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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


Control Valves ........................................T3-6-8

Outline .....................................................T3-3-1
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
pump[pump 1 (1) and pump 2 (2)] and pilot pump (3).
The engine output is transmitted to transmission (11)
via coupling (12). After being distributed by the gear
train in the transmission, the engine power drives
pump 1 (1), pump 2 (2), and pilot pump (3). Both
reduction gear ratios of the main pumps and pilot
pump are 1:1. The transmission is lubricated with
engine oil.

The main pump is a bent-axis type variable


displacement axial plunger pump. Pump 1 (1) and
pump 2 (2) are integrated as two units in one housing.
The pilot pump is a gear pump.
Pump delivery pressure sensors (4 and 5), pump
control pressure sensors (8 and 9), and N sensor
(engine speed sensor) (10) are provided to control
pump and valve operations.

6
7

8
3

10

1
11

T178-03-01-001

12

T178-03-01-003

T178-03-01-002

1 - Pump 1
2 - Pump 2
3 - Pilot Pump

4 - Pump 1 Delivery Pressure


Sensor
5 - Pump 2 Delivery Pressure
Sensor
6 - Pump 1 Flow Rate Control
Solenoid Valve

7 - Torque Control Solenoid Valve

10 - N Sensor

8 - Pump 1 Control Pressure Sensor

11 - Transmission

9 - Pump 2 Control Pressure Sensor

12 - Coupling

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.

6
3

4
T178-03-01-005

1 - Regulator
2 - Housing

3 - Shaft
4 - Plunger

5 - Valve Plate

T3-1-2

6 - Cylinder Block

COMPOMRNT OPERATION / Pump Device


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

COMPOMRNT OPERATION / Pump Device


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

3
T105-02-03-021

Minimum Displacement Angle (Operable Limit Angle):

5
6
T178-03-01-005

T105-02-03-022

2 - Plunger
3 - Cylinder Block

4 - Valve Plate

5 - Pin

T3-1-4

6 - Servo Piston

COMPOMRNT OPERATION / Pump Device


(Blank)

T3-1-5

COMPOMRNT OPERATION / Pump Device


REGULATOR
The regulator controls the main pump flow rate in
response to the various command signal pressures so
that the pump driving power doesnt exceed the engine
power. Pump 1 and pump 2 are provided with one
regulator each. The major parts of the regulator are
spring (1), sleeve A (2), sleeve B (7), spool A (3), spool
B (6), piston (4), load piston (5), outer spring (8), and
inner spring (9). According to the various command
signal pressures, the regulator opens or closes the
circuit to servo piston (10), causing the inclination of
cylinder block (11) to change, by which the pump flow
rate is controlled.
NOTE: Pilot oil pressure is constantly supplied in
the smaller side chamber of servo piston
(10).

2
Dr

Pi
Pd2

Air
Bleeding
Circuit

Pps

Dr

Pd1

6
10

Increase

Pg

12

Decrease

Cylinder Block Inclination


Pd1 -Pump 1 Delivery
Pressure
Pd2 -Pump 2 Delivery
Pressure
Dr - Returning to Hydraulic
Oil Tank

T3-1-6

8, 9
T176-03-01-009

Pi - Pump Control Pressure


Pps -Torque Control Pressure
Pg - Primary Pilot Pressure
(From Pilot Pump)

COMPOMRNT OPERATION / Pump Device

T178-03-01-006

12
11

10

T178-03-01-005

1 - Spring
2 - Sleeve A
3 - Spool A

4 - Piston
5 - Load Piston
6 - Spool B

7 - Sleeve B
8 - Outer Spring
9 - Inner Spring

T3-1-7

10 - Servo Piston
11 - Cylinder Block
12 - Link

COMPOMRNT OPERATION / Pump Device


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
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
decreases, causing the regulator to reduce the
pump flow rate.

Flow
Rate (Q)

Pump Control Pressure (Pi)

Control by Own or Opponent Pump Delivery


Pressure
The regulator receives own pump delivery pressure
Pd1 and opponent pump delivery pressure Pd2 as
control signal pressures. If the two average
pressures increase over the set P-Q line, the
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.
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)

Flow
Rate (Q)

Pressure Increase
Flow Rate Decrease

Pressure (P)

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
information signals and outputs signals to the torque
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.)

T3-1-8

Flow
Rate (Q)

Pressure (P)

COMPOMRNT OPERATION / Pump Device


Control by Pilot Pressure from Flow Rate Control
Solenoid Valve
(Pump 2 Side Only)
When the MC receives signals from the work mode
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)
(Refer to the CONTROL SYSTEM section.)

Flow
Rate (Q)

Pressure (P)
Dr

Pi
Pd2

Air
Bleeding
Circuit
Dr

Pps
Pd1

Pg
Increase

Decrease

Cylinder Block Inclination


Pd1 -Pump 1 Delivery
Pressure
Pd2 - Pump 2 Delivery
Pressure
Dr - Returning to Hydraulic
Oil Tank

T3-1-9

T176-03-01-009

Pi - Pump Control Pressure


Pps -Torque Control Pressure
Pg - Primary Pilot Pressure
(From Pilot Pump)

COMPOMRNT OPERATION / Pump Device


Control by Pump Control Pressure

Increasing Flow Rate


1. When a control lever is operated, the flow rate
control valve in the signal control valve is shifted,
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
the arrow. Then, the cylinder block rotated in the
maximum inclination direction, increasing the
pump flow rate.
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
as spool A (3), the circuit from the large chamber
of servo piston (10) to the hydraulic oil tank is
closed so that servo piston (10) is stopped,
completing flow rate increase operation.

Flow
Rate (Q)

Pump Control Pressure (Pi)

Dr

Pi
Pd2

Air
Bleeding
Circuit

Pps

Dr

Pd1

Pg

10

12

Increase
Decrease
Cylinder Block Inclination

T176-03-01-009

1 - Spring
2 - Sleeve A
3 - Spool A

4 - Piston
10 - Servo Piston
12 - Link

Pd1 -Pump 1 Delivery


Pressure
Pd2 - Pump 2 Delivery
Pressure
Dr - Returning to Hydraulic
Oil Tank

Pi - Pump Control Pressure

T3-1-10

Pps -Torque Control Pressure


Pg - Primary Pilot Pressure
(From Pilot Pump)

ANIMATION

COMPOMRNT OPERATION / Pump Device

To Hydraulic
Oil Tank

Primary Pilot Oil


Pressure

Pump Control
Pressure Pi

Torque
Control
Pressure
Pps

Pump 2
Delivery
Pressure
Pd2
Pump 1
Delivery
Pressure
Pd1

12

10

To Hydraulic
Oil Tank

Primary Pilot Oil


Pressure

T178-03-01-008

Pump Control
Pressure Pi

Torque
Control
Pressure
Pps

Pump 2
Delivery
Pressure
Pd2
Pump 1
Delivery
Pressure
Pd1

12

10

T3-1-11

T178-03-01-009

COMPOMRNT OPERATION / Pump Device


Decreasing Flow Rate
Flow
Rate (Q)

1. When a control lever is operated, the flow rate


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
moved toward the direction of the arrow so that
the cylinder block is rotated in the minimum
inclination direction, decreasing the pump flow
rate.
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
as spool A (3), the pilot oil pressure circuit to
servo piston (10) through sleeve A (2) and spool A
(3) is closed so that servo piston (10) is stopped,
completing flow rate decrease operation.

Pump Control Pressure (Pi)

Dr

Pi
Air
Bleeding
Circuit

Pd2
Pps

Dr

Pd1

Pg

10

12

Increase
Decrease
Cylinder Block Inclination

T176-03-01-009

1 - Spring
2 - Sleeve A
3 - Spool A

4 - Piston
10 - Servo Piston
12 - Link

Pd1 -Pump 1 Delivery


Pressure
Pd2 -Pump 2 Delivery
Pressure
Dr - Returning to Hydraulic
Oil Tank

Pi - Pump Control Pressure

T3-1-12

Pps -Torque Control Pressure


Pg - Primary Pilot Pressure
(From Pilot Pump)

ANIMATION

COMPOMRNT OPERATION / Pump Device

To Hydraulic
Oil Tank

Primary Pilot
Pressure

Pump Control
Pressure Pi

Torque
Control
Pressure
Pps

Pump 2
Delivery
Pressure
Pd2
Pump 1
Delivery
Pressure
Pd1

12

10

To Hydraulic
Oil Tank

Primary Pilot
Pressure

T178-03-01-010

Pump Control
Pressure Pi

Torque
Control
Pressure
Pps

Pump 2
Delivery
Pressure
Pd2
Pump 1
Delivery
Pressure
Pd1

12

10

T3-1-13

T178-03-01-011

COMPOMRNT OPERATION / Pump Device


Control by Own or Opponent Pump Delivery
Pressure

Decreasing Flow Rate


1. When the pump is loaded by operating any of the
control levers, either pump 1 delivery pressure
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).
4. Due to the difference in diameter between the
large and small chambers, servo piston (10)
moved toward the direction of the arrow so that
the cylinder block is rotated in the minimum
inclination direction, decreasing the pump flow
rate.
5. The movement of the cylinder block is transmitted
to sleeve B (7) via link (12). Then, sleeve B (7) is
moved in the same direction as spool B (6).
6. When sleeve B (7) is moved by the same stroke
as spool B (6), the pilot oil pressure circuit to
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.

Flow
Rate (Q)

Pressure (P)
Dr

Pi
Pd1

Air
Bleeding
Circuit
Dr

Pps
Pd2

6
10

Pg

12

Increase
Decrease
Cylinder Block Inclination

5678-

Load Piston
Spool B
Sleeve B
Inner Spring

Pd1 - Pump 1 Delivery


Pressure
Pd2 - Pump 2 Delivery
Pressure
Dr - Returning to Hydraulic
Oil Tank

T3-1-14

8, 9
T176-03-01-009

9 - Outer Spring
10 - Servo Piston
12 - Link

Pi - Pump Control Pressure


Pps -Torque Control Pressure
Pg - Primary Pilot Pressure
(From Pilot Pump)

ANIMATION

COMPOMRNT OPERATION / Pump Device

To Hydraulic
Oil Tank

Primary Pilot
Pressure

Pump Control
Pressure Pi

Torque
Control
Pressure
Pps

Pump 2
Delivery
Pressure
Pd2

12

Pump 1
Delivery
Pressure
Pd1

10
5

To Hydraulic
Oil Tank

Primary Pilot
Pressure

T178-03-01-012

Pump Control
Pressure Pi

Torque
Control
Pressure
Pps

Pump 2
Delivery
Pressure
Pd2

12

Pump 1
Delivery
Pressure
Pd1

10

T3-1-15

T178-03-01-013

COMPOMRNT OPERATION / Pump Device


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.)
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
arrow. Then, the cylinder block is rotated in the
maximum inclination direction, increasing the
pump flow rate.
5. The movement of the cylinder block is transmitted
to sleeve B (7) via link (12). Then, sleeve B (7) is
moved in the same direction as spool B (6).
6. When sleeve B (7) is moved by the same stroke
as spool B (6), the pilot oil pressure circuit to
servo piston (10) through sleeve B (7) and spool B
(6) is closed so that servo piston (10) is stopped,
completing flow rate increase operation.

Flow
Rate (Q)

Pressure (P)
Dr

Pi
Air
Bleeding
Circuit

Pd2
Pps

Dr

Pd1

6
10

Pg

12

Increase
Decrease
Cylinder Block Inclination

5678-

Load Piston
Spool B
Sleeve B
Inner Spring

Pd1 -Pump 1 Delivery


Pressure
Pd2 -Pump 2 Delivery
Pressure
Dr - Returning to Hydraulic
Oil Tank

T3-1-16

8, 9
T176-03-01-009

9 - Outer Spring
10 - Servo Piston
12 - Link

Pi - Pump Control Pressure


Pps -Torque Control Pressure
Pg - Primary Pilot Pressure
(From Pilot Pump)

ANIMATION

COMPOMRNT OPERATION / Pump Device


5

To Hydraulic
Oil Tank

Primary Pilot
Pressure

Pump Control
Pressure Pi

Torque
Control
Pressure
Pps

Pump 2
Delivery
Pressure
Pd2

Pump 1
Delivery
Pressure
Pd1

12

10
5

To Hydraulic
Oil Tank

Primary Pilot
Pressure

T178-03-01-014

Pump Control
Pressure Pi

Torque
Control
Pressure
Pps

Pump 2
Delivery
Pressure
Pd2

Pump 1
Delivery
Pressure
Pd1

12

10

T3-1-17

T178-03-01-015

COMPOMRNT OPERATION / Pump Device


Control by Pilot Pressure from Torque Control
Solenoid Valve

Decreasing Flow Rate


1. When the torque control solenoid valve is
activated by the signals from the MC, torque
control pressure Pps increases.
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
pressure is routed into the large chamber of servo
piston (10).
5. Due to the difference in diameter between the
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
direction, decreasing the pump flow rate.
6. The movement of the cylinder block is transmitted
to sleeve B (7) via link (12). Then, sleeve B (7) is
moved in the same direction as spool B (6).
7. When sleeve B (7) is moved by the same stroke
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
operation.

Flow
Rate (Q)

Pressure (P)
Dr

Pi
Pd2

Air
Bleeding
Circuit

Pps

Dr

Pd1

6
10

Pg

12

Increase
Decrease
Cylinder Block Inclination

5678-

Load Piston
Spool B
Sleeve B
Inner Spring

Pd1 -Pump 1 Delivery


Pressure
Pd2 - Pump 2 Delivery
Pressure
Dr - Returning to Hydraulic
Oil Tank

T3-1-18

8, 9
T176-03-01-009

9 - Outer Spring
10 - Servo Piston
12 - Link

Pi - Pump Control Pressure


Pps -Torque Control Pressure
Pg - Primary Pilot Pressure
(From Pilot Pump)

ANIMATION

COMPOMRNT OPERATION / Pump Device

To Hydraulic
Oil Tank

Primary Pilot
Pressure

Pump Control
Pressure Pi

Torque
Control
Pressure
Pps

Pump 2
Delivery
Pressure
Pd2

12

Pump 1
Delivery
Pressure
Pd1

10

To Hydraulic
Oil Tank

Primary Pilot
Pressure

T178-03-01-016

Pump Control
Pressure Pi

Torque
Control
Pressure
Pps

Pump 2
Delivery
Pressure
Pd2

12

Pump 1
Delivery
Pressure
Pd1

10

T3-1-19

T178-03-01-017

COMPOMRNT OPERATION / Pump Device


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)
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
opened to the hydraulic oil tank.
5. Since the pilot oil pressure is constantly routed
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
maximum inclination direction, increasing the
pump flow rate.
6. 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).
7. When sleeve A (2) is moved by the same stroke
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.
8. As the pump control pressure is restricted, the
maximum flow rate is reduced more than normal.

Pressure (P)

Dr

Pi
Air
Bleeding
Circuit

Pd2
Pps

Dr

Pd1

Pg

10

12

Increase
Decrease
Cylinder Block Inclination

T176-03-01-009

1 - Spring
2 - Sleeve A
3 - Spool A

4 - Piston
10 - Servo Piston
12 - Link

Pd1 - Pump 1 Delivery


Pressure
Pd2 - Pump 2 Delivery
Pressure
Dr - Returning to Hydraulic
Oil Tank

Pi - Pump Control Pressure

T3-1-20

Pps -Torque Control Pressure


Pg - Primary Pilot Pressure
(From Pilot Pump)

ANIMATION

COMPOMRNT OPERATION / Pump Device


1

To Hydraulic
Oil Tank

Primary Pilot Oil


Pressure

Pump Control
Pressure Pi
Regulated by
Maximum Pump
Flow Rate Control
Solenoid Valve

Torque
Control
Pressure
Pps

Pump 2
Delivery
Pressure
Pd2

12

Pump 1
Delivery
Pressure
Pd1

10

To Hydraulic
Oil Tank

Primary Pilot Oil


Pressure

T178-03-01-018

Pump Control
Pressure Pi
Regulated by
Maximum Pump
Flow Rate Control
Solenoid Valve

Torque
Control
Pressure
Pps

Pump 2
Delivery
Pressure
Pd2
Pump 1
Delivery
Pressure
Pd1

12

10

T3-1-21

T178-03-01-019

COMPOMRNT OPERATION / Pump Device


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

COMPOMRNT OPERATION / Pump Device


When Neutral:
Solenoid

Sleeve

Spring 2

Spring 1

Spool

T176-03-01-030

Port P

Port T

Output Port

When in Operation:
Solenoid

Sleeve

Spring 2

Spring 1

Spool

T176-03-01-031

Port T

Port P
Output Port

T3-1-23

COMPOMRNT OPERATION / Pump Device


PILOT PUMP
Drive gear (1) is driven by the engine via the
transmission which in turn rotates driven gear (2) as
they are meshed together.
1 - Drive Gear

Inlet Port

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
speed.
3 - Tooth
4 - Output

5 - 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.
6 - Ground
7 - Output

8 - Power Source (5V)


9 - Pressure Receiving Area
(Diaphragm)

T157-02-03-010

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.
10 - Pressure Receiving Area
(Diaphragm)
11 - Ground

12 - Output

T176-03-01-023

10

13 - Power Source (5V)

T3-1-24

11 12

13

COMPONENT OPERATION / Swing Device


OUTLINE
The swing device consists of the valve unit, swing motor, and swing reduction gear. The valve unit prevents
cavitation in the swing circuit from occurring and protects the circuit from being overloaded. The swing motor 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.

The swing reduction gear converts the swing motor


output into slow large torque to rotate the shaft.
Thereby, the upperstructure is rotated.

ZAXIS200,225USR,225US,230

ZAXIS270

Valve Unit

Valve Unit

Swing Motor

Swing Reduction
Gear

Swing Motor

Swing Reduction
Gear

T178-03-02-001
T1HG-03-02-003

T3-2-1

ANIMATION

COMPONENT OPERATION / Swing Device


SWING REDUCTION GEAR
The swing reduction gear is a two stage reduction
planetary gear type. The ring gear is formed on the
internal surface of the housing so that they are integrated. As the housing is bolted on the upperstructure,
the ring gear doesnt 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 planetary gear and carrier.

The shaft meshes with the swing bearing internal gear


secured to the undercarriage, causing the upperstructure to rotate.

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

COMPONENT OPERATION / Swing Device


ZAXIS270

First Stage Sun Gear

Swing Motor Shaft


First Stage Planetary Gear

First Stage Carrier

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

COMPONENT OPERATION / Swing Device


SWING MOTOR
The swing motor consists of the swash plate, rotor,
plungers, valve plate, housing and swing parking brake
(springs, brake piston, plates, friction plates, and swing
parking brake switch valve). The rotor in which the
plungers are inserted is splined onto the shaft.

When pressure oil is supplied from the pump, the


pressure oil pushes the plungers. Since the swash
plate is inclined, the shoes on top of the plungers slide
along the swash plate, causing the rotor and shaft to
rotate. The shaft tip end is splined into the first stage
sun gear in the swing reduction gear so that shaft rotation is transmitted to the swing reduction gear.

ZAXIS200,225USR,225US,230

Spring
Valve Plate
Brake Piston
Rotor

Plate

Housing
Friction Plate
Shoe

Plunger

Retainer

Swash Plate

Shaft
T178-03-02-002

T3-2-4

COMPONENT OPERATION / Swing Device


ZAXIS270

Valve Plate
Rotor
Spring
Swing Parking
Brake Switch Valve

Brake Piston

Plate
Friction Plate
Plunger

Retainer

Shoe
Swash Plate
Housing

Shaft
T1HH-03-02-002

T3-2-5

ANIMATION

COMPONENT OPERATION / Swing Device


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 operation 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.
ZAXIS200,225USR,225US,230
Releasing Brake:
1. When the swing and/or front attachment control
levers are operated, the swing parking brake release spool in the signal pilot pressure control
valve is shifted. Thereby, the pilot pressure oil
from the pilot pump is routed to port SH.
2. Pilot pressure at port SH pushes to open the
check valve and flows into the brake piston
chamber.
3. Then, the brake piston is raised, breaking contact
between the plates and friction plates so that the
brake is released.

Applying Brake:
1. When the swing and/or front attachment control
levers are released, the swing parking brake release spool in the signal pilot pressure control
valve is returned to neutral so that the pilot pressure routed to port SH is reduced.
2. Therefore, the check valve is closed, allowing
brake release pressure to flow into the swing motor housing through the orifice.
3. Consequently, spring force is applied to plates
and friction plates which are meshed with the
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 pressure is routed to port SH, allowing the brake to be
automatically applied.

Spring
Brake Piston
Orifice

Check Valve

Friction Plate

Port SH
(Brake Release
Pressure)
Plate
Brake Piston Chamber

T178-03-02-003

T3-2-6

COMPONENT OPERATION / Swing Device


ZAXIS270
Releasing Brake:
1. When the swing and/or front attachment control
levers are operated, the swing parking brake release spool in the signal pilot pressure control
valve is shifted. Thereby, the pilot pressure oil
from the pilot pump is routed to port SH.
2. The spool is shifted to the right side by the pilot
pressure supplied to port SH.
The pilot pressure supplied to port PG is routed to
the brake piston chamber via the spool.
3. At the same time, the pressure oil in port PG is
routed to the check valve via the spool. The pressure difference is developed between the front
and the rear of the check valve caused by the orifice, moving the check valve to the right when the
pressure difference is increased more than the
force of spring 2. Thereby, the drain circuit to the
housing is blocked.
4. Then, the brake piston is raised, breaking contact
between the plates and friction plates so that the
brake is released.

Applying Brake:
1. When the swing and/or front attachment control
levers are released, the swing parking brake release spool in the signal pilot pressure control
valve is returned to neutral so that the pilot pressure routed to port SH is reduced.
2. Thereby, the spool returns to the original position.
The pilot pressure from port PG is blocked, opening the check valve.
3. The pressure oil in the brake piston chamber is released to the swing motor housing through the orifice of the check valve.
4. Consequently spring 1 force is applied to plates
and friction plates which are meshed with the
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 pressure is routed to port SH, allowing the brake to be
automatically applied.

Spring 1
Check Valve

Spring 2

Brake Piston

Rotor
Port PG
(Brake Release
Pressure)

Plate
Friction Plate

Spool

Port SH
(Brake Release
Pressure)

T1HG-03-02-004

Orifice

T3-2-7

Brake Piston Chamber

COMPONENT OPERATION / Swing Device


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
and overloads in the circuit.
Make-Up Valve
During swing stop operation, the swing motor is
driven by inertia force of the upperstructure. The motor is rotated by inertia force more than by pressure
oil delivered from the pump, causing cavitation to develop in the circuit. To prevent cavitation, when pressure in the swing circuit is reduced more than the return circuit (port C) pressure, the poppets are opened
so that hydraulic oil is drawn into the circuit from the
hydraulic oil tank to compensate for the lack of oil in
the circuit.

Relief Valve

Make-Up Valve

Port C

Control Valve
T107-02-04-013

Control Valve

ZAXIS200,225USR,225US,230

Poppet

Make-Up Valve

Make-Up Valve

Port C

T178-03-02-004

Relief Valve

T3-2-8

COMPONENT OPERATION / Swing Device

ZAXIS270

Control Valve
Poppet

Make-Up Valve
Make-Up Valve

Port C

T1HG-03-02-001

Relief Valve

T3-2-9

ANIMATION

COMPONENT OPERATION / Swing Device


Relief Valve
During starting or stopping swing operation, oil pressure in the swing circuit becomes high. The relief
valve prevents the circuit pressure from rising higher
than the set-pressure.
ZAXIS200,225USR,225US,230
Low Pressure Relief Operation (Shock Reducing Function):
1. Pressure at port HP (swing circuit) is routed into
oil chamber C through the poppet orifice.
2. Pressure oil in oil chamber C is further routed into
oil chambers A and B via passages A and B respectively.
3. The pressure receiving area in oil chamber B is
larger than oil chamber A so that the piston moves
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

High Pressure Relief Operation (Overload Prevention):


1. After the piston is moved full stroke, the spring is
compressed so that the circuit pressure is increased to the set-pressure.
2. If pressure in port HP increases more than the
spring set-pressure, the poppet is unseated, causing pressure oil to flow to port LP from port HP.
3. When pressure in port HP is reduced to the specified level, the poppet is seated by spring force.

Passage A

Passage B

Piston

HP

LP
Oil Chamber C
Oil Chamber B
Oil Chamber A

T3-2-10

T178-03-02-005

COMPONENT OPERATION / Swing Device


ZAXIS270
Low Pressure Relief Operation (Shock Reducing Function):
1. Pressure at port HP (swing circuit) is routed into
oil chamber through the poppet orifice.
2. When the pressure in the oil chamber is increased more than the force of spring 2, the piston moves to the left side.
3. 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.
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

High Pressure Relief Operation (Overload Prevention):


1. After the piston is moved full stroke, so that the
circuit pressure is increased to the set-pressure.
2. If pressure in port HP increases more than the
spring 1 set-pressure, the poppet is unseated,
causing pressure oil to flow to port LP from port
HP.
3. When pressure in port HP is reduced to the specified level, the poppet is seated by spring 1 force.

Spring 1

Plunger

Poppet
Orifice

LP

HP

Oil Chamber
T157-02-04-006

T3-2-11

COMPONENT OPERATION / Swing Device


(Blank)

T3-2-12

COMPONENT OPERATION / Control Valve


OUTLINE
The control valve controls oil pressure, flow rate, and
flow direction in the hydraulic circuit. The major parts of
the control valve are the main relief valve, overload
relief valve, flow combiner valve, anti-drift valve, flow
rate control valve, regenerative valve, auxiliary flow
combiner valve, bypass shut-out valve, and spools.
The spools are operated by pilot oil pressure.

In the 4-spool section, the right travel, bucket, boom 1,


and arm 2 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].
In the 5-spool section, the left travel, auxiliary, boom 2,
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
ZAXIS270

Right Travel
Bucket
Boom 1
Arm 2

Left Travel

Main Relief Valve

4-Spool Section

Auxiliary
Boom 2
Arm 1
Swing

5-Spool Section

Front
ZAXIS225US
ZAXIS225USR

M178-05-003

T3-3-1

COMPONENT OPERATION / Control Valve


HYDRAULIC CIRCUIT
1

10

36

35
34
33

11
12
13

32
31
30

14
15

16
17

29
28

18
19
20
21
22

27
26

25

24 23

T178-03-03-016

1 - Load Check Valve (Travel


Parallel Circuit)
2 - Check Valve
(Main Relief Circuit)
3 - Main Relief Valve

4 - Check Valve
(Main Relief Circuit)
5 - Check Valve
(Flow Combiner Valve
Circuit)
6 - Flow Combiner Valve
7 - Auxiliary Flow Combiner
Valve
8 - Check Valve
(Aux. Flow Combiner
Valve Circuit)
9 - Bucket Flow Rate Control
Valve (Switch Valve)

10 - Bucket Flow Rate Control


Valve (Poppet Valve)
11 - Bucket Regenerative Valve
12 - Overload Relief Valve
(Bucket: Rod Side)
13 - Overload Relief Valve
(Bucket: Bottom Side)
14 - Load Check Valve (Boom 1
Parallel Circuit)
15 - Boom Regenerative Valve
16 - Overload Relief Valve
(Boom: Bottom Side)
17 - Overload Relief Valve
(Boom: Rod Side)
18 - Boom Anti-Drift Valve
(Check Valve)

19 - Boom Anti-Drift Valve


(Switch Valve)
20 - Load Check Valve (Arm
Tandem Circuit)
21 - Check Valve (Orifice)
(4-Spool Side Parallel
Circuit)
22 - Bypass Shut-Out Valve

28 - Overload Relief Valve


(Arm: Bottom Side)
29 - Overload Relief Valve
(Arm: Rod Side)
30 - Arm Anti-Drift Valve (Check
Valve)

23 - Arm Flow Rate Control


Valve (Poppet Valve)

31 - Arm Anti-Drift Valve


(Switch Valve)
32 - Load Check Valve (Boom 2
Parallel Circuit)

24 - Arm Flow Rate Control


Valve (Switch Valve)
25 - Load Check Valve (Swing
Circuit)
26 - Check Valve
(Arm Regenerative Circuit)

33 - Auxiliary Flow Rate Control


Valve (Switch Valve)
34 - Auxiliary Flow Rate Control
Valve (Poppet Valve)
35 - Load Check Valve (Travel
Tandem Circuit)

27 - Arm Regenerative Valve

36 - Load Check Valve (Orifice)


(Bucket)

T3-3-2

COMPONENT OPERATION / Control Valve

19

12

Front
ZAXIS225US
ZAXIS225USR

29
3
18
35

22

20
14

9,10
36

Front
ZAXIS200
ZAXIS230
ZAXIS270

Front
ZAXIS225US
ZAXIS225USR

W178-02-05-017

25
30

16

31

23,24
32
33,34
1
8

7
26

Front
ZAXIS200
ZAXIS230
ZAXIS270

28
6

T3-3-3

13

17

W178-02-05-018

COMPONENT OPERATION / Control Valve


1

10

36

35
34
33

11
12
13

32
31
30

14
15

16
17

29
28

18
19
20
21
22

27
26

25

24 23

T178-03-03-016

1 - Load Check Valve (Travel


Parallel Circuit)
2 - Check Valve
(Main Relief Circuit)
3 - Main Relief Valve

4 - Check Valve
(Main Relief Circuit)
5 - Check Valve
(Flow Combiner Valve
Circuit)
6 - Flow Combiner Valve
7 - Auxiliary Flow Combiner
Valve
8 - Check Valve
(Aux. Flow Combiner
Valve Circuit)
9 - Bucket Flow Rate Control
Valve (Switch Valve)

10 - Bucket Flow Rate Control


Valve (Poppet Valve)
11 - Bucket Regenerative Valve
12 - Overload Relief Valve
(Bucket: Rod Side)
13 - Overload Relief Valve
(Bucket: Bottom Side)
14 - Load Check Valve (Boom 1
Parallel Circuit)
15 - Boom Regenerative Valve
16 - Overload Relief Valve
(Boom: Bottom Side)
17 - Overload Relief Valve
(Boom: Rod Side)
18 - Boom Anti-Drift Valve
(Check Valve)

19 - Boom Anti-Drift Valve


(Switch Valve)
20 - Load Check Valve (Arm
Tandem Circuit)
21 - Check Valve (Orifice)
(4-Spool Side Parallel
Circuit)
22 - Bypass Shut-Out Valve

28 - Overload Relief Valve


(Arm: Bottom Side)
29 - Overload Relief Valve
(Arm: Rod Side)
30 - Arm Anti-Drift Valve (Check
Valve)

23 - Arm Flow Rate Control


Valve (Poppet Valve)

31 - Arm Anti-Drift Valve


(Switch Valve)
32 - Load Check Valve (Boom 2
Parallel Circuit)

24 - Arm Flow Rate Control


Valve (Switch Valve)
25 - Load Check Valve (Swing
Circuit)
26 - Check Valve
(Arm Regenerative Circuit)

33 - Auxiliary Flow Rate Control


Valve (Switch Valve)
34 - Auxiliary Flow Rate Control
Valve (Poppet Valve)
35 - Load Check Valve (Travel
Tandem Circuit)

27 - Arm Regenerative Valve

36 - Load Check Valve (Orifice)


(Bucket)

T3-3-4

COMPONENT OPERATION / Control Valve


Cross Section A

D
E
F

View K

8
a

M178-05-003

6
T178-03-03-003

Cross Section C

Cross Section a
Auxiliary

Bucket

12

34

Cross Section J

10

33

T178-03-03-047

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

COMPONENT OPERATION / Control Valve

10

36

35
34
33

11
12
13

32
31
30

14
15

16
17

29
28

18
19
20
21
22

27
26

25

24 23

T178-03-03-016

1 - Load Check Valve (Travel


Parallel Circuit)
2 - Check Valve
(Main Relief Circuit)
3 - Main Relief Valve

4 - Check Valve
(Main Relief Circuit)
5 - Check Valve
(Flow Combiner Valve
Circuit)
6 - Flow Combiner Valve
7 - Auxiliary Flow Combiner
Valve
8 - Check Valve
(Aux. Flow Combiner
Valve Circuit)
9 - Bucket Flow Rate Control
Valve (Switch Valve)

10 - Bucket Flow Rate Control


Valve (Poppet Valve)
11 - Bucket Regenerative Valve
12 - Overload Relief Valve
(Bucket: Rod Side)
13 - Overload Relief Valve
(Bucket: Bottom Side)
14 - Load Check Valve (Boom 1
Parallel Circuit)
15 - Boom Regenerative Valve
16 - Overload Relief Valve
(Boom: Bottom Side)
17 - Overload Relief Valve
(Boom: Rod Side)
18 - Boom Anti-Drift Valve
(Check Valve)

19 - Boom Anti-Drift Valve


(Switch Valve)
20 - Load Check Valve (Arm
Tandem Circuit)
21 - Check Valve (Orifice)
(4-Spool Side Parallel
Circuit)
22 - Bypass Shut-Out Valve

28 - Overload Relief Valve


(Arm: Bottom Side)
29 - Overload Relief Valve
(Arm: Rod Side)
30 - Arm Anti-Drift Valve (Check
Valve)

23 - Arm Flow Rate Control


Valve (Poppet Valve)

31 - Arm Anti-Drift Valve


(Switch Valve)
32 - Load Check Valve (Boom 2
Parallel Circuit)

24 - Arm Flow Rate Control


Valve (Switch Valve)
25 - Load Check Valve (Swing
Circuit)
26 - Check Valve
(Arm Regenerative Circuit)

33 - Auxiliary Flow Rate Control


Valve (Switch Valve)
34 - Auxiliary Flow Rate Control
Valve (Poppet Valve)
35 - Load Check Valve (Travel
Tandem Circuit)

27 - Arm Regenerative Valve

36 - Load Check Valve (Orifice)


(Bucket)

T3-3-6

COMPONENT OPERATION / Control Valve


Cross Section D

Cross Section F
Boom 2

Boom 1

Swing

19

16

18

32

27

14

25

15
26
17
T178-03-03-008
T178-03-03-006

Cross Section E

Arm 1

Cross Section G

Arm 2

22

31

29

30

23
20

T178-03-03-009

24

28
T178-03-03-007

T3-3-7

COMPONENT OPERATION / Control Valve


1

10

36

35
34
33

11
12
13

32
31
30

14
15

16
17

29
28

18
19
20
21
22

27
26

25

24 23

T178-03-03-016

1 - Load Check Valve (Travel


Parallel Circuit)
2 - Check Valve
(Main Relief Circuit)
3 - Main Relief Valve

4 - Check Valve
(Main Relief Circuit)
5 - Check Valve
(Flow Combiner Valve
Circuit)
6 - Flow Combiner Valve
7 - Auxiliary Flow Combiner
Valve
8 - Check Valve
(Aux. Flow Combiner
Valve Circuit)
9 - Bucket Flow Rate Control
Valve (Switch Valve)

10 - Bucket Flow Rate Control


Valve (Poppet Valve)
11 - Bucket Regenerative Valve
12 - Overload Relief Valve
(Bucket: Rod Side)
13 - Overload Relief Valve
(Bucket: Bottom Side)
14 - Load Check Valve (Boom 1
Parallel Circuit)
15 - Boom Regenerative Valve
16 - Overload Relief Valve
(Boom: Bottom Side)
17 - Overload Relief Valve
(Boom: Rod Side)
18 - Boom Anti-Drift Valve
(Check Valve)

19 - Boom Anti-Drift Valve


(Switch Valve)
20 - Load Check Valve (Arm
Tandem Circuit)
21 - Check Valve (Orifice)
(4-Spool Side Parallel
Circuit)
22 - Bypass Shut-Out Valve

28 - Overload Relief Valve


(Arm: Bottom Side)
29 - Overload Relief Valve
(Arm: Rod Side)
30 - Arm Anti-Drift Valve (Check
Valve)

23 - Arm Flow Rate Control


Valve (Poppet Valve)

31 - Arm Anti-Drift Valve


(Switch Valve)
32 - Load Check Valve (Boom 2
Parallel Circuit)

24 - Arm Flow Rate Control


Valve (Switch Valve)
25 - Load Check Valve (Swing
Circuit)
26 - Check Valve
(Arm Regenerative Circuit)

33 - Auxiliary Flow Rate Control


Valve (Switch Valve)
34 - Auxiliary Flow Rate Control
Valve (Poppet Valve)
35 - Load Check Valve (Travel
Tandem Circuit)

27 - Arm Regenerative Valve

36 - Load Check Valve (Orifice)


(Bucket)

T3-3-8

COMPONENT OPERATION / Control Valve


Cross Section H

Cross Section I

21

T178-03-03-042

View K

T178-03-03-041

Cross Section L
36

T178-03-03-045

Cross Section M

35

T178-03-03-046

T178-03-03-048

T3-3-9

COMPONENT OPERATION / Control Valve


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

COMPONENT OPERATION / Control Valve


Left Travel Motor

Main
Relief Valve

4-Spool Section
Parallel Passage

5-Spool Section

Right Travel Motor

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

COMPONENT OPERATION / Control Valve


Pilot Control Circuit
Pilot pressure oil (indicated with numbers) from the
pilot valve exerts onto the spool ends in the control
valve, shifting them. In the following operations, the
pilot pressure oil exerts on the switch valves while
shifting the spools.
When the arm is rolled in, the pilot pressure oil
shifts the switch valve in the arm anti-drift valve
while exerting onto the arm spool end.
When the boom is lowered, the pilot pressure oil
shifts the switch valve in the boom anti-drift valve
while exerting onto the boom spool end.
As the air bleed circuit is provided in the upper
section of the control valve so that any air trapped in
the control valve will automatically be bled.

External Pilot Pressure Oil Circuit


The main relief valve set-pressure is increased by
the pilot pressure oil delivered from solenoid valve
unit (SG).
The arm regenerative valve is shifted by the pilot
pressure oil delivered from solenoid valve unit
(SC).
The arm flow rate control valve is shifted by the
pilot pressure oil delivered from solenoid valve unit
(SE).
The flow combiner valve is shifted by the pilot
pressure oil delivered from the flow combiner valve
control spool in the signal control valve.
The bucket flow rate control valve is shifted by the
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

COMPONENT OPERATION / Control Valve


Pilot Pressure from Flow Combiner Valve Control
Spool in Signal Control Valve

Pilot Pressure
from Solenoid
Valve Unit (SG)

Pilot Pressure Oil from Aux. Pilot Valve


Pilot Pressure from Bucket Flow Rate Control
Valve Spool in Pilot pressure Signal Control Valve

Auxiliary Flow
Combiner
Valve
Main Relief
Valve
10

11

12
Bucket Flow
Rate Control
Valve

Flow
Combiner
Valve
Pilot Pressure
Oil from
Auxiliary Flow
Rate Control
Solenoid
Valve

Auxiliary Flow
Rate Control
Solenoid
Valve
Arm AntiDrift Valve

Pilot
Pressure Oil
from
Solenoid
Valve Unit
Arm
Regenerative
Valve

8
7

Boom AntiDrift Valve

4
3

6
Pilot
Pressure Oil
from
Solenoid
Valve Unit
(SE)

Air Bleeding
Circuit

Arm Flow Rate


Control Valve

Pilot Pressure
Oil from Aux.
Pilot Valve

Bypass Shut-Out Valve

T178-03-03-040

1 - Boom Raise
2 - Boom Lower
3 - Arm Roll-Out

4 - Arm Roll-In
5 - Left Swing
6 - Right Swing

7 - Bucket Roll-In
8 - Bucket Roll-Out
9 - Left Travel Forward

T3-3-13

10 - Left Travel Reverse


11 - Right Travel Forward
12 - Right Travel Reverse

COMPONENT OPERATION / Control Valve


(Blank)

T3-3-14

ANIMATION

COMPONENT OPERATION / Control Valve


FLOW COMBINER VALVE
1. When a combined operation of the front
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
the flow combiner valve spool.
2. When the flow combiner valve spool is shifted,
pressure oil from pump 1 flows to the left travel
spool.
3. Therefore, pressure oil from pump 1 is routed to
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.

To Hydraulic
Oil Tank

To Left Travel
Spool
Pressure Oil
from Pump 1
Spool

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

T3-3-15

T176-03-03-026

COMPONENT OPERATION / Control Valve


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 setpressure to increase.

T3-3-16

ANIMATION

COMPONENT OPERATION / Control Valve


During Normal Operation:
Main Poppet

Orifice A

Orifice B

Seat

Passage Spring B

HP

SG

LP

Spring
Chamber

Sleeve

Sprind A

Pilot Poppet

Piston

T157-02-05-003

During Relief Operation:


Main Poppet

Orifice A

Orifice B

Seat

Passage Spring B

HP

LP

Sleeve

Spring
Chamber

Spring A

Pilot Poppet

T157-02-05-003

During Set-Pressure Increase Operation:


Spring B

SG

HP

LP

Pilot Poppet

T3-3-17

Piston

T157-02-05-004

COMPONENT OPERATION / Control Valve


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.
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 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.
3. When pressure in port HP increases more than
the specified pressure, the sleeve is closed by
spring C .

T3-3-18

ANIMATION

COMPONENT OPERATION / Control Valve


During Normal Operation:
Make-Up Valve

Main Poppet

Sleeve

Spring A

Passage A

Spring B

HP

LP
Orifice

Piston

Spring
Chamber

Pilot
Poppet

Spring C

T107-02-05-019

During Relief Operation:


Main Poppet

Sleeve

Spring A

Passage A

Spring B

HP

LP
Orifice Piston

Spring
Chamber

T178-03-03-049

Pilot
Poppet

During Make-Up Operation:


Sleeve

HP

LP
Spring C

T3-3-19

T178-03-03-050

ANIMATION

COMPONENT OPERATION / Control Valve


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 Regenerative Valve
NOTE: Operational principle of the boom regenerative valve is identical to that of the
bucket regenerative valve. Therefore, the
bucket generative valve is explained as an
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
the check valve.
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
speed.
4. When the cylinder is moved full stroke or the
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

Pressure Oil from Pump 1

Bucket
Cylinder

Check Valve
T176-03-03-027

COMPONENT OPERATION / Control Valve

Orifice

Return Oil from


Cylinder Rod
Side

Hole A

Spool

Pressure Oil to
Cylinder Bottom
Side

Check
Valve

T178-03-03-052

T3-3-21

COMPONENT OPERATION / Control Valve


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

COMPONENT OPERATION / Control Valve


Arm 1
Return Oil from Arm
Cylinder Rod Side

Arm Regenerative
Valve

Arm 2

To Arm
Regenerative Valve
Spool
Spool
To Hydraulic
Oil Tank
From Arm 1
Spool

Hole

Pilot Pressure
Oil from
Solenoid Valve
Unit (SC)

T178-03-03-007
T178-03-03-018

T3-3-23

COMPONENT OPERATION / Control Valve


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
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
piston in the anti-drift valve so that the switch
valve is shifted.
2. Then, oil in the check valve spring chamber flows
back to the hydraulic oil tank through the switch
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.

Boom Cylinder

T176-03-03-028

Anti-Drift Valve
(Switch Valve)
Pressure Oil
from Pump 1

Anti-Drift Valve
(Check Valve)
To
Hydraulic
Oil Tank Boom Cylinder

From Pilot
Valve

To
Hydraulic
Oil Tank

T176-03-03-029

Anti-Drift Valve
(Switch Valve)

T3-3-24

Anti-Drift Valve
(Check Valve)

COMPONENT OPERATION / Control Valve

Pilot Pressure Oil


from Pilot Valve

Piston

To Hydraulic Oil Tank

Switch Valve

To Main Spool

T178-03-03-051

Check Valve
Cylinder
Bottom Side
Circuit

T3-3-25

ANIMATION

COMPONENT OPERATION / Control Valve


FLOW RATE CONTROL VALVE
The flow rate control valves are provided in the arm,
bucket and auxiliary circuits to restrict oil flow rate in
the circuit when a combined operation is made, giving
priority to other actuators.

Arm
Cylinder

To Hydraulic
Oil Tank

NOTE: Each flow rate control valve functions in


respective combined operation as shown
below. As an example, the arm flow rate
control valve operation is explained in this
section.
Flow Rate
Control Valve

Combined Operation

Arm

Swing and Arm Roll-In

Bucket

Boom Raise and Arm Roll-In

Auxiliary

Front Attachment and Auxiliary

Switch
Valve
Poppet
Valve

Normal Operation
1. Pressure oil from pump 2 exerts on the check
valve in the poppet valve.
2. Normally, the switch valve is kept opened. Then,
pressure oil from pump 2 opens the check valve
and flows to the main spool through the switch
valve.
3. Thereby, the poppet valve is opened so that
pressure oil from pump 2 flows to the main spool.

Pressure Oil
from Pump 2
T178-03-03-030

Arm
Cylinder

To Hydraulic
Oil Tank

Flow Rate Control Operation


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
to the main spool, allowing pressure oil to be
supplied to the swing motor which is loaded more
than the arm.

Switch
Valve
Poppet
Valve
Solenoid
Valve Unit
(SE)

Pressure Oil
from Pump 2
T178-03-03-031

T3-3-26

COMPONENT OPERATION / Control Valve

Spring A

Check Valve

Poppet

Spring B
To Main Spool

To Hydraulic Oil Tank


Pressure Oil from
Main Pump 2

Switch Valve

Boom Raise
Pilot Pressure

To Main Spool
T178-03-03-013

T3-3-27

COMPONENT OPERATION / Control Valve


AUXILIARY FLOW COMBINER VALVE AND
BYPASS SHUT-OUT VALVE

During Single Operation of Attachment:


When only the aux. pilot valve is operated, pressure
oil from both pumps 1 and 2 is combined and
supplied together to the attachment, increasing
attachment speed.
1. When only the aux. pilot valve is operated, the aux.
pilot valve pilot pressure is routed to port SM and
port SJ, shifting the auxiliary flow combiner valve
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.

The auxiliary flow combiner valve and the bypass


shut-out valve are provided in the front and the rear of
the 4-spool control valve section respectively. These
valve functions differ depending on whether only the
aux. pilot valve is operated or a combined operation
with other front attachments is made.

Pilot Pressure from


Aux. Pilot Valve
Auxiliary Flow Combiner
Valve Control Solenoid
Auxiliary Flow
Valve
Combiner Valve

Signal Control Valve

Port SN

Port SM

Attachment

Neutral
Passage

Auxiliary

Port SJ
Bypass Shut-Out Valve

5-Spool Section
Pump 2

4-Spool Section

Pump 1

T176-03-03-033

T3-3-28

COMPONENT OPERATION / Control Valve


Auxiliary Flow Combiner Valve

Bypass Shut-Out Valve

To Auxiliary Spool

Neutral Passage in
4-Spool Section
Spool

Port SM

Spring

Pressure Oil
from Pump 1
Spool
Port SJ

Check Valve
Spring

Port SN

T178-03-03-054

To Hydraulic
Oil Tank

T178-03-03-053

T3-3-29

COMPONENT OPERATION / Control Valve


During a Combined Operation of Attachment and
Front Attachment:
When the the aux. pilot valve and the boom, arm,
bucket
or
travel
functions
are
operated
simultaneously, the auxiliary flow combiner valve is
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
function is operated at the same time, pilot
pressure from the signal pilot pressure control
valve is routed to port SN.
3. The auxiliary flow combiner valve spool receives
pressure from port SM in the opening direction
and pressure from port SN in the closing direction.
In addition, spring force acts on the spool in the
closing direction.
4. Therefore, spool closing direction force is larger
than opening direction force, holding the spool
closed.

Auxiliary Flow Combiner Valve


To Auxiliary Spool
Port SM

Pressure Oil
From Pump 1
Spool

Check Valve
Spring

Port SN

T3-3-30

T178-03-03-053

COMPONENT OPERATION / Pilot Valve


OUTLINE
The pilot valve controls the pilot oil pressure by which
the control valve spools are operated.
Two types of the standard pilot valves are located on
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.

The reducing valves in both the front attachment /


swing and travel pilot valves are identical construction
except for the pusher moving cam.

Travel Pilot Valve


1
2
3
4

Front Attachment / Swing Pilot Valve

Right

Left

Port
No.
1
2
3
4
1
2
3
4

ISO Control
Pattern
Bucket Roll-Out
Boom Lower
Bucket Roll-In
Boom Raise
Right Swing
Arm Roll-Out
Left Swing
Arm Roll-In

Hitachi Pattern

Arm Roll-In
Right Swing
Arm Roll-Out
Left Swing

Right Travel Reverse


Right Travel Forward
Left Travel Forward
Left Travel Reverse

Hydraulic
Symbol

T105-02-07-020

Hydraulic
Symbol

4
T105-02-07-020

T
P

1
T178-03-04-002

T
4
2
P
T178-03-04-001

T3-4-1

COMPONENT OPERATION / Pilot Valve


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
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
that in port T.
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
guide (3). At this time, as oil pressure in the output
port is equal to that in port T, spool (6) moves
downward while keeping the under face of the
spool head in contact with spring guide (3).
3. This status continues until hole (7) on spool (6) is
opened to port P.

T3-4-2

D
Pilot
Pressure
C

Lever Stroke
T522-02-05-001

COMPONENT OPERATION / Pilot Valve


Front Attachment / Swing Pilot Valve

7
Port P

Output Port
Port T

Port T

Port P

Output Port

Port T

Port P

Output Port

T178-03-04-005

T178-03-04-007

Travel Pilot Valve


1

Port T

7
3

Output Port

Port P

Port T

Port T

6
Port P

Output Port
1 - Cam
2 - Pusher

Port P

Output Port

T178-03-04-006

3 - Spring Guide
4 - Balance Spring

5 - Return Spring
6 - Spool

T3-4-3

7 - Hole

T178-03-04-011

COMPONENT OPERATION / Pilot Valve


During Metering or Decompressing (Output
Diagram: C to D)
1. When the control lever is further tilted to move
pusher (2) downward more, hole (7) on spool (6)
is opened to port P, allowing pressure oil in port P
to flow into the output port.
2. Oil pressure in the output port acts on the bottom
face of spool (6) so that spool (6) is pushed
upward.
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,
spool (6) is not raised, allowing oil pressure in the
output port to increase.
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

D
Pilot
Pressure
C

Lever Stroke
T522-02-05-001

COMPONENT OPERATION / Pilot Valve


Front Attachment / Swing Pilot Valve

6
Port T

Port T

Port P

Output Port

Port P

Output Port

T178-03-04-008

T178-03-04-009

Travel Pilot Valve


1

6
Port T

Port P

Output Port
1 - Cam
2 - Pusher

Port T

Port P

Output Port

T178-03-04-012

3 - Spring Guide
4 - Balance Spring

5 - Return Spring
6 - Spool

T3-4-5

7 - Hole

T178-03-04-013

COMPONENT OPERATION / Pilot Valve


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
attachment / swing pilot valve comes in contact
with the casing shoulder, or cam (1) on the travel
pilot valve comes in contact with the casing.
2. At this moment, the bottom of pusher (2) directly
pushes spool (6). Therefore, even if oil pressure
in the output port increases further, hole (7) on
spool (6) is kept open.
3. Consequently, oil pressure in the output port is
equal to oil pressure in port P.
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

D
Pilot
Pressure

Lever Stroke
T522-02-05-001

COMPONENT OPERATION / Pilot Valve


Front Attachment / Swing Pilot Valve

3
4
5
E

6
Port T

Port P

T178-03-04-010

Output Port

T178-03-04-005

Travel Pilot Valve

3
4
5
6

Port T

Port P

Output Port

1 - Cam
2 - Pusher

T178-03-04-006
T178-03-04-014

3 - Spring Guide
4 - Balance Spring

5 - Return Spring
6 - Spool

T3-4-7

7 - Hole

COMPONENT OPERATION / Pilot Valve


(Blank)

T3-4-8

COMPONENT OPERATION / Travel Device


OUTLINE
The travel device consists of the travel motor, travel
reduction gear, and travel brake valve. The travel motor is a swash plate type variable displacement axial
plunger motor, equipped with parking brake (wet-type
negative multi-disc brake). The travel motor is driven
by pressure oil from the pump and transmits its rotary
power to the travel reduction gear.

The travel reduction gear is a three stage reduction


planetary gear type, converting rotary power transmitted from the travel motor to slow large torque causing
the sprocket and track to rotate. The travel brake valve
protects the travel circuit from being overloaded and
prevents the occurrence of cavitation.
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 Brake Valve

Travel Reduction Gear

T1HG-03-05-001

T178-03-05-001

Travel Motor

Travel Motor

T3-5-1

Travel Reduction Gear

COMPONENT OPERATION / Travel Device


TRAVEL REDUCTION GEAR
The travel reduction gear is a two stage reduction
planetary gear type.
The travel motor rotates propeller shaft (7). This rotation is transmitted to ring gear (1) via first stage planetary gear (8), first stage carrier (6), first stage sun gear
(5), second stage planetary gear (9), second stage
carrier (4), second stage sun gear (3), third stage
planetary gear (10), and third stage carrier (2).

Travel motor housing (14) is bolted to the track frame


and is secured to third stage carrier (2) by hub (11).
Ring gear (1) is bolted to drum (13). Drum (13) is
bolted to sprocket (12). Accordingly, when ring gear (1)
is rotated, drum (13) and sprocket (12) are also rotated.

ZAXIS200,225USR,225US,230
1

14

13

11

10

12
T178-03-05-001

1 - Ring Gear

5 - First Stage Sun Gear

2 - Third Stage Carrier


3 - Second Stage Sun Gear
4 - Second Stage Carrier

6 - First Stage Carrier


7 - Propel Shaft
8 - First Stage Planetary Gear

9 - Second Stage Planetary


Gear
10 - Third Stage Planetary Gear
11 - Hub

T3-5-2

12 - Sprocket
13 - Drum
14 - Housing

COMPONENT OPERATION / Travel Device

ZAXIS270

11

14

10

13

12

T3-5-3

T1HG-03-05-001

COMPONENT OPERATION / Travel Device


TRAVEL MOTOR
The travel motor is a swash plate type variable displacement axial plunger motor, consists of valve plate
(6), swash plate (4), rotor (2), plungers (5), and shaft
(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.

Shoes (3) on the tips of plungers (5) slide along the


swash plate (4) surface due to the inclination of swash
plate (4), causing the rotor to rotate (2).

ZAXIS200,225USR,225US,230
1

3
4

T178-03-05-002

1 - Shaft
2 - Rotor

3 - Shoe
4 - Swash Plate

5 - Plunger

T3-5-4

6 - Valve Plate

COMPONENT OPERATION / Travel Device


ZAXIS270
Pressure oil supplied to port AM of valve plate (2) flows
into rotor (14) bores underneath port AM, pushing
plungers (13). Vertical component force (FV) of
plunger pushing force (F) rotates drive disc (7). As
drive disc (7) rotates, rotor (14) also rotates.
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.

The travel motor is a variable-displacement bent-axis


axial plunger motor.
The travel motor consists of the motor are plate (1),
valve plate (2), rotor (14), plungers (13), center shaft
(5), drive disc (7), servo piston (16), parking brake piston (12), friction plates (11), and plates (10).

2
14
13
7

BM

AM

16

15

11
13 12

14

FR

10
FV

T140-03-02-002

T107-03-04-014

1234-

Plate
Valve Plate
Disc Spring
Spring

5678-

Center Shaft
Housing
Drive Disc
Roller Bearing

910 11 12 -

T3-5-5

Roller Bearing
Plate
Friction Plate
Brake Piston

13 14 15 16 -

Plunger
Rotor
Link
Servo Piston

COMPONENT OPERATION / Travel Device


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 automatically 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 returned 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 returned to the drain circuit via the orifice of reducing 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

COMPONENT OPERATION / Travel Device

Plate

Friction Plate

When Applying Brake

Disc Spring

Orifice

Brake Piston

When Releasing Brake

Disc Spring

Friction Plate

Plate

Brake Piston

ZAXIS200,225US,225USR,230

BM

To Brake
Piston

AM

Counterbalance Spool

ZAXIS270
To Brake Piston
T178-03-05-008

Reducing Valve

Drain

Counterbalance Spool
AM

BM

T137-03-02-009

T3-5-7

COMPONENT OPERATION / Travel Device


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) doesnt send
signals to solenoid valve unit (SI) so that the pilot
pressure oil is not routed to pilot port (1). Therefore, 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

COMPONENT OPERATION / Travel Device

6
1

Motor Port
(AM, BM)

3
To Drain

10

T178-03-05-004

1 - Pilot Port
2 - Spool
3 - Spring

4 - Piston Operating Shuttle


Valve
5 - Slow-Speed Orifice
6 - Plunger

7 - Swash Plate

9 - Fast-Speed Piston

8 - Slow-Speed Piston

10 - Fast-Speed Orifice

T3-5-9

COMPONENT OPERATION / Travel Device


Fast Speed Mode
1. When the travel mode switch is in the FAST position, 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

COMPONENT OPERATION / Travel Device

6
1

Motor Port
(AM, BM)

10

T178-03-05-005

1 - Pilot Port
2 - Spool
3 - Spring

4 - Piston Operating Shuttle


Valve
5 - Slow-Speed Orifice
6 - Plunger

7 - Swash Plate

9 - Fast-Speed Piston

8 - Slow-Speed Piston

10 - Fast-Speed Orifice

T3-5-11

COMPONENT OPERATION / Travel Device


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
MC (Main Controller) does not send out an
electronic control signal to solenoid valve unit (SI).
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.

3. Accordingly, as the stroke of the plungers in the


motor is increased, slower revolution of the travel
motor for low speed mode is obtained.

6
7
1

2
Drain

3
5

Pilot Pressure

T157-03-02-001

1 - Servo Piston
2 - Spring

3 - Spool
4 - Orifice

5 - Link
6 - Valve Plate

T3-5-12

7 - Rotor

COMPONENT OPERATION / Travel Device


Fast Speed

Travel Mode

1. When the fast speed travel mode is selected,


corresponding to travel loads, the MC sends out
an electronic control signal to solenoid valve unit
(SI). Therefore, speed change pilot pressure is
routed to chamber D, moving spool (3) upward.
2. Then, passage E opens and oil in chamber C
is drained through the inner passages in spool (3).

3. As pressure oil P from the motor port is led to


chamber B, servo piston (1) is moved down,
reducing the swash angle of rotor (7).
Accordingly, as the stroke of the plungers in the
motor is decreased, faster revolution of the travel
motor for fast speed mode is obtained.
(Refer to the Control System Group in the
SYSTEM Section.)
1

2
Drain

E
Pilot Pressure

Drain

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
2 - Spring

3 - Spool
4 - Orifice

5 - Link
6 - Valve Plate

T3-5-13

7 - Rotor

COMPONENT OPERATION / Travel Device


TRAVEL BRAKE VALVE
The travel brake valve is located on the travel motor
head, consisting of the following valves.
ZAXIS200,225USR,225US,230
Counterbalance Valve:
Makes starting and stopping travel operations smooth,
prevents the machine from running away while descending 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 prevents cavitation in the motor circuit.
Overload Relief Valve:
Prevents the occurrence of overload and surge pressure in the motor circuit and reduces shock loads developed 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 shuttle 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

COMPONENT OPERATION / Travel Device


Counterbalance
Valve
Check Valve

Shuttle Valve

Slow-Speed Orifice

Travel Motor
Swash Plate Angle
Control Valve

Fast-Speed
Orifice

Overload Relief
Valve
T178-03-05-003

T3-5-15

COMPONENT OPERATION / Travel Device


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

COMPONENT OPERATION / Travel Device


Overload Relief Valve

Reducing Valve
Check Valve

Check Valve
AM

BM

B
BV

AV

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

COMPONENT OPERATION / Travel Device


While Traveling:
1. When pressure oil from the control valve enters
port BV (8), pressure oil flows around the outer
diameter of spool (9), unseats check valve BC (7),
and flows further to motor port BM (6).
2. On the other hand, the return oil from the travel
motor is routed to motor port AM (4). However, its
passage is blocked by check valve AC (3) and
spool (9).
3. When oil pressure in port BV (8) increases, pressure oil is routed into chamber B (10) through orifice (f) in spool (9), moving spool (9) to the right.
4. Consequently, the return oil from the travel motor
flows to port AV (1) through notch (h) on spool (9).
Then, pressure oil is allowed to flow so that the
travel motor starts rotating.
5. When the travel lever is returned to neutral, spool
(9) is returned to the original position by spring
force, blocking the oil passage so that the travel
motor rotation is stopped.

While descending:
1. While descending a slope, the travel motor is
forcibly rotated by the machine weight so that the
motor operates like a pump, drawing oil.
2. If the travel motor draws oil, oil pressure in port
BV (8) and chamber B (10) will decrease, causing
spool (9) to the left so that the return oil flow from
the travel motor is restricted.
3. Therefore, oil pressure in motor port AM (4) will
increase, braking the travel motor.
4. Once pressure oil flow is restricted, oil pressure in
motor port AM (4) will increase again, moving
spool (9) to the right. As this operation (hydraulic
braking operation) is repeated, the machine is
prevented from running away.
Circuit Protection Operation:
1. When oil pressure in the circuit increases over the
set-pressure of overload relief valve (5), the overload relief valve is opened, allowing the high pressure oil to relieve to the low pressure side so that
the travel motor is protected from being overloaded.
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

COMPONENT OPERATION / Travel Device


ZAXIS200,225USR,225US,230
8

10

BV

AV

h
f
6

7
3

T178-03-05-006

ZAXIS270
4
5

6
7

f
AV

BV
T140-03-02-005

10

1 - Port AV

4 - Motor Port AM

7 - Check Valve BC

2 - Chamber A
3 - Check Valve AC

5 - Overload Relief Valve


6 - Motor Port BM

8 - Port BV

T3-5-19

9 - Spool (Counterbalance
Valve)
10 - Chamber B

COMPONENT OPERATION / Travel Device


(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 controls 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 control valve, pump 2 flow rate control valve, flow combiner 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

Bucket Flow Rate Control Valve

Auxiliary

Pump 2 Flow Rate Control Valve

Pump 1 Flow Rate Control Valve

Swing Parking Brake


Release Spool

Flow Combiner Valve Control Spool

T178-03-06-002

T3-6-1

COMPONENT OPERATION / Signal Control Valve


PILOT PORT
Pilot Valve Side
Port Name
Port A

Port B
Port C
Port D
Port E
Port F
Port G
Port H
Port I
Port J
Port K
Port L
Port M
Port N
Port SA
Port SB
Port PI
Port PH
Port SH
Port DF
Control Valve Side
Port Name
Port 1
Port 2
Port 3
Port 4
Port 5
Port 6
Port 7
Port 8
Port 9
Port 10
Port 11
Port 12
Port 13
Port 14
Port SE
Port SM
Port SN
Port SP
Port SL
Port SK

Connecting to
Right Pilot Valve
Boom Electronic Cushion Solenoid
Valve (Only ZAXIS225US)
Right Pilot Valve
Left Pilot Valve
Left Pilot Valve
Left Pilot Valve
Left Pilot Valve
Right Pilot Valve
Right Pilot Valve
Travel Pilot Valve
Travel Pilot Valve
Travel Pilot Valve
Travel Pilot Valve
Auxiliary Pilot Valve
Auxiliary Pilot Valve
Pump 1 Regulator
Pump 2 Regulator
Pilot Shut-Off Valve
Pilot Shut-Off Valve
Swing Parking Brake
Hydraulic Oil Tank

Boom Lower Pilot Pressure


Arm Roll-Out Pilot Pressure
Arm Roll-In Pilot Pressure
Left Swing Pilot Pressure
Right Swing Pilot Pressure
Bucket Roll-In Pilot Pressure
Bucket Roll-Out Pilot Pressure
Left Travel Forward Pilot Pressure
Left Travel Reverse Pilot Pressure
Right Travel Forward Pilot Pressure
Right Travel Reverse Pilot Pressure
Auxiliary Open Pilot Pressure
Auxiliary Close Pilot Pressure
Pump 1 Control Pressure
Pump 2 Control Pressure
Primary Pilot Pressure
Primary Pilot Pressure (Heating Circuit)
Brake Release Pressure
Returning to Hydraulic Oil Tank

Connecting to
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve

Hydraulic Oil Tank

Hydraulic Oil Tank


Control Valve
Control Valve

Note
Boom Raise Pilot Pressure
Boom Lower Pilot Pressure
Arm Roll-Out Pilot Pressure
Arm Roll-In Pilot Pressure
Left Swing Pilot Pressure
Right Swing Pilot Pressure
Bucket Roll-In Pilot Pressure
Bucket Roll-Out Pilot Pressure
Left Travel Forward Pilot Pressure
Left Travel Reverse Pilot Pressure
Right Travel Forward Pilot Pressure
Right Travel Reverse Pilot Pressure
Auxiliary Open Pilot Pressure
Auxiliary Close Pilot Pressure
Plug
Returning to Hydraulic Oil Tank
Plug
Returning to Hydraulic Oil Tank
Flow Combiner Valve Control Pressure
Bucket Flow Rate Control Valve Control Pressure

T3-6-2

Note
Boom Raise Pilot Pressure

COMPONENT OPERATION / Signal Control Valve


Pilot Valve Side

PH

E
M
D
H
B

SB
G

PI

Pilot Valve Side

I
SH

J
DF
SA

L
T178-03-06-016

Control Valve Side


SM

3
5

1
13
2
SK

4
SE
8

Pressure Sensor (Swing)

14
Control Valve Side

7
9
6

10

SN

SL

11

Pressure Sensor (Travel)

12

T3-6-3

SP

T178-03-06-015

COMPONENT OPERATION / Signal Control Valve


SHUTTLE VALVE
The shuttle valve selects the pilot pressure oil used to
perform each operation and routes it to the corresponding 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
Rate Control
Valve
{
{
{
{
{
{
{
{

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
Travel

Pump 2 Flow
Rate Control
Valve

Flow Combiner
Valve Control
Spool

{
{
{
{
{
{
{
Right 5
Travel

Bucket Flow
Rate Control
Valve Control
Spool
{
-

{
-

7
Swing

8
Arm

Swing Parking
Brake Release
Spool
{
{
{
{
{
{
{
{
{

9
Boom

Bucket

10
11
12
13
14 15 16 17

T178-03-06-001

Pump 1 Flow
Rate Control
Valve

Pump 2 Flow
Rate Control
Valve

T3-6-4

Bucket Flow
Rate Control
Valve Control
Spool

Flow Combiner
Valve Control
Spool

Swing Parking
Brake Release
Spool

COMPONENT OPERATION / Signal Control Valve

Pilot Valve Side

T178-03-06-016

Cross Section B-B


9
5

7
16
17
15

13

11

14
10

12

4
2

T178-03-06-009

1- Left Travel
2- Left Travel/Right Travel

6- Boom/Arm/Bucket/Right Travel
7- Boom/Arm

3- Right Travel
4- Boom/Arm/Bucket/ Right Travel
5- Arm

8- Boom
9- Arm/Boom Raise
10- Boom/Arm/Bucket/Left
Travel/Swing

T3-6-5

11- Boom/Arm/Bucket
12- Boom/Arm/Bucket/
Swing/Auxiliary
13- Arm/Boom Raise/Swing/Auxiliary
14- Bucket
15- Swing

16- Swing/Auxiliary
17- Auxiliary

COMPONENT OPERATION / Signal Control Valve


SHOCKLESS VALVE
The shockless valve is provided in the boom raise circuit 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 between the spool and the housing, and inner passage 2.
3. The set-force of spring A is weaker than that of
spring B. Therefore, when the pilot pressure increases, the spool is moved to the left.
4. As the spool is moved to the right, port A is connected to port 1, increasing pressure in port 1 so
that the spool in the control valve is moved.
During Boom Lowering Operation (Shock Reducing 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 passage 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 pressure 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

COMPONENT OPERATION / Signal Control Valve

Pilot Valve Side


Port A
Inner Passage 1

Spring A

Spool

Inner Passage 2

Spring B

Oil Chamber

Port 1
T178-03-06-013

Control Valve Side

T3-6-7

COMPONENT OPERATION / Signal Control Valve


PUMP 1 AND PUMP 2 FLOW RATE CONTROL 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 selected 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 operates when the boom (raise or lower), arm
(roll-in or out), bucket (roll-in or out), auxiliary, and travel (right) functions are operated. 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

COMPONENT OPERATION / Signal Control Valve

Spring

Port SA, SB
Spool

Primary Pilot Pressure


Pilot Pressure

Shuttle Valve

T178-03-06-017

T3-6-9

COMPONENT OPERATION / Signal Control Valve


BUCKET FLOW RATE CONTROL VALVE,
FLOW COMBINER VALVE CONTROL
SPOOL, SWING PARKING BRAKE RELEASE SPOOL
Bucket Flow Rate Control Valve Control Spool:
To Hydraulic Boom Raise Control
Oil Tank
Pilot Pressure
Spool
Spring

NOTE: The three captioned spools are identical in


operational principle.
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
right travel control pilot pressure, allowing the primary
pilot pressure to flow to the flow combiner valve in the
control valve.
The swing parking brake release spool is shifted by the
boom, arm, bucket, or auxiliary control pilot pressure,
allowing the primary pilot pressure to flow to the swing
motor.

T178-03-06-014

Arm Roll-In
Control Pilot
Pressure

To Bucket Flow Rate


Control Valve

Flow Combiner Valve Control Spool:


To Hydraulic Primary Pilot
Oil Tank
Pressure
Spring

Spool

Right Travel
Control Pilot
Pressure

T178-03-06-014

To Flow Combiner
Valve

Swing Parking Brake Release Spool:


To Hydraulic
Oil Tank

Primary Pilot
Pressure

Spool

Spring

T178-03-06-014

Pilot
Pressure

T3-6-10

To Swing Motor

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
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.

Section Z-Z

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
pilot valves are operated, in other words, as the
control levers are operated.
A2

To Signal
Control Valve

A1

From Pilot
Valve

T178-03-07-002

T1

T2

T3

A3

A4

A5
A1 - Right Pilot Valve
A2 - Travel Pilot Valve
A3 - Left Pilot Valve

T4

T178-03-07-003

A4 - Signal Control Valve


(Port PI)
A5 - Signal Control Valve
(Port PH)
P - Primary Pilot Pressure

T1 - Travel Pilot Valve


T2 - Left Pilot Valve
T3 - Right Pilot Valve

T3-7-1

T - Hydraulic Oil Tank

COMPONENT OPERATION / Others (Upperstructure)


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 : 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

SE

SC SI

SG

T178-01-02-003

ANIMATION

COMPONENT OPERATION / Others (Upperstructure)


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):
The spring pushes the spool to the right,
connecting the output port S to the tank port T.

Because of the pressure receiving area difference


between the two walls, the pressure at port S acts
as a force to push the spool to the right. As the
pressure at port S increases, the force to push the
spool to the right also increases. When this force
overcomes the force to push the spool to the left
by solenoid, the spool moves back to the right
side, closing the passage between output port S
and port P. As a result, pressure increase at port S
stops.

When energized:
The solenoid pushes the spool to the left for a
distance proportional to the electric current
flowing through the solenoid. Pilot oil from port (P)
flows into output port S, increasing the pressure at
output port S. The pressure at port S acts on the
two banks of walls on the spool. (See detail a.)
Spool
T

Spring

Solenoid

a
T107-02-07-005

T3-7-3

COMPONENT OPERATION / Others (Upperstructure)


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
pushes spring 1.
3. As spring 1 pushes the spool, the output port and
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

T1GF-03-07-001

Port P

Port T

COMPONENT OPERATION / Others (Upperstructure)


When Neutral:
Solenoid

Sleeve

Spring 2

Spring 1

Spool

T176-03-01-030

Port P

Port T

Output Port

When in Operation:
Solenoid

Sleeve

Spring 2

Spring 1

Spool

T176-03-01-031

Port T

Port P

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

COMPONENT OPERATION / Others (Upperstructure)


PILOT RELIEF VALVE

Pilot Relief
Valve

The pilot relief valve has a pilot filter incorporated.


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

Pilot Filter

T178-03-07-001

Output
Gear

EC MOTOR

Output
Shaft

Worm
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
Gear

EC
Sensor

Worm
Wheel
T157-02-05-018

T3-7-6

COMPONENT OPERATION / Others (Undercarriage)


SWING BEARING
This bearing is a single-row shear ball-type bearing,
comprising outer race (1), inner race (3), balls (6),
supports (5), and seals (2), (4). Outer race (1) is
bolted to the upperstructure and inner race (3) is
bolted to the undercarriage.

The internal gear of inner race (3) engages with the


output shaft of the swing reduction gear.

4
6

T135-03-02-001

1 - Outer Race
2 - Seal

3 - Inner Race
4 - Seal

5 - Support

T3-8-1

6 - Ball

COMPONENT OPERATION / Others (Undercarriage)


CENTER JOINT
The center joint is a 360 rotating joint. When the
upperstructure is rotated, the center joint avoids
twisting of hoses and allows hydraulic oil to flow
smoothly to or from the travel motors. Spindle (1) is
attached to the main frame, and body (2) is bolted to
the swing center of the undercarriage.

To Left Travel
Motor (Reverse)

To Right Travel
Motor (Forward)

To Left Travel
Motor (Forward)

To Right Travel
Motor (Reverse)

Hydraulic oil flows to the right and left travel motors


via spindle (1) and the oil ports of body (2). Seals (3)
prevent oil leaks between spindle (1) and body (2)
into adjacent passages.

To Left Travel
Motor (Forward)

To Right Travel
Motor (Forward)

To Left Travel
Motor (Reverse)

To Right Travel
Motor (Reverse)

1
Pilot Pressure
for Travel Speed Selection

Pilot Pressure
for Travel Speed
Selection

Drain

2
Drain

Drain

Drain
: Forward
: Reverse
: Pilot Pressure
for Travel Speed Selection

T157-03-02-004

1 - Spindle

2 - Body

3 - Seal

T3-8-2

COMPONENT OPERATION / Others (Undercarriage)


TRACK ADJUSTER
The track adjuster located on the side frame is
composed of spring (5) and adjuster cylinder (6).
Spring (5) absorbs loads applied to the front idler.
Adjuster cylinder (6) adjusts track sag.
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


turns counterclockwise to release grease from
the track adjuster cylinder through the grease
discharge hole.

Grease Fitting

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
face away from valve (1).
Never loosen grease fitting.

Grease Discharge Hole


M104-07-119

W178-03-04-002

1 - Valve
2 - Nut

3 - Washer
4 - Spacer

5 - Spring
6 - Adjuster Cylinder

T3-8-3

7 - Flange
8 - Piston Rod

COMPONENT OPERATION / Others (Undercarriage)


(Blank)

T3-8-4

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