate
Switch
to the main spool, allowing pressure oil to be Valve
supplied to the swing motor which is loaded more
than the arm. Poppet
Valve
Solenoid
Valve Unit
(SE) Pressure Oil
from Pump 2
T178-03-03-031
T3-3-26
Spring A Check Valve Poppet
Spring B
To Main Spool
To Hydraulic Oil Tank

Pressure Oil from
Switch Valve Main Pump 2
Boom Raise
Pilot Pressure
To Main Spool
T178-03-03-013
T3-3-27
AUXILIARY FLOW COMBINER VALVE AND During Single Operation of Attachment:
BYPASS SHUT-OUT VALVE When only the aux. pilot valve is operated, pressure
oil from both pumps 1 and 2 is combined and
The auxiliary flow combiner valve and the bypass supplied together to the attachment, increasing
shut-out valve are provided in the front and the rear of attachment speed.
the 4-spool control valve section respectively. These 1. When only the aux. pilot valve is operated, the aux.
valve functions differ depending on whether only the pilot valve pilot pressure is routed to port SM and
aux. pilot valve is operated or a combined operation port SJ, shifting the auxiliary flow combiner valve
with other front attachments is made. and the bypass shut-off valve spools.
2. When the bypass shut-out valve spool is shifted,
the neutral passage in the 4-spool section is
blocked.
3. At the same time, as the auxiliary flow combiner
valve spool is shifted, pressure oil to be supplied
to the 4-spool section from pump 1 is routed to the
auxiliary spool via the auxiliary flow combiner
valve.
4. Therefore, pressure oil from both pumps 1 and 2
is supplied to the attachment, increasing
attachment operation speed.
Pilot Pressure from
Signal Control Valve Aux. Pilot Valve
Auxiliary Flow Combiner
Auxiliary Flow Valve Control Solenoid
Combiner Valve Valve
Port SN Port SM
Attachment Neutral
Passage
Auxiliary
Port SJ
Bypass Shut-Out Valve
4-Spool Section
5-Spool Section
Pump 2 Pump 1
T176-03-03-033
T3-3-28
Auxiliary Flow Combiner Valve Bypass Shut-Out Valve
To Auxiliary Spool Neutral Passage in

4-Spool Section
Port SM Spool Spring
Pressure Oil
from Pump 1
Spool
Port SJ T178-03-03-054
Check Valve
Spring To Hydraulic
Oil Tank
Port SN T178-03-03-053
T3-3-29
During a Combined Operation of Attachment and Auxiliary Flow Combiner Valve
Front Attachment: To Auxiliary Spool
When the the aux. pilot valve and the boom, arm,
bucket or travel functions are operated
simultaneously, the auxiliary flow combiner valve is Port SM
kept closed so that the boom, arm, or bucket travel
operation speed is maintained.
1. When the the aux. pilot valve is operated, the
attachment pilot pressure is routed to port SM of
the auxiliary flow combiner valve.
2. Then when the boom, arm, bucket, or travel Pressure Oil
function is operated at the same time, pilot From Pump 1
pressure from the signal pilot pressure control
valve is routed to port SN. Spool
3. The auxiliary flow combiner valve spool receives
pressure from port SM in the opening direction Check Valve
and pressure from port SN in the closing direction.
In addition, spring force acts on the spool in the Spring
closing direction.
4. Therefore, spool closing direction force is larger
than opening direction force, holding the spool
closed.
Port SN T178-03-03-053
T3-3-30
COMPONENT OPERATION / Pilot Valve
OUTLINE
The pilot valve controls the pilot oil pressure by which The reducing valves in both the front attachment /
the control valve spools are operated. swing and travel pilot valves are identical construction
Two types of the standard pilot valves are located on except for the pusher moving cam.
this machine. Both have four oil ports. One type is
used for the front attachment / swing function control.
Another is used for the travel function control. Optional
type has two oil ports.
• Travel Pilot Valve
• Front Attachment / Swing Pilot Valve 1 Right Travel Reverse
Port ISO Control 2 Right Travel Forward
Hitachi Pattern 3 Left Travel Forward
No. Pattern
1 Bucket Roll-Out ұ 4 Left Travel Reverse
2 Boom Lower ұ
Right
3 Bucket Roll-In ұ Hydraulic P T
Symbol
4 Boom Raise ұ
1 Right Swing Arm Roll-In
2 Arm Roll-Out Right Swing
Left
3 Left Swing Arm Roll-Out
1 3 2 4
4 Arm Roll-In Left Swing
T105-02-07-020
Hydraulic P T
Symbol
1 3 2 4
T105-02-07-020
T
3 4
2 1
1
T178-03-04-002
P
T178-03-04-001
T3-4-1
OPERATION
Spool (6) head comes in contact with the upper face of
spring guide (3) which is kept raised by return spring
(5).
Neutral (Output Diagram: A to B):

1. When neutral, spool (6) totally blocks pressure oil
port P (from the pilot pump).The output port is E F
opened to port T (hydraulic oil tank) through the
passage in spool (6). Therefore, oil pressure in
the output port (to the control valve) is equal to D
that in port T. Pilot
Pressure
2. When the control lever is slightly tilted, cam (1) is
tilted, moving pusher (2) downward. Then, pusher
(2) compress return spring (5) along with spring C
guide (3). At this time, as oil pressure in the output
port is equal to that in port T, spool (6) moves A B
downward while keeping the under face of the Lever Stroke
spool head in contact with spring guide (3). T522-02-05-001
3. This status continues until hole (7) on spool (6) is

opened to port P.
T3-4-2
Front Attachment / Swing Pilot Valve
1 1
2 2
6
3 3 Port T
4 4
7
5 5 Port P
6 Output Port
6
Port T Port T
7 Port P 7 Port P
Output Port T178-03-04-005

Travel Pilot Valve

1 1
2 2 Port T
7
Port P
3 3 6
4 4
5 Output Port
5
6
Port T Port T
6
Port P Port P
7 7

1 - Cam 3 - Spring Guide 5 - Return Spring 7 - Hole

2 - Pusher 4 - Balance Spring 6 - Spool
T3-4-3
During Metering or Decompressing (Output
Diagram: C to D)
1. When the control lever is further tilted to move E F
pusher (2) downward more, hole (7) on spool (6)
is opened to port P, allowing pressure oil in port P
D
to flow into the output port.
Pilot
2. Oil pressure in the output port acts on the bottom Pressure
face of spool (6) so that spool (6) is pushed
upward.
C
3. However, until upward force acting on the bottom
face of spool (6) overcomes balance spring (4)
force, balance spring (4) is not compressed. Then, A B
Lever Stroke
spool (6) is not raised, allowing oil pressure in the
output port to increase. T522-02-05-001
4. As oil pressure in the output port increases, force

to push spool (6) upward increases. When, this
force overcomes balance spring (4) force,
balance spring (4) is compressed so that spool (6)
is moved upward.
5. As spool (6) is moved upward, hole (7) is closed
so that pressure oil from port P stops flowing into
the output port, stopping pressure oil in the output
port to increase.
6. As spool (6) is moved downward, balance spring
(4) is compressed, increasing the spring force.
Therefore, oil pressure in the output port becomes
equal to the oil pressure acting on the bottom face
of spool (6) being balanced in position with the
spring force.
T3-4-4
1 1
2 2
3 3
4 4
5 5
6 6
Port T Port T
7 Port P 7 Port P
Output Port T178-03-04-008 Output Port T178-03-04-009
Travel Pilot Valve

1 1
2 2
3 3
4 4
5 5
6 6
Port T Port T
Port P Port P
7 7
Output Port T178-03-04-012 Output Port T178-03-04-013

T3-4-5
Full Stroke (Output Diagram: E to F)
1. When the control lever is fully stroked, pusher (2)
is moved downward until pusher (2) in the front E F
attachment / swing pilot valve comes in contact
with the casing shoulder, or cam (1) on the travel
D
pilot valve comes in contact with the casing. Pilot
2. At this moment, the bottom of pusher (2) directly Pressure
pushes spool (6). Therefore, even if oil pressure
in the output port increases further, hole (7) on
C
spool (6) is kept open.
3. Consequently, oil pressure in the output port is
equal to oil pressure in port P. A B
Lever Stroke
T522-02-05-001
NOTE: Total lever strokes for the front attachment
and swing controls are determined by
stroke dimension (E) of pusher (2). Total
lever stroke for the travel control is
determined by stroke dimension (E) of cam
(1).
T3-4-6
2 2
4
5
6
Port T
7 Port P
T178-03-04-010
Travel Pilot Valve

1
1
E
2
4
5
6
Port T
Port P
7
T178-03-04-006

T3-4-7
(Blank)
T3-4-8
COMPONENT OPERATION / Travel Device
OUTLINE
The travel device consists of the travel motor, travel The travel reduction gear is a three stage reduction
reduction gear, and travel brake valve. The travel mo- planetary gear type, converting rotary power transmit-
tor is a swash plate type variable displacement axial ted from the travel motor to slow large torque causing
plunger motor, equipped with parking brake (wet-type the sprocket and track to rotate. The travel brake valve
negative multi-disc brake). The travel motor is driven protects the travel circuit from being overloaded and
by pressure oil from the pump and transmits its rotary prevents the occurrence of cavitation.
power to the travel reduction gear.
NOTE: The structure and theory of operation of the
travel device for ZAXIS200,225US,225USR
and 230 can be thought as identical. Only
some parts differs. This section describes
the operation of ZAXIS200 and ZAXIS270.
ZAXIS200,225US,225USR,230 ZAXIS270
Travel Brake Valve Travel Reduction Gear Travel Brake Valve Travel Reduction Gear
T178-03-05-001 T1HG-03-05-001
Travel Motor Travel Motor
T3-5-1
TRAVEL REDUCTION GEAR
The travel reduction gear is a two stage reduction Travel motor housing (14) is bolted to the track frame
planetary gear type. and is secured to third stage carrier (2) by hub (11).
The travel motor rotates propeller shaft (7). This rota- Ring gear (1) is bolted to drum (13). Drum (13) is
tion is transmitted to ring gear (1) via first stage plane- bolted to sprocket (12). Accordingly, when ring gear (1)
tary gear (8), first stage carrier (6), first stage sun gear is rotated, drum (13) and sprocket (12) are also ro-
(5), second stage planetary gear (9), second stage tated.
carrier (4), second stage sun gear (3), third stage
planetary gear (10), and third stage carrier (2).
1 2 3 4 5 6
14 13 11 10 9 8
12
T178-03-05-001
1 - Ring Gear 5 - First Stage Sun Gear 9 - Second Stage Planetary 12 - Sprocket
Gear
2 - Third Stage Carrier 6 - First Stage Carrier 10 - Third Stage Planetary Gear 13 - Drum
3 - Second Stage Sun Gear 7 - Propel Shaft 11 - Hub 14 - Housing
4 - Second Stage Carrier 8 - First Stage Planetary Gear
T3-5-2
ZAXIS270
1 2 3 4 5 6
9
10
11
14 13
12 T1HG-03-05-001
T3-5-3
TRAVEL MOTOR
The travel motor is a swash plate type variable dis- Shoes (3) on the tips of plungers (5) slide along the
placement axial plunger motor, consists of valve plate swash plate (4) surface due to the inclination of swash
(6), swash plate (4), rotor (2), plungers (5), and shaft plate (4), causing the rotor to rotate (2).
(1). Shaft (1) is splined to rotor (2), in which plungers
(5) are inserted. When pressure oil is supplied from the
pump, plungers (5) are pushed.
1 2 3
4
6 5
T178-03-05-002
1 - Shaft 3 - Shoe 5 - Plunger 6 - Valve Plate

2 - Rotor 4 - Swash Plate
T3-5-4
ZAXIS270
The travel motor is a variable-displacement bent-axis Pressure oil supplied to port AM of valve plate (2) flows
axial plunger motor. into rotor (14) bores underneath port AM, pushing
The travel motor consists of the motor are plate (1), plungers (13). Vertical component force (FV) of
valve plate (2), rotor (14), plungers (13), center shaft plunger pushing force (F) rotates drive disc (7). As
(5), drive disc (7), servo piston (16), parking brake pis- drive disc (7) rotates, rotor (14) also rotates.
ton (12), friction plates (11), and plates (10). When plungers (13) moves to port BM side, oil is
routed to the hydraulic oil tank.
Whether pressure oil from the pump is supplied to port
AM or BM determines travel direction.
1 2 3 4 5 6
14
13
BM 7
8 AM
9
FR
10
11
16 15 14 13 12
FV F
T140-03-02-002
T107-03-04-014
1- Plate 5- Center Shaft 9- Roller Bearing 13 - Plunger

2- Valve Plate 6- Housing 10 - Plate 14 - Rotor
3- Disc Spring 7- Drive Disc 11 - Friction Plate 15 - Link
4- Spring 8- Roller Bearing 12 - Brake Piston 16 - Servo Piston
T3-5-5
PARKING BRAKE
The parking brake is a wet-type multi disc brake. The

brake is a negative type so that it is released only
when the brake release pressure oil is routed into the
brake piston chamber. The parking brake is automati-
cally applied unless the travel function is operated. The
friction plates and the plates are splined to the housing
and rotor respectively.
Releasing Brake
1. When the travel lever is operated, pressure oil
from the main pump is routed to port AM or BM
through the control valve.
2. ZAXIS200,225US,225USR,230:
This pressure oil shifts the counterbalance valve
spool and acts on the brake piston via the notch
on the spool.
ZAXIS270:
This pressure oil shifts the counterbalance valve
spool and acts on the brake piston via notch (I)
reducing valve on the spool.
3. Then, the brake piston is pushed against the disc
spring, allowing the plates and friction plates to be
freed each other so that the brake is released.
Applying Brake
1. When the travel lever is returned to neutral, the
counterbalance spool in the travel brake valve is
returned to neutral.
2. ZAXIS200,225US,225USR,230:
Then, pressure oil acting on the brake piston is re-
turned to the drain circuit via the orifice of brake
piston. Therefore, the brake piston is slowly
pushed back by the disc spring.
ZAXIS270:
Then, pressure oil acting on the brake piston is re-
turned to the drain circuit via the orifice of reduc-
ing valve. Therefore, the brake piston is slowly
pushed back by the discspring.
3. Consequently, spring force is applied to the plates
engaging on the outer diameter of the rotor and
the friction plates engaging on the inner diameter
of the housing via the brake piston, securing the
rotor outer diameter by friction between the friction
plates and the plates.
T3-5-6
ANIMATION
Friction Plate Plate Friction Plate Plate

When Applying Brake When Releasing Brake
Disc Spring Orifice Brake Piston Disc Spring Brake Piston
ZAXIS200,225US,225USR,230
To Brake
Piston
BM AM
Counterbalance Spool
ZAXIS270
To Brake Piston
T178-03-05-008
Reducing Valve
Drain
I
Counterbalance Spool
AM BM T137-03-02-009
T3-5-7
TRAVEL MODE CHANGE
The tilt angle of swash plate (8) is changed by piston

(9) and (10) movement to select the travel mode.
• Slow Speed Mode

1. When the travel mode switch is in the SLOW
position, the MC (main controller) doesn’t send
signals to solenoid valve unit (SI) so that the pilot
pressure oil is not routed to pilot port (1). There-
fore, spool (2) is kept raised by spring (3).
2. Pressure oil in high pressure motor port (AM or
BM) acts on slow-speed piston (8) through piston
operating shuttle valve (4) and slow-speed orifice
(5).
3. Slow-speed piston (8) moves swash plate (7) so
that swash plate (7) angle is increased. Thereby,
plunger (6) stroke is increased, causing the travel
motor to rotate at slow speed.
T3-5-8
ANIMATION
6 7 8
1
Motor Port
(AM, BM)
To Drain
4 10 9
T178-03-05-004
1 - Pilot Port 4 - Piston Operating Shuttle 7 - Swash Plate 9 - Fast-Speed Piston

Valve
2 - Spool 5 - Slow-Speed Orifice 8 - Slow-Speed Piston 10 - Fast-Speed Orifice
3 - Spring 6 - Plunger
T3-5-9
• Fast Speed Mode

1. When the travel mode switch is in the FAST posi-
tion, the MC sends signals to solenoid valve unit
(SI) in response to change in travel loads. (Refer
to the pages for the Travel Motor Swash Angle
Control in the SYSTEM / Control System group.)
Then, the pilot pressure oil is routed to port (1),
moving spool (2) downward.
2. Pressure oil in high pressure motor port (AM or
BM) acts on fast-speed piston (9) through piston
operating shuttle valve (4) and fast-speed orifice
(10).
3. Fast-speed piston (9) moves swash plate (7) so
that swash plate (7) angle is reduced. Thereby,
plunger (6) stroke is reduced, causing the travel
motor to rotate at fast speed.
T3-5-10
ANIMATION
6 7 8
1
Motor Port
(AM, BM)
4 10 9
T178-03-05-005
1 - Pilot Port 4 - Piston Operating Shuttle 7 - Swash Plate 9 - Fast-Speed Piston

Valve
2 - Spool 5 - Slow-Speed Orifice 8 - Slow-Speed Piston 10 - Fast-Speed Orifice
3 - Spring 6 - Plunger
T3-5-11
Travel Speed Selection
Servo piston (1) is interconnected to valve plate (6)

via link (5) so that when servo piston (1) is moved,
swash angle of rotor (7) is shifted through valve plate
(6), leading to travel speed change.
• Slow Speed
1. When the slow speed travel mode is selected, the 3. Accordingly, as the stroke of the plungers in the
MC (Main Controller) does not send out an motor is increased, slower revolution of the travel
electronic control signal to solenoid valve unit (SI). motor for low speed mode is obtained.
Therefore, speed change pilot pressure is not
routed to servo piston (1). Thus, spool (3) is held
down by spring (2).
2. Then, pressure oil P from the motor port is led to
both chambers “B” and “C”.
Since the pressure-receiving area in chamber “C”
is larger than that in chamber “B”, servo piston (1)
moves upward, increasing swash angle to the
maximum.
7
1
2
Drain
B
P
4 Pilot Pressure
T157-03-02-001
1 - Servo Piston 3 - Spool 5 - Link 7 - Rotor

2 - Spring 4 - Orifice 6 - Valve Plate
T3-5-12
• Fast Speed Travel Mode
1. When the fast speed travel mode is selected, 3. As pressure oil P from the motor port is led to
corresponding to travel loads, the MC sends out chamber “B”, servo piston (1) is moved down,
an electronic control signal to solenoid valve unit reducing the swash angle of rotor (7).
(SI). Therefore, speed change pilot pressure is Accordingly, as the stroke of the plungers in the
routed to chamber “D”, moving spool (3) upward. motor is decreased, faster revolution of the travel
2. Then, passage “E” opens and oil in chamber “C” motor for fast speed mode is obtained.
is drained through the inner passages in spool (3). (Refer to the Control System Group in the
SYSTEM Section.)
6
7 2
Drain
3
B
Pilot Pressure
5
4 Drain
P
D
Position of servo piston at initial
stage of fast speed travel operation:
Pilot Pressure
Position of servo piston at during

stage of fast speed travel operation:
T157-03-02-002
1 - Servo Piston 3 - Spool 5 - Link 7 - Rotor

2 - Spring 4 - Orifice 6 - Valve Plate
T3-5-13
TRAVEL BRAKE VALVE
The travel brake valve is located on the travel motor

head, consisting of the following valves.
Counterbalance Valve:
Makes starting and stopping travel operations smooth,
prevents the machine from running away while de-
scending slopes, and routes the travel motor operating
pressure oil in high pressure port (AV or BV) to the
parking brake.
Check Valve:
Assists the counterbalance valve operation and pre-
vents cavitation in the motor circuit.
Overload Relief Valve:

Prevents the occurrence of overload and surge pres-
sure in the motor circuit and reduces shock loads de-
veloped when stopping travel operation.
Shuttle Valve:
Routes the travel motor operating high pressure oil in
high pressure port (AM or BM) to the slow or fast side
piston so that the piston is controlled.
Travel Motor Swash Plate Angle Control Valve:

Delivers pressure oil routed by the piston control shut-
tle valve to the slow or fast side piston.
Slow-Speed Orifice, Fast-Speed Orifice:

Makes the travel mode change (swash plate angle
control) smooth.
T3-5-14
Counterbalance
Valve
Check Valve Slow-Speed Orifice
Shuttle Valve Travel Motor Fast-Speed

Swash Plate Angle Orifice
Control Valve
Overload Relief
Valve
T178-03-05-003
T3-5-15
ZAXIS270
Check Valve:
ensures smooth starts and stops, and prevents
cavitation from occurring in the motor circuit by
functioning together with counterbalance valve.
Reducing Valve:
reduces parking brake release pressure and
prevents sudden operation of the brake.
Parking Brake Release Shuttle Valve:

leads travel motor drive pressure to the parking
brake.
Overload Relief Valve:

prevents overloads and surge pressure in the
motor circuit.
Counterbalance Valve:
ensures smooth starts and stops and prevents
overrunning when traveling down slopes.
Servo-Piston Operating Shuttle Valve:

leads divided hydraulic oil flow for travel motor
operation to the servo-piston.
T3-5-16
Overload Relief Valve

A
Reducing Valve
Check Valve Check Valve
AM BM
B
AV BV
Counter balance
Valve
A
Section A-A
Servo Piston-Operating
Shuttle Valve Parking Brake Release
Shuttle Valve
Section B
Section C
T1HG-03-05-002
T3-5-17
While Traveling: While descending:
1. When pressure oil from the control valve enters 1. While descending a slope, the travel motor is
port BV (8), pressure oil flows around the outer forcibly rotated by the machine weight so that the
diameter of spool (9), unseats check valve BC (7), motor operates like a pump, drawing oil.
and flows further to motor port BM (6). 2. If the travel motor draws oil, oil pressure in port
2. On the other hand, the return oil from the travel BV (8) and chamber B (10) will decrease, causing
motor is routed to motor port AM (4). However, its spool (9) to the left so that the return oil flow from
passage is blocked by check valve AC (3) and the travel motor is restricted.
spool (9). 3. Therefore, oil pressure in motor port AM (4) will
3. When oil pressure in port BV (8) increases, pres- increase, braking the travel motor.
sure oil is routed into chamber B (10) through ori- 4. Once pressure oil flow is restricted, oil pressure in
fice (f) in spool (9), moving spool (9) to the right. motor port AM (4) will increase again, moving
4. Consequently, the return oil from the travel motor spool (9) to the right. As this operation (hydraulic
flows to port AV (1) through notch (h) on spool (9). braking operation) is repeated, the machine is
Then, pressure oil is allowed to flow so that the prevented from running away.
travel motor starts rotating.
5. When the travel lever is returned to neutral, spool Circuit Protection Operation:
(9) is returned to the original position by spring 1. When oil pressure in the circuit increases over the
force, blocking the oil passage so that the travel set-pressure of overload relief valve (5), the over-
motor rotation is stopped. load relief valve is opened, allowing the high pres-
sure oil to relieve to the low pressure side so that
the travel motor is protected from being over-
loaded.
2. In addition, the overload relief valve relieves the
shock loads developed due to inertia force when
stopping the travel motor.
3. If the travel motor draws oil like a pump, check
valve BC (7) is unseated (make-up operation) so
that cavitation is prevented.
T3-5-18
ANIMATION

8 9 1
10 AV 2
BV
6
4
7
T178-03-05-006
5
ZAXIS270
4
5
6
3
9
h
f
AV BV
T140-03-02-005
8 2
10 1
1 - Port AV 4 - Motor Port AM 7 - Check Valve BC 9 - Spool (Counterbalance

Valve)
2 - Chamber A 5 - Overload Relief Valve 8 - Port BV 10 - Chamber B
3 - Check Valve AC 6 - Motor Port BM
T3-5-19
(Blank)
T3-5-20
COMPONENT OPERATION / Signal Control Valve
OUTLINE
The signal control valve is provided in the pilot circuit

between the pilot valve and the control valve and con-
trols pilot signal pressure used to regulate the pumps
and various kinds of valves.
The major components of the signal control valve are,
shuttle valves, shockless valve, pump 1 flow rate con-
trol valve, pump 2 flow rate control valve, flow com-
biner valve control spool, bucket flow rate control valve
control spool, and swing parking brake release spool.
Pilot Valve Side
T178-03-06-016
Cross Section A-A
Shockless Valve
Auxiliary Bucket Flow Rate Control Valve
Pump 1 Flow Rate Control Valve Pump 2 Flow Rate Control Valve
Swing Parking Brake Flow Combiner Valve Control Spool

Release Spool
T178-03-06-002
T3-6-1
PILOT PORT
Pilot Valve Side

Port Name Connecting to Note
Port A Right Pilot Valve Boom Raise Pilot Pressure
Boom Electronic Cushion Solenoid
Valve (Only ZAXIS225US)
Port B Right Pilot Valve Boom Lower Pilot Pressure
Port C Left Pilot Valve Arm Roll-Out Pilot Pressure
Port D Left Pilot Valve Arm Roll-In Pilot Pressure
Port E Left Pilot Valve Left Swing Pilot Pressure
Port F Left Pilot Valve Right Swing Pilot Pressure
Port G Right Pilot Valve Bucket Roll-In Pilot Pressure
Port H Right Pilot Valve Bucket Roll-Out Pilot Pressure
Port I Travel Pilot Valve Left Travel Forward Pilot Pressure
Port J Travel Pilot Valve Left Travel Reverse Pilot Pressure
Port K Travel Pilot Valve Right Travel Forward Pilot Pressure
Port L Travel Pilot Valve Right Travel Reverse Pilot Pressure
Port M Auxiliary Pilot Valve Auxiliary Open Pilot Pressure
Port N Auxiliary Pilot Valve Auxiliary Close Pilot Pressure
Port SA Pump 1 Regulator Pump 1 Control Pressure
Port SB Pump 2 Regulator Pump 2 Control Pressure
Port PI Pilot Shut-Off Valve Primary Pilot Pressure
Port PH Pilot Shut-Off Valve Primary Pilot Pressure (Heating Circuit)
Port SH Swing Parking Brake Brake Release Pressure
Port DF Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Control Valve Side

Port Name Connecting to Note
Port 1 Control Valve Boom Raise Pilot Pressure
Port 2 Control Valve Boom Lower Pilot Pressure
Port 3 Control Valve Arm Roll-Out Pilot Pressure
Port 4 Control Valve Arm Roll-In Pilot Pressure
Port 5 Control Valve Left Swing Pilot Pressure
Port 6 Control Valve Right Swing Pilot Pressure
Port 7 Control Valve Bucket Roll-In Pilot Pressure
Port 8 Control Valve Bucket Roll-Out Pilot Pressure
Port 9 Control Valve Left Travel Forward Pilot Pressure
Port 10 Control Valve Left Travel Reverse Pilot Pressure
Port 11 Control Valve Right Travel Forward Pilot Pressure
Port 12 Control Valve Right Travel Reverse Pilot Pressure
Port 13 Control Valve Auxiliary Open Pilot Pressure
Port 14 Control Valve Auxiliary Close Pilot Pressure
Port SE ӸӸӸ Plug
Port SM Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Port SN ӸӸӸ Plug
Port SP Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Port SL Control Valve Flow Combiner Valve Control Pressure
Port SK Control Valve Bucket Flow Rate Control Valve Control Pressure
T3-6-2
Pilot Valve Side

PH
C
A
E
M
D
H
B
F
SB
PI G
Pilot Valve Side
K N
I
SH
J
DF
SA L
T178-03-06-016
Control Valve Side

SM
3
1 5
13
2 4
SK
SE
8
Pressure Sensor (Swing)
14
Control Valve Side
7
9
6
10
SN
SL
11
Pressure Sensor (Travel) 12 SP T178-03-06-015
T3-6-3
SHUTTLE VALVE
The shuttle valve selects the pilot pressure oil used to

perform each operation and routes it to the corre-
sponding flow rate control valves and/or switch valve
spools. The flow rate control valves and/or switch valve
spools corresponding to each operation are as follows:
Pump 1 Flow Pump 2 Flow Flow Combiner Bucket Flow Swing Parking
Rate Control Rate Control Valve Control Rate Control Brake Release
Valve Valve Spool Valve Control Spool
Spool
Boom Raise { { - - {
Boom Lower { { - - {
Arm Roll-In { { - - {
Arm Roll-Out { { - { {
Bucket Roll-In { - - - {
Bucket Roll-Out { - - - {
Right Swing - { - - {
Left Swing - { - - {
Right Travel { - { - -
Left Travel - { - - -
Auxiliary { - - - {
Left Right 5 6 7 8 9
Travel Travel Swing Arm Boom Bucket 10
1 2 3 4 11
12
13
14 15 16 17
T178-03-06-001
Pump 1 Flow Pump 2 Flow Bucket Flow Flow Combiner Swing Parking
Rate Control Rate Control Rate Control Valve Control Brake Release
Valve Valve Valve Control Spool Spool
Spool
T3-6-4
Pilot Valve Side
T178-03-06-016
Cross Section B-B
9
5
8
7
16
17
15
13
11
14
6 10
12
3
1
4
2
T178-03-06-009
1- Left Travel 6- Boom/Arm/Bucket/Right Travel 11- Boom/Arm/Bucket 16- Swing/Auxiliary

2- Left Travel/Right Travel 7- Boom/Arm 12- Boom/Arm/Bucket/ 17- Auxiliary
Swing/Auxiliary
3- Right Travel 8- Boom 13- Arm/Boom Raise/Swing/Auxiliary
4- Boom/Arm/Bucket/ Right Travel 9- Arm/Boom Raise 14- Bucket
5- Arm 10- Boom/Arm/Bucket/Left 15- Swing
Travel/Swing
T3-6-5
SHOCKLESS VALVE
The shockless valve is provided in the boom raise cir-

cuit and functions during boom lowering operation.
During Boom Raising Operation:

1. Boom raise pilot pressure oil is routed into port A
and acts on the spool.
2. Immediately after operation is started, the low pilot
pressure oil flows to port 1 via clearance C be-
tween the spool and the housing, and inner pas-
sage 2.
3. The set-force of spring A is weaker than that of
spring B. Therefore, when the pilot pressure in-
creases, the spool is moved to the left.
4. As the spool is moved to the right, port A is con-
nected to port 1, increasing pressure in port 1 so
that the spool in the control valve is moved.
During Boom Lowering Operation (Shock Reduc-

ing Operation)
1. When the boom is lowered, the return oil from the
boom raise spool in the control valve is routed to
port 1.
2. Since the spool blocks the oil passage between
port 1 and port A, the return oil cannot flow directly
to port A.
3. Port 1 is connected to spring A side via inner pas-
sage 1 and to the oil chamber via inner passage
2.
4. Pressure oil in the oil chamber flows out from
clearance C between the spool and the housing,
reducing pressure in the oil chamber. Then, the
spool is moved to the right by pressure in the
spring A side. Thereby, clearance C between the
spool and the housing is closed, blocking pres-
sure oil flow.
5. When clearance C is closed, pressure in the oil
chamber increases, moving the spool to the left.
Therefore, clearance C is opened again, allowing
pressure oil to flow to port A.
6. As operations in steps (4 and 5) are repeated,
pressure oil is gradually returned to port A so that
the control spool returns slowly.
T3-6-6
ANIMATION
Pilot Valve Side
Port A
Inner Passage 1 C Spool Spring B
Spring A Inner Passage 2 Oil Chamber
Port 1
T178-03-06-013
Control Valve Side
T3-6-7
PUMP 1 AND PUMP 2 FLOW RATE CON-
TROL VALVES
The pump flow rate control valve delivers pump control

pressure Pi to the pump regulator in response to the
pilot oil pressure from the pilot valve.
1. The pilot oil pressure from the pilot valve is routed

into the spring chamber side in either the pump 1
or pump 2 flow rate control valve after being se-
lected by the shuttle valves in the signal pilot
pressure control valve.
2. Then, the spool is moved to the right, causing the
primary pilot pressure to flow in either port SA or
SB.
3. Therefore, pressure in port SA or SB increases.
4. Oil pressure in port SA or SB acts on the right end
of the spool. Thus, the spool is moved back to the
left until pressure force in port SA or SB balances
with pilot pressure force in the spring chamber so
that pressure in poert SA or SB stops increasing
NOTE: The pump 1 flow rate control valve oper-

ates when the boom (raise or lower), arm
(roll-in or out), bucket (roll-in or out), auxil-
iary, and travel (right) functions are oper-
ated. The pump 2 flow rate control valve
operates when the boom (raise or lower),
arm (roll-in or out), swing (right or left), and
travel (left) functions are operated.
T3-6-8
ANIMATION
Port SA, SB
Spring Spool
Primary Pilot Pressure
Pilot Pressure
Shuttle Valve
T178-03-06-017
T3-6-9
BUCKET FLOW RATE CONTROL VALVE,
FLOW COMBINER VALVE CONTROL
SPOOL, SWING PARKING BRAKE RE-
LEASE SPOOL
Bucket Flow Rate Control Valve Control Spool:
NOTE: The three captioned spools are identical in To Hydraulic Boom Raise Control
Oil Tank Pilot Pressure
operational principle. Spool Spring
The bucket flow rate control valve control spool is

shifted by the arm roll-in control pilot pressure, allowing
the boom raise control pilot pressure to flow to the
bucket flow rate control valve in the control valve.
The flow combiner valve control spool is shifted by the T178-03-06-014
right travel control pilot pressure, allowing the primary Arm Roll-In To Bucket Flow Rate
pilot pressure to flow to the flow combiner valve in the Control Pilot Control Valve
Pressure
control valve.
The swing parking brake release spool is shifted by the Flow Combiner Valve Control Spool:
boom, arm, bucket, or auxiliary control pilot pressure, Oil Tank Pressure
allowing the primary pilot pressure to flow to the swing Spool Spring
motor.
T178-03-06-014
Right Travel To Flow Combiner
Control Pilot Valve
Pressure
Swing Parking Brake Release Spool:
Oil Tank Pressure
Spool Spring
T178-03-06-014
Pilot To Swing Motor
Pressure
T3-6-10
COMPONENT OPERATION / Others (Upperstructure)
PILOT SHUT-OFF VALVE
The pilot shut-off valve is a manual-operated switch

valve. The spool in the pilot shut-off valve is rotated by
moving the pilot control shut-off lever to turn on or off
the pilot oil flow to the pilot valves.
• Valve Operation with Pilot Control Shut-Off

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

Lever in UNLOCK Position
The pilot shut-off valve is set in the operating
position, allowing pressure oil from the pilot pump to
flow into the pilot valves. The pilot pressure can be
and will be routed to the control valve to operate the
respective hydraulic cylinders and/or motors as the To Signal From Pilot
pilot valves are operated, in other words, as the Control Valve Valve T178-03-07-002
control levers are operated.
A2 A1
Z
T1 T2 A3 A4 T4
T3 P
A5 T178-03-07-003
A1 - Right Pilot Valve A4 - Signal Control Valve T1 - Travel Pilot Valve T - Hydraulic Oil Tank
(Port PI)
A2 - Travel Pilot Valve A5 - Signal Control Valve T2 - Left Pilot Valve
(Port PH)
A3 - Left Pilot Valve P - Primary Pilot Pressure T3 - Right Pilot Valve
T3-7-1
SOLENOID VALVE UNIT
Two kinds of solenoid valve are provided: the solenoid

valve unit to control pumps and valves, and the boom
electronic cushion solenoid valve to control the boom
electronic cushion.
Solenoid Valve Unit

The solenoid valve unit functions to control the pump
regulator, control valve and travel motor servo piston
upon receiving signals from the main controller (MC).
The solenoid valve unit consists of four solenoid valves
(SE), (SC), (SI), and (SG). (Refer to the Control
System Group in the SYSTEM Section.)
SE SC SI SG T178-01-02-003
SE : Controls the arm flow rate control valve located in

the control valve
SC : Controls the arm regenerative valve located in the
control valve.
SI : Controls the travel motor servo piston.
(Travel Speed Selection)
SG : Functions to increase the main relief valve
pressure setting.
T3-7-2
ANIMATION

Proportional Solenoid Valve
Upon receiving an electric current signal from the MC,

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

T S P
a
T107-02-07-005
T3-7-3
Boom Electronic Cushion Solenoid Valve (Only
ZAXIS225US)
Output Port
The boom electronic cushion solenoid valve reduces
the boom raise pilot pressure by the signal from MC
(Main Controller).
By reducing the pressure, the spool in the control valve
is controlled to reduce the shock which may occur
when the boom reaches to its full stroke position.
(Refer to SYSTEM / Control System group.)
Operation:
1. Port P and output port are connected by the spool
notch when neutral.
2. When the power flows to the solenoid from MC
(Main Controller), the solenoid is energized and
T1GF-03-07-001
pushes spring 1.
3. As spring 1 pushes the spool, the output port and Port P Port T
port T are connected by the spool notch.
Therefore, the pressure in the output port begins
to decrease.
4. As the left (A) diameter of the spool notch is larger
than the right (B), the spool returns to the left side.
5. The spool stops when the spool and sleeve notch
close. Therefore, the pressure in the output port
stops to decrease.
T3-7-4
When Neutral:
T176-03-01-030
A Port P Port T B
Output Port
When in Operation:
T176-03-01-031
A Port P Port T B
Output Port
NOTE: The theory of operation of this solenoid

valve is similar to that of the solenoid valve
to control the pump. Refer to T3-1-23 also
for the illustration.
T3-7-5
PILOT RELIEF VALVE
Pilot Relief
Valve
The pilot relief valve has a pilot filter incorporated.
The pilot relief valve functions to regulate the pilot
P
pump pressure oil routed to port P to a set constant
pressure.
Pilot Filter
T178-03-07-001
Output Output Worm

EC MOTOR Gear Shaft Gear
The EC motor is used to control engine speed. A worm

gear is incorporated into the EC motor to prevent a
loss of synchronism from occurring. The EC sensor is
provided to detect the degrees of the EC motor rotation
to calculate the governor lever position. (Refer to the
Control System Group in SYSTEM Section.)
Motor
Sensor EC Worm
Gear Sensor Wheel
T157-02-05-018
T3-7-6
COMPONENT OPERATION / Others (Undercarriage)
SWING BEARING
This bearing is a single-row shear ball-type bearing, The internal gear of inner race (3) engages with the
comprising outer race (1), inner race (3), balls (6), output shaft of the swing reduction gear.
supports (5), and seals (2), (4). Outer race (1) is
bolted to the upperstructure and inner race (3) is
bolted to the undercarriage.
T135-03-02-001
1 - Outer Race 3 - Inner Race 5 - Support 6 - Ball

2 - Seal 4 - Seal
T3-8-1
CENTER JOINT
The center joint is a 360° rotating joint. When the Hydraulic oil flows to the right and left travel motors
upperstructure is rotated, the center joint avoids via spindle (1) and the oil ports of body (2). Seals (3)
twisting of hoses and allows hydraulic oil to flow prevent oil leaks between spindle (1) and body (2)
smoothly to or from the travel motors. Spindle (1) is into adjacent passages.
attached to the main frame, and body (2) is bolted to
the swing center of the undercarriage.
To Left Travel To Right Travel To Left Travel To Right Travel

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

To Right Travel Motor (Reverse)
Motor (Forward) Motor (Reverse)
Motor (Reverse)
1
Pilot Pressure Pilot Pressure
for Travel Speed Selection Drain for Travel Speed
Selection
Drain
Drain 3
Drain
: Forward
: Reverse
: Pilot Pressure
for Travel Speed Selection
T157-03-02-004
1 - Spindle 2 - Body 3 - Seal
T3-8-2
TRACK ADJUSTER
The track adjuster located on the side frame is

composed of spring (5) and adjuster cylinder (6).
Spring (5) absorbs loads applied to the front idler.
Adjuster cylinder (6) adjusts track sag.
• Grease is applied through grease fitting into

chamber A of adjuster cylinder (6) as illustrated
below. The pressure of the grease pushes piston
rod (8) out and decreases track sag.
1
• To increases track sag, loosen valve (1) 1 to 1.5 Grease Fitting
turns counterclockwise to release grease from
the track adjuster cylinder through the grease
discharge hole.
CAUTION: Do not loosen valve (1) quickly

or loosen too much since high-pressure
grease in the adjusting cylinder may spout
out.
Loosen carefully, keeping body parts and
Grease Discharge Hole
face away from valve (1).
Never loosen grease fitting.
M104-07-119
1 2 3 4 a
5 6 7 8
W178-03-04-002
1 - Valve 3 - Washer 5 - Spring 7 - Flange

2 - Nut 4 - Spacer 6 - Adjuster Cylinder 8 - Piston Rod
T3-8-3
(Blank)
T3-8-4

Component Operation: Section 3

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Component Operation: Section 3

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SECTION 3

COMPONENT OPERATION / Pump Device

1 - Pump 1 4 - Pump 1 Delivery Pressure 7 - Torque Control Solenoid Valve 10 - N Sensor

The main pump supplies pressure oil to actuate the

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

Maximum Displacement Angle:

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

NOTE: Pilot oil pressure is constantly supplied in 5 7 6

Pd1 -Pump 1 Delivery Pi - Pump Control Pressure

1 - Spring 4 - Piston 7 - Sleeve B 10 - Servo Piston

• Control by Pump Control Pressure

• Control by Own or Opponent Pump Delivery

• Control by Pilot Pressure from Torque Control

• Control by Pilot Pressure from Flow Rate Control

Pd1 -Pump 1 Delivery Pi - Pump Control Pressure

• Increasing Flow Rate

Pd1 -Pump 1 Delivery Pi - Pump Control Pressure

COMPOMRNT OPERATION / Pump Device

To Hydraulic Primary Pilot Oil

To Hydraulic Primary Pilot Oil

• Decreasing Flow Rate

Pd1 -Pump 1 Delivery Pi - Pump Control Pressure

COMPOMRNT OPERATION / Pump Device

To Hydraulic Primary Pilot

To Hydraulic Primary Pilot

• Decreasing Flow Rate

5- Load Piston 9 - Outer Spring

Pd1 - Pump 1 Delivery Pi - Pump Control Pressure

COMPOMRNT OPERATION / Pump Device

To Hydraulic Primary Pilot

• Increasing Flow Rate

5- Load Piston 9 - Outer Spring

Pd1 -Pump 1 Delivery Pi - Pump Control Pressure

COMPOMRNT OPERATION / Pump Device

To Hydraulic Primary Pilot

To Hydraulic Primary Pilot

• Decreasing Flow Rate

5- Load Piston 9 - Outer Spring

Pd1 -Pump 1 Delivery Pi - Pump Control Pressure

COMPOMRNT OPERATION / Pump Device

To Hydraulic Primary Pilot

To Hydraulic Primary Pilot

Pd1 - Pump 1 Delivery Pi - Pump Control Pressure

COMPOMRNT OPERATION / Pump Device

To Hydraulic Primary Pilot Oil

To Hydraulic Primary Pilot Oil

The torque control solenoid valve and the pump 2 flow

COMPOMRNT OPERATION / Pump Device

Solenoid Spring 1 Spring 2 Sleeve Spool

Solenoid Spring 1 Spring 2 Sleeve Spool

1 - Drive Gear 2 - Driven Gear

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

The N sensor detects the engine speed, which is used

PUMP DELIVERY PRESSURE SENSOR

This sensor detects the pump delivery pressures,

PUMP CONTROL PRESSURE SENSOR

This sensor detects the pump control pressures, which