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: KM-178-E
Vol. No. : TO178-E-04
200·225·230·270 class
Technical Manual
(Operational Principle)
Excavator
200 class
200•200LC•210H•210LCH•210•210LC•210N•240
225 class
Excavator
Service Manual (Manual No. KM-178-E) consists of the following three separate volumes;
Technical Manual (Operational Principle) : Vol. No. TO178-E
Technical Manual (Troubleshooting) : Vol. No. T T 178-E
Workshop Manual : Vol. No. W178-E
• This manual is written for an experienced technician • If you have any questions or comments, at if you
to provide technical information needed to maintain found any errors regarding the contents of this
and repair this machine. manual, please contact using “Service Manual
Revision Request Form” at the end of this man-
• Be sure to thoroughly read this manual for cor- ual.
rect product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-298-32-7173
FAX: 81-298-31-1162
ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition • Operation Manual of the Engine
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog
MANUAL COMPOSITION
• This manual consists of three portions: the Techni- • Information included in the Technical Manual
cal Manual (Operational Principle), the Technical (Troubleshooting):
Manual (Troubleshooting) and the Workshop Man- technical information needed for operational per-
ual. formance tests, and troubleshooting procedures.
• Information included in the Technical Manual • Information included in the Workshop Manual:
(Operational Principle): technical information needed for maintenance
technical information needed for redelivery and and repair of the machine, tools and devices
delivery, operation and activation of all devices needed for maintenance and repair, maintenance
and systems. standards, and removal/installation and assem-
ble/disassemble procedures.
IN-01
INTRODUCTION
PAGE NUMBER
Example : T 1-3-5
This is the safety alert symbol. When you see this • IMPORTANT:
symbol, be alert to the potential for personal injury. Indicates a situation which, if not conformed to the
Never fail to follow the safety instructions prescribed instructions, could result in damage to the machine.
along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to component/part weights. • NOTE:
To avoid injury and damage, be sure to use appropri- Indicates supplementary technical information or
ate lifting techniques and equipment when lifting know-how.
heavy parts.
IN-02
INTRODUCTION
UNITS USED
• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm2, 3560 psi)
this manual.
MKSA system units and English units are also A table for conversion from SI units to other system
indicated in parenthheses just behind SI units. units is shown below for reference purposees.
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
Length mm in 0.03937 Pressure MPa kgf/cm2 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
m3 yd3 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
Force N kgf 0.10197 min-1 rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque N⋅m kgf⋅m 1.0197 mL/rev cc/rev 1.0
N⋅m lbf⋅ft 0.7375
IN-03
INTRODUCTION
IN-04
SECTION AND GROUP
SECTION 1 GENERAL
CONTENTS Group 1 Specification
Group 2 Component Layout
Group 3 Component Specifications
SECTION 2 SYSTEM
Group 1 Control System
TECHNICAL MANUAL Group 2 Hydraulic System
Group 3 Electrical System
(Operational Principle)
SECTION 3 COMPONENT OPERATION
Group 1 Pump Device
Group 2 Swing Device
Group 3 Control Valve
Group 4 Pilot Valve
Group 5 Travel Device
Group 6 Signal Control Valve
Group 7 Others(Upperstructure)
Group 8 Others(Undercarriage)
TECHNICAL MANUAL (Troubleshooting)
SECTION 4 OPERATIONAL PER- SECTION 5 TROUBLESHOOTING
FORMANCE TEST Group 1 Diagnosing Procedure
Group 1 Introduction Group 2 Component Layout
Group 2 Standard Group 3 Troubleshooting A
Group 3 Engine Test Group 4 Troubleshooting B
Group 4 Excavator Test Group 5 Troubleshooting C
All information, illustrations and speci- Group 5 Component Test Group 6 Electrical System Inspection
fications in this manual are based on Group 6 Adjustment Group 7 ICX
the latest product information available
at the time of publication. The right is WORKSHOP MANUAL
reserved to make changes at any time
without notice. SECTION 1 GENERAL INFORMA- SECTION 3 UNDERCARRIAGE
TION Group 1 Swing Bearing
Group 1 Precautions for Disassem- Group 2 Travel Device
bling and Assembling Group 3 Center Joint
Group 2 Tightening Torque Group 4 Track Adjuster
Group 3 Painting Group 5 Front Idler
Group 4 Bleeding Air from Hydrau- Group 6 Upper and Lower Roller
COPYRIGHT(C)2005 lic Oil Tank Group 7 Track
Hitachi Construction Machinery Co., Ltd. SECTION 2 UPPERSTRUCTURE SECTION 4 FRONT ATTACHMENT
Tokyo, Japan Group 1 Cab Group 1 Front Attachment
All rights reserved Group 2 Counterweight Group 2 Cylinder
Group 3 Main Frame SECTION 5 ENGINE
Group 4 Pump Device
Group 5 Control Valve
Group 6 Swing Device
Group 7 Pilot Valve
Group 8 Pilot Shut-Off Valve
Group 9 Signal Control Valve
Group 10 Solenoid Valve
←これ以下
記載しない
SECTION 1
GENERAL
―CONTENTS―
Group 1 Specifications
Specifications............................................ T1-1-1
Working Ranges ..................................... T1-1-14
178T-1-1
(Blank)
178T-1-2
GENERAL / Specifications
SPECIFICATIONS
ZAXIS200, ZAXIS200LC, ZAXIS210H, ZAXIS210LCH
A C
E
D
K J
I H
M178-12-001
T1-1-1
GENERAL / Specifications
E
D
K J
I H
M178-12-001
T1-1-2
GENERAL / Specifications
ZAXIS225USR, ZAXIS225USRLC
A,G C
B
F
E
D
K J
I
H
M178-12-007
T1-1-3
GENERAL / Specifications
ZAXIS225US, ZAXIS225USLC
A C
B
F
E
D
K J
I H
M1GF-12-001
T1-1-4
GENERAL / Specifications
ZAXIS240
A C
E
D
K J
I H
M178-12-001
Model ZAXIS240
Type of Front-End Attachment 2.91 m (9 ft 7 in) Arm
3 3 3
Bucket Capacity (Heaped) PCSA 0.8 m (1.05 yd ), CECE 0.7 m
Operating Weight 22400 kg (49400 lb)
Basic Machine Weight 17900 kg (39500 lb)
–1
Isuzu AA-6BG1T 103 kW/1900 min (140 PS/1900 rpm)
Engine –1
110 kW / 2100 min (150 PS /2100 rpm)
A: Overall Width (Excluding back mirrors) 2500 mm (8 ft 2 in)
B: Cab Height 2950 mm (9 ft 8 in)
C: Rear End Swing Radius 2750 mm (9 ft 0 in)
D: Minimum Ground Clearance * 450 mm (18 in)
E: Counterweight Clearance * 1030 mm (3 ft 5 in)
F: Engine Cover Height * 2220 mm (7 ft 3 in)
G: Overall Width of Upperstructure 2500 mm (8 ft 2 in)
H: Undercarriage Length 4260 mm (13 ft 12 in)
I: Undercarriage Width 2480 mm (8 ft 2 in)
J: Sprocket Center to Idler Center 3460 mm (11 ft 4 in)
K: Track Shoe Width 550 mm (22 in) (Grouser shoe)
53 kPa
Ground Pressure 2
(0.54 kgf/cm , 7.7 psi)
–1
Swing Speed 13.3 min (rpm)
Travel Speed (fast/slow) 5.5/3.6 km/h (3.4/2.2 mph)
Gradeability 35° (tanθ = 0.70)
T1-1-5
GENERAL / Specifications
E
D
K J
I H
M178-12-001
T1-1-6
GENERAL / Specifications
E
D
K J
I H
M178-12-001
T1-1-7
GENERAL / Specifications
ZAXIS270, ZAXIS270LC
A C
B
F
E
D
K J
I H
M178-12-001
T1-1-8
GENERAL / Specifications
ZAXIS280LC, 280LCN
A C
E
D
K J
I
H
M178-12-001
T1-1-9
GENERAL / Specifications
E
D
K J
I H
M178-12-001
ZAXIS210LC 2-piece
Model ZAXIS210 2-piece Boom ZAXIS210N 2-piece Boom
Boom
Type of Front-End Attachment 2.03 m (6 ft 8 in) Arm
3 3 3
Bucket Capacity (Heaped) PCSA 0.8 m (1.05 yd ), CECE 0.7 m
Operating Weight 20100 kg (44300 lb) 20600 kg (45400 lb) 20000 kg (44100 lb) 20300 kg (44800 lb)
Basic Machine Weight 15200 kg (33500 lb) 15700 kg (34600 lb) 15100 kg (33300 lb) 15400 kg (34000 lb)
–1
Isuzu AA-6BG1T 103 kW/1900 min (140 PS/1900 rpm)
Engine –1
110 kW / 2100 min (150 PS /2100 rpm)
A: Overall Width
2860 mm (9 ft 5 in) 2990 mm (9 ft 10 in) 2500 mm (8 ft 2 in) 2580 mm (8 ft 6 in)
(Excluding back mirrors)
B: Cab Height 2950 mm (9 ft 8 in)
C: Rear End Swing Radius 2750 mm (9 ft 0 in)
D: Minimum Ground Clearance * 450 mm (18 in)
E: Counterweight Clearance * 1030 mm (3 ft 5 in)
F: Engine Cover Height * 2220 mm (7 ft 3 in)
G: Overall Width of Upperstructure 2710 mm (8 ft 11 in) 2500 mm (8 ft 2 in)
H: Undercarriage Length 4170 mm (13 ft 8 in) 4460 mm (14 ft 8 in) 4170 mm (13 ft 8 in)
I: Undercarriage Width 2800 mm (9 ft 2 in) 2990 mm (9 ft 10 in) 2480 mm (8 ft 2 in) 2580 mm (8 ft 6 in)
J: Sprocket Center to Idler Center 3370 mm (11 ft 1 in) 3660 mm (12 ft 0 in) 3370 mm (11 ft 1 in)
500 mm (20 in) 600 mm (24 in)
K: Track Shoe Width 600 mm (24 in) (Grouser shoe)
(Grouser shoe) (Grouser shoe)
45 kPa 43 kPa 54 kPa 45 kPa
Ground Pressure 2 2
(0.44 kgf/cm , 6.3 psi) (0.55 kgf/cm , 7.8 psi) (0.46 kgf/cm , 6.5 psi)
2 2
(0.46 kgf/cm , 6.5 psi)
–1
Swing Speed 13.3 min (rpm)
Travel Speed (fast/slow) 5.5/3.6 km/h (3.4/2.2 mph)
Gradeability 35° (tanθ = 0.70)
T1-1-10
GENERAL / Specifications
E
D
K J
I H
M178-12-001
T1-1-11
GENERAL / Specifications
E
D
K J
I H
M178-12-001
T1-1-12
GENERAL / Specifications
E
D
K J
I
H
M178-12-001
T1-1-13
GENERAL / Specifications
WORKING RANGES
ZAXIS200, ZAXIS200LC, ZAXIS210H, ZAXIS210LCH
G G
C C
D
D
E E
F F
A A
B B
A: Maximum Digging Reach 9250 30’4” 9390 30’10” 9910 32’6” 10060 33’0” 9910 32’6” 10060 33’0”
B: Maximum Digging Depth *5980 *19’7” *6120 *20’0” *6670 *21’11” *6820 *22’5” *6670 *21’11” *6820 *22’5”
C: Maximum Cutting Height *9170 *30’1” *9450 *31’0” *9600 *31’6” *9850 *32’4” *9600 *31’6” *9850 *32’4”
D: Maximum Dumping Height *6390 *21’0” *6290 *20’8” *6780 *22’3” *6720 *22’1” *6780 *22’3” *6720 *22’1”
E: Transport Height 3130 10’3” 3130 10’3” 2970 9’9” 2970 9’9” 2970 9’9” 2970 9’9”
F: Overall Transport Length 9620 31’7” 9620 31’7” 9500 31’2” 9500 31’2” 9500 31’2” 9500 31’2”
G: Minimum Swing Radius 3530 11’7” 3530 11’7” 3540 11’7” 3540 11’7” 3540 11’7” 3540 11’7”
NOTE: * The dimensions do not include the height of the shoe lug.
T1-1-14
GENERAL / Specifications
E E
A
B
Backhoe M178-12-002
2.03 m (6 ft 8 in) Arm 2.42 m (7 ft 11in) Arm 2.91 m (9 ft 7 in) Arm 3.51 m (11 ft 6 in) Arm
Category
Backhoe Backhoe Backhoe Backhoe
Item
mm ftxin mm ftxin mm ftxin mm ftxin
A: Maximum Digging Reach 9215 30’3” 9415 30’11” 9910 32’6” 10445 34’3”
B: Maximum Digging Depth *5790 *18’12” *6175 *20’3” *6670 *21’11” *7265 *23’10”
C: Maximum Cutting Height *9475 *31’1” *9245 *30’4” *9600 *31’6” *9855 *32’4”
D: Maximum Dumping Height *6610 *21’8” *6460 *21’2” *6780 *22’3” *7035 *23’1”
E: Transport Height 3120 10’3” 3150 10’4” 2970 9’9” 3110 10’2”
F: Overall Transport Length 9620 31’7” 9610 31’6” 9500 31’2” 9560 31’4”
G: Minimum Swing Radius 3605 11’10” 3525 11’7” 3540 11’7” 3555 11’8”
NOTE: * The dimensions do not include the height of the shoe lug.
T1-1-15
GENERAL / Specifications
ZAXIS225USR, ZAXIS225USRLC
G G
C C
D D
E E
F F
A A
B B
M178-12-009
A: Maximum Digging Reach 9250 30′ 4″ 9390 30′ 10″ 9910 32′ 6″ 10060 33′ 0″
B: Maximum Digging Depth *5980 *19′ 7″ *6120 *20′ 1″ *6670 *21′ 11″ *6820 *22′ 5″
C: Maximum Cutting Height *9170 *30′ 1″ *9450 *31′ 0″ *9600 *31′ 6″ *9850 *32′ 4″
D: Maximum Dumping Height *6390 *21′ 0″ *6290 *20′ 8″ *6780 *22′ 3″ *6720 *22′ 1″
G: Minimum Swing Radius 3530 11′ 7″ 3530 11′ 7″ 3540 11′ 7″ 3540 11′ 7″
NOTE: * The dimensions do not include the height of the shoe lug.
T1-1-16
GENERAL / Specifications
ZAXIS225US, ZAXIS225USLC
G G
C
C
D D
E E
F F
A A
B B
*NOTE: *The dimensions do not include the height of the shoe lug.
T1-1-17
GENERAL / Specifications
G G
C C
D
D
E E
F F
A A
B B
NOTE: * The dimensions do not include the height of the shoe lug.
NOTE: * The dimensions do not include the height of the shoe lug.
T1-1-18
GENERAL / Specifications
A
B
Backhoe M178-12-002
NOTE: * The dimensions do not include the height of the shoe lug.
T1-1-19
GENERAL / Specifications
ZAXIS270, ZAXIS270LC
G G
C C
D D
E E
F F
A A
B B
A: Maximum Digging Reach 10060 33′ 0″ 10240 33′ 7″ 10710 35′ 2″ 10880 35′ 8″
B: Maximum Digging Depth *6540 *21′ 5″ *6720 *22′ 1″ *7230 *23′ 9″ *7410 *24′ 4″
C: Maximum Cutting Height *9640 *31′ 8″ *10050 *33′ 0″ *9980 *32′ 9″ *10360 *34′ 0″
D: Maximum Dumping Height *6750 *22′ 2″ *6670 *21′ 11″ *7070 *23′ 2″ *6990 *22′ 11″
E: Transport Height 3420 11′ 3″ 3420 11′ 3″ 3170 10′ 5″ 3170 10′ 5″
F: Overall Transport Length 10370 34′ 0″ 10370 34′ 0″ 10290 33′ 9″ 10290 33′ 9″
G: Minimum Swing Radius 4310 14′ 2″ 4310 14′ 2″ 4140 13′ 7″ 4140 13′ 7″
NOTE: * The dimensions do not include the height of the shoe lug.
T1-1-20
GENERAL / Specifications
ZAXIS280LC, 280LCN
E E
A
B
Backhoe M178-12-002
NOTE: * The dimensions do not include the height of the shoe lug.
T1-1-21
GENERAL / Specifications
F
A
Backhoe
M1G6-13-012
A: Maximum Digging Reach 9185 30’2” 9405 30’10” 9900 32’6” 10445 34’3”
B: Maximum Digging Depth *5480 *17’12” *5785 *18’12” *6290 *20’8” *6875 *22’7”
C: Maximum Cutting Height *10475 *34’4” *10515 *34’6” *10955 *35’11” *11375 *37’4”
D: Maximum Dumping Height *7570 *24’10” *7600 *24’11” *8040 *26’5” *8465 *27’9”
E: Transport Height 3010 9’11” 3060 10’1” 2950 9’8” 3110 10’2”
F: Overall Transport Length 9750 31’12” 9540 31’4” 9500 31’2” 9490 31’2”
G: Minimum Swing Radius 2640 8’8” 2635 8’8” 2280 7’6” 2325 7’8”
NOTE: * The dimensions do not include the height of the shoe lug.
T1-1-22
GENERAL / Specifications
A
B
M1G6-13-012
Backhoe
NOTE: * The dimensions do not include the height of the shoe lug.
T1-1-23
GENERAL / Specifications
A
B
M1G6-13-012
Backhoe
NOTE: * The dimensions do not include the height of the shoe lug.
T1-1-24
GENERAL / Component Layout
MAIN COMPONENT LAYOUT
ZAXIS200 class, 230 class, 270 class
1
3
4
5
6
7
8
9
21
10
11
12
20 13
14
15
19 16
18
17 T178-01-02-001
T1-2-1
GENERAL / Component Layout
ZAXIS225US
3
4
5
6
7
8
9
21
18
20
19
10
18
11
17
16 12
13
15 14 T1GF-01-02-001
1 - Bucket Cylinder 7 - Hydraulic Oil Tank 13 - Oil Cooler 19 - Pilot Shut-Off Valve
2 - Arm Cylinder 8 - Swing Device 14 - Intercooler 20 - Travel Pilot Valve
3 - Boom Cylinder 9 - Pump Device 15 - Battery 21 - Boom Electronic Cushion
Solenoid Valve*
4 - Signal Control Valve 10 - Pilot Filter and Pilot Relief 16 - Fuel Tank
Valve
5 - Control Valve 11 - Engine 17 - Center Joint
6 - Solenoid Valve Unit 12 - Radiator 18 - Front Attachment/Swing
Pilot Valve
T1-2-2
GENERAL / Component Layout
ZAXIS225USR
1
2
3
4
5
6
7
8
20
9
10
11
19
18 12
17 13
14 T1GD-01-02-001
16
15
1 - Bucket Cylinder 6 - Solenoid Valve Unit 11 - Pilot Filter and Pilot Relief 16 - Battery
Valve
2- Arm Cylinder 7- Fuel Tank 12 - Engine 17 - Center Joint
3- Boom Cylinder 8- Hydraulic Oil Tank 13 - Radiator 18 - Pilot Shut-Off Valve
4- Signal Control Valve 9- Swing Device 14 - Oil Cooler 19 - Travel Pilot Valve
5- Control Valve 10 - Pump Device 15 - Inter Cooler 20 - Front Attachment/Swing
Pilot Valve
T1-2-3
GENERAL / Component Layout
ELECTRICAL COMPONENT LAYOUT
(Overview)
18
17
16
15
14
10
13
T1-2-4
GENERAL / Component Layout
ZAXIS225US
• Pump 1 and 2 Delivery Pressure Sensor
• Pump 1 and 2 Control Pressure Sensor
• N Sensor 1 2 3 4 5 6
• Torque Control Solenoid Valve
• Pump 2 Flow Rate Control Solenoid Valve
Refer to the Pump Device group.
9
10
11
12
19
18
17
16
15
13 T1GF-01-02-002
14
• Pressure Sensor (Boom Raise) • Pressure Sensor (Travel) • Pressure Sensor (Front Attachment)
• Pressure Sensor (Arm Roll-In) • Pressure Sensor (Swing) Refer to the Swing Device group.
Refer to the Control Valve group. Refer to the Signal Control
Valve group.
1 - Overheat Switch 6 - Air Cleaner Restriction 11 - Wiper Motor 16 - Hydraulic Oil Temperature
Switch sensor
2 - Coolant Temperature 7 - Fuel Sensor 12 - Boom Angle Sensor 17 - Engine Oil Level Switch*
Sensor
3 - Battery Relay 8 - Coolant Level Switch* 13 - Horn 18 - EC Motor and EC Sensor
4 - Glow Relay 9 - Starter Relay 14 - Boom Electronic Cushion
Solenoid Valve
5 - Fusible Link 10 - Battery 15 - Solenoid Valve Unit
T1-2-5
GENERAL / Component Layout
ZAXIS225USR
• Pump 1 and 2 Delivery Pressure Sensor
• Pump 1 and 2 Control Pressure Sensor
• N Sensor 1 2 3 4 5
• Torque Control Solenoid Valve
• Pump 2 Flow Rate Control Solenoid Valve
Refer to the Pump Device group.
6
17
8
9
10
16
15
14
13
12
T1GD-01-02-002
11
• Pressure Sensor (Boom Raise) • Pressure Sensor (Travel) • Pressure Sensor (Front Attachment)
• Pressure Sensor (Arm Roll-In) • Pressure Sensor (Swing) Refer to the Swing Device group.
Refer to the Control Valve group. Refer to the Signal Control
Valve group.
T1-2-6
GENERAL / Component Layout
ELECTRICAL SYSTEM (Relays and Related Equipment)
Except ZAXIS225US
5
4
3 6
2
Rear Deck
7
8
9
10
T178-01-02-006
15
14
18 13
17 12
16 11
T178-01-02-007
1 - Satellite Terminal ON/OFF 6- Fuse Box 11 - Load Damp Relay (R1) 16 - Wiper Relay A (R6)
Switch (Satellite Navigation
System Equipped Machines
only)
2 - QOS Controller 7- Learning Switch 12 - Washer Relay (R2) 17 - Wiper Relay B (R7)
3 - ICX (Information Controller) 8- Dr. ZX Connector to MC 13 - Work Light Relay 2 (R3) 18 - Wiper Relay C (R8)
4 - MC (Main Controller) 9- Download Connector 14 - Work Light Relay 1 (R4)
(Not connected in Satellite
Terminal equipped machines)
5 - Satellite Terminal (Optional) 10 - Dr. ZX Connector to ICX 15 - Horn Relay (R5)
T1-2-7
GENERAL / Component Layout
ZAXIS225US
15
4
16
14
17
13
12
11 5
10
T1GF-01-02-003
1, 2 3
6
9 8 7
T1SM-01-02-006
1 - ICX (Information Controller) 6 - Fuse Box 11 - Work Light Relay 1 (R4) 16 - Wiper Relay B (R7)
2 - MC (Main Controller) 7 - Dr. ZX Connector to MC 12 - Work Light Relay 2 (R3) 17 - Wiper Relay C (R8)
3 - Satellite Terminal 8 - Dr. ZX Connector to ICX 13 - Washer Relay (R2)
(Optional)
4 - Download Connector 9 - * Learning Switch 14 - Load Dump Relay (R1)
5 - Diode D1, D2, D3, D4 10 - Horn Relay (R5) 15 - Wiper Relay A (R6)
T1-2-8
GENERAL / Component Layout
ELECTRICAL SYSTEM (Monitors and
Switches)
1 2
20
19
21
18
3
17
22
16 4
15
23
5
14 24
6
13 7
12 8
25
11
9
10
T178-01-02-008
T178-01-01-004
1- Coolant Temperature Gauge 8- Alternator Indicator 15- Digging Mode Indicator 22- Power Mode Switch
2- Fuel Gauge 9- Hydraulic Oil Filter Indicator 16- Attachment Mode Indicator 23- Travel Mode Switch
(Optional)
3- Display Selection Switch 10- Coolant Level Indicator * 17- Liquid Crystal Display 24- Work Light Switch
4- SET Switch 11- Engine Oil Level Indicator * 18- Auto-Idle Indicator 25- Wiper/Washer Switch
5- Work Mode Switch 12- Engine Oil Pressure 19- Auto-Acceleration Indicator
Indicator
6- Fuel Level Indicator 13- Preheat Indicator 20- Engine Control Dial
7- Air Filter Restriction Switch 14- Overheat Indicator 21- Auto-Idle/Acceleration
Selector
T1-2-9
GENERAL / Component Layout
PUMP DEVICE
9
3 2 1
6
7
8
10
T178-03-01-001
5 4 T178-03-01-003
SWING DEVICE
ZAXIS200class, 225 class, 230 class ZAXIS270 class 11
11
12
12
T178-03-02-001 T1HG-03-02-003
T1-2-10
GENERAL / Component Layout
CONTROL VALVE SOLENOID VALVE UNIT
T178-03-07-005
7 8 9
3
T178-01-02-011
7 6 8 9 T178-01-02-003
T178-03-06-015
1 - Main Relief Valve 4 - Pressure Sensor (Swing) 7 - Solenoid Valve Unit (SC) 10 - Solenoid Valve Unit (SG)
2 - Pressure Sensor 5 - Pressure Sensor (Travel) 8 - Solenoid Valve Unit (SI)
(Arm Roll-in)
3 - Pressure Sensor 6 - Solenoid Valve Unit (SE)*
(Boom Raise)
T1-2-11
GENERAL / Component Layout
TRAVEL DEVICE
ZAXIS200 class, 225 class and 230 class
1
T1HD-01-02-001
ZAXIS270 class (Up to serial No. 20226) ZAXIS270 class (Serial No. 20227 and up)
2
1
1 1
T178-01-02-014
T1HG-01-02-002
2
T1-2-12
GENERAL / Component Layout
POSITIONING CONTROL VALVE
(2-piece Boom Only)
ZAXIS200 class
T178-03-03-071
T178-03-03-068
T1-2-13
GENERAL / Component Layout
(Blank)
T1-2-14
GENERAL / Component Specifications
ENGINE
ZAXIS230 class:
Manufacturer........................... ISUZU
Model ................................. CC-6BG1TRA
Type .................................. Diesel, 4-Cycle, Water-cooled, Inline, Direct Injection
Cyl. No.- Bore × Stroke .................. 6-105 mm×125 mm (4.13 in×4.92 in)
Piston Displacement .................... 6494 cm3 (396 in3)
Rated Output .......................... 118 kW/2000 min-1 (160 PS/2000 rpm)
HP Mode: 125 kW / 2100 min-1 (170 PS / 2100 rpm)
Compression Ratio ..................... 18:1
Dry Weight............................. 490 kg (1080 lb)
Firing Order............................ 1-5-3-6-2-4
Rotation Direction....................... Clockwise (Viewed from fan side)
T1-3-1
GENERAL / Component Specifications
ZAXIS270 class:
Manufacturer........................ ISUZU
Model .............................. CC-6BG1TRA
Type ............................... Diesel, 4-Cycle, Water-cooled, Inline, Direct Injection
Cyl. No.- Bore × Stroke ............... 6-105 mm×125 mm (4.13 in×4.92 in)
Piston Displacement ................. 6494 cm3 (396 in3)
Rated Output ....................... 125 kW/2050 min-1 (170 PS/2050 rpm)
HP Mode: 132 kW / 2150 min-1 (180 PS / 2150 rpm)
Compression Ratio .................. 18:1
Dry Weight.......................... 490 kg (1080 lb)
Firing Order......................... 1-5-3-6-2-4
Rotation Direction.................... Clockwise (Viewed from fan side)
COOLING SYSTEM
ZAXIS200 class, ZAXIS225 class:
Cooling Fan ........................ Dia. 650 mm (25.6 in), 7 Blades (N-Type Blade, Unequal Pitch),
Draw-in Type
Fan Pulley Ratio ..................... Engine rpm × 0.80
Thermostat ......................... Cracking Temperature at Atmospheric Pressure: 82 °C (180 °F)
Full Open (Stroke: 10 mm or more) Temperature: 95 °C (203 °F)
Water Pump ........................ Centrifugal Belt Driven Type
T1-3-2
GENERAL / Component Specifications
LUBRICATION SYSTEM
Lubrication Pump Type .................. Gear Pump
Oil Filter ............................... Full-Flow Paper Element Type with Bypass
Oil Cooler ............................. Water Cooled Integral Type
STARTING SYSTEM
Motor ................................. Magnetic Pinion Shift Reduction Type
Voltage / Output ........................ 24 V / 4.5 kW
PREHEAT SYSTEM
Preheating Method...................... Glow Plug (QOS Type)
ALTERNATOR
Type .................................. Regulator Integrated AC Type
Voltage / Output ........................ 24 V / 50 A (Brushless)
SUPERCHARGING SYSTEM
Type .................................. Exhaust-Turbocharger Type RHG 6
FUEL SYSTEM
Type .................................. BOSCH Type (AD Concave Cam)
Governor .............................. Centrifugal All Speed Control RSV Type
Injection Nozzle ....................... Multi-Hole Type
T1-3-3
GENERAL / Component Specifications
PERFORMANCE
IMPORTANT: This list shows design specifications, which are not servicing standards.
ZAXIS200 class, ZAXIS225 class:
Fuel Consumption Ratio ................. Less than 237 g/kW/h (174 g/PS⋅h) at 110 kW / (at Full Load:
2100 min-1)
Less than 227 g/kW/h (166 g/PS⋅h) at 103 kW / (at Working
Load: 1900 min-1)
Injection Timing......................... 10 ° before T.D.C.
Maximum Output Torque................. More than 550±60 N⋅m (54±6 kgf⋅m) at approx. 1600 min-1
Injection Pressure ...................... 18.14 MPa (185 kgf/cm2)
Compression Pressure .................. 3.04 MPa (31 kgf/cm2)
Valve Clearance (Inlet / Exhaust) ......... 0.4 / 0.4 mm (when cool)
No Load Speed ........................ Slow: (at Full Load: 900±20 min-1)
Fast: (at Full Load: 2350+20-50 min-1)
(at Working Load: 2100±50 min-1)
ZAXIS230 class:
Fuel Consumption Ratio ................. Less than 237 g/kW/h (174 g/PS⋅h) at 125 kW / (at Full Load:
2100 min-1)
Less than 227 g/kW/h (166 g/PS⋅h) at 118 kW / (at Working
load: 2000 min-1)
Injection Timing......................... 10° before T.D.C.
Maximum Output Torque................. More than 637±60 N⋅m (65±6 kgf⋅m) at approx. 1800 min-1
Injection Pressure ...................... 18.14 MPa (185 kgf/cm2)
Compression Pressure .................. 3.04 MPa (31 kgf/cm2)
Valve Clearance (Inlet / Exhaust) ......... 0.4 / 0.4 mm (when cool)
No Load Speed ........................ Slow: (at Full Load: 900±20 min-1)
Fast: (at Full Load: 2420+20-50 min-1)
(at Working Load: 2300±50 min-1)
ZAXIS270 class:
Fuel Consumption Ratio ................. Less than 243 g/kW/h (179 g/PS⋅h) at 132 kW / (at Full
Load: 2150 min-1)
Less than 238 g/kW/h (175 g/PS⋅h) at 125 kW / (at Working
Load: 2050 min-1)
Injection Timing......................... 10 ° before T.D.C.
Maximum Output Torque................. More than 637±60 N⋅m (65±6 kgf⋅m) at approx. 1800 min-1
Injection Pressure ...................... 18.14 MPa (185 kgf/cm2)
Compression Pressure .................. 3.04 MPa (31 kgf/cm2)
Valve Clearance (Inlet / Exhaust) ......... 0.4 / 0.4 mm (when cool)
No Load Speed ........................ Slow: (at Full Load: 900±20 min-1)
Fast: (at Full Load: 2470+20-50 min-1)
(at Working Load: 2350±50 min-1)
T1-3-4
GENERAL / Component Specifications
ZAXIS200 class, ZAXIS225 class:
Engine Performance Curve (AA-6BG1TRA)
Test Condition: 1. In conformity with JIS D1005 (Performance Test Method for Diesel Engine Used for Construc-
tion Machinery) under standard atmospheric pressure.
2. Equipped with the fan and alternator.
Torque
Output
kw
N⋅m
Fuel Consumption
Ratio
g/kw⋅h
-1
Engine Speed min (rpm) T178-01-03-002
T1-3-5
GENERAL / Component Specifications
ZAXIS230 class:
Engine Performance Curve (CC-6BG1TRA)
Test Condition: 1. In conformity with JIS D1005 (Performance Test Method for Diesel Engine Used for Construc-
tion Machinery) under standard atmospheric pressure.
2. Equipped with the fan and alternator.
Torque
N⋅m
Output
kw
Fuel Consumption
Ratio
g/kw⋅h
T1HD-01-03-001
-1
Engine Speed min (rpm)
T1-3-6
GENERAL / Component Specifications
ZAXIS270 class:
Engine Performance Curve (CC-6BG1TRA)
Test Condition: 1. In conformity with JIS D1005 (Performance Test Method for Diesel Engine Used for Construc-
tion Machinery) under standard atmospheric pressure.
2. Equipped with the fan and alternator.
Torque
N⋅m
Output
kw
Fuel Consumption
Ratio
g/kw⋅h
-1
Engine Speed min (rpm) T1HG-01-03-001
T1-3-7
GENERAL / Component Specifications
ENGINE ACCESSORIES
RADIATOR ASSEMBLY
ZAXIS200 class, ZAXIS225USR:
Type .................................. Radiator/Oil Cooler Tandem Type Assembly
Weight ................................ 78 kg (172 lb)
Intercooler
Capacity............................... 7.9 L (1.7 US gal)
Air-Tight Test Pressure .................. 245 kPa (2.5 kgf/cm2, 36 psi)
Cap Opening Pressure .................. −
ZAXIS225US:
Type .................................. Radiator/Oil Cooler Tandem Type Assembly
Weight ................................ 79.5 kg (176 lb)
Intercooler
Capacity............................... 7.2 L (1.9 US gal)
Air-Tight Test Pressure .................. 245 kPa (2.5 kgf/cm2, 36 psi)
Cap Opening Pressure .................. −
T1-3-8
GENERAL / Component Specifications
Intercooler
Capacity............................... 7.9 L (1.7 US gal)
Air-Tight Test Pressure .................. 245 kPa (2.5 kgf/cm2, 36 psi)
Cap Opening Pressure .................. −
BATTERY
Capacity............................... 96 Ah (5-Hour Rate)
Voltage ................................ 12 V
Weight ................................ 27.2 kg (60 lb)×2
HYDRAULIC COMPONENT
PUMP DEVICE
Drive Gear Ratio........................ Main Pump: 1, Pilot Pump: 1
MAIN PUMP
ZAXIS200 class, ZAXIS225 class:
Model ................................. HPV102GW-RH23A
Type .................................. Bent-Axis Type Variable Displacement Axial Plunger Pump
Maximum Flow (Theoretical Value) ........ 193.8 L/min (51.1 US gpm)×2
ZAXIS230 class:
Model ................................. HPV102GW-RH25A
Type .................................. Bent-Axis Type Variable Displacement Axial Plunger Pump
Maximum Flow (Theoretical Value) ........ 204 L/min (54 US gpm)×2
ZAXIS270 class:
Model ................................. HPV102GW-RH26A
Type .................................. Bent-Axis Type Variable Displacement Axial Plunger Pump
Maximum Flow (Theoretical Value) ........ 209.1 L/min (55.24 US gpm)×2
REGULATOR
Type .................................. Hydraulic Pressure Operated Type
T1-3-9
GENERAL / Component Specifications
PILOT PUMP
ZAXIS200 class, ZAXIS225 class:
Model ................................. HY/ZFS 11/16.8
Type .................................. Fixed Displacement Type Gear Pump
Maximum Flow (Theoretical Value) ........ 31.9 L/min (8.4 US gpm)
HP Mode: 35.28 L/min (9.32 US gpm)
ZAXIS230 class:
Model ................................. HY/ZFS11/16.8
Type Fixed Displacement Type Gear Pump
Maximum Flow (Theoretical Value) ........ 33.6 L/min (8.88 US gpm)
HP Mode: 35.28 L/min (9.32 US gpm)
ZAXIS270 class:
Model ................................. HY/ZFS11/16.8
Type Fixed Displacement Type Gear Pump
Maximum Flow (Theoretical Value) ........ 34.44 L/min (9.10 US gpm)
HP Mode: 36.12 L/min (9.54 US gpm)
CONTROL VALVE
ZAXIS200 class, ZAXIS225 class:
Model ................................. KVMG-270-HE
Type .................................. Pilot Pressure Operated Type (4-Spools + 5-Spools)
Main Relief Set-Pressure ................ Normal: 34.3 MPa (350 kgf/cm2, 4980 psi) at
110 L/min (29.0 US gpm)
Power Digging: 36.3 MPa (370 kgf/cm2) at
110 L/min (29.0 US gpm)
Overload Relief Set-Pressure ............ 37.2 MPa (379 kgf/cm2, 5390 psi) at 50 L/min (13.2 US gpm)
(Boom, Arm Roll-In, Bucket Roll-In)
39.2 MPa (400 kgf/cm2, 5690 psi) at 50 L/min (13.2 US gpm)
(Arm Roll-Out, Bucket Roll-Out)
T1-3-10
GENERAL / Component Specifications
SWING DEVICE
ZAXIS200 class, ZAXIS225 class:
Type .................................. Two-Stage Reduction Planetary Gear
Reduction Gear Ratio ................... 13.385
ZAXIS230 class:
Type .................................. Two-Stage Reduction Planetary Gear
Reduction Gear Ratio ................... 21.75
ZAXIS270 class:
Type .................................. Two-Stage Reduction Planetary Gear
Reduction Gear Ratio ................... 17.022
SWING MOTOR
ZAXIS200 class, ZAXIS225 class:
Model ................................. M5X130C
Type .................................. Swash-Plate Type, Fixed Displacement Axial Plunger Motor
ZAXIS230 class:
Model ................................. M5X130CHB
Type .................................. Swash-Plate Type, Fixed Displacement Axial Plunger Motor
ZAXIS270 class:
Serial No. 020038 and up
Model ................................. M5X180
Type .................................. Swash-Plate Type, Fixed Displacement Axial Plunger Motor
Up to serial No. 020037
Model ................................. M2X210CHB
Type .................................. Swash-Plate Type, Fixed Displacement Axial Plunger Motor
T1-3-11
GENERAL / Component Specifications
VALVE UNIT
ZAXIS200 class, ZAXIS225 class:
Type .................................. Non Counterbalance Valve Type
Relief Set-Pressure ..................... 30.9 MPa (315 kgf/cm2, 4480 psi) at 140 L/min
ZAXIS230 class:
Type .................................. Non Counterbalance Valve Type
Relief Set-Pressure ..................... 29.4+1-0 MPa (300+10-0 kgf/cm2, 4270+142-0 psi) at 170 L/min
ZAXIS270 class:
Type .................................. Non Counterbalance Valve Type
Relief Set-Pressure ..................... 30.2+1.40 MPa (308+14 kgf/cm2, 4380+200 psi) at 140 L/min
(Serial No. 020038 and up)
27.7±0.3 MPa (282±3 kgf/cm2, 4010±43 psi) at 140 L/min
(Up to Serial No. 020037)
SWING PARKING BRAKE
ZAXIS200 class, ZAXIS225 class:
Type .................................. Multi-Disc-Wet Negative Type
Release Pressure ..................... 1.96 to 2.64 MPa (20 to 27 kgf/cm2, 284 to 384 psi)
ZAXIS230 class:
Type .................................. Multi-Disc-Wet Negative Type
Release Pressure ..................... 1.57 to 2.35 MPa (16 to 24 kgf/cm2, 228 to 341 psi)
ZAXIS270 class:
Type .................................. Multi-Disc-Wet Negative Type
Release Pressure ..................... 2.25 to 2.84 MPa (23 to 29 kgf/cm2, 327 to 412 psi)
TRAVEL DEVICE
ZAXIS200 class:
Type .................................. Three-Stage Reduction Planetary Gear
Reduction Gear Ratio ................... 53.289 (ZAXIS210N and ZAXIS 240: 53.234)
ZAXIS270 class:
Type .................................. Three-Stage Reduction Planetary Gear
Reduction Gear Ratio ................... 70.842
T1-3-12
GENERAL / Component Specifications
TRAVEL MOTOR
ZAXIS200 class, ZAXIS225 class, ZAXIS230 class:
Type .............................. Swash-Plate Type Variable Displacement Axial Plunger Motor
T1-3-13
GENERAL / Component Specifications
CYLINDER
ZAXIS200 class, ZAXIS225 class:
Boom Arm
Rod Diameter ...................... 85 mm (3.35”) 95 mm (3.74”)
Cylinder Bore ...................... 120 mm (4.72”) 135 mm (5.31”)
Stroke............................. 1220 mm (4’0”) 1475 mm (4’10”)
Fully Retracted Length .............. 1759 mm (5’9”) 2040 mm (6’8”)
Plating Thickness ................... 30 µm (1.18 µm) 30 µm (1.18 µm)
ZAXIS230 class:
Boom Arm
Rod Diameter ...................... 90 mm (3.54”) 105 mm (4.13”)
Cylinder Bore ...................... 125 mm (4.92”) 140 mm (5.51”)
Stroke............................. 1350±3 mm (4’51±0.1”) 1610±3 mm (5’3±0.1”)
Fully Retracted Length .............. 1950±2.2 mm (6’4±0.1”) 2235±2.2 mm (7’4±0.1”)
Plating Thickness ................... 30 µm (1.18 µm) 30 µm (1.18 µm)
ZAXIS270 class:
Boom Arm
Rod Diameter ...................... 95 mm (3.74”) 108 mm (4.25”)
Cylinder Bore ...................... 135 mm (5.32”) 145 mm (5.71”)
Stroke............................. 1340±3 mm (4’5±0.1”) 1555±3.2 mm (5’1±0.1”)
Fully Retracted Length .............. 1920±2 mm (6’4±0.1”) 2155±2.7 mm (7’1±0.1”)
Plating Thickness ................... 30 µm (1.18 µm) 30 µm (1.18 µm)
T1-3-14
GENERAL / Component Specifications
FRONT ATTACHMENT PILOT VALVE
Model ................................. HVP05P-040-101
T1-3-15
GENERAL / Component Specifications
ELECTRICAL COMPONENT
BATTERY RELAY
Voltage / Current ....................... 24 V / 100 A
GLOW RELAY
Voltage ................................ 24 V
HORN
Voltage / Current ....................... 24 V⋅1.5±0.5 A
Sound Pressure ........................ 113 dB (A)
ILLUMINATION
Specifications .......................... Work Light : Halogen 24V, 70 W / 60 W
Cab Light : ZAXIS200 class, ZAXIS225USR,
ZAXIS230 class, ZAXIS270 class
24 V, 12 W
ZAXIS225US,
24 V, 12 W
AIR CONDITIONER
ZAXIS200 class, ZAXIS225USR, ZAXIS230 class, ZAXIS270 class:
Refrigerant ........................... 134 a
Cooling Ability .......................... 19.3 MJ/h (4600 kcal/h)
Cool Air Volume ........................ 550 m3/h or More
Heating Ability .......................... 21.0 MJ/h (5000 kcal/h) or More
Warm Air Volume ....................... 500 m3/h or More
Temperature Adjusting System ........... Electronic Type
Refrigerant Quantity..................... 850±50 g
Compressor Oil Quantity................. 210 cm3
ZAXIS225US:
Refrigerant ........................... 134 a
Cooling Ability .......................... 16.0 MJ/h (3830 kcal/h)
Cool Air Volume ........................ 395 m3/h or More
Heating Ability .......................... 14.9 MJ/h (3570 kcal/h) or More
Warm Air Volume ....................... 365 m3/h or More
Temperature Adjusting System ........... Electronic Type
Refrigerant Quantity..................... 900±50 g
Compressor Oil Quantity................. 210 cm3
T1-3-16
MEMO
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SECTION 2
SYSTEM
—CONTENTS—
Group 1 Control System
Outline ...................................................... T2-1-1
Engine Control .......................................... T2-1-2
Pump Control .......................................... T2-1-23
Valve Control .......................................... T2-1-32
Other Controls ........................................ T2-1-46
178T-2-1
(Blank)
178T-2-2
SYSTEM / Control System
OUTLINE
The main controller (MC) is used to control machine After prcessing the received signals in the logic circuit,
operations. Electronic signals from the engine control the MC sends out control signals to the EC motor,
dial, various sensors and switches are sent to the MC. solenoid valve units, torque control solenoid valve,
and other control circuits to regulate the engine,
pumps, motors and valves.
∗
NOTE: Only on the machines equipped with the
corresponding optional parts
∗∗
Refer to T2-2-2
T2-1-1
SYSTEM / Control System
ENGINE CONTROL
The engine control system is grouped as follows:
∗
NOTE: Only on the machines with the corre-
sponding optional parts.
Travel
Front Attachment Pump 2 Pump 1
Swing Delivery Pres- Delivery Pres-
Boom Raise sure Sensor sure Sensor
Key Switch
Arm Roll-In
Auxiliary (Optional)
Engine Con- EC Sensor
trol Dial
Auto-Idle /
Acceleration
Selector
Auto-Idle
EC Motor
Auto-Acceleration
T2-1-2
SYSTEM / Control System
(Blank)
T2-1-3
SYSTEM / Control System
Engine Control Dial Control
Engine
Function: Controls the engine speed in response to Speed
the rotation angle of the engine control dial
and reduces the engine speed by 100
min-1 to reduce fuel consumption and Engine speed is
noise level when all control levers are in Control Range reduced by 100
-1
neutral. min when the
control levers are
in neutral.
Operation: The MC drives the governor lever in re-
sponse to the rotation angle of the engine
control dial to regulate the engine speed. Engine Con-
trol Dial Posi-
Slow Fast tion
NOTE: Even if the control dial is rotated to the full Idle Idle
speed position, the governor lever doesn’t
come in contact with the full speed stopper.
(Refer to the HP mode control.)
When all control levers are turned to neutral (the NOTE: The engine speed is reduced from the
travel and front attachment sensors are OFF), the MC maximum speed by 100 min-1. Therefore,
drives the EC motor so that the engine speed is re- when the engine speed set by the engine
duced from the maximum speed by 100 min-1. control dial is already slower than the
maximum speed by 100 min-1, the engine
speed remains unchanged. This engine
speed reduction control is activated re-
gardless of whether the auto-idle and/or
auto-acceleration control is activated or
not.
T2-1-4
SYSTEM / Control System
Pressure Sensor
Travel
Front Attachment
Engine Con-
trol Dial
EC Motor
T178-02-01-004
T2-1-5
SYSTEM / Control System
HP Mode Control
T2-1-6
SYSTEM / Control System
Pressure Sensor
Pump 2 Pump 1
Delivery Delivery
Pressure Pressure
Boom Raise Sensor Sensor
Arm Roll-In
Engine
Control Dial
EC Motor
HP Mode
T178-02-01-005
T2-1-7
SYSTEM / Control System
E Mode Control
Engine
Speed
Function: Reduce the engine speed by the constant
specified ratio.
Engine speed is
reduced at the
Operation: The MC drives the EC motor to reduce the constant speci-
engine speed set by the engine control dial fied ratio.
when the power mode switch is in the E
mode position. The engine speed is re-
duced in proportion to the rotation angle of
the engine control dial.
Engine Con-
trol Dial Posi-
tion
Slow Idle Fast Idle
Engine Con-
trol Dial
EC Motor
E Mode
T178-02-01-006
T2-1-8
SYSTEM / Control System
(Blank)
T2-1-9
SYSTEM / Control System
Auto-Idle Control
T2-1-10
SYSTEM / Control System
Pressure Sensor
Travel
Front Attachment
Engine
Control Dial
Auto-Idle
Auto-Idle/
Acceleration
Selector EC Motor
E Mode
T178-02-01-007
T2-1-11
SYSTEM / Control System
Auto Acceleration Control
Function: Automatically regulates the engine speed Engine Speed VS. Control Lever Operations:
to meet the machine operating conditions.
When all the control levers are in neutral,
the engine speed is reduced to reduce fuel Engine
Speed
consumption and noise level.
Engine speed is reduced
Fast Speed from the maximum speed
Operation: When a control lever is operated with the -1
by 400 min .
auto-idle / acceleration selector in auto Auto-
acceleration position, the MC calculates Acceleration
the most proper engine operating speed Speed
Engine speed is reduced
corresponding to the signals from pressure Auto-Idle to the auto-idle speed 3.5
sensors (travel, swing, boom raise, and Speed seconds later.
arm roll-in), the pump control pressure Slow Speed
sensors, and the pump delivery pressure
Engine Con-
sensors. Then, the MC drives the EC motor trol Dial Posi-
Slow Fast
so that the engine speed is set to the rota- Idle Idle
tion
tion speed calculated by the MC.
When all control levers are returned to
neutral, the engine speed is reduced by
400 min-1 from the maximum speed first.
Then, 3.5 seconds later, the engine speed Operating Time Progress VS. Engine Speed Change
is further reduced to the auto-idle speed. Control Lever Stroke
Time
T2-1-12
SYSTEM / Control System
Pressure Sensor
Travel
Pump 2 Pump 1
Delivery Delivery
Swing
Pressure Pressure
Engine Boom Raise Sensor Sensor
Control Dial Arm Roll-In
Auto-Idle/
Acceleration EC Motor
Selector
Auto-
Acceleration
Pump 2 Pump 1
Control Control
Pressure Pressure
Sensor Sensor
T178-02-01-008
T2-1-13
SYSTEM / Control System
Auto Warming Up Control
Fast
Operation: When the hydraulic oil temperature is be- Speed
low 0 °C (32 °F), the MC drives the EC
motor in response to signals from the key
switch and the hydraulic oil temperature Auto
sensor to run the engine at the auto warm Warm Up Increasing
Speed Speed
up speed for 15 minutes after starting the
engine. Slow
Speed Engine
Control Dial
IMPORTANT: When adjusting the auto-idle speed Slow Idle Fast Idle Position
deactivate the auto warming up
control function using Dr. ZX, or
wait to adjust until 15 minutes after
starting the engine.
Key Switch
Engine
Control Dial
EC Motor
Hydraulic Oil
Temperature
Sensor
T178-02-01-009
T2-1-14
SYSTEM / Control System
Idle Speed-Up Control
Engine
Function: Prevents the engine from hunting when Speed
running the engine at slow speed.
Pressure Sensor
Travel
Front Attachment
Engine
Control Dial
EC Motor
T178-02-01-010
T2-1-15
SYSTEM / Control System
Engine Speed Automatic Increase Control at
Travel (ZAXIS270 class only)
Pressure Sensor
Travel
Front At-
tachment
Engine
Control Dial
EC Motor
T1HG-02-01-001
T2-1-16
SYSTEM / Control System
(Blank)
T2-1-17
SYSTEM / Control System
Attachment Operation Speed Increase Control
(Only on the machines equipped with the auxil-
iary mode switch (Optional).)
Function: Increases the maximum engine speed to Engine When all condi-
tions exist, the
the attachment (hydraulic breaker, secon- Speed
maximum en-
dary crusher, primary crusher or vibrating gine speed is
hammer) operating engine speed set by Dr. increased to the
speed set by Dr.
ZX when the attachment is operated. ZX.
T2-1-18
SYSTEM / Control System
Pressure Sensor
Auxiliary (Optional)
Engine
Control Dial
EC Motor
HP Mode
Work Mode
Switch
Auxiliary Mode
Attachment Switch
Mode (Optional)
T178-02-01-011
T2-1-19
SYSTEM / Control System
Attachment Operation Speed Limit Control (Only
on the machines equipped with the auxiliary
mode switch (Optional).)
Engine
Function: Decreases the maximum engine speed to Speed
the attachment (hydraulic breaker, secon-
dary crusher, primary crusher or vibrating When all condi-
tions exist, the
hammer) operating engine speed set by Dr. maximum en-
ZX when the attachment mode is selected. gine speed is
reduced to the
speed set by Dr.
Operation: When the following conditions exists, the ZX.
MC drives the EC motor so that the engine
maximum speed is reduced to the attach-
ment operating speed set by Dr. ZX when
the attachment mode is selected.
Slow Idle Fast Idle
Operating Conditions:
Dr. ZX: Resets the maximum engine speed to a
slower (−) attachment (hydraulic breaker, secondary
crusher, primary crusher, or vibrator) operating speed
in the service mode.
T2-1-20
SYSTEM / Control System
EC Motor
Work Mode
Switch
Auxiliary Mode
Attachment Switch
Mode (Optional)
T178-02-01-012
T2-1-21
SYSTEM / Control System
Engine Learning Control
Function: Inputs the governor lever stopper positions IMPORTANT: Be sure to perform the engine
on both the STOP and FULL sides as the learning if the following repair work
standard data to control the engine. is done. (Refer to the Troubleshoot-
ing Section in T/M.) After performing
Operation: When the learning switch in the rear con- the engine learning, check that the
sole is turned to the engine learning posi- engine learning has been performed
tion, the EC motor is driven by the signals correctly using Dr. ZX.
from the MC. The EC motor moves the After the engine, engine control ca-
governor lever from the IDLE to FULL and ble, or EC motor has been removed
to STOP positions in this order. The EC or replaced.
sensor detects the stopper positions of the After the MC has been replaced.
governor lever on both the FULL and
STOP sides and sends each stopper posi- NOTE: The engine learning is not required when
tion signal to the MC. The MC stores these the batteries are replaced.
signals in its memory.
Learning Switch
Key Switch
EC Sensor
EC Motor
T178-02-01-014
T2-1-22
SYSTEM / Control System
PUMP CONTROL
Pressure Sensor
Travel
Pump 3
Pump 2 Pump 1 Delivery
Delivery Delivery Pressure
Pressure Pressure Sensor
N Sensor Sensor Sensor (Optional)
Auxiliary
Engine (Optional)
Control Dial
Torque Control
Solenoid Valve
T2-1-23
SYSTEM / Control System
Speed Sensing Control
T2-1-24
SYSTEM / Control System
N Sensor
Engine
Control Dial
Torque Control
Solenoid Valve
T178-02-01-015
T2-1-25
SYSTEM / Control System
Slow Speed Torque Increase Control
Q
Function: Allows the machine to travel at the maxi- Flow Rate B
mum pump flow rate when the engine is
running at slow speed. When travel opera- Increased Torque
P-Q Curve
tion is made with the engine running at slow A
speed, normally, the hydraulic pump delivers
pressure oil at the flow rate corresponding to
point A on the P-Q curve illustrated to the
right. Therefore, if any difference exists be-
tween pump 1 and pump 2 flow rate, the
machine will mistrack. To prevent mistrack-
Normal P-Q Curve
ing, the pump P-Q curve is raised so that,
when traveling the machine with the engine
running at slow speed, the pump delivers
pressure oil at the flow rate corresponding to
Pressure P
point B (maximum flow rate).
Operation:
1. When the engine speed set by the engine control
dial is slow, the MC processes signals from the
travel pressure sensor, and pump 1 and 2 deliv-
ery pressure sensors and sends control signals
to the torque control solenoid valve.
2. The torque control solenoid valve delivers the pi-
lot pressure oil corresponding to the signals re-
ceived from the MC to the regulator, increasing
the pump flow rate.
T2-1-26
SYSTEM / Control System
Pressure Sensor
Travel Pump 2 Pump 1
Delivery Pres-Delivery Pres-
sure Sensor sure Sensor
Engine
Control Dial
T178-02-01-016
T2-1-27
SYSTEM / Control System
Pump 1 Flow Rate Limit Control (Only on the Pump 2 Flow Rate Limit Control (Only on the
machines with the auxiliary sensor (Optional).) machines with the auxiliary sensor (Optional).)
Function: Limits the maximum pump 1 flow rate when Function: Limits the maximum pump 2 flow rate when
a front attachment (mainly a vibrating ham- a front attachment (mainly a hydraulic
mer) is used. breaker) is used.
Operation: Operation:
1. When a front attachment is used, the MC re- 1. When a front attachment is used, the MC re-
ceives signals from the pressure sensor (auxil- ceives signals from the pressure sensor (auxil-
iary). iary).
2. In response to the signals arriving from the pres- 2. In response to the signals arriving from the pres-
sure sensor, the MC drives the maximum pump 1 sure sensor, the MC drives the maximum pump 2
flow rate limit solenoid valve (optional) to reduce flow rate limit solenoid valve to reduce the maxi-
the maximum pump flow rate. mum pump flow rate.
NOTE: In proportion to the attachment control NOTE: In proportion to the attachment control
pedal stroke, the maximum pump flow pedal stroke, the maximum pump flow
rated is reduced. The minimum pump rated is reduced. The minimum pump
swash set-angle for a front attachment swash set-angle for a front attachment
(hydraulic breaker, secondary crusher, (hydraulic breaker, secondary crusher,
primary crusher or vibrating hammer) can primary crusher or vibrating hammer) can
be set in the service mode of Dr. ZX. be set in the service mode of Dr. ZX.
Flow Rate
Q
Maximum flow rate is reduced.
Pressure
T2-1-28
SYSTEM / Control System
Pressure Sensor
Auxiliary (Optional)
T178-02-01-017
T2-1-29
SYSTEM / Control System
Pump 3 Torque Decrease Control (Only on the
machines equipped with pump 3 (Optional).) Q
Function: Reduces pump 1 and pump 2 driving Flow Rate P-Q curve is controlled in
proportion to pump 3 delivery
torque to prevent the engine from stalling, pressure.
utilizing the engine output efficiently when
the pump 3 driving torque increases.
Normal P-Q Curve
Operation: When the MC receives signals from pump
3 delivery pressure sensor (optional), the
MC drives the torque control solenoid
valve so that pump 1 and pump 2 flow
rates are reduced. Thereby, the total pump
1, 2, and 3 driving torque is maintained not
to exceed the engine output, utilizing the
engine output efficiently.
Pressure P
Pump 3
Delivery Pres-
sure Sensor
(Optional)
Torque Control
Solenoid Valve
T178-02-01-018
T2-1-30
SYSTEM / Control System
(Blank)
T2-1-31
SYSTEM / Control System
VALVE CONTROL
The valve control system functions as follows:
T2-1-32
SYSTEM / Control System
Valve Control System Layout
Pressure Sensor
Learning
Switch
Pump 2 Pump 1
Swing Delivery Delivery
Pressure Pressure
Boom Raise
Sensor Sensor
Key Switch Arm Roll-In
Auxiliary (Optional)
Engine Con-
trol Dial
Power Dig-
ging Switch
Hydraulic Oil Tem-
perature Sensor
Fast
Travel Motor
T2-1-33
SYSTEM / Control System
Power Digging Control
T2-1-34
SYSTEM / Control System
Power
Digging
Switch
SG
T178-02-01-019
T2-1-35
SYSTEM / Control System
Auto-Power Lift Control
Operating Conditions:
Boom Raise Pressure Sensor: Outputting signals.
(The boom must be raised to a certain extent.)
Pump 1 delivery Pressure Sensor: High pressure.
Arm Roll-In Pressure Sensor: Output zero. (The con-
trol lever is in neutral.)
T2-1-36
SYSTEM / Control System
Pressure Sensor
Pump 1 Delivery
Boom Raise Pressure Sensor
Arm Roll-In
T178-02-01-020
T2-1-37
SYSTEM / Control System
Arm Flow Rate Control
Up to serial No.104678 and up (ZAXIS200 and 225
class)
Up to serial No.010326 and up (ZAXIS230 class)
Up to serial No.020042 and up (ZAXIS270 class)
Operating Conditions:
Pump 2 Delivery Pressure Sensor: High pressure.
Swing Pressure Sensor: Must have some output. (The
swing control lever is stroked to a certain extent.)
Arm Pressure Sensor: Outputting signals.
T2-1-38
SYSTEM / Control System
Pressure Sensor
Pump 2
Swing Delivery
Pressure
Sensor
Arm Roll-In
SE
T178-02-01-021
Arm Flow Rate Control Valve
T2-1-39
SYSTEM / Control System
Arm Regenerative Control
Operating Conditions:
Machines manufactured up to Mar. 2003:
Pump 1 and 2 delivery pressure sensors:
Either pump 1 or 2 delivery pressure is low. (The arm
does not need much power to operate.)
Arm Roll-In Pressure Sensor: High output. (The arm
control lever stroke is large.)
Swing or Boom Raise Pressure Sensor: Outputting
signal.
T2-1-40
SYSTEM / Control System
Pressure Sensor
*Pump 2 Pump 1
Swing Delivery Delivery
Boom Raise Pressure Pressure
Sensor Sensor
Arm Roll-In
Hydraulic Oil
Temperature Sensor
SC
T2-1-41
SYSTEM / Control System
Travel Motor Swash Angle Control
NOTE: When one side track is raise off the ground NOTE: When one side track is raise off the ground
using the front attachment and is rotated, using the front attachment and is rotated,
the one side pump control pressure in- the one side pump displacement target
creases, allowing the raised track to rotate angle remains small so that the travel mo-
at fast speed. tor speed does not increase.
When the machine is traveling in the fast
mode, even if the front attachment is oper-
ated (the front attachment pressure sensor
is turned ON), the travel mode is kept un-
changed in the fast mode.
T2-1-42
SYSTEM / Control System
Pressure Sensor
Travel
Pump 2 Pump 1
Delivery Delivery
Pressure Pressure
Sensor Sensor
Fast
Mode
Pump 2 Control Pres-
sure Sensor
Pump 1 Control
Pressure Sensor
Solenoid Valve Unit
SI
Travel Motor
T2-1-43
SYSTEM / Control System
Auxiliary Flow Rate Control (Only on the ma-
chines equipped with the auxiliary pressure
sensor and auxiliary flow rate control solenoid
valve)
Operating Conditions:
Auxiliary Pressure Sensor: ON
Swing, Boom Raise, Arm Roll-In Pressure Sensors:
ON
T2-1-44
SYSTEM / Control System
Pressure Sensor
Swing
Boom Raise
Arm Roll-In
Auxiliary (Optional)
Auxiliary Flow
Rate Control
Solenoid Valve
(Optional)
Auxiliary Flow
Rate Control Valve
T178-02-01-024
T2-1-45
SYSTEM / Control System
OTHER CONTROLS
Boom Electronic Cushion Control
(Up to serial No.104908 (ZAXIS225US))
T1GF-02-01-001
T2-1-46
SYSTEM / Control System
Boom Raise
Boom Electronic
Cushion Solenoid
Valve
Boom 2 Boom 1
1 1
T1GF-02-01-002
T2-1-47
SYSTEM / Control System
Work Mode Control
Two work modes, digging and front attachment, are
available by operating the work mode switch.
• Digging Mode:
Normal control is performed.
T2-1-48
SYSTEM / Control System
Travel Alarm Control (Only on the machines
equipped with the travel alarm device (Optional))
Pressure Sensor
Travel
Travel Alarm
Device (Optional)
Buzzer Deactivation
Switch (Optional)
T2-1-49
SYSTEM / Control System
Overload Alarm Control
(Only on the machine fitted with options)
Pressure Sensor
Boom Bottom (OP)
C16
MC
A28
Buzzer
Overload
Relay
Alarm Switch (OP)
(OP) T16R-02-01-001
T2-1-50
SYSTEM / Hydraulic System
OUTLINE
The hydraulic system is broadly divided into two cir-
cuits, the main circuit and the pilot circuit.
Main Circuit:
Pilot Circuit:
T2-2-1
SYSTEM / Hydraulic System
PILOT CIRCUIT
Outline:
• Pressure oil from the pilot pump is used to oper-
ate the operation control circuit, pump control
circuit, valve control circuit, swing parking brake
release circuit, travel motor swash angle control
circuit, positioning circuit (optional) and hydraulic
oil heat circuit.
T2-2-2
SYSTEM / Hydraulic System
Operation Control Circuit
Swing Parking Brake
Release Circuit
Maximum Pump 2
Flow Rate Control Torque Control
Solenoid Valve Solenoid Valve
Pilot Shut-
Off Valve
Signal Control Valve SB ST
Hydraulic Oil SA
Heat Circuit
Maximum Pump 1 Flow
Rate Control Solenoid
Valve (Optional)
To Control Valve
2 1
Boom
Spools
Control Valve
Arm Flow Bucket Flow
Auxiliary Flow Combining Combiner Rate Control
Posi- Solenoid Valve (When Valve Valve Regulator
tioning the auxiliary spool is
used.)
Holding Boom Anti-Drift Valve
Valve
(Optional)
Arm Anti-Drift Valve
Auxiliary Flow Rate Control
Solenoid Valve (When the
auxiliary spool is used.) Auxiliary Flow Combiner Valve
T2-2-3
SYSTEM / Hydraulic System
Operation Control Circuit
• The pilot valves control the pressure oil from the • The boom electronic cushion solenoid valve is
pilot pump to operate the control valve spools. provided between the pilot valve (right) and the
signal control valve on ZAXIS225US (Up to serial
• The signal control valve is provided between the No.104908).
pilot valves and the control valve. The shockless This valve reduces the shock which may occur
valve (in the boom raise circuit) built in the signal when the boom reaches to its full stroke position.
control valve dampens quick spool movement in (Refer to SYSTEM / Control System group.)
the control valve. (Refer to the COMPONENT
OPERATION / Signal Control Valve group.)
ZAXIS225US:
(Up to serial No.104908)
Pilot Valve (Right)
Boom Electronic
Cushion Solenoid
Valve
T2-2-4
SYSTEM / Hydraulic System
ZAXIS200 class, ZAXIS225USR, 230 class, 270 class,
ZAXIS225US (Serial No.104909 and up)
Positioning Pilot Valve
(2-piece Boom Only)
Shockless Valve
13 14
9 10 11 12 4
3 2 1 8 7 6 5
10 11
9
8
7
2 1
1
4
3 3
5 6
14
13
Control Valve
T178-02-02-016
1- Boom Raise 5- Left Swing 9 - Left Travel Forward 12 - Right Travel Reverse
2- Boom Lower 6- Right Swing 10 - Left Travel Reverse 13 - Positioning Lower
3- Arm Roll-Out 7- Bucket Roll-In 11 - Right Travel Forward 14 - Positioning Raise
4- Arm Roll-In 8- Bucket Roll-Out
T2-2-5
SYSTEM / Hydraulic System
Pump Control Circuit (Refer to the COMPOMENT
OPERATION / Pump Device group.)
T2-2-6
SYSTEM / Hydraulic System
Signal
control
Valve
Control Valve
Torque
Control
Solenoid
Valve
Pump 2 Pump 1
Pilot Pump
T178-02-02-006
T2-2-7
SYSTEM / Hydraulic System
Valve Control Circuit (Refer to the COMPONENT
OPERATION / Control Valve and Travel Device
groups.)
• The following valves are controlled by pressure oil
from the pilot valves, solenoid valve unit (SC, SE*,
and SG), the flow combiner valve control spool in
the signal control valve, the bucket flow rate control
valve control spool and the arm flow rate controll
valve control spool**.
• Boom Lower Pilot Pressure: Boom Anti-Drift • Auxiliary Flow Rate Control Solenoid Valve: Aux-
Valve, Holding Valve (Optional) iliary Flow Rate Control Valve (When the auxiliary
spool is used.)
• Arm Roll-In Pilot Pressure: Arm Anti-Drift Valve,
Holding Valve (Optional) • Auxiliary Flow Combining Solenoid Valve: Boom,
Arm, and Bucket Pilot Pressure
• Auxiliary Pilot Pressure: Auxiliary Flow Combiner
Valve, Bypass Shut-Out Valve (When the auxil- • Flow Combiner Valve Control Spool: Flow Com-
iary spool is used.) biner Valve
• Positioning Lower Pilot Pressure (2-Piece boom • Bucket Flow Rate Control Valve Control Spool:
only): Bypass Shut-Out Valve, Holding Valve (Op- Bucket Flow Rate Control Valve
tional)
• Arm Flow Rate Control Valve Control Spool**:
• Positioning Raise Pilot Pressure (2-Piece boom Arm Flow Rate Control Valve
only): Bypass Shut-Out Valve
NOTE: * Up to serial No.104678
• Solenoid Valve SC: Arm Regenerative Valve (ZAXIS200 class and 225 class)
Up to serial No.010326 (ZAXIS230 class)
• Solenoid Valve SE*: Arm Flow Rate Control Valve Up to serial No.020042 (ZAXIS270 class)
T2-2-8
SYSTEM / Hydraulic System
Positioning
(2-piece Boom Only) Travel (Right) Arm Roll-In Boom Lower
Auxiliary
13
Signal 4
Control Main Relief Valve Auxiliary Flow
Valve 2
Combining
Solenoid Valve
Auxiliary
Flow Combiner Valve
Flow
Control Spool
Rate
Control Bucket Flow Rate
4 Valve Control Valve Con-
trol Spool
Auxiliary Auxiliary Flow Com-
Holding Valve Flow Rate biner Valve
(Arm) (Optional) Control So- Flow Combiner Valve
lenoid Valve
Bucket Flow Rate
Control Valve
Boom Auti-Drift Valve
Arm Anti-Drift
Valve
2
Solenoid 2
Valve Unit
4
SG
2
SC
Holding Valve (Boom)
SE* (Optional)
Bypass Shutout Valve
Holding Valve 13
(Positioning)
Pilot Pump (Optional)
T178-02-02-015
T2-2-9
SYSTEM / Hydraulic System
Swing Parking Brake Release Circuit (Refer to
the COMPONENTS OPERATION / Swing Device
group.)
• When the front attachment and/or swing function
is operated, the pilot oil pressure selected by the
shuttle valves in the signal control valve shifts the
swing parking brake release spool.
T2-2-10
SYSTEM / Hydraulic System
Orifice
Signal
Control
Valve Swing Parking Brake
Release Spool
Solenoid
Valve Unit
Control Valve Swing Motor
Travel Motor
SI
T178-02-02-017
Swash Angle Control Valve
T2-2-11
SYSTEM / Hydraulic System
MAIN CIRCUIT
Outline
• Main pumps (1 and 2) draw hydraulic oil from the
hydraulic oil tank. Main pump 1 and main pump 2
deliver pressure oil to the 4-spool control valve,
positioning control valve (2-piece boom only) and
the 5-spool control valve respectively.
T2-2-12
SYSTEM / Hydraulic System
Bucket Cylinder
4-Spool
Arm Cylinder Side
Auxiliary Bucket
Boom 2 Boom 1
Arm 1 Arm 2
Swing
Positioning Cylinder
5-Spool Side (2-Piece Boom only)
Bypass Check
Valve
Swing Motor
Oil Main Main
Cooler Pump 2 Pump 1
Positioning Control Vale
(2-Piece Boom only)
Suction Hydraulic
Filter Oil Tank
T2-2-13
SYSTEM / Hydraulic System
Neutral Circuit
• When the control lever is in neutral, pressure oil
from the main pump passes through the control
valve and returns to the hydraulic oil tank.
T2-2-14
SYSTEM / Hydraulic System
Control Valve
Bucket Cylinder
Auxiliary
Bucket
Arm Cylinder
Boom 1
Boom Cylinder
Boom 2
Swing Motor
Arm 1
Arm 2
Swing
5-Spool Side
4-Spool Side
Pump 2 Pump 1
T178-02-02-001
T2-2-15
SYSTEM / Hydraulic System
Combined Operation Circuit
• Swing and Boom Raise Operation
• When the boom is raised while swinging, the pilot
oil pressure shifts the swing, boom 1, and boom
2 spools.
T2-2-16
SYSTEM / Hydraulic System
Parallel Circuit
Swing Motor
Swing
Parallel
Circuit
Pump 2 Pump 1
T178-02-02-002
T2-2-17
SYSTEM / Hydraulic System
• Travel and Arm Roll-In Operation
• When the arm is rolled in while traveling, the pilot
oil pressure shifts the travel, arm 1 and 2 spools.
T2-2-18
SYSTEM / Hydraulic System
Pilot Pressure
Travel Motor (Left) Travel Motor (Right)
Oil from Flow
Combiner Valve
Control Spool in
Signal Control
Valve
Left
Travel Right
Travel
Arm Cylinder
Arm 1
5-Spool Side
4-Spool Side
Pump 2 Pump 1
T178-02-02-003
T2-2-19
SYSTEM / Hydraulic System
Positioning circuit (2-piece boom only)
Neutral Circuit
• When the control lever is in neutral, the pressure
oil from pump 1 is returned to the hydraulic oil
tank via the control valve.
Positioning Cylinder
Single Operation Circuit
• During positioning operation, the spools in the
bypass shut-out valve and positioning control
valve are shifted.
• The pressurized oil from pump 1 is divided on the
four-spool side, and combined in the positioning
control valve and goes into the positioning cylin-
der.
T2-2-20
SYSTEM / Hydraulic System
4 Spool Side
Parallel Circuit
Pilot Pressure
from Position-
ing Pilot Valve
Positioning
Cylinder
Bypass Shut-Out
Valve
Pump 1
T178-03-03-065
Positioning
Control Valve
T2-2-21
SYSTEM / Hydraulic System
Auxiliary Circuit
• When a front attachment such as a hydraulic NOTE: During boom (raise or lower), arm (roll-in
breaker is operated, the pilot pressure oil from or roll–out), bucket (roll-in or roll–out),
the hydraulic breaker pilot valve shifts the auxil- and/or right travel operation, pilot pressure
iary flow combiner valve and bypass shut-out oil is routed to port SN from the signal pilot
valve. pressure control valve so that the aux. flow
combiner valve is not shifted. (Refer to the
• Therefore, the neutral circuit in the 4-spool con- SYSTEM / Control System group.)
trol valve is blocked so that pressure oil from
pump1 is routed to the auxiliary spool via the
auxiliary flow combiner valve.
T2-2-22
SYSTEM / Hydraulic System
Front
Attachment
Neutral
Circuit
Auxiliary
Bypass
Cut Valve
Pump 2 Pump 1
T178-02-02-004
T2-2-23
SYSTEM / Hydraulic System
(Blank)
T2-2-24
SYSTEM / Electrical System
OUTLINE
The electrical circuit is broadly divided into the main
circuit, monitor circuit, and control circuit.
• Main Circuit
The engine and accessory operation related circuit.
• Monitor Circuit
The electrical circuit group consists of the monitors,
sensors, and switches, and displays the machine
operation status.
T2-3-1
SYSTEM / Electrical System
MAIN CIRCUIT
The major functions and circuits in the main circuit are
as follows.
T2-3-2
SYSTEM / Electrical System
ELECTRIC POWER CIRCUIT (KEY
SWITCH: OFF)
The battery ground terminal is connected to the
vehicle frame. Current from the battery plus terminal
flows as shown below when the key switch is OFF.
Battery
→Glow Plug Relay
↓ →Terminal #1: Radio (Backup Power)
(Power)
Fusible Link Monitor (Backup Power)
→Key Switch (B)
ICX Controller (Backup Power)
→Load Damp Relay
→Terminal #2: MC (Power)
→Fuse Box
→Terminal #3: MC (EC Motor Power)
→Terminal #10: Optional
Key Switch
Battery
Load
Damp
Relay
Glow
Plug
Relay
Radio, Monitor,
ICX Controller
Optional
MC
MC
T178-02-03-001
T2-3-3
SYSTEM / Electrical System
INDICATOR LIGHT CHECK CIRCUIT (KEY
SWITCH: ON)
• When the key switch is turned ON, terminal B is
connected to terminals ACC and M in the key
switch.
Key Switch
Battery
Battery
Relay
Fuse
Box
Monitor
Controller
T178-02-03-002
T2-3-4
SYSTEM / Electrical System
ACCESSORY CIRCUIT
Fuse
Box
Horn
Radio
Lighter
Cab Light
Auxiliary
T178-02-03-003
T2-3-5
SYSTEM / Electrical System
PREHEAT CIRCUIT (KEY SWITCH: ON /
START)
• When the key switch is turned ON or to the • When preheating begins, QOS controller terminal
START position, terminal B is connected to #6 is connected to terminal #5 for 8 seconds,
terminal M in the key switch. Current from turning the preheat indicator ON. (When
terminal M is routed to QOS controller terminal preheating is not performed, the preheat indicator
#1 through fuse #19. comes ON for 2 seconds for indicator light
check.)
• When the key switch is ON or in the START
position with the coolant switch OFF (when the
coolant temperature is 10 °C (50 °F) or below), NOTE: After preheating has been performed,
QOS controller terminal #4 is connected to heating will continue for approx. 30
terminal #5 (ground). seconds after the engine starts.
T2-3-6
SYSTEM / Electrical System
Monitor
Fuse
Box
Glow
Plug
Relay
Glow Plug
T178-02-03-004
T2-3-7
SYSTEM / Electrical System
STARTING CIRCUIT (KEY SWITCH:
START)
• When the key switch is turned to the START • Consequently, the relay in the starter is turned
position, terminal B is connected to terminals M ON so that the starter begins rotating.
and ST in the key switch.
• On the other hand, current from key switch
• As current from terminal M excites the battery terminal M flows to the MC via fuse #6 as a
relay, battery current is routed to starter terminal signal indicating that the key switch is in the ON
B and starter relay terminal B via the battery or START position.
relay.
• As soon as the MC receives this signal, the MC
• Key switch terminal ST is connected to starter drives the EC motor, moving the governor lever
relay terminal S so that current flows through the to the engine start position.
starter relay coil.
T2-3-8
SYSTEM / Electrical System
Key Switch
Battery
Battery
Relay
Starter Fuse
Box
Starter Relay
EC Motor
MC
T178-02-03-005
T2-3-9
SYSTEM / Electrical System
Starter Relay Operation
• When the key switch is turned to the START • When this voltage increases up to 21 to 22 V,
position, key switch terminal B is connected to Zener diode (Z) is turned ON so that transistor
terminal ST so that current is routed to the base (Q1) is turned ON. Then, current to the base of
in transistor (Q2) through resistance R4 in the transistor (Q2) is not routed, turning transistor
starter relay. Then, transistor (Q2) is turned ON, (Q2) OFF. At this moment, starter terminal B is
allowing current to flow to coil (L) in the starter disconnected from terminal C, stopping the
relay. Therefore, starter terminal B is connected starter.
to terminal C, rotating the starter.
Condenser C1 is used to stabilize the operating
• After the engine starts, the alternator starts voltage and diode D4 protects the circuit in case the
generating electricity, increasing voltage at starter battery terminals are reversely connected.
relay terminal R.
Starter Relay
S B
D3
(1)
R4 L
C
R3 (2) (1)
R2 Z D2 C
To Alternator R Q2 M
Q1 B
Terminal L
(2)
C1 C Starter
E D4
12V
B
ST
Battery
T107-04-04-003
T2-3-10
SYSTEM / Electrical System
CHARGING CIRCUIT (KEY SWITCH: ON)
• When the alternator starts generating electricity,
• After the engine starts and the key switch is current flows from alternator terminal B to the
released, the key switch moves to the ON batteries via the battery relay, charging the
position. batteries.
• Then, key switch terminal B is connected to • Current from alternator terminal L flows to the
terminals ACC and M in the key switch. monitor controller and the ICX controller, turning
the alternator indicator OFF.
Key Switch
Battery Monitor
Controller
ICX
Battery Controller
Relay
Alternator
T178-02-03-006
T2-3-11
SYSTEM / Electrical System
Alternator Operation
• The alternator consists of field coil FC, stator coil • At the beginning, no current is flowing through
SC, and diodes D. The regulator consists of field coil FC. When the rotor starts turning,
transistors (T1 and T2), Zener diode ZD, and alternate current is generated in stator coil SC by
resistances (R1 and R2). the rotor remanent magnetism.
• Alternator terminal B is connected to base B of • When current starts to flow through field coil FC,
transistor T1 through the circuit [B → R → RF the rotor is further magnetized so that the
→ ( R ) → (R1)]. generating voltage increases. Thereby, current
flowing through field coil FC increases and
• When battery relay BS is ON, the battery voltage generating voltage is increased further, to charge
is applied to base B of transistor T1 so that the batteries.
collector C is connected to emitter E. Therefore,
field coil FC is grounded via transistor T1.
Alternator
B R L Regulator
BS RF (R) R3 R4 R5
R6
D
ZD
R2
Battery SC B
E
R1 C
T2
FC B
D1 C E
T1
(F)
(E)
E
T157-04-02-008
T2-3-12
SYSTEM / Electrical System
Regulator Operation
• When generating voltage increases more than • When generating voltage decreases lower than
the set-voltage of Zener diode ZD, current is the set-voltage of Zener diode ZD, transistor T2
routed to base B of transistor T2, connecting is turned OFF, causing transistor T1 to turn ON
collector C to emitter E. again.
• Then, current which was routed to base B of • Then, current flows through field coil FC,
transistor disappears, turning transistor T1 OFF. increasing generating voltage at the stator coil.
The above operation is repeated so that the
• Therefore, no current flows through filed coil FC, alternator generating voltage is kept constant.
reducing generating voltage at stator coil SC.
BS RF R3 R4 R5
R6
ZD
R2
Battery B
SC
A E
C
FC T2
B
R1 C E
T1
(F) D1
(E)
E
T157-04-02-009
T2-3-13
SYSTEM / Electrical System
SERGE VOLTAGE PREVENTION CIRCUIT
• When the engine is stopped (key switch: OFF), • When the alternator is generating electricity,
current from key switch terminal M is generating current from alternator terminal L
disconnected, turning the battery relay OFF. flows to monitor controller terminal #A-2 so that
the monitor controller connects terminal #C-3 to
• The engine continues to rotate due to inertia ground.
force just after the key switch is turned OFF so
that the alternator continues to generate • Then, current flows through the load damp relay
electricity. exciting circuit, turning the load damp relay ON.
• As the generating current cannot flow to the • Accordingly, even if the key switch is turned OFF
battery, surge voltage arises in the circuit, while the engine is rotating, the battery current
possibly causing failures of the electronic continues to excite the battery relay via the load
components, such as the controller. To prevent damp relay until the alternator stops generating.
the occurrence of surge voltage, the surge Therefore, the battery relay is kept ON, allowing
voltage prevention circuit is provided. the generating current to flow to the batteries.
T2-3-14
SYSTEM / Electrical System
Key Switch
Battery
Battery
Relay
Load
Damp
Relay
Alternator
Monitor Controller
T178-02-03-007
T2-3-15
SYSTEM / Electrical System
ENGINE STOP CIRCUIT
Key Switch
EC Motor
MC
T178-02-03-008
T2-3-16
MEMO
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SECTION 3
COMPONENT OPERATION
CONTENTS
Group 1 Pump Device Group 5 Travel Device
Outline ...................................................... T3-1-1 Outline ......................................................T3-5-1
Main Pump................................................ T3-1-2 Travel Reduction Gear ..............................T3-5-4
Regulator .................................................. T3-1-6 Travel Motor ..............................................T3-5-6
Solenoid Valve ........................................ T3-1-22 Parking Brake .........................................T3-5-10
Pilot Pump .............................................. T3-1-24 Travel Mode Change ...............................T3-5-12
N Sensor (Engine Speed Sensor) ........... T3-1-24 Travel Brake Valve ..................................T3-5-22
Pump Delivery Pressure Sensor ............. T3-1-24
Group 6 Signal Control Valve
Pump Control Pressure Sensor .............. T3-1-25
Outline ......................................................T3-6-1
Valve Unit ................................................. T3-2-8 Bucket Flow Rate Control Valve Control Spool,
Flow Combiner Valve Control Spool,
Group 3 Control Valve Swing Parking Brake Release Spool
Outline ...................................................... T3-3-1 Arm Flow Rate Control Valve
Hydraulic Circuit ..................................... T3-3-14 Control Spool.........................................T3-6-14
Flow Combiner Valve .............................. T3-3-20
Main Relief Valve .................................... T3-3-22 Group 7 Others (Upperstructure)
Overload Relief Valve ............................. T3-3-24 Pilot Shut-Off Valve ...................................T3-7-1
Regenerative Valve................................. T3-3-26 Solenoid Valve Unit ...................................T3-7-2
Arm Regenerative Valve ......................... T3-3-28 Holding Valve ............................................T3-7-6
Anti-Drift Valve ........................................ T3-3-30 Pilot Relief Valve .....................................T3-7-10
Flow Rate Control Valve ......................... T3-3-32 EC Motor .................................................T3-7-10
Auxiliary Flow Combiner Valve and
Group 8 Others (Undercarriage)
Bypass Shut-Out Valve ......................... T3-3-34
Swing Bearing ...........................................T3-8-1
Group 4 Pilot Valve Center Joint...............................................T3-8-2
178T-3-1
(Blank)
178T-3-2
COMPONENT OPERATION / Pump Device
OUTLINE
The pump device consists of transmission (11), main The main pump is a bent-axis type variable displace-
pump[pump 1 (1) and pump 2 (2)] and pilot pump (3). ment axial plunger pump. Pump 1 (1) and pump 2 (2)
The engine output is transmitted to transmission (11) are integrated as two units in one housing.
via coupling (12). After being distributed by the gear The pilot pump is a gear pump.
train in the transmission, the engine power drives Pump delivery pressure sensors (4 and 5), pump con-
pump 1 (1), pump 2 (2), and pilot pump (3). Both re- trol pressure sensors (8 and 9), and N sensor (engine
duction gear ratios of the main pumps and pilot pump speed sensor) (10) are provided to control pump and
are 1:1. The transmission is lubricated with engine oil. valve operations.
6
7
8
3 2 1 10
11 T178-03-01-001
12
5 4 T178-03-01-003
T178-03-01-002
T3-1-1
COMPOMRNT OPERATION / Pump Device
MAIN PUMP
The main pump supplies pressure oil to actuate the
hydraulic components such as motors or cylinders.
The main pump consists of pump 1 and pump 2. Shaft
(3) is connected to each pump cylinder block (6) via
seven plungers (4) so that the shaft and cylinder block
rotate together. When cylinder block (6) is rotated,
plungers (4) oscillate in the cylinder block, suctioning
and delivering hydraulic oil. Each main pump is
equipped with a regulator which controls the flow rate.
1 2
4
T178-03-01-005
T3-1-2
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 al-
ternately 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 depend-
ing 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 con-
tact with the surface of valve plate (4) and slides
along it.
T105-02-03-021
5
Minimum Displacement Angle (Operable Limit Angle): 6
T178-03-01-005
2
4
T105-02-03-022
T3-1-4
COMPOMRNT OPERATION / Pump Device
(Blank)
T3-1-5
COMPOMRNT OPERATION / Pump Device
REGULATOR
1 3 2 4
The regulator controls the main pump flow rate in re-
sponse to the various command signal pressures so Dr
that the pump driving power doesn’t exceed the en-
gine power. Pump 1 and pump 2 are provided with
one regulator each. The major parts of the regulator
Pi
are spring (1), sleeve A (2), sleeve B (7), spool A (3),
spool B (6), piston (4), load piston (5), outer spring (8), Pd2 Air
and inner spring (9). According to the various com- Bleeding
Circuit
mand signal pressures, the regulator opens or closes Pps
Dr
the circuit to servo piston (10), causing the inclination
of cylinder block (11) to change, by which the pump Pd1
flow rate is controlled.
T3-1-6
COMPOMRNT OPERATION / Pump Device
1 2 3 4
T178-03-01-006
5 6 7 8 9
12
11
10
T178-03-01-005
T3-1-7
COMPOMRNT OPERATION / Pump Device
Regulator Control Function
The regulator has the following four control func-
tions.
T3-1-8
COMPOMRNT OPERATION / Pump Device
• Control by Pilot Pressure from Torque Control So-
lenoid Valve
The main controller (MC) operates based on both
the engine target speed input data and actual Flow
Rate (Q)
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.) 0 Pressure (P)
Pi
Pd2 Air
Bleeding
Circuit
Pps
Dr
Pd1
Pg
Increase Decrease
Cylinder Block Inclination T176-03-01-009
T3-1-9
COMPOMRNT OPERATION / Pump Device
Control by Pump Control Pressure
Pd1
Pg
10 12
Increase Decrease
Cylinder Block Inclination T176-03-01-009
1 - Spring 4 - Piston
2 - Sleeve A 10 - Servo Piston
3 - Spool A 12 - Link
T3-1-10
COMPOMRNT OPERATION / Pump Device
Torque
Control
Pressure
Pps
Pump 2
Delivery
Pressure
Pd2
Pump 1 12
Delivery
Pressure
Pd1
10
T178-03-01-008
Torque
Control
Pressure
Pps
Pump 2
Delivery
Pressure
Pd2
Pump 1 12
Delivery
Pressure
Pd1
10
T178-03-01-009
T3-1-11
COMPOMRNT OPERATION / Pump Device
Pg
10 12
Increase Decrease
Cylinder Block Inclination T176-03-01-009
1 - Spring 4 - Piston
2 - Sleeve A 10 - Servo Piston
3 - Spool A 12 - Link
T3-1-12
COMPOMRNT OPERATION / Pump Device
Torque
Control
Pressure
Pps
Pump 2
Delivery
Pressure
Pd2
Pump 1
Delivery
12
Pressure
Pd1
10
T178-03-01-010
Torque
Control
Pressure
Pps
Pump 2
Delivery
Pressure
Pd2
Pump 1 12
Delivery
Pressure
Pd1
10
T178-03-01-011
T3-1-13
COMPOMRNT OPERATION / Pump Device
Control by Own or Opponent Pump Delivery
Pressure
T3-1-14
COMPOMRNT OPERATION / Pump Device
Torque
Control
Pressure
Pps
Pump 2
Delivery 8 9
Pressure
Pd2
Pump 1 12
Delivery
Pressure
Pd1
10
T178-03-01-012
To Hydraulic Primary Pilot
5 Oil Tank Pressure 6 7 Pump Control
Pressure Pi
Torque
Control
Pressure
Pps
Pump 2
Delivery 8 9
Pressure
Pd2
Pump 1 12
Delivery
Pressure
Pd1
10
T178-03-01-013
T3-1-15
COMPOMRNT OPERATION / Pump Device
5 7 6 Pg
10 12 8, 9
Increase Decrease
Cylinder Block Inclination T176-03-01-009
T3-1-16
COMPOMRNT OPERATION / Pump Device
Torque
Control
Pressure
Pps
Pump 2
Delivery 8 9
Pressure
Pd2
Pump 1 12
Delivery
Pressure
Pd1
10
T178-03-01-014
Torque
Control
Pressure
Pps
Pump 2
Delivery
Pressure
8 9
Pd2
Pump 1 12
Delivery
Pressure
Pd1
10
T178-03-01-015
T3-1-17
COMPOMRNT OPERATION / Pump Device
Control by Pilot Pressure from Torque Control
Solenoid Valve
T3-1-18
COMPOMRNT OPERATION / Pump Device
Torque
Control
Pressure
Pps
Pump 2
Delivery 8 9
Pressure
Pd2
Pump 1 12
Delivery
Pressure
Pd1
10
T178-03-01-016
Torque
Control
Pressure
Pps
Pump 2
Delivery 8 9
Pressure
Pd2
Pump 1 12
Delivery
Pressure
Pd1
10
T178-03-01-017
T3-1-19
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, decreasing
pump control pressure Pi.
3. Piston (4) is moved toward the arrowed direction
0 Pressure (P)
by reduced pump control pressure Pi.
4. Then, piston (4) pushes spool A (3) and spring
(1) until force acting on piston (4) by pump con-
1 3 2 4
trol pressure Pi becomes balanced with spring
(1) force, causing spool A (3) to move toward the Dr
arrowed direction.
5. As pump control pressure has been reduced,
spool A (3) is moved in a shorter distance than
Pi
usual.
6. Due to the movement of spool A (3), the circuit Pd2 Air
from the large chamber of servo piston (10) is Bleeding
Circuit
opened to the hydraulic oil tank. Pps
Dr
7. Since the pilot oil pressure is constantly routed
into the small chamber of servo piston (10), servo Pd1
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. Pg
8. The movement of the cylinder block is transmit- 10 12
ted to sleeve A (2) via link (12). Then, sleeve A Increase Decrease
Cylinder Block Inclination T176-03-01-009
(2) is moved in the same direction as spool A (3).
9. When sleeve A (2) is moved by the same stroke
1 - Spring 4 - Piston
as spool A (3), the pilot oil pressure circuit to the 2 - Sleeve A 10 - Servo Piston
large chamber of servo piston (10) is closed. 3 - Spool A 12 - Link
10. So that servo piston (10) is stopped, completing
flow rate increase operation. Pd1 - Pump 1 Delivery Pres- Pi - Pump Control Pressure
11. Accordingly, pump control pressure Pi increases sure
in proportion to the stroke of the control lever, al- Pd2 - Pump 2 Delivery Pres- Pps -Torque Control Pressure
lowing the pump delivery flow rate to increase. sure
However, as pump control pressure Pi is regu- Dr - Returning to Hydraulic Pg - Primary Pilot Pressure
Oil Tank (From Pilot Pump)
lated, the strokes of spool A (3) and servo piston
(10) are reduced so that the maximum flow rate
becomes less than usual.
Fig:
Maximum Flow Rate
Limited Maximum Flow Rate
T3-1-20
COMPOMRNT OPERATION / Pump Device
Torque
Control
Pressure
Pps
Pump 2
Delivery
Pressure
Pd2
Pump 1 12
Delivery
Pressure
Pd1
10
T178-03-01-018
Torque
Control
Pressure
Pps
Pump 2
Delivery
Pressure
Pd2
Pump 1 12
Delivery
Pressure
Pd1
10
T178-03-01-019
T3-1-21
COMPOMRNT OPERATION / Pump Device
SOLENOID VALVE
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 out-
put port is connected to port T through the notch
on the spool.
4. Thereby, pressure at the output port begins to
decrease.
5. Left side spool diameter (A) at the notch is larger
than right side diameter (B).
6. Accordingly, until the oil pressure at the output
port disappears, the external force applied onto
the spool is expressed as P1 × B + S1 > P1 × A +
S2. Then, the spool is move toward the right side.
7. When the oil pressure at the output port disap-
pears so that when P1 × B + S1 becomes equal
to P1 × A + S2 (P1 × B + S1 = P1 × A + S2), the
spool stops moving.
T3-1-22
COMPOMRNT OPERATION / Pump Device
When Neutral:
T176-03-01-030
A Port P Port T B
Output Port
When in Operation:
T176-03-01-031
A Port P Port T B
Output Port
T3-1-23
COMPOMRNT OPERATION / Pump Device
PILOT PUMP
Inlet Port
1
Drive gear (1) is driven by the engine via the trans-
mission which in turn rotates driven gear (2) as they 2
are meshed together.
Outlet Port
3 - Tooth 5 - Output 3
4 - Output
T178-03-01-020
T157-02-03-010
6 - Ground 8 - Power Source (5V) 7
6 8 9
7 - Output 9 - Pressure Receiving Area
(Diaphragm)
T3-1-24
COMPOMRNT OPERATION / Pump Device
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 dia-
phragm is deformed. The deformation of the dia-
phragm is detected as electrical signals.
T3-1-25
COMPOMRNT OPERATION / Pump Device
(Blank)
T3-1-26
COMPONENT OPERATION / Swing Device
OUTLINE
The swing device consists of the valve unit, swing The swing reduction gear converts the swing motor
motor, and swing reduction gear. The valve unit pre- output into slow large torque to rotate the shaft.
vents cavitation in the swing circuit from occurring and Thereby, the upperstructure is rotated.
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.
Valve Unit
Valve Unit
Swing Motor
Swing Motor
T178-03-02-001
T1HG-03-02-003
T3-2-1
COMPONENT OPERATION / Swing Device
SWING REDUCTION GEAR
The swing reduction gear is a two stage reduction The shaft meshes with the swing bearing internal gear
planetary gear type. The ring gear is formed on the secured to the undercarriage, causing the upper-
internal surface of the housing so that they are inte- structure to rotate.
grated. As the housing is bolted on the upperstructure,
the ring gear doesn’t rotate. The swing motor shaft
rotates the first stage sun gear. Then, its torque is
transmitted to the second stage sun gear via the first
stage planetary gear and carrier. The second stage
sun gear rotates the shaft via the second stage plane-
tary gear and carrier.
Shaft
T178-03-02-006
T3-2-2
COMPONENT OPERATION / Swing Device
ZAXIS270 class
Shaft
T164-03-02-003
T3-2-3
COMPONENT OPERATION / Swing Device
SWING MOTOR
The swing motor consists of the swash plate, rotor, When pressure oil is supplied from the pump, the
plungers, valve plate, housing and swing parking pressure oil pushes the plungers. Since the swash
brake (springs, brake piston, plates, friction plates, plate is inclined, the shoes on top of the plungers slide
and swing parking brake switch valve). The rotor in along the swash plate, causing the rotor and shaft to
which the plungers are inserted is splined onto the rotate. The shaft tip end is splined into the first stage
shaft. sun gear in the swing reduction gear so that shaft ro-
tation is transmitted to the swing reduction gear.
Spring
Valve Plate
Brake Piston
Rotor Plate
Housing
Friction Plate
Shoe
Plunger
Retainer
Swash Plate
Shaft
T178-03-02-002
T3-2-4
COMPONENT OPERATION / Swing Device
ZAXIS270 class
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
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 (nega-
tive 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 automati-
cally applied by spring.
Spring
Brake Piston
Orifice
T178-03-02-003
T3-2-6
COMPONENT OPERATION / Swing Device
ZAXIS270 class
(Up to serial No 20744)
Spring 1
Rotor
Port PG
(Brake Release Friction Plate
Pressure)
Plate
Spool
Port SH
(Brake Release
Pressure) T1HG-03-02-004
T3-2-7
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 Relief Valve
and overloads in the circuit.
Make-Up Valve
Make-Up Valve
During swing stop operation, the swing motor is
driven by inertia force of the upperstructure. The
motor is rotated by inertia force more than by pres-
sure oil delivered from the pump, causing cavitation
to develop in the circuit. To prevent cavitation, when Port C
pressure in the swing circuit is reduced more than
the return circuit (port C) pressure, the poppets are
Control Valve
opened so that hydraulic oil is drawn into the circuit
from the hydraulic oil tank to compensate for the
T107-02-04-013
lack of oil in the circuit.
Control Valve
ZAXIS200 class, 225 class, 230class
Poppet
Port C
T178-03-02-004
Relief Valve
T3-2-8
COMPONENT OPERATION / Swing Device
ZAXIS270 class
Relief Valve
Poppet
Make-Up Valve
Make-Up Valve
T1HH-03-02-003
T3-2-9
COMPONENT OPERATION / Swing Device
Relief Valve
During starting or stopping swing operation, oil
pressure in the swing circuit becomes high. The re-
lief valve prevents the circuit pressure from rising
higher than the set-pressure.
HP
LP
Oil Chamber A
T3-2-10
COMPONENT OPERATION / Swing Device
ZAXIS270 class
Low Pressure Relief Operation (Shock Reducing
Function): High Pressure Relief Operation (Overload Preven-
1. Pressure at port HP (swing circuit) is routed into tion):
oil chamber through the poppet orifice. 1. After the piston is moved full stroke, so that the
2. When the pressure in the oil chamber is in- circuit pressure is increased to the set-pressure.
creased more than the force of spring 2, the pis- 2. If pressure in port HP increases more than the
ton moves to the left side. spring 1 set-pressure, the poppet is unseated,
3. As long as the piston keeps moving, a pressure causing pressure oil to flow to port C (Serial
difference is developed between the front and the No.020038 and up) (Up to serial No. 020037:
rear of the poppet. When this pressure difference port LP) from port HP.
is increased more than spring force, the poppet is 3. When pressure in port HP is reduced to the
unseated, allowing pressure oil to flow to port C specified level, the poppet is seated by spring 1
(Serial No.020038 and up) (Up to serial No. force.
020037: port LP).
4. When the piston is moved full stroke, the pres-
sure difference between the front and the rear of
the poppet disappears, causing the poppet to be
seated.
Hp
Poppet
T107-02-04-020
Up to serial No.020037
Spring 1 Poppet Orifice
Spring 2 Piston
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 In the 4-spool section, the right travel, bucket, boom 1,
flow direction in the hydraulic circuit. The major parts and arm 2 spool sections are arranged in that order
of the control valve are the main relief valve, overload as viewed from the machine front (ZAXIS200 class,
relief valve, flow combiner valve, anti-drift valve, flow 230 class and 270 class) [as viewed from the machine
rate control valve, regenerative valve, auxiliary flow right on ZAXIS225 class]. In the 5-spool section, the
combiner valve, bypass shut-out valve, and spools. left travel, auxiliary, boom 2, arm 1, and swing spool
The spools are operated by pilot oil pressure. sections are arranged in that order as viewed from the
machine front (ZAXIS200 class, 230 class and 270
class) [as viewed from the machine right on
ZAXIS225 class].
4-Spool Section
Auxiliary
Boom 2
Arm 1
Swing
5-Spool Section
Front
ZAXIS225 class
T178-03-03-072
Positioning Control Valve (2-piece Boom only) ZAXIS230 class, ZAXIS270 class
ZAXIS200 class
T178-03-03-068
T178-03-03-070
T3-3-1
COMPONENT OPERATION / Control Valve
HYDRAULIC CIRCUIT
1 2 3 4 5 6 7 8 9 10
36
35
34
33
11
12
13
32 14
31 15
30
16
17
29
28
18
19
20
21
27 22
26
25 24 23
T178-03-03-016
T3-3-2
COMPONENT OPERATION / Control Valve
19 Front
12 ZAXIS225 class
29
18
22 3
35
2
20
14 4
9, 10
Front
36
ZAXIS200 class
ZAXIS230 class W178-02-05-017
ZAXIS270 class
1 - Load Check Valve 10 - Bucket Flow Rate Control 19 - Boom Anti-Drift Valve 28 - Overload Relief Valve
(Travel Parallel Circuit) Valve (Poppet Valve) (Switch Valve) (Arm: Bottom Side)
2 - Check Valve 11 - Bucket Regenerative Valve 20 - Load Check Valve 29 - Overload Relief Valve
(Main Relief Circuit) (Arm Tandem Circuit) (Arm: Rod Side)
3 - Main Relief Valve 12 - Overload Relief Valve 21 - Check Valve (Orifice) 30 - Arm Anti-Drift Valve
(Bucket: Rod Side) (4-Spool Side Parallel Cir- (Check Valve)
cuit)
4 - Check Valve 13 - Overload Relief Valve 22 - Bypass Shut-Out Valve 31 - Arm Anti-Drift Valve (Switch
(Main Relief Circuit) (Bucket: Bottom Side) Valve)
5 - Check Valve 14 - Load Check Valve (Boom 1 23 - Arm Flow Rate Control 32 - Load Check Valve
(Flow Combiner Valve Cir- Parallel Circuit) Valve (Poppet Valve) (Boom 2 Parallel Circuit)
cuit)
6 - Flow Combiner Valve 15 - Boom Regenerative Valve 24 - Arm Flow Rate Control 33 - Auxiliary Flow Rate Control
Valve (Switch Valve) Valve (Switch Valve)
7 - Auxiliary Flow Combiner 16 - Overload Relief Valve 25 - Load Check Valve 34 - Auxiliary Flow Rate Control
Valve (Boom: Bottom Side) (Swing Circuit) Valve (Poppet Valve)
8 - Check Valve 17 - Overload Relief Valve 26 - Check Valve 35 - Load Check Valve
(Aux. Flow Combiner (Boom: Rod Side) (Arm Regenerative Circuit) (Travel Tandem Circuit)
Valve Circuit)
9 - Bucket Flow Rate Control 18 - Boom Anti-Drift Valve 27 - Arm Regenerative Valve 36 - Load Check Valve (Orifice)
Valve (Switch Valve) (Check Valve) (Bucket)
T3-3-3
COMPONENT OPERATION / Control Valve
1 2 3 4 5 6 7 8 9 10
36
35
34
33
11
12
13
32 14
31 15
30
16
17
29
28
18
19
20
21
27 22
26
25 24 23
T178-03-03-016
T3-3-4
COMPONENT OPERATION / Control Valve
Front
ZAXIS225 class
25
31
16
30
23, 24
32
33, 34
26
Front
ZAXIS200 class
ZAXIS230 class 28
ZAXIS270 class 17
W178-02-05-018
13
6
1 - Load Check Valve 10 - Bucket Flow Rate Control 19 - Boom Anti-Drift Valve 28 - Overload Relief Valve
(Travel Parallel Circuit) Valve (Poppet Valve) (Switch Valve) (Arm: Bottom Side)
2 - Check Valve 11 - Bucket Regenerative Valve 20 - Load Check Valve 29 - Overload Relief Valve
(Main Relief Circuit) (Arm Tandem Circuit) (Arm: Rod Side)
3 - Main Relief Valve 12 - Overload Relief Valve 21 - Check Valve (Orifice) 30 - Arm Anti-Drift Valve
(Bucket: Rod Side) (4-Spool Side Parallel Cir- (Check Valve)
cuit)
4 - Check Valve 13 - Overload Relief Valve 22 - Bypass Shut-Out Valve 31 - Arm Anti-Drift Valve (Switch
(Main Relief Circuit) (Bucket: Bottom Side) Valve)
5 - Check Valve 14 - Load Check Valve (Boom 1 23 - Arm Flow Rate Control 32 - Load Check Valve
(Flow Combiner Valve Cir- Parallel Circuit) Valve (Poppet Valve) (Boom 2 Parallel Circuit)
cuit)
6 - Flow Combiner Valve 15 - Boom Regenerative Valve 24 - Arm Flow Rate Control 33 - Auxiliary Flow Rate Control
Valve (Switch Valve) Valve (Switch Valve)
7 - Auxiliary Flow Combiner 16 - Overload Relief Valve 25 - Load Check Valve 34 - Auxiliary Flow Rate Control
Valve (Boom: Bottom Side) (Swing Circuit) Valve (Poppet Valve)
8 - Check Valve 17 - Overload Relief Valve 26 - Check Valve 35 - Load Check Valve
(Aux. Flow Combiner (Boom: Rod Side) (Arm Regenerative Circuit) (Travel Tandem Circuit)
Valve Circuit)
9 - Bucket Flow Rate Control 18 - Boom Anti-Drift Valve 27 - Arm Regenerative Valve 36 - Load Check Valve (Orifice)
Valve (Switch Valve) (Check Valve) (Bucket)
T3-3-5
COMPONENT OPERATION / Control Valve
1 2 3 4 5 6 7 8 9 10
36
35
34
33
11
12
13
32 14
31 15
30
16
17
29
28
18
19
20
21
27 22
26
25 24 23
T178-03-03-016
H A
B
I C Auxiliary Bucket
D Cross Section C
E
F 12
View K
G
34 10
33
9
11
13 T178-03-03-005
M178-05-003
T3-3-6
COMPONENT OPERATION / Control Valve
Cross Section A Cross Section a
5
3
T178-03-03-047
1
Cross Section J
T178-03-03-044
7 6
T178-03-03-003
1- Load Check Valve 10 - Bucket Flow Rate Control 19 - Boom Anti-Drift Valve 28 - Overload Relief Valve
(Travel Parallel Circuit) Valve (Poppet Valve) (Switch Valve) (Arm: Bottom Side)
2 - Check Valve 11 - Bucket Regenerative Valve 20 - Load Check Valve 29 - Overload Relief Valve
(Main Relief Circuit) (Arm Tandem Circuit) (Arm: Rod Side)
3 - Main Relief Valve 12 - Overload Relief Valve 21 - Check Valve (Orifice) 30 - Arm Anti-Drift Valve (Check
(Bucket: Rod Side) (4-Spool Side Parallel Cir- Valve)
cuit)
4- Check Valve 13 - Overload Relief Valve 22 - Bypass Shut-Out Valve 31 - Arm Anti-Drift Valve
(Main Relief Circuit) (Bucket: Bottom Side) (Switch Valve)
5 - Check Valve 14 - Load Check Valve 23 - Arm Flow Rate Control 32 - Load Check Valve
(Flow Combiner Valve Cir- (Boom 1 Parallel Circuit) Valve (Poppet Valve) (Boom 2 Parallel Circuit)
cuit)
6 - Flow Combiner Valve 15 - Boom Regenerative Valve 24 - Arm Flow Rate Control 33 - Auxiliary Flow Rate Control
Valve (Switch Valve) Valve (Switch Valve)
7- Auxiliary Flow Combiner 16 - Overload Relief Valve 25 - Load Check Valve 34 - Auxiliary Flow Rate Control
Valve (Boom: Bottom Side) (Swing Circuit) Valve (Poppet Valve)
8 - Check Valve 17 - Overload Relief Valve 26 - Check Valve 35 - Load Check Valve
(Aux. Flow Combiner (Boom: Rod Side) (Arm Regenerative Circuit) (Travel Tandem Circuit)
Valve Circuit)
9 - Bucket Flow Rate Control 18 - Boom Anti-Drift Valve 27 - Arm Regenerative Valve 36 - Load Check Valve (Orifice)
Valve (Switch Valve) (Check Valve) (Bucket)
T3-3-7
COMPONENT OPERATION / Control Valve
1 2 3 4 5 6 7 8 9 10
36
35
34
33
11
12
13
32 14
31 15
30
16
17
29
28
18
19
20
21
27 22
26
25 24 23
T178-03-03-016
19
29 27
18
32
14 25
26
15
17
T178-03-03-008
T178-03-03-006
T3-3-8
COMPONENT OPERATION / Control Valve
Cross Section E Cross Section G
22
31 16
30
23
20
T178-03-03-009
24
28
T178-03-03-007
1- Load Check Valve 10 - Bucket Flow Rate Control 19 - Boom Anti-Drift Valve 28 - Overload Relief Valve
(Travel Parallel Circuit) Valve (Poppet Valve) (Switch Valve) (Arm: Bottom Side)
2 - Check Valve 11 - Bucket Regenerative Valve 20 - Load Check Valve 29 - Overload Relief Valve
(Main Relief Circuit) (Arm Tandem Circuit) (Arm: Rod Side)
3 - Main Relief Valve 12 - Overload Relief Valve 21 - Check Valve (Orifice) 30 - Arm Anti-Drift Valve (Check
(Bucket: Rod Side) (4-Spool Side Parallel Cir- Valve)
cuit)
4- Check Valve 13 - Overload Relief Valve 22 - Bypass Shut-Out Valve 31 - Arm Anti-Drift Valve
(Main Relief Circuit) (Bucket: Bottom Side) (Switch Valve)
5 - Check Valve 14 - Load Check Valve 23 - Arm Flow Rate Control 32 - Load Check Valve
(Flow Combiner Valve Cir- (Boom 1 Parallel Circuit) Valve (Poppet Valve) (Boom 2 Parallel Circuit)
cuit)
6 - Flow Combiner Valve 15 - Boom Regenerative Valve 24 - Arm Flow Rate Control 33 - Auxiliary Flow Rate Control
Valve (Switch Valve) Valve (Switch Valve)
7- Auxiliary Flow Combiner 16 - Overload Relief Valve 25 - Load Check Valve 34 - Auxiliary Flow Rate Control
Valve (Boom: Bottom Side) (Swing Circuit) Valve (Poppet Valve)
8 - Check Valve 17 - Overload Relief Valve 26 - Check Valve 35 - Load Check Valve
(Aux. Flow Combiner (Boom: Rod Side) (Arm Regenerative Circuit) (Travel Tandem Circuit)
Valve Circuit)
9 - Bucket Flow Rate Control 18 - Boom Anti-Drift Valve 27 - Arm Regenerative Valve 36 - Load Check Valve (Orifice)
Valve (Switch Valve) (Check Valve) (Bucket)
T3-3-9
COMPONENT OPERATION / Control Valve
1 2 3 4 5 6 7 8 9 10
36
35
34
33
11
12
13
32 14
31 15
30
16
17
29
28
18
19
20
21
27 22
26
25 24 23
T178-03-03-016
21
4 2
T178-03-03-042 T178-03-03-041
T3-3-10
COMPONENT OPERATION / Control Valve
View K Cross Section L
36
T178-03-03-045
M Cross Section M
35
T178-03-03-046
T178-03-03-048
1 - Load Check Valve 10 - Bucket Flow Rate Control 19 - Boom Anti-Drift Valve 28 - Overload Relief Valve
(Travel Parallel Circuit) Valve (Poppet Valve) (Switch Valve) (Arm: Bottom Side)
2 - Check Valve 11 - Bucket Regenerative Valve 20 - Load Check Valve 29 - Overload Relief Valve
(Main Relief Circuit) (Arm Tandem Circuit) (Arm: Rod Side)
3 - Main Relief Valve 12 - Overload Relief Valve 21 - Check Valve (Orifice) 30 - Arm Anti-Drift Valve
(Bucket: Rod Side) (4-Spool Side Parallel Cir- (Check Valve)
cuit)
4 - Check Valve 13 - Overload Relief Valve 22 - Bypass Shut-Out Valve 31 - Arm Anti-Drift Valve (Switch
(Main Relief Circuit) (Bucket: Bottom Side) Valve)
5 - Check Valve 14 - Load Check Valve 23 - Arm Flow Rate Control 32 - Load Check Valve
(Flow Combiner Valve Cir- (Boom 1 Parallel Circuit) Valve (Poppet Valve) (Boom 2 Parallel Circuit)
cuit)
6 - Flow Combiner Valve 15 - Boom Regenerative Valve 24 - Arm Flow Rate Control 33 - Auxiliary Flow Rate Control
Valve (Switch Valve) Valve (Switch Valve)
7 - Auxiliary Flow Combiner 16 - Overload Relief Valve 25 - Load Check Valve 34 - Auxiliary Flow Rate Control
Valve (Boom: Bottom Side) (Swing Circuit) Valve (Poppet Valve)
8 - Check Valve 17 - Overload Relief Valve 26 - Check Valve 35 - Load Check Valve
(Aux. Flow Combiner (Boom: Rod Side) (Arm Regenerative Circuit) (Travel Tandem Circuit)
Valve Circuit)
9 - Bucket Flow Rate Control 18 - Boom Anti-Drift Valve 27 - Arm Regenerative Valve 36 - Load Check Valve (Orifice)
Valve (Switch Valve) (Check Valve) (Bucket)
T3-3-11
COMPONENT OPERATION / Control Valve
2-piece Boom (Optional)
4
T178-03-03-064
3
1 - Load Check Valve 2- Overload Relief Valve 3- Overload Relief Valve 4- Load Check Valve
(Positioning Circuit) (Positioning: Rod Side) (Positioning: Bottom Side) (Positioning Parallel Circuit)
T3-3-12
COMPONENT OPERATION / Control Valve
ZAXIS200 class
X
2
X
3 Section X-X T198-03-03-003
T198-03-03-002
D
4
Section D-D
1 3
T178-03-03-067
T178-03-03-066
T3-3-13
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 pro-
vided 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.
T3-3-14
COMPONENT OPERATION / Control Valve
Auxiliary
Bucket
Cylinder
Overload
Relief Valve
Arm Cyl-
inder Overload Re-
lief Valve
Swing Motor
Boom
Cylinder
Oil Flow
Combiner Circuit
5-Spool Section
Parallel Circuit
Pump 2 Pump 1
T178-02-02-001
T3-3-15
COMPONENT OPERATION / Control Valve
Positioning Circuit
(2-Piece Boom Only)
Neutral Circuit
• When the control lever is in neutral, the pressure
oil from the pump 1 is returned to the hydraulic oil
tank via the control valve.
T3-3-16
COMPONENT OPERATION / Control Valve
4 Spool Side
Parallel Circuit
Pilot Pressure
from Position-
ing Pilot Valve
Positioning
Cylinder
Bypass Shut-Out
Valve
Pump 1
T178-03-03-065
Positioning
Control Valve
T3-3-17
COMPONENT OPERATION / Control Valve
Pilot Control Circuit External Pilot Pressure Oil Circuit
Pilot pressure oil (indicated with numbers) from the • The main relief valve set-pressure is increased by
pilot valve exerts onto the spool ends in the control the pilot pressure oil delivered from solenoid valve
valve, shifting them. In the following operations, the unit (SG).
pilot pressure oil exerts on the switch valves while • The arm regenerative valve is shifted by the pilot
shifting the spools. pressure oil delivered from solenoid valve unit
• When the arm is rolled in, the pilot pressure oil (4) (SC).
shifts the switch valve in the arm anti-drift valve • The arm flow rate control valve is shifted by the
while exerting onto the arm spool end. pilot pressure oil delivered from solenoid valve unit
• When the boom is lowered, the pilot pressure oil (SE) (Serial No.104678 and earlier (ZAXIS200
(2) shifts the switch valve in the boom anti-drift class and 225 class),
valve while exerting onto the boom spool end. Serial No.010326 and earlier (ZAXIS230 class),
• The auxiliary flow combiner valve and the bypass Serial No.020042 and earlier (ZAXIS270 class))
shut-out valve are shifted by the pilot pressure oil • The arm flow rate control valve is shifted by the
from auxiliary pilot valve. pilot pressure oil delivered from the arm flow rate
As the air bleed circuit is provided in the upper sec- control valve control spool in the signal control
tion of the control valve so that any air trapped in the valve. (Serial No.104679 and later (ZAXIS200
control valve will automatically be bled. class and 225 class),
Serial No.010327 and later (ZAXIS230 class),
Serial No.020043 and later (ZAXIS270 class))
• 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 rate control valve is shifted by
the pilot pressure oil from the auxiliary flow rate
control solenoid valve.
• The bypass shut-out valve is shifted by the pilot
pressure oil from the positioning pilot valve.
(2-piece boom only)
(Refer to the SYSTEM / Control System group.)
T3-3-18
COMPONENT OPERATION / Control Valve
Pilot Pressure from Flow Combiner Valve Control
Spool in Signal Control Valve
Pilot Pressure Pilot Pressure Oil from Aux. Pilot Valve
from Solenoid
Pilot Pressure from Bucket Flow Rate Control
Valve Unit (SG)
Valve Spool in Pilot pressure Signal Control Valve
Auxiliary Flow
Combiner
Valve
Main Relief
Valve
10
11
9
12
Bucket Flow
Flow Rate Control
Combiner Valve
Valve
Pilot Pressure 8
Oil from Aux-
iliary Flow 7
Rate Control
Solenoid
Valve
Auxiliary Flow
Rate Control 2
1
Solenoid 1
Valve
Arm Anti-Drift
Valve
Pilot Pres-
sure Oil from
Boom
Solenoid
Anti-Drift
Valve Unit 4 Valve
(SC)
3
3
Arm Regen-
erative Valve
(Up to serial
No.104678
(ZAXIS200 and Arm Flow Rate
225 class), Up to Control Valve
Bypass Shut-Out Valve
serial No.010326
(ZAXIS230 class),
Up to serial
No.020042
(ZAXIS270 class)) T178-03-03-040
Pilot Pressure Oil
from SE
T3-3-19
COMPONENT OPERATION / Control Valve
FLOW COMBINER VALVE
To Hydraulic
1. When a combined operation of the front attach- Oil Tank
ment and travel functions is made, the flow com-
biner control valve spool in the signal control
valve is shifted, causing pilot pressure oil to shift To Left Travel
Spool
the flow combiner valve spool.
2. When the flow combiner valve spool is shifted, Pressure Oil
from Pump 1
pressure oil from pump 1 flows to the left travel
spool.
3. Therefore, pressure oil from pump 1 is routed to Spool
both right and left travel spools. Then, pressure
oil from pump 2 is routed to the front attachment
and swing functions. Consequently, when a com-
bined operation of travel, front attachment, and
swing is made, the machine can travel straight.
T178-03-03-010
Pump 1 T176-03-03-026
T3-3-20
COMPONENT OPERATION / Control Valve
(Blank)
T3-3-21
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.
T3-3-22
COMPONENT OPERATION / Control Valve
During Normal Operation:
Main Poppet Orifice A Orifice B Seat Passage Spring B
HP SG
LP
HP
LP
HP SG
LP
T3-3-23
COMPONENT OPERATION / Control Valve
OVERLOAD RELIEF VALVE
(with Make-Up Function)
Passage A Valve
Pilot Pop-
Spring B Spring
pet
Chamber LP T198-03-03-006
T3-3-24
COMPONENT OPERATION / Control Valve
Boom, Arm and Bucket
HP
LP
Orifice Piston Spring Pilot Spring C T107-02-05-019
Chamber Poppet
During Relief Operation:
Main Poppet Sleeve Spring A Passage A Spring B
HP
LP
Orifice Piston Spring Pilot T178-03-03-049
Chamber Poppet
During Make-Up Operation:
Sleeve
HP
LP
Spring C T178-03-03-050
T3-3-25
COMPONENT OPERATION / Control Valve
REGENERATIVE VALVE
The regenerative valves are provided in the boom
lower, arm roll-in, and bucket roll-in circuits to in-
crease cylinder speeds and to prevent cylinder hesita-
tion, improving machine controllability.
Operation
1. When the bucket is rolled in, the return oil from
the cylinder rod side (bottom side of the boom
cylinder) enters hole A in the spool and acts on Bucket
the check valve. Cylinder
2. At this time, if pressure in the cylinder bottom
side (rod side of the boom cylinder) is lower than
the rod side, the check valve is opened.
3. Then, the return oil from the cylinder rod side
flows into the bottom side together with oil deliv-
ered from the pump, increasing the cylinder Check Valve
speed.
4. When the cylinder is moved full stroke or the dig- T176-03-03-027
T3-3-26
COMPONENT OPERATION / Control Valve
Orifice
Spool
Pressure Oil to
Cylinder Bottom
Check Valve Side
T178-03-03-052
T3-3-27
COMPONENT OPERATION / Control Valve
ARM REGENERATIVE VALVE
Operation
1. Normally, during arm rolled-in operation, the re-
turn 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 pres-
sure 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 deliv-
ered from the pump, increasing the cylinder
speed.
T3-3-28
COMPONENT OPERATION / Control Valve
Arm Regenerative
Valve
Arm 1 Arm 2
Spool
Spool
To Hydraulic
Oil Tank Hole
From Arm 1
Spool Pilot Pressure
Oil from
Solenoid Valve
Unit (SC)
T178-03-03-007
T178-03-03-018
T3-3-29
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 cir-
cuit, preventing the cylinders from drifting.
Holding Operation
1. When the control lever is in the neutral position
(neutral spool position), the switch valve in the Boom Cylinder
anti-drift valve is not shifted.
2. Thus, pressure oil from the boom cylinder bottom
side (arm cylinder rod side) exerts on the check
valve (spring side) in the anti-drift valve though
the switch valve.
3. Consequently, the check valve is closed so that
the return circuit from the cylinder is blocked, re-
ducing cylinder drift.
Releasing Operation
1. When the arm is rolled in or the boom is lowered,
pilot pressure oil from the pilot valve pushes the
T176-03-03-028
piston in the anti-drift valve so that the switch Anti-Drift Valve Anti-Drift Valve
valve is shifted. (Switch Valve) (Check Valve)
2. Then, oil in the check valve spring chamber flows To
back to the hydraulic oil tank through the switch Pressure Oil Hydraulic
from Pump 1 Oil Tank Boom Cylinder
valve.
3. Thereby, the check valve is opened, allowing the
return oil from the boom cylinder bottom side
(arm cylinder rod side) to flow to the spool.
From Pilot
Valve
To Hydrau-
lic Oil Tank
T176-03-03-029
T3-3-30
COMPONENT OPERATION / Control Valve
To Main Spool
T178-03-03-051
Check Valve
Cylinder
Bottom Side
Circuit
T3-3-31
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 Arm Cyl-
the circuit when a combined operation is made, giving inder
priority to other actuators.
NOTE: Each flow rate control valve functions in
respective combined operation as shown To Hydraulic
Oil Tank
below. As an example, the arm flow rate
control valve operation is explained in this
section.
Flow Rate
Combined Operation
Control Valve
Arm Swing and Arm Roll-In
Switch
Bucket Boom Raise and Arm Roll-In Valve
T178-03-03-031
T3-3-32
COMPONENT OPERATION / Control Valve
Spring B
To Main Spool
T178-03-03-013
T3-3-33
COMPONENT OPERATION / Control Valve
AUXILIARY FLOW COMBINER VALVE
AND BYPASS SHUT-OUT VALVE
NOTE: As for 2-piece boom, when the positioning During Single Operation of Attachment:
pilot valve is operated, the positioning pilot When only the aux. pilot valve is operated, pressure
pressure is routed to port SJ, shifting the oil from both pumps 1 and 2 is combined and sup-
bypass shut-out valve spool. plied together to the attachment, increasing attach-
ment speed.
The auxiliary flow combiner valve and the bypass 1. When only the aux. pilot valve is operated, the
shut-out valve are provided in the front and the rear of aux. pilot valve pilot pressure is routed to port SM
the 4-spool control valve section respectively. These and port SJ, shifting the auxiliary flow combiner
valve functions differ depending on whether only the valve and the bypass shut-off valve spools.
aux. pilot valve is operated or a combined operation 2. When the bypass shut-out valve spool is shifted,
with other front attachments is made. 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 attach-
ment operation speed.
T3-3-34
COMPONENT OPERATION / Control Valve
Pilot Pressure from
Signal Control Valve Aux. Pilot Valve
Auxiliary Flow Combiner
Auxiliary Flow Valve Control Solenoid
Combiner Valve Valve
Port SN Port SM
Attachment Neutral
Passage
Auxiliary
Port SJ
4-Spool Section
5-Spool Section
Pump 2 Pump 1
Positioning Pilot Valve
(2-Piece Boom Only)
Auxiliary Flow Combiner Valve
To Auxiliary Spool
T178-03-03-062
Port SM
Neutral Passage in
4-Spool Section
Spool Spring
Pressure Oil
from Pump 1
Spool
Check Valve
Spring
Port SJ T178-03-03-054
To Hydraulic
Port SN T178-03-03-053 Oil Tank
T3-3-35
COMPONENT OPERATION / Control Valve
During a Combined Operation of Attachment and Auxiliary Flow Combiner Valve
Front Attachment: To Auxiliary Spool
When 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 Port SM
the boom, arm, or bucket travel operation speed is
maintained.
1. When the aux. pilot valve is operated, the at-
tachment pilot pressure is routed to port SM of
the auxiliary flow combiner valve.
2. Then when the boom, arm, bucket, or travel func- Pressure Oil
tion is operated at the same time, pilot pressure From Pump 1
from the signal pilot pressure control valve is
routed to port SN. Spool
3. The auxiliary flow combiner valve spool receives
pressure from port SM in the opening direction Check Valve
and pressure from port SN in the closing direc-
tion. In addition, spring force acts on the spool in Spring
the closing direction.
4. Therefore, spool closing direction force is larger
than opening direction force, holding the spool
closed.
Port SN T178-03-03-053
T3-3-36
COMPONENT OPERATION / Pilot Valve
OUTLINE
1
Hydraulic P T
Symbol T
2
1 3 2 4 P
T105-02-07-020 T178-03-04-001
T3-4-1
COMPONENT OPERATION / Pilot Valve
ZAXIS200 class : Up to serial No. 107148
ZAXIS225 class
(ZAXIS225USR) : Up to serial No. 107149
(ZAXIS225US) : Up to serial No. 107197
ZAXIS230 class : Up to serial No. 10770
ZAXIS270 class : Up to serial No. 20234
Hydraulic P T
Symbol T
1 3 2 4
3 4
T105-02-07-020
2 1
T178-03-04-002
T3-4-2
COMPONENT OPERATION / Pilot Valve
ZAXIS200 class : Serial No. 109562 and up
ZAXIS225 class
(ZAXIS225USR) : Serial No. 109556 and up
(ZAXIS225US) : Serial No. 109546 and up
ZAXIS230 class : Serial No. 11231 and up
ZAXIS270 class : Serial No. 20336 and up
P
Hydraulic Symbol
T1M9-03-05-001
A
View A 4
2 P T 4 1 3 2 PT 4 1 3
1
T1M7-03-04-001 3
T1M9-03-05-002
2
T3-4-3
COMPONENT OPERATION / Pilot Valve
ZAXIS200 class : Serial No. 109562 and up
ZAXIS225 class
(ZAXIS225USR) : Serial No. 107150 and up
(ZAXIS225US) : Serial No. 107198 and up
ZAXIS230 class : Serial No. 10771 and up
ZAXIS270 class : Serial No. 20235 and up
P T P
T1M9-03-05-004
B
View B 3 4
1 2 4 3
T1M9-03-05-006
2
1
T1M9-03-05-005
T3-4-4
COMPONENT OPERATION / Pilot Valve
(Blank)
T3-4-5
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).
T3-4-6
COMPONENT OPERATION / Pilot Valve
Front Attachment / Swing Pilot Valve
1 1
2 2
6
3 3 Port T
4 4
7
5 5 Port P
6 Output Port
6
Port T Port T
7 Port P 7 Port P
2 2 Port T
7
Port P
3 3 6
4 4
5 Output Port
5
6
Port T Port T
6
Port P Port P
7 7
T3-4-7
COMPONENT OPERATION / Pilot Valve
During Metering or Decompressing (Output Dia-
gram: C to D)
1. When the control lever is further tilted to move E F
pusher (2) downward more, hole (7) on spool (6)
is opened to port P, allowing pressure oil in port P
D
to flow into the output port.
Pilot
2. Oil pressure in the output port acts on the bottom Pressure
face of spool (6) so that spool (6) is pushed up-
ward.
C
3. However, until upward force acting on the bottom
face of spool (6) overcomes balance spring (4)
force, balance spring (4) is not compressed. Then, A B
Lever Stroke
spool (6) is not raised, allowing oil pressure in the
output port to increase. T522-02-05-001
T3-4-8
COMPONENT OPERATION / Pilot Valve
Front Attachment / Swing Pilot Valve
1 1
2 2
3 3
4 4
5 5
6 6
Port T Port T
7 Port P 7 Port P
2 2
3 3
4 4
5 5
6 6
Port T Port T
Port P Port P
7 7
T3-4-9
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 E F
attachment / swing pilot valve comes in contact
with the casing shoulder, or cam (1) on the travel
D
pilot valve comes in contact with the casing. Pilot Pres-
2. At this moment, the bottom of pusher (2) directly sure
pushes spool (6). Therefore, even if oil pressure
in the output port increases further, hole (7) on
C
spool (6) is kept open.
3. Consequently, oil pressure in the output port is
equal to oil pressure in port P. A B
Lever Stroke
T522-02-05-001
T3-4-10
COMPONENT OPERATION / Pilot Valve
2 2
4
5
6
Port T
7 Port P
T178-03-04-010
Output Port T178-03-04-005
E
2
4
5
6
Port T
Port P
7
T178-03-04-006
Output Port T178-03-04-014
T3-4-11
COMPONENT OPERATION / Pilot Valve
SHOCKLESS FUNCTION
(ONLY FOR TRAVEL PILOT VALVE) Damper Spring Pin Travel Pedal
Operation
1. If the travel lever is released from the hand during T1M7-03-04-002
Pin
T1M7-03-04-003
T3-4-12
COMPONENT OPERATION / Travel Device
OUTLINE
The travel device consists of the travel motor, travel The travel reduction gear is a three stage reduction
reduction gear, and travel brake valve. The travel mo- planetary gear type, converting rotary power transmit-
tor is a swash plate type variable displacement axial ted from the travel motor to slow large torque causing
plunger motor, equipped with parking brake (wet-type the sprocket and track to rotate. The travel brake valve
negative multi-disc brake). The travel motor is driven protects the travel circuit from being overloaded and
by pressure oil from the pump and transmits its rotary prevents the occurrence of cavitation.
power to the travel reduction gear.
NOTE: The structure and theory of operation of the
travel device for ZAXIS 200 class, ZAXIS
225 class and ZAXIS 230 class can be
thought as identical. Only some parts differs.
This section describes the operation of
ZAXIS 200 class and ZAXIS 270 class.
Travel Brake Valve Travel Reduction Gear Travel Brake Valve Travel Reduction Gear
Sprocket
Sprocket
T178-03-05-012
T178-03-05-001
Travel Motor Travel Motor
T3-5-1
COMPONENT OPERATION / Travel Device
ZAXIS270 class
(ZAXIS270) : Up to serial No 20226
(ZAXIS270LCN): Up to serial No 82518
ZX270 class
The travel device consists of the travel motor, travel
reduction gear, and travel brake valve. The travel mo- Travel Brake Valve Travel Reduction Gear
tor is a bent axis type 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 transmit-
ted 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.
T1HG-03-05-001
Travel Motor
T3-5-2
COMPONENT OPERATION / Travel Device
ZAXIS270 class
(ZAXIS270) : Serial No 20227 and up
(ZAXIS270LCN): Serial No 22519 and up
The travel device consists of the travel motor, travel Travel Brake Valve Travel Reduction Gear
reduction gear, and travel brake valve. The travel mo-
tor is a swash plate type variable displacement axial
Sprocket
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 transmit-
ted 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.
T1HG-03-05-001
Travel Motor
T3-5-3
COMPONENT OPERATION / Travel Device
TRAVEL REDUCTION GEAR
The travel reduction gear is a Three stage reduction Travel motor housing (14) is bolted to the track frame
planetary gear type. and is secured to third stage carrier (2) by hub (11).
The travel motor rotates propeller shaft (7). This rota- Ring gear (1) is bolted to drum (13). Drum (13) is
tion is transmitted to ring gear (1) via first stage plane- bolted to sprocket (12). Accordingly, when ring gear (1)
tary gear (8), first stage carrier (6), first stage sun gear is rotated, drum (13) and sprocket (12) are also ro-
(5), second stage planetary gear (9), second stage tated.
carrier (4), second stage sun gear (3), third stage
planetary gear (10), and third stage carrier (2).
ZAXIS200 class
ZAXIS225 class
(ZAXIS225USR) : Up to serial No 108986
(ZAXIS225US) : Up to serial No 108985
ZAXIS230 class : Up to serial No 11128
1 2 3 4 5 6
14 13 11 10 9 8
12
T178-03-05-001
1 - Ring Gear 5 - First Stage Sun Gear 9 - Second Stage Planetary 12 - Sprocket
Gear
2 - Third Stage Carrier 6 - First Stage Carrier 10 - Third Stage Planetary Gear 13 - Drum
3 - Second Stage Sun Gear 7 - Propel Shaft 11 - Hub 14 - Housing
4 - Second Stage Carrier 8 - First Stage Planetary Gear
T3-5-4
COMPONENT OPERATION / Travel Device
ZAXIS270 class
(ZAXIS270) : Up to serial No 20226
(ZAXIS270LCN) : Up to serial No 82518
NOTE: The travel motor is another type of
ZAXIS270 (Serial No 20227 and up),
ZAXIS270LCN (Serial No 82519 and up).
(Refer to T3-5-7)
1 2 3 4 5 6
Travel Motor
11 10 9
14 13
12 T1HG-03-05-001
T3-5-5
COMPONENT OPERATION / Travel Device
TRAVEL MOTOR
ZAXIS200 class
ZAXIS225 class
(ZAXIS225USR) : Up to serial No 108986
(ZAXIS225US) : Up to serial No 108985
ZAXIS230 class : Up to serial No 11128
The travel motor is a variable-displacement swash Shoes on the tips of plungers slide along swash plate
plate axial plunger motor. The travel motor consists of surface due to the inclination of swash plate, causing
valve plate, swash plate, rotor, plungers, and shaft. rotor to rotate.
Shaft is splined to rotor, in which plungers are inserted.
When pressure oil is supplied from the pump, the
plungers are pushed.
T178-03-05-002
T3-5-6
COMPONENT OPERATION / Travel Device
ZAXIS225 class
(ZAXIS225USR) : Serial No 108987 and up
(ZAXIS225US) : Serial No 108986 and up
ZAXIS230 class : Serial No 11129 and up
T178-03-05-014
T3-5-7
COMPONENT OPERATION / Travel Device
ZAXIS270 class
(ZAXIS270) : Up to serial No 20226
(ZAXIS270LCN) : Up to serial No 82518
The travel motor is a variable-displacement bent-axis Pressure oil supplied to port AM of valve plate (2)
axial plunger motor. flows into rotor (14) bores underneath port AM, push-
The travel motor consists of the motor are plate (1), ing plungers (13). Vertical component force (FV) of
valve plate (2), rotor (14), plungers (13), center shaft plunger pushing force (F) rotates drive disc (7). As
(5), drive disc (7), servo piston (16), parking brake drive disc (7) rotates, rotor (14) also rotates.
piston (12), friction plates (11), and plates (10). When plungers (13) moves to port BM side, oil is
routed to the hydraulic oil tank.
Whether pressure oil from the pump is supplied to port
AM or BM determines travel direction.
1 2 3 4 5 6
14
13
BM 7
8
AM
9
FR
FV F
16 15 14 13 12 11 10
T140-03-02-002
T107-03-04-014
T3-5-8
COMPONENT OPERATION / Travel Device
ZAXIS270 class
(ZAXIS270): Serial No 20227 and up
(ZAXIS270LCN): Serial No 82519 and up
W1HH-03-02-006
T3-5-9
COMPONENT OPERATION / Travel Device
PARKING BRAKE
T3-5-10
COMPONENT OPERATION / Travel Device
When Applying Brake Plate Friction Plate When Releasing Brake Plate Friction Plate
Counterbalance
Spool
ZAXIS270 class
(ZAXIS270) Up to serial No 20226
(ZAXIS270LCN) Up to serial No 82518
To Breke Piston T178-03-05-008
Reducing Valve
NOTE: The drawing shown in the above is from
ZAXIS200.
Drain
I
Counterbalance Spool
BM T137-03-02-009
AM
T3-5-11
COMPONENT OPERATION / Travel Device
TRAVEL MODE CHANGE
ZAXIS200 class
ZAXIS225 class
(ZAXIS225USR) : Up to serial No 108986
(ZAXIS225US) : Up to serial No 108985
ZAXIS230 class : Up to serial No 11128
T3-5-12
COMPONENT OPERATION / Travel Device
6 7 8
1
Motor Port
(AM, BM)
To Drain
4 10 9
T178-03-05-004
T3-5-13
COMPONENT OPERATION / Travel Device
T3-5-14
COMPONENT OPERATION / Travel Device
6 7 8
1
Motor Port
(AM, BM)
4 10 9
T178-03-05-005
T3-5-15
COMPONENT OPERATION / Travel Device
ZAXIS225 class
(ZAXIS225USR): Serial No 108987 and up
(ZAXIS225US): Serial No 108986 and up
(ZAXIS225US for EN): Serial No 10876 and up
ZAXIS230 class: Serial No 11129 and up
ZAXIS270 class
(ZAXIS270): Serial No 20227 and up
(ZAXIS270LCN): Serial No 82519 and up
T3-5-16
COMPONENT OPERATION / Travel Device
1
Motor Port
(AM, BM)
ドレンへ
4 5 7 8
T178-03-05-010
T3-5-17
COMPONENT OPERATION / Travel Device
T3-5-18
COMPONENT OPERATION / Travel Device
1
Motor Port
(AM, BM)
4 5 6 7 8
T178-03-05-011
T3-5-19
COMPONENT OPERATION / Travel Device
ZAXIS270 class
(ZAXIS270): Up to serial No 20226
(ZAXIS270LCN): Up to serial No 82518
• Slow Speed
1. When the slow speed travel mode is selected, the 3. Accordingly, as the stroke of the plungers in the
MC (Main Controller) does not send out an motor is increased, slower revolution of the travel
electronic control signal to solenoid valve unit (SI). motor for low speed mode is obtained.
Therefore, speed change pilot pressure is not
routed to servo piston (1). Thus, spool (3) is held
down by spring (2).
2. Then, pressure oil P from the motor port is led to
both chambers “B” and “C”.
Since the pressure-receiving area in chamber “C”
is larger than that in chamber “B”, servo piston (1)
moves upward, increasing swash angle to the
maximum.
6 7
2 Drain
Pilot Pressure
T157-03-02-001
T3-5-20
COMPONENT OPERATION / Travel Device
• Fast Speed Travel Mode
1. When the fast speed travel mode is selected, 3. As pressure oil P from the motor port is led to
corresponding to travel loads, the MC sends out chamber “B”, servo piston (1) is moved down,
an electronic control signal to solenoid valve unit reducing the swash angle of rotor (7).
(SI). Therefore, speed change pilot pressure is Accordingly, as the stroke of the plungers in the
routed to chamber “D”, moving spool (3) upward. motor is decreased, faster revolution of the travel
2. Then, passage “E” opens and oil in chamber “C” motor for fast speed mode is obtained.
is drained through the inner passages in spool (Refer to the Control System Group in the
(3). SYSTEM Section.)
6 1
7
2
Drain
P
3
B
E
Pilot Pressure
Drain
5 4
P
Pilot Pressure
T157-03-02-002
T3-5-21
COMPONENT OPERATION / Travel Device
TRAVEL BRAKE VALVE
T3-5-22
COMPONENT OPERATION / Travel Device
1 2 3
7 6 5 4
T178-03-05-003
1 - Counter Balance Valve 3- Slow-Speed Orifice 5- Travel Motor Swash Plate 7- Overload Relief Valve
Angle Control Valve
2 - Check Valve 4- Fast-Speed Orifice 6 - Shuttle Valve
T3-5-23
COMPONENT OPERATION / Travel Device
ZAXIS270 class
(ZAXIS270) : Up to serial No 20226
(ZAXIS270LCN): Up to serial No 82518
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.
Counterbalance Valve:
ensures smooth starts and stops and prevents
overrunning when traveling down slopes.
T3-5-24
COMPONENT OPERATION / Travel Device
4 2
1 1
AM BM
AV BV
A
Section A-A
6 3
Section B Section C
T1HG-03-05-002
1 - Check Valve 3- Parking Brake Release 5- Counterbalance Valve 6- Servo Piston Operating
Shuttle Valve Shuttle Valve
2 - Reducing Valve 4 - Overload Relief Valve
T3-5-25
COMPONENT OPERATION / Travel Device
While Traveling: While descending:
1. When pressure oil from the control valve enters 1. While descending a slope, the travel motor is
port BV (8), pressure oil flows around the outer forcibly rotated by the machine weight so that the
diameter of spool (9), unseats check valve BC (7), motor operates like a pump, drawing oil.
and flows further to motor port BM (6). 2. If the travel motor draws oil, oil pressure in port
2. On the other hand, the return oil from the travel BV (8) and chamber B (10) will decrease, causing
motor is routed to motor port AM (4). However, its spool (9) to the left so that the return oil flow from
passage is blocked by check valve AC (3) and the travel motor is restricted.
spool (9). 3. Therefore, oil pressure in motor port AM (4) will
3. When oil pressure in port BV (8) increases, increase, braking the travel motor.
pressure oil is routed into chamber B (10) through 4. Once pressure oil flow is restricted, oil pressure in
orifice (f) in spool (9), moving spool (9) to the motor port AM (4) will increase again, moving
right. spool (9) to the right. As this operation (hydraulic
4. Consequently, the return oil from the travel motor braking operation) is repeated, the machine is
flows to port AV (1) through notch (h) on spool (9). prevented from running away.
Then, pressure oil is allowed to flow so that the
travel motor starts rotating. Circuit Protection Operation:
5. When the travel lever is returned to neutral, spool 1. When oil pressure in the circuit increases over the
(9) is returned to the original position by spring set-pressure of overload relief valve (5), the
force, blocking the oil passage so that the travel overload relief valve is opened, allowing the high
motor rotation is stopped. pressure oil to relieve to the low pressure side so
that the travel motor is protected from being over-
loaded.
2. In addition, the overload relief valve relieves the
shock loads developed due to inertia force when
stopping the travel motor.
3. If the travel motor draws oil like a pump, check
valve BC (7) is unseated (make-up operation) so
that cavitation is prevented.
T3-5-26
COMPONENT OPERATION / Travel Device
ZAXIS 200 class, 225 class, 230 class,
ZAXIS270 class
(ZAXIS270): Serial No 20227 and up
(ZAXIS270LCN): Serial No 82519 and up
10 8 9 1 2
BV AV
6
4
7
3
T178-03-05-006
ZAXIS270 class
5
(ZAXIS270): Up to serial No 20226
(ZAXIS270LCN): Up to serial No 82518
4 6
h
f
AV BV
T140-03-02-005
10 1 8 2
T3-5-27
COMPONENT OPERATION / Travel Device
(Blank)
T3-5-28
COMPONENT OPERATION / Signal Control Valve
OUTLINE
The signal control valve is provided in the pilot circuit
between the pilot valve and the control valve and con-
trols pilot signal pressure used to regulate the pumps
and various kinds of valves.
The major components of the signal control valve are,
shuttle valves, shockless valve, pump 1 flow rate con-
trol valve, pump 2 flow rate control valve, flow com-
biner valve control spool, bucket flow rate control
valve control spool, swing parking brake release spool
and *arm flow rate control valve control spool.
T178-03-06-016
Cross Section A-A
Shockless Valve
Pump 1 Flow Rate Control Valve Pump 2 Flow Rate Control Valve
T178-03-06-002
NOTE: * Serial No.104679 and Up (ZX200 class NOTE: **Up to Serial No.104678
and 225 class) ((ZX200 class and 225 class)
Serial No.010327 and Up (ZX230 class) Up to Serial No.010326 (ZX230 class)
Serial No.020043 and Up (ZX270 class) Up to Serial No.020042 (ZX270 class)
T3-6-1
COMPONENT OPERATION / Signal Control Valve
PILOT PORT
T3-6-2
COMPONENT OPERATION / Signal Control Valve
E
M
D
H
B
F
SB
PI G
K N
I
SH
J
DF
SA L
T178-03-06-016
1 5
13
2 4
SK
SE
14
Control Valve Side
7
9
6
10
SN
SL
11
T3-6-3
COMPONENT OPERATION / Signal Control Valve
T3-6-4
COMPONENT OPERATION / Signal Control Valve
Pilot Valve Side
PH
C
A
E
M
D
H
B
F
SB
PI G
K N
I
SH
J
DF
SA L
T178-03-06-016
1 5
13
2 4
SK
SE
14
Control Valve Side
7
9
6
10
SN
SL
11
T3-6-5
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 corre-
sponding flow rate control valves and/or switch valve
spools. The flow rate control valves and/or switch
valve spools corresponding to each operation are as
follows:
Pump 1 Flow Pump 2 Flow Flow Com- Bucket Flow Swing Park- *Arm Flow
Rate Control Rate Control biner Valve Rate Control ing Brake Rate Con-
Valve Valve Control Spool Valve Control Release trol Valve
Spool Spool Control
Spool
Boom Raise { { - - { -
Boom Lower { - - - { -
Arm Roll-In { { - - { -
Arm Roll-Out { { - { { {
Bucket Roll-In { - - - { -
Bucket Roll-Out { - - - { -
Right Swing - { - - { -
Left Swing - { - - { -
Right Travel { - { - - -
Left Travel - { - - - -
Auxiliary **{ - - - { -
NOTE: *Serial No.104679 and up (ZAXIS200
class and 225 class)
Serial No.010327 and up (ZAXIS230
class)
Serial No.020043 and up (ZAXIS270
class)
NOTE: **The pump 1 flow rate control valve is op-
erated by pressure oil from the auxiliary
pilot valve as for only the machine
equipped with the optional parts.
T3-6-6
COMPONENT OPERATION / Signal Control Valve
5 6 7 8 9 10
Left Right
Swing Arm Boom Bucket
Travel Travel 11
1 2 3 4
12
13
14 15 16 17
Pump 1 Flow Pump 2 Flow Bucket Flow Flow Combiner Swing Parking *Arm Flow Rate
Rate Control Rate Control Rate Control Valve Control Brake Release Control Valve
Valve Valve Valve Control Spool Spool Control Spool
Spool
T178-03-06-018
T3-6-7
COMPONENT OPERATION / Signal Control Valve
T178-03-06-016
9
5
8
7
16
17
15 13
11
14
6 10
12
3
1
4
2
T178-03-06-009
1 - Left Travel 6- Boom / Arm / Bucket / Right 11 - Boom / Arm / Bucket 16 - Swing / Auxiliary
Travel
2 - Left Travel/Right Travel 7 - Boom/Arm 12 - Boom / Arm / Bucket / Swing / 17 - Auxiliary
Auxiliary
3 - Right Travel 8- Boom 13 - Arm / Boom Raise / Swing /
Auxiliary
4 - Boom / Arm / Bucket / Right 9- Arm / Boom Raise 14 - Bucket
Travel
5 - Arm 10 - Boom Raise / Arm / Bucket / 15 - Swing
Left Travel / Swing
T3-6-8
COMPONENT OPERATION / Signal Control Valve
(Blank)
T3-6-9
COMPONENT OPERATION / Signal Control Valve
SHOCKLESS VALVE
The shockless valve is provided in the boom raise cir-
cuit and functions during boom lowering operation.
T3-6-10
COMPONENT OPERATION / Signal Control Valve
Port A
Inner Passage 1 C Spool Spring B
Port 1
T178-03-06-013
T3-6-11
COMPONENT OPERATION / Signal Control Valve
PUMP 1 AND PUMP 2 FLOW RATE CON-
TROL VALVES
The pump flow rate control valve delivers pump con-
trol pressure Pi to the pump regulator in response to
the pilot oil pressure from the pilot valve.
T3-6-12
COMPONENT OPERATION / Signal Control Valve
Port SA, SB
Spool
Spring
To Hydraulic Oil
Tank
Camber A
Shuttle Valve
Primary Pilot
Pressure
Pilot Pressure
T1V1-03-06-005
T3-6-13
COMPONENT OPERATION / Signal Control Valve
BUCKET FLOW RATE CONTROL VALVE
CONTROL SPOOL, FLOW COMBINER
VALVE CONTROL SPOOL, SWING PARK-
ING BRAKE RELEASE SPOOL, *ARM
FLOW RATE CONTROL VALVE CONTROL Bucket Flow Rate Control Valve Control Spool:
SPOOL To Hydraulic Boom Raise Control
Oil Tank Pilot Pressure
Spool Spring
NOTE: The three captioned spools are identical in
operational principle.
T178-03-06-014
Boom, Arm, To Swing
Bucket and Motor
Auxiliary Pilot
Pressure
T178-03-06-014
Arm Roll-in Arm Flow
Control Pilot Rate Control
Pressure Valve
T3-6-14
COMPONENT OPERATION / Others (Upperstructure)
PILOT SHUT-OFF VALVE
Section Z-Z
The pilot shut-off valve is a manual-operated switch ZAXIS200, 225USR class
valve. The spool in the pilot shut-off valve is rotated by ZAXIS230, 270 class
moving the pilot control shut-off lever to turn on or off
the pilot oil flow to the pilot valves.
T1 T2 A3 A4 T4
T3 P
A5 T178-03-07-003
A1 - Right Pilot Valve A4 - Signal Control Valve T1 - Travel Pilot Valve T - Hydraulic Oil Tank
(Port PH)
A2 - Travel Pilot Valve A5 - Signal Control Valve T2 - Left Pilot Valve
(Port PI)
A3 - Left Pilot Valve P - Primary Pilot Pressure T3 - Right Pilot Valve
T3-7-1
COMPONENT OPERATION / Others (Upperstructure)
SOLENOID VALVE UNIT
Two kinds of solenoid valve are provided: the solenoid Serial No.104679 and up (ZX200 class and 225 class)
valve unit to control pumps and valves, and the boom Serial No.010327 and up (ZX230 class)
electronic cushion solenoid valve (ZAXIS225US: Up to Serial No.020043 and up (ZX270 class)
serial No.104908) to control the boom electronic
cushion.
SC SE SI SG T178-01-02-003
T3-7-2
COMPONENT OPERATION / Others (Upperstructure)
Proportional Solenoid Valve
• When not energized (In neutral): • Because of the pressure receiving area difference
The spring pushes the spool to the right, between the two walls, the pressure at port S acts
connecting the output port S to the tank port T. as a force to push the spool to the right. As the
pressure at port S increases, the force to push the
• When energized: spool to the right also increases. When this force
The solenoid pushes the spool to the left for a overcomes the force to push the spool to the left
distance proportional to the electric current by solenoid, the spool moves back to the right
flowing through the solenoid. Pilot oil from port (P) side, closing the passage between output port S
flows into output port S, increasing the pressure and port P. As a result, pressure increase at port
at output port S. The pressure at port S acts on S stops.
the two banks of walls on the spool. (See detail
“a.”)
a
T107-02-07-005
T3-7-3
COMPONENT OPERATION / Others (Upperstructure)
Boom Electronic Cushion Solenoid Valve
(Up to Serial No.104908 (ZAXIS225US))
Output Port
The boom electronic cushion solenoid valve reduces
the boom raise pilot pressure by the signal from MC
(Main Controller).
By reducing the pressure, the spool in the control
valve is controlled to reduce the shock which may
occur when the boom reaches to its full stroke position.
(Refer to SYSTEM / Control System group.)
Operation:
1. Port P and output port are connected by the spool
notch when neutral.
2. When the power flows to the solenoid from MC
(Main Controller), the solenoid is energized and
T1GF-03-07-001
pushes spring 1.
3. As spring 1 pushes the spool, the output port and Port P Port T
port T are connected by the spool notch.
Therefore, the pressure in the output port begins
to decrease.
4. The right side of spool diameter (B) is larger than
the left side of spool diameter (A).
5. Therefore, until the pressure at the output port
disappears, the external force applied onto the
spool is expressed as P1 × B + S1 > P1 × A + S2.
Then, the spool is move toward the right side.
6. When the oil pressure at the output port disap-
pears so that when P1 × B + S1 becomes equal to
P1 × A + S2 (P1 × B + S1 = P1 × A + S2), the
spool stops moving.
T3-7-4
COMPONENT OPERATION / Others (Upperstructure)
When Neutral:
T176-03-01-030
A Port P Port T B
Output Port
When in Operation:
T176-03-01-031
A Port P Port T B
Output Port
T3-7-5
COMPONENT OPERATION / Others (Upperstructure)
HOLDING VALVE
(Only on the machines equipped with the corre-
sponding optional parts.)
Valve
through passage c, is blocked by the spool. The
pressure in the chamber a is applied to the spool
through passage c, but not transmitted to pas-
sage a by blocking with the spool.
4. As a result, the cylinder pressure at cylinder port
B is maintained unchanged. Therefore, even if
any hose at the front attachment is punctured, the
front attachment is held in position to avoid unin-
tended lowering.
T3-7-6
COMPONENT OPERATION / Others (Upperstructure)
X Passage a
Section X-X
Passage b
Spool
Passage c
Chamber a
Poppet
Port A Port B
X
T178-03-07-008
T3-7-7
COMPONENT OPERATION / Others (Upperstructure)
• Holding valve operation when the boom lower con-
trol lever is operated The Boom Lower Control Lever: Half Stroke or less
1. When moving the boom lower control lever at half
stroke or less, the pilot pressure Pi acts on the Chamber a Passage c Passage b Relief
spool, and makes the spool move to the orifice B Valve
position.
2. At this time, the spool blocks passage B, so that
the poppet is pushed against the seat.
3. As a result, the pressurized oil from the port B Orifice A
flows through passages c and a in order to lower
Poppet
the boom.
4. When moving the boom lower control lever at half
stroke or more, the pilot pressure Pi acts on the
Pressure
spool, and makes the spool shift to the orifice C Pi
position.
5. Then, passages b and a are connected through Port B
Spool
orifice C. At this time, an oil passage, from port B Port A
to orifice A to chamber a to passage b to orifice C To the Spool
to passage a to port A, is opened. in the Control Seat Passage a Orifice B
6. The oil from passage c is blocked by the spool, so Valve T178-03-07-009
Passage A
Orifice C
Pressure
Pi
Port B
Spool
T3-7-8
COMPONENT OPERATION / Others (Upperstructure)
Section X-X
X Relief Valve
Passage a
Orifice B Spool
Pressure Pi
Orifice C Passage b
Passage c Chamber a
Spring
Orifice A
From Port B
Poppet
Port A Port B
X
T178-03-07-008
T3-7-9
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
P
pump pressure oil routed to port P to a set constant
pressure.
Pilot Filter
T178-03-07-001
Motor
Sensor EC Worm
Gear Sensor Wheel
T157-02-05-018
T3-7-10
COMPONENT OPERATION / Others (Undercarriage)
SWING BEARING
This bearing is a single-row shear ball-type bearing, The internal gear of inner race (3) engages with the
comprising outer race (1), inner race (3), balls (6), output shaft of the swing reduction gear.
supports (5), and seals (2), (4). Outer race (1) is
bolted to the upperstructure and inner race (3) is
bolted to the undercarriage.
T135-03-02-001
T3-8-1
COMPONENT OPERATION / Others (Undercarriage)
CENTER JOINT
The center joint is a 360° rotating joint. When the Hydraulic oil flows to the right and left travel motors
upperstructure is rotated, the center joint avoids via spindle (1) and the oil ports of body (2). Seals (3)
twisting of hoses and allows hydraulic oil to flow prevent oil leaks between spindle (1) and body (2)
smoothly to or from the travel motors. Spindle (1) is into adjacent passages.
attached to the main frame, and body (2) is bolted to
the swing center of the undercarriage.
1
Pilot Pressure Pilot Pressure
for Travel Speed Selection Drain for Travel Speed
Selection
Drain
Drain 3
Drain
: Forward
: Reverse
: Pilot Pressure
for Travel Speed Selection
T157-03-02-004
T3-8-2
COMPONENT OPERATION / Others (Undercarriage)
TRACK ADJUSTER
The track adjuster located on the side frame is CAUTION: Do not loosen valve (1) quickly
composed of spring (5) and adjuster cylinder (6). or loosen too much since high-pressure
Spring (5) absorbs loads applied to the front idler. grease in the adjusting cylinder may spout
Adjuster cylinder (6) adjusts track sag. out.
Loosen carefully, keeping body parts and
• Grease is applied through grease fitting into face away from valve (1).
chamber A of adjuster cylinder (6) as illustrated Never loosen grease fitting.
below. The pressure of the grease pushes
piston rod (8) out and decreases track sag.
M104-07-119
1 2 3 4 A 5 6 7 8
W178-03-04-002
T3-8-3
COMPONENT OPERATION / Others (Undercarriage)
(Blank)
T3-8-4
MEMO
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Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-29-831-1162
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