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Technical Manual

(Operational Principle)

Vol No.: TO178E-02


INTRODUCTION
TO THE READER

• 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 manual.
• Be sure to thoroughly read this manual for correct (Note: Do not tear off the form. Copy it for us-
product information and service procedures. 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

• Each page has a number, located on the center


lower part of the page, and each number contains
the following information:

Example : T 1-3-5

Consecutive Page Number for Each Group


Group Number
Section Number
T: Technical Manual W: Workshop Manual

SAFETY ALERT SYMBOL AND HEADLINE


NOTATIONS
• CAUTION:
In this manual, the following safety alert symbol and Indicated potentially hazardous situation which could,
signal words are used to alert the reader to the if not avoided, result in personal injury or death.
potential for personal injury of machine damage.
• IMPORTANT:
This is the safety alert symbol. When you see this Indicates a situation which, if not conformed to the
symbol, be alert to the potential for personal injury. instructions, could result in damage to the machine.
Never fail to follow the safety instructions prescribed
along with the safety alert symbol.
The safety alert symbol is also used to draw attention • NOTE:
to component/part weights. Indicates supplementary technical information or
To avoid injury and damage, be sure to use appropri- know-how.
ate lifting techniques and equipment when lifting heavy
parts.

IN-02
INTRODUCTION
UNITS USED
2
• SI Units (International System of Units) are used in Example : 24.5 MPa (250 kgf/cm , 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
2
Length mm in 0.03937 Pressure MPa kgf/cm 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
3 3
m yd 1.308 Temperature °C °F °C×1.8+32
Weight kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min 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

Hitachi machine models are classified into 4 classes and 1 model as


shown in the table below. When referring to the texts and/or illustrations
indicated with the applicable machine class names in this manual,
check that the machine models concerned are included using this table.
Class
ZX200 Class ZAXIS200, 200LC, 210H, 210LCH, 210, 210LC, 210N
ZX225 Class ZAXIS225USR, 225USRLC, 225US, 225USLC
ZX230 Class ZAXIS230, 230LC, 240H, 240LCH, 250, 250LC
ZX270 Class ZAXIS270, 270LC, 280LC
Model
Std. Model 200, 200LC, 210, 210LC, 210H, 210LCH, 210N, 225USR, 225USRLC,
225US, 225USLC, 230, 230LC, 240H, 240LCH, 250, 250LC, 270, 270LC, 280LC

IN-04
SECTION 1
GENERAL

―CONTENTS―
Group 1 Specifications
Specifications .......................................... T1-1-1
Working Ranges ...................................... T1-1-8

Group 2 Component Layout


Main Component Layout .......................... T1-2-1
Electrical Component Layout ................... T1-2-4
(Overview)
Electrical System .................................... T-1-2-7
(Relays and Related Equipment)
Electrical System .................................. T-1-2-9
(Monitors and Switches)
Pump Device ......................................... T1-2-10
Swing Device......................................... T1-2-10
Control Valve ..........................................T1-2-11
Signal Control Valve ...............................T1-2-11
Solenoid Valve Unit.................................T1-2-11
Travel Device......................................... T1-2-12
Positioning Control Valve ....................... T1-2-12

Group 3 Component Specifications


Engine ..................................................... T1-3-1
Engine Accessories ................................. T1-3-8
Hydraulic Component .............................. T1-3-9
Electrical Component............................. T1-3-15

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

ZX200 Hydraulic ZX200LC Hydraulic ZX210H Hydraulic ZX210LCH Hydraulic


Model
Excavator Excavator Excavator Excavator
Type of Front-End Attachment 2.22 m (7 ft 3 in) Arm or 2.91 m (9 ft 7 in) Arm 2.91 m (9 ft 7 in) H Arm
Bucket Capacity (Heaped) PCSA 0.8 m3 (1.05 yd3), CECE 0.7 m3
Operating Weight 19400 kg (42800 lb) 19900 kg (43900 lb) 20300 kg (44800 lb) 20800 kg (45900 lb)
Basic Machine Weight 15100 kg (33300 lb) 15600 kg (34400 lb) 15800 kg (34800 lb) 16300 kg (35900 lb)
Isuzu AA-6BG1T 103 kW/1900 min–1 (140 PS/1900 rpm)
Engine
’ 110 kW / 2100 min–1 (150 PS /2100 rpm)
A: Overall Width
2860 mm (9 ft 5 in) 2990 mm (9 ft 10 in) 2860 mm (9 ft 5 in) 2990 mm (9 ft 10 in)
(Excluding back mirrors)
B: Cab Height 2950 mm (9 ft 8 in) 2950 mm (9 ft 8 in) 2950 mm (9 ft 8 in) 2950 mm (9 ft 8 in)
C: Rear End Swing Radius 2750 mm (9 ft 0 in) 2750 mm (9 ft 0 in) 2750 mm (9 ft 0 in) 2750 mm (9 ft 0 in)
D: Minimum Ground Clearance * 450 mm (18 in) (Excluding shoe lug)
E: Counterweight Clearance * 1030 mm (3 ft 5 in) (Excluding shoe lug)
F: Engine Cover Height * 2220 mm (7 ft 3 in) (Excluding shoe lug)
G: Overall Width of Upperstructure 2710 mm (8 ft 11 in) 2710 mm (8 ft 11 in) 2710 mm (8 ft 11 in) 2710 mm (8 ft 11 in)
H: Undercarriage Length 4170 mm (13 ft 8 in) 4460 mm (14 ft 8 in) 4170 mm (13 ft 8 in) 4460 mm (14 ft 8 in)
I: Undercarriage Width 2800 mm (9 ft 2 in) 2990 mm (9 ft 10 in) 2800 mm (9 ft 2 in) 2990 mm (9 ft 10 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) 3660 mm (12 ft 0 in)
K: Track Shoe Width 600 mm (24 in) (Grouser shoe)
43 kPa 41 kPa 45 kPa 43 kPa
Ground Pressure
(0.44 kgf/cm2, 6.3 psi) (0.42 kgf/cm2, 6.0 psi) (0.46 kgf/cm2, 6.5 psi) (0.44 kgf /cm2, 6.1 psi)
Swing Speed 13.3 min–1 (rpm) 13.3 min–1 (rpm) 13.3 min–1 (rpm) 13.3 min–1 (rpm)
Travel Speed (fast/slow) 5.5/3.6 km/h (3.4/2.2 mph)
Gradeability 35° (tanθ = 0.70)

NOTE: ’ H/P mode


* The dimensions do not include the height of the shoe lug.

T1-1-1
GENERAL / Specifications

ZAXIS210, ZAXIS210LC, ZAXIS210N


A C

E
D

K J

I H

M178-12-001

Model ZAXIS210 ZAXIS210LC ZAXIS210N


Type of Front-End Attachment 2.91 m (9 ft 7 in) Arm
Bucket Capacity (Heaped) PCSA 0.8 m3 (1.05 yd3), CECE 0.7 m3
Operating Weight 19600 kg (43200 lb) 20100 kg (44300 lb) 19500 kg (43000 lb) 19800 kg (43700 lb)
Basic Machine Weight 15200 kg (33500 lb) 15700 kg (34600 lb) 15100 kg (33300 lb) 15400 kg (34000 lb)
Isuzu AA-6BG1T 103 kW/1900 min–1 (140 PS/1900 rpm)
Engine
’ 110 kW / 2100 min–1 (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) 2950 mm (9 ft 8 in) 2950 mm
C: Rear End Swing Radius 2750 mm (9 ft 0 in) 2750 mm (9 ft 0 in) 2680 mm (8 ft 10 in)
D: Minimum Ground Clearance * 450 mm (18 in) (Excluding shoe lug)
E: Counterweight Clearance * 1030 mm (3 ft 5 in) (Excluding shoe lug)
F: Engine Cover Height * 2220 mm (7 ft 3 in) (Excluding shoe lug)
G: Overall Width of Upperstructure 2710 mm (8 ft 11 in) 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)
44 kPa 42 kPa 52 kPa 44 kPa
Ground Pressure 2
(0.45 kgf/cm2, 6.4 psi) (0.43 kgf/cm2, 6.1 psi) (0.53 kgf/cm , 7.5 psi) (0.45 kgf/cm2, 6.4 psi)
Swing Speed 13.3 min–1 (rpm)
Travel Speed (fast/slow) 5.5/3.6 km/h (3.4/2.2 mph)
Gradeability 35° (tanθ = 0.70)
NOTE: ’ H/P mode
* The dimensions do not include the height of the shoe lug.

T1-1-2
GENERAL / Specifications

ZAXIS225USR, ZAXIS225USRLC
A,G C

B
F

E
D

K J
I
H
M178-12-007

Model ZAXIS225USR ZAXIS225USRLC


Type of Front-End Attachment 2.91 m (9 ft 7 in) Arm
Bucket Capacity (Heaped) PCSA 0.8 m3 (1.05 yd3), CECE 0.7 m3
Operating Weight 22000 kg (48500 lb) 22500 kg (49600 lb)
Basic Machine Weight 17800 kg (39240 lb) 18300 kg (40340 lb)
–1
Isuzu AA-6BG1T 103 kW/1900 min (140 PS/1900 rpm)
Engine
’110 kW/2100 min–1 (150 PS/2100 rpm)
A: Overall Width
2860 mm (9 ft 5 in) 2990 mm (9 ft 10 in)
(Excluding back mirrors)
B: Cab Height 2950 mm (9 ft 8 in)
C: Rear End Swing Radius 1990 mm (6 ft 6 in)
D: Minimum Ground Clearance *450 mm (18 in)
E: Counterweight Clearance * 1020 mm (3 ft 4 in)
F: Engine Cover Height * 2220 mm (7 ft 3 in)
G: Overall Width of Upperstructure 2860 mm (9 ft 5 in)
H: Undercarriage Length 4170 mm (13 ft 8 in) 4460 mm (14 ft 8 in)
I: Undercarriage Width 2800 mm (9 ft 2 in) 2990 mm (9 ft 10 in)
J: Sprocket Center to Idler Center 3370 mm (11 ft 1 in) 3660 mm (12 ft)
K: Track Shoe Width 600 mm (24 in) (Grouser shoe)
Ground Pressure 49 kPa (0.50 kgf/cm2, 7.1 psi) 47 kPa (0.48 kgf/cm2, 6.8 psi)
–1
Swing Speed 13.3 min (rpm)
Travel Speed (fast/slow) 5.3/13.3 km/h (3.3/2.1 mph)
Gradeability 35° (tanθ = 0.70)

NOTE: ’ H/P mode


* The dimensions do not include the height of the shoe lug.

T1-1-3
GENERAL / Specifications

ZAXIS225US, ZAXIS225USLC
A C

B
F

E
D

K J
I H

M1GF-12-001

Model ZAXIS225US ZAXIS225USLC


Type of Front-End Attachment 2.91 m (9 ft 7 in) Arm
Bucket Capacity (Heaped) PCSA 0.8 m3 (1.05 yd3), CECE 0.7 m3
Operating Weight 23000 kg (50710 lb) 23500 kg (51810 lb)
Basic Machine Weight 18800 kg (41450 lb) 19300 kg (42550 lb)
Isuzu AA-6BG1T 103 kW/1900 min–1 (140 PS/1900 rpm)
Engine
’110 kW/2100 min–1 (150 PS/2100 rpm)
A: Overall Width
2810 mm (9 ft 3 in) 2990 mm (9 ft 10 in)
(Excluding back mirrors)
B: Cab Height 2950 mm (9 ft 8 in)
C: Rear End Swing Radius 1680 mm (5 ft 6 in)
D: Minimum Ground Clearance *450 mm (18 in)
E: Counterweight Clearance * 980 mm (3 ft 3 in)
F: Engine Cover Height * 2220 mm (7 ft 3 in)
G: Overall Width of Upperstructure 2810 mm (9 ft 3 in)
H: Undercarriage Length 4170 mm (13 ft 8 in) 4460 mm (14 ft 8 in)
I: Undercarriage Width 2800 mm (9 ft 2 in) 2990 mm (9 ft 10 in)
J: Sprocket Center to Idler Center 3370 mm (11 ft 1 in) 3660 mm (12 ft)
K: Track Shoe Width 600 mm (24 in) (Grouser shoe)
Ground Pressure 52 kPa (0.53 kgf/cm2, 7.5 psi) 49 kPa (0.50 kgf/cm2, 7.1 psi)
–1
Swing Speed 13.3 min (rpm)
Travel Speed (fast/slow) 5.3/3.3 km/h (3.3/2.1 mph)
Gradeability 35° (tanθ = 0.70)

NOTE: ’ H/P mode


* The dimensions do not include the height of the shoe lug.

T1-1-4
GENERAL / Specifications

ZAXIS230, 230LC, 240H, 240LCH, 250, 250LC


A C

E
D

K J

I H

M178-12-001

ZX230, 250 Hydraulic ZX230LC, 250LC ZX240H Hydraulic ZX240LCH Hydraulic


Model
Excavator Hydraulic Excavator Excavator Excavator
Type of Front-End Attachment 2.96 m (9 ft 9 in) 2.96 m (9 ft 9 in) H Arm
Bucket Capacity (Heaped) PCSA 1.0 m3 (1.3 yd3), CECE 0.9 m3
Operating Weight 23000 kg (50700 lb) 23600 kg (52000 lb) 24300 kg (53600 lb) 24900 kg (54900 lb)
Basic Machine Weight 17500 kg (38600 lb) 18100 kg (39900 lb) 18500 kg (40800 lb) 19100 kg (42100 lb)
Isuzu CC-6BG1T 118 kW/2000 min–1 (160 PS/2000 rpm)
Engine
’125 kW/2100 min–1 (170 PS/2100 rpm)
A: Overall Width
2990 mm (9 ft 10 in) 3090 mm (10 ft 2 in) 2990 mm (9 ft 10 in) 3090 mm (10 ft 2 in)
(Excluding back mirrors)
B: Cab Height 3020 mm (9 ft 11 in)
C: Rear End Swing Radius 2940 mm (9 ft 8 in)
D: Minimum Ground Clearance *460 mm (18 in) (Excluding shoe lug)
E: Counterweight Clearance * 1090 mm (3 ft 7 in) (Excluding shoe lug)
F: Engine Cover Height * 2290 mm (7 ft 6 in) (Excluding shoe lug)
G: Overall Width of Upperstructure 2890 mm (9 ft 6 in)
H: Undercarriage Length 4260 mm (13 ft 12 in) 4640 mm (15 ft 3 in) 4260 mm (13 ft 12 in) 4640 mm (15 ft 3 in)
I: Undercarriage Width 2990 mm (9 ft 10 in) 3190 mm (10 ft 6 in) 2990 mm (9 ft 10 in) 3190 mm (10 ft 6 in)
J: Sprocket Center to Idler Center 3460 mm (11 ft 4 in) 3840 mm (12 ft 7 in) 3460 mm (11 ft 4 in) 3845 mm (12 ft 7 in)
K: Track Shoe Width 600 mm (24 in) (Grouser shoe)
50 kPa 47 kPa 53 kPa 49 kPa
Ground Pressure
(0.51 kgf/cm2, 7.2 psi) (0.48 kgf/cm2, 6.8 psi) (0.54 kgf/cm2, 7.7 psi) (0.50 kgf /cm2, 6.7 psi)
Swing Speed 12.6 min–1 (rpm)
Travel Speed (fast/slow) 5.5/3.4 km/h (3.4/2.1 mph)
Gradeability 35° (tanθ = 0.70)

NOTE: ’ H/P mode


* The dimensions do not include the height of the shoe lug.

T1-1-5
GENERAL / Specifications

ZAXIS270, ZAXIS270LC, ZAXIS280LC


A C

B
F

E
D

K J

I H

M178-12-001

Model ZAXIS270 ZAXIS270LC, ZAXIS280LC


Type of Front-End Attachment 3.10 m (10 ft 2 in) Arm
Bucket Capacity (Heaped) PCSA 1.1 m3 (1.44 yd3), CECE 1.0 m3
Operating Weight 27000 kg (59520 lb) 27500 kg (60630 lb)
Basic Machine Weight 21100 kg (46520 lb) 21600 kg (47620 lb)
Isuzu CC-6BG1T 125 kW/2050 min–1 (170 PS/2050 rpm)
Engine
’132 kW/2150 min–1 (180 PS/2150 rpm)
A: Overall Width
3090 mm (10 ft 2 in)
(Excluding back mirrors)
B: Cab Height 3110 mm (10 ft 2 in)
C: Rear End Swing Radius 2940 mm (9 ft 8 in)
D: Minimum Ground Clearance *510 mm (20 in)
E: Counterweight Clearance * 1180 mm (3 ft 11 in)
F: Engine Cover Height * 2380 mm (7 ft 10 in)
G: Overall Width of Upperstructure 2890 mm (9 ft 6 in)
H: Undercarriage Length 4640 mm (15 ft 3 in) 4940 mm (16 ft 3 in)
I: Undercarriage Width 3190 mm (10 ft 6 in)
J: Sprocket Center to Idler Center 3730 mm (12 ft 3 in) 4050 mm (13 ft 3in)
K: Track Shoe Width 600 mm (24 in) (Grouser shoe)
Ground Pressure 55 kPa (0.56 kgf/cm2, 8.0 psi) 52 kPa (0.53 kgf/cm2, 7.7 psi)
–1
Swing Speed 10.6 min (rpm)
Travel Speed (fast/slow) 4.9/2.9 km/h (3.0/1.8 mph)
Gradeability 35° (tanθ = 0.70)

NOTE: ’ H/P mode


* The dimensions do not include the height of the shoe lug.

T1-1-6
GENERAL / Specifications

ZAXIS210, ZAXIS210LC, ZAXIS210N (2-piece Boom)


A C

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
Bucket Capacity (Heaped) PCSA 0.8 m3 (1.05 yd3), CECE 0.7 m3
Operating Weight 19500 kg (44300 lb) 20000 kg (45400 lb) 19500 kg (44100 lb) 19600 kg (44800 lb)
Basic Machine Weight 15200 kg (33500 lb) 15700 kg (34600 lb) 15100 kg (33300 lb) 15400 kg (34000 lb)
Isuzu AA-6BG1T 103 kW/1900 min–1 (140 PS/1900 rpm)
Engine
’ 110 kW / 2100 min–1 (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) 2680 mm (8 ft 10 in)
D: Minimum Ground Clearance * 450 mm (18 in) (Excluding shoe lug)
E: Counterweight Clearance * 1030 mm (3 ft 5 in) (Excluding shoe lug)
F: Engine Cover Height * 2220 mm (7 ft 3 in) (Excluding shoe lug)
G: Overall Width of Upperstructure 2710 mm (8 ft 11 in) 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
(0.46 kgf/cm2, 6.5 psi) (0.44 kgf/cm2, 6.3 psi) (0.55 kgf/cm , 7.8 psi) (0.46 kgf/cm2, 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)

NOTE: ’ H/P mode


* The dimensions do not include the height of the shoe lug.

T1-1-7
GENERAL / Specifications
WORKING RANGES
ZAXIS200, ZAXIS200LC, ZAXIS210H, ZAXIS210LCH

G G

C C

D
D

E E

F F

A A
B B

Backhoe Face shovel (Reversed hoe bucket) M178-12-002

Model ZAXIS200, 200LC ZAXIS210H, 210LCH


2.22 m (7 ft 3 in) Arm 2.91 m (9 ft 7 in) Standard Arm 2.91 m (9 ft 7 in) H Arm
Category
Backhoe Shovel Backhoe Shovel Backhoe Shovel
Item
mm ftxin mm ftxin mm ftxin mm ftxin mm ftxin mm ftxin

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.

T1-1-8
GENERAL / Specifications

ZAXIS210, ZAXIS210LC, ZAXIS210N


G

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.

T1-1-9
GENERAL / Specifications

ZAXIS225USR, ZAXIS225USRLC

G G

C C

D D

E E

F F

A A
B B

Backhoe Face shovel (Reversed hoe bucket)

M178-12-009

2.22 m (7 ft 3 in) Arm 2.91 m (9 ft 7 in) Standard Arm


Category
Backhoe Shovel Backhoe Shovel
Item
mm ftxin mm ftxin mm ftxin mm ftxin

A: Maximum Digging Reach 9250 30′ 4″ 9390 30′ 10″ 9910 32′ 6″ 10060 33′ 0″

B: Maximum Digging Depth *15980 *119′ 7″ *16120 *120′ 1″ *16670 *121′ 11″ *16820 *122′ 5″

C: Maximum Cutting Height *19170 *130′ 1″ *19450 *131′ 0″ *19600 *131′ 6″ *19850 *132′ 4″

D: Maximum Dumping Height *16390 *121′ 0″ *16290 *120′ 8″ *16780 *122′ 3″ *16720 *122′ 1″

E: Transport Height 3130 10′ 3″ 3130 10′ 3″ 2970 9′ 9″ 2970 9′ 9″

*28985 *229′ 6″ *28985 *229′ 6″ *28865 *229′ 1″ *28865 *229′ 1″


F: Overall Transport Length
*39130 *329′11″ *39130 *329′11″ *39010 *329′ 7″ *39010 *329′ 7″

G: Minimum Swing Radius 3530 11′ 7″ 3530 11′ 7″ 3540 11′ 7″ 3540 11′ 7″
1
NOTE: * The dimensions do not include the height of the shoe lug.
2
* ZAXIS225USR
3
* ZAXIS225USRLC

T1-1-10
GENERAL / Specifications

ZAXIS225US, ZAXIS225USLC

G G

C
C

D D

E E

F F

A A

B B

Backhoe Face shovel (Reversed hoe bucket) M1GF-12-002

2.22 m (7 ft 3 in) Arm 2.91 m (9 ft 7 in) Standard Arm


Category
Backhoe Shovel Backhoe Shovel
Item
mm ftxin mm ftxin mm ftxin mm ftxin

A: Maximum Digging Reach 9350 30′ 8″ 9490 31′ 2″ 10010 32′ 10″ 10150 33′ 4″

B: Maximum Digging Depth *6100 *20′ 0″ *6240 *20′ 6″ *6790 *22′ 3″ *6930 *22′ 9″

C: Maximum Cutting Height *10550 *34′ 7″ *10710 *35′ 2″ *11100 *36′ 5″ *11250 *36′ 11″

D: Maximum Dumping Height *7640 *25′ 1″ *7730 *25′ 4″ *8190 *26′ 10″ *8340 *27′ 4″

E: Transport Height 3160 10′ 4″ 3100 10′ 2″ 2990 9′ 10″ 2950 9′ 8″

F: Overall Transport Length 9040 29′ 8″ 9030 29′ 8″ 8920 29′ 3″ 8910 29′ 3″

G: Minimum Swing Radius 2590 8′ 6″ 2590 8′ 6″ 2300 7′ 7″ 2300 7′ 7″

*NOTE: *The dimensions do not include the height of the shoe lug.

T1-1-11
GENERAL / Specifications

ZAXIS230, ZAXIS230LC, ZAXIS240H, ZAXIS240LCH, ZAXIS250, ZAXIS250LC

G G

C C

D
D

E E

F F

A A
B B

Backhoe Face shovel (Reversed hoe bucket) M178-12-002

ZAXIS230, 230LC, 250, 250LC


2.32 m (7 ft 7 in) Arm 2.96 m (9 ft 9 in) Standard Arm 3.61m (11 ft 10 in) Arm
Category
Backhoe Shovel Backhoe Shovel Backhoe Shovel
Item
mm ftxin mm ftxin mm ftxin mm ftxin mm ftxin mm ftxin
A: Maximum Digging Reach 9710 31’10” 9900 32’6” 10270 33’8” 10460 34’4” 10900 35’9” 11080 36’4”
*22’10
B: Maximum Digging Depth *6300 *20’8” *6490 *21’4” *6950 *7130 *23’5” 7590 24’11” 7780 25’6”

*30’10
C: Maximum Cutting Height *9410 *9810 *32’2” *9630 *31’7” *10040 *32’11” 9990 32’9” 10380 34’1”

D: Maximum Dumping Height *6540 *21’5” *6420 *21’1” *6760 *22’2” *6640 *21’9” 7100 23’4” 6980 22’11”
E: Transport Height 3290 10’10” 3290 10’10” 3100 10’2” 3100 10’2” 3320 10’11” 3320 10’11”
F: Overall Transport Length 10260 33’8” 10260 33’8” 10140 33’3” 10640 33’3” 10200 33’6” 10200 33’6”
G: Minimum Swing Radius 3960 12’12” 3960 12’12” 3870 12’8” 3890 12’8” 3890 12’9” 3890 12’9”
NOTE: * The dimensions do not include the height of the shoe lug.

ZAXIS240H, 240LCH
2.96 m (9 ft 9 in) H Arm
Category
Backhoe Shovel
Item
mm ftxin mm ftxin
A: Maximum Digging Reach 10270 33’8” 10460 34’5”
B: Maximum Digging Depth *6950 *22’10” *7130 *23’5”
C: Maximum Cutting Height *9630 *31’7” *10040 *32’11″
D: Maximum Dumping Height *6760 *22’2” *6640 *21’9”
E: Transport Height 3100 10’2” 3100 *10’2”
F: Overall Transport Length 10140 33’3” 10140 33’3”
G: Minimum Swing Radius 3870 12’8” 3870 12’8”

NOTE: * The dimensions do not include the height of the shoe lug.

T1-1-12
GENERAL / Specifications

ZAXIS270, ZAXIS270LC, ZAXIS280LC

G G

C C

D D
E E

F F
A A
B B

Backhoe Face shovel (Reversed hoe bucket) M178-12-002

2.4 m (7 ft 11 in) Arm 3.1 m (10 ft 2 in) Standard Arm


Category
Backhoe Shovel Backhoe Shovel
Item
mm ftxin mm ftxin mm ftxin mm ftxin

A: Maximum Digging Reach 10060 33′ 0″ 10240 33′ 7″ 10710 35′ 2″ 10880 35′ 8″

B: Maximum Digging Depth *6540 *21′ 6″ *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″

3.75 m (12 ft 4 in) Arm


Category
Backhoe Shovel
Item
mm ftxin mm ftxin

A: Maximum Digging Reach 11270 37′ 0″ 11480 37′ 8″

B: Maximum Digging Depth *7880 *25′ 10″ *8060 *26′ 5″

C: Maximum Cutting Height *10150 *33′ 4″ *10620 *34′ 10″

D: Maximum Dumping Height *7250 *23′ 9″ *7250 *23′ 9″

E: Transport Height 3350 11′ 0″ 3350 11′ 0″

F: Overall Transport Length 10340 33′ 11″ 10340 33′ 11″

G: Minimum Swing Radius 4120 13′ 6″ 4120 13′ 6″

NOTE: * The dimensions do not include the height of the shoe lug.

T1-1-13
GENERAL / Specifications

ZAXIS210, ZAXIS210LC, ZAXIS210N (2-piece Boom)


G

F
A

Backhoe
M1G6-13-012

Model ZAXIS210, 210LC, 210N


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 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.

T1-1-14
PHOTO

GENERAL / Component Layout


MAIN COMPONENT LAYOUT
ZX200 class, 230 class, 270 class

1
3

4
5
6
7
8
9

21

10
11

12
13
20 14
15
19 16
18
17 T178-01-02-001

1- Bucket Cylinder 7- Fuel Tank 13- Intercooler 19- Pilot Shut-Off Valve
2- Arm Cylinder 8- Hydraulic Oil Tank 14- Radiator 20- Travel Pilot Valve
3- Boom Cylinder 9- Control Valve 15- Oil Cooler 21- Front Attachment/Swing
Pilot Valve
4- Center Joint 10- Pilot Filter and Pilot Relief Valve 16- Battery
5- Swing Bearing 11- Pump Device 17- Travel Device
6- Swing Device 12- Engine 18- Signal Control Valve

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

NOTE: *Up to serial No.104908.

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
PHOTO

GENERAL / Component Layout


ELECTRICAL COMPONENT LAYOUT
(Overview)

ZX200 class, 230 class and 270 class


• Pump 1 and 2 Delivery Pressure Sensor
• Pump 1 and 2 Control Pressure Sensor
• N Sensor 1 2 3
• Torque Control Solenoid Valve 4
• Pump 2 Flow Rate Control Solenoid Valve 5
Refer to the Pump Device group.
7
6 8 • Pressure Sensor (Travel)
• Pressure Sensor (Swing)
9 Refer to the Signal Control
Valve group.

18

17
16
15
14
10
13

• Pressure Sensor (Boom Raise)


• Pressure Sensor (Arm Roll-In)
11 Refer to the Control Valve group.
T178-01-02-002
• Pressure Sensor (Front Attachment)
Refer to the Swing Device group. 12

1 - Overheat Switch 6 - Coolant Level Switch* 11 - Horn 15 - Solenoid Valve Unit


2 - Coolant Temperature 7 - Battery 12 - Work Light 16 - Engine Oil Level Switch*
Sensor
3 - Battery Relay 8 - Starter Relay 13 - Fuel Sensor 17 - Engine Oil Pressure Switch
4 - Glow Relay 9 - Air Cleaner Restriction 14 - Hydraulic Oil Temperature 18 - EC Motor and EC Sensor
Switch Sensor
5 - Fusible Link 10 - Wiper Motor

NOTE: *Up to serial No.104679 (ZX200 class)


Up to serial No.010326 (ZX230 class)
Up to serial No.020042 (ZX270 class)

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

NOTE: *Up to serial No.104679.

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.

1 - Over Heat Switch 6 - Fusible Link 11 - Horn 16 - Fuel Sensor


2 - Coolant Temperature 7 - Starter Relay 12 - Solenoid Valve Unit 17 - EC Motor and EC Sensor
Sensor
3 - Air Cleaner Restriction 8 - Coolant Level Switch* 13 - Hydraulic Oil Temperature
Switch Sensor
4 - Glow Relay 9 - Battery 14 - Engine Oil Lever Switch*
5 - Battery Relay 10 - Wiper Motor 15 - Engine Oil Pressure switch

NOTE: *Up to serial No.104679.

T1-2-6
PHOTO

GENERAL / Component Layout


ELECTRICAL SYSTEM (Relays and Related Equipment)
Except ZAXIS225US
5
4
Rear Deck 3 6
2

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 (Not connected in 14- Work Light Relay 1 (R4)
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 6 - Fuse Box 11 - Work Light Relay 1 (R4) 16 - Wiper Relay B (R7)
Controller)
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)

NOTE: It is used for engine learning and the


initialization of the boom electronic cushion
(Up to serial No.104908).

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 8- Alternator Indicator 15- Digging Mode Indicator 22- Power Mode Switch
Gauge
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

NOTE: * Up to serial No.104679 (ZX200 class and 225 class)


Up to serial No.010322 (ZX230 class)
Up to serial No.020040 (ZX270 class)

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
ZX200 class, 225 class, 230 class ZX270 class 11

11

12
12

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

1- Pump 1 4- Pump 1 Delivery Pressure 7- Torque Control Solenoid Valve 10- N Sensor
Sensor
2- Pump 2 5- Pump 2 Delivery Pressure 8- Pump 1 Control Pressure Sensor 11- Swing Relief Valve
Sensor
3- Pilot Pump 6- Pump 2 Flow Rate Control 9- Pump 2 Control Pressure Sensor 12- Pressure Sensor
Solenoid Valve (Front Attachment)

T1-2-10
GENERAL / Component Layout
CONTROL VALVE SOLENOID VALVE UNIT
2
1 Serial No.104679 and up (ZX200 class and 225 class)
Serial No.010327 and up (ZX230 class)
Serial No.020043 and up (ZX270 class)

T178-03-07-005
7 8 9

3
T178-03-03-001

SIGNAL CONTROL VALVE Up to serial No.104678 (ZX200 class and 225 class)
Up to serial No.010326 (ZX230 class)
Up to serial No.020042 (ZX270 class)

6 7 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 (Arm 5 - Pressure Sensor (Travel) 8 - Solenoid Valve Unit (SI)
Roll-in)
3 - Pressure Sensor (Boom 6 - Solenoid Valve Unit (SE)*
Raise)

NOTE: * Up to serial No.104678 (ZX200 class and 225 class)


Up to serial No.010326 (ZX230 class)
Up to serial No.020042 (ZX270 class)

T1-2-11
GENERAL / Component Layout
TRAVEL DEVICE POSITIONING CONTROL VALVE
ZX200 class, 225 class and 230 class (2-piece Boom Only)

1
T1HD-01-02-001 T1SM-01-02-007

ZX270 class

2
1

T1HG-01-02-002

1- Counterbalance Valve 2- Travel Relief Valve 3- Overload Relief Valve


(Positioning)

T1-2-12
GENERAL / Component Specifications
ENGINE

ZX200 class, ZX225 class:


Manufacturer........................... ISUZU
Model ................................. AA-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)
3 3
Piston Displacement .................... 6494 cm (396 in )
-1
Rated Output........................... 103 kW/1900 min (140 PS/1900 rpm)
-1
HP Mode: 110 kW / 2100 min (150 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)

ZX230 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)
3 3
Piston Displacement .................... 6494 cm (396 in )
-1
Rated Output........................... 118 kW/2000 min (160 PS/2000 rpm)
-1
HP Mode: 125 kW / 2100 min (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

ZX270 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)
3 3
Piston Displacement ................... 6494 cm (396 in )
-1
Rated Output.......................... 125 kW/2050 min (170 PS/2050 rpm)
-1
HP Mode: 132 kW / 2150 min (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
ZX200 class, ZX225 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

ZX200 class, ZX270 class:


Cooling Fan........................... Dia. 650 mm (25.6 in), 7 Blades (N-Type Blade, Unequal Pitch),
Draw-in Type
Fan Pulley Ratio ....................... Engine rpm × 0.88
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)

ENGINE STOP SYSTEM


Stop Method ........................... Fuel Shut-Off

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.
ZX200 class, ZX225 class:
Fuel Consumption Ratio ................. Less than 237 g/kW/h (174 g/PS⋅h) at 110 kW / (at Full Load:
-1
2100 min )
Less than 227 g/kW/h (166 g/PS⋅h) at 103 kW / (at Working
-1
Load: 1900 min )
Injection Timing......................... 10 ° before T.D.C.
-1
Maximum Output Torque................. More than 550±60 N⋅m (54±6 kgf⋅m) at approx. 1600 min
2
Injection Pressure ...................... 18.14 MPa (185 kgf/cm )
2
Compression Pressure .................. 3.04 MPa (31 kgf/cm )
Valve Clearance (Inlet / Exhaust).......... 0.4 / 0.4 mm (when cool)
-1
No Load Speed ........................ Slow: (at Full Load: 900 ± 20 min )
+20 -1
Fast: (at Full Load: 2350 – 50 min )
-1
(at Working Load: 2100±50 min )

ZX230 class:
Fuel Consumption Ratio ................. Less than 237 g/kW/h (174 g/PS⋅h) at 125 kW / (at Full Load:
-1
2100 min )
Less than 227 g/kW/h (166 g/PS⋅h) at 118 kW / (at Working
-1
load: 2000 min )
Injection Timing......................... 10 ° before T.D.C.
-1
Maximum Output Torque................. More than 637±60 N⋅m (65±6 kgf⋅m) at approx. 1800 min
2
Injection Pressure ...................... 18.14 MPa (185 kgf/cm )
2
Compression Pressure .................. 3.04 MPa (31 kgf/cm )
Valve Clearance (Inlet / Exhaust).......... 0.4 / 0.4 mm (when cool)
-1
No Load Speed ........................ Slow: (at Full Load: 900 ± 20 min )
+20 -1
Fast: (at Full Load: 2420 – 50 min )
-1
(at Working Load: 2300±50 min )

ZX270 class:
Fuel Consumption Ratio ................. Less than 243 g/kW/h (179 g/PS⋅h) at 132 kW / (at Full
-1
Load:2150 min )
Less than 238 g/kW/h (175 g/PS⋅h) at 125 kW / (at Working
-1
Load: 2050 min )
Injection Timing......................... 10 ° before T.D.C.
-1
Maximum Output Torque................. More than 637±60 N⋅m (65±6 kgf⋅m) at approx. 1800 min
2
Injection Pressure ...................... 18.14 MPa (185 kgf/cm )
2
Compression Pressure .................. 3.04 MPa (31 kgf/cm )
Valve Clearance (Inlet / Exhaust).......... 0.4 / 0.4 mm (when cool)
-1
No Load Speed ........................ Slow: (at Full Load: 900 ± 20 min )
+20 -1
Fast: (at Full Load: 2470 – 50 min )
-1
(at Working Load: 2350±50 min )

T1-3-4
GENERAL / Component Specifications
ZX200 class, ZX225 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

Engine Speed min-1 (rpm) T178-01-03-002

T1-3-5
GENERAL / Component Specifications
ZX230 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
Engine Speed min-1 (rpm)

T1-3-6
GENERAL / Component Specifications
ZX270 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
Engine Speed min-1 (rpm) T1HG-01-03-001

T1-3-7
GENERAL / Component Specifications
ENGINE ACCESSORIES
RADIATOR ASSEMBLY
ZX200 class, ZAXIS225USR:
Type .................................. Radiator/Oil Cooler Tandem Type Assembly
Weight ................................ 81.5 kg (180 lb)

Radiator Oil Cooler


Capacity............................... 8.0 L (2.1 US gal) 6.35 L (1.7 US gal)
2 2
Air-Tight Test Pressure .................. 98 kPa (1.0 kgf/cm , 14 psi) 1470 kPa (15 kgf/cm , 213 psi)
2
Cap Opening Pressure .................. 49 kPa (0.5 kgf/cm , 7 psi) −

Intercooler
Capacity............................... 7.9 L (1.7 US gal)
2
Air-Tight Test Pressure .................. 25 kPa (0.25 kgf/cm , 4 psi)
Cap Opening Pressure .................. −

ZAXIS225US:
Type .................................. Radiator/Oil Cooler Tandem Type Assembly
Weight ................................ 81.5 kg (180 lb)

Radiator Oil Cooler


Capacity............................... 8.0 L (2.1 US gal) 6.35 L (1.7 US gal)
2 2
Air-Tight Test Pressure .................. 98 kPa (1.0 kgf/cm , 14 psi) 1470 kPa (15 kgf/cm , 213 psi)
2
Cap Opening Pressure .................. 49 kPa (0.5 kgf/cm , 7 psi) −

Intercooler
Capacity............................... 7.9 L (1.7 US gal)
2
Air-Tight Test Pressure .................. 25 kPa (0.25 kgf/cm , 4 psi)
Cap Opening Pressure .................. −

T1-3-8
GENERAL / Component Specifications

ZX230 class, ZX270 class:


Type .................................. Radiator/Oil Cooler Tandem Type Assembly
Weight ................................ 81.5 kg (180 lb)

Radiator Oil Cooler


Capacity............................... 8.0 L (2.1 US gal) 6.35 L (1.7 US gal)
2 2
Air-Tight Test Pressure .................. 98 kPa (1.0 kgf/cm , 14 psi) 1470 kPa (15 kgf/cm , 213 psi)
2
Cap Opening Pressure .................. 49 kPa (0.5 kgf/cm , 7 psi) −

Intercooler
Capacity............................... 7.9 L (1.7 US gal)
2
Air-Tight Test Pressure .................. 25 kPa (0.25 kgf/cm , 4 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
ZX200 class, ZX225 class:
Model ................................. HPV102GW-RH23A
Type .................................. Bent-Axis Type Variable Displacement Axial Plunger Pump
Maximum Flow (Theoretical Value) ........ 198.9 L/min (52.5 US gpm) × 2
ZX230 class:
Model ................................. HPV102GW-RH23A
Type .................................. Bent-Axis Type Variable Displacement Axial Plunger Pump
Maximum Flow (Theoretical Value) ........ 204 L/min (54 US gpm) × 2
ZX270 class:
Model ................................. HPV102GW-RH23A
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
ZX200 class, ZX225 class:
Model ................................. HY/ZFS 11 / 16.8
Type .................................. Fixed Displacement Type Gear Pump
Maximum Flow (Theoretical Value) ........ 31.92 L/min (8.43 US gpm)
HP Mode: 35.28 L/min (9.32 US gpm)
ZX230 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)
ZX270 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
ZX200 class, ZX225 class:
Model ................................. KVMG-270-HE
Type .................................. Pilot Pressure Operated Type (4-Spools + 5-Spools)
2
Main Relief Set-Pressure ................ Normal: 34.3 MPa (350 kgf/cm , 4980 psi) at
110 L/min (29.0 US gpm)
2
Power Digging: 36.3 MPa (370 kgf/cm ) at
110 L/min (29.0 US gpm)
2
Overload Relief Set-Pressure............. 37.2 MPa (379 kgf/cm , 5390 psi) at 50 L/min (13.2 US gpm)
(Boom, Arm Roll-In, Bucket Roll-In)
2
39.2 MPa (400 kgf/cm , 5690 psi) at 50 L/min (13.2 US gpm)
(Arm Roll-Out, Bucket Roll-Out)

ZX230 class, ZX270 class:


Model ................................. KVMG-270-HE
Type .................................. Pilot Pressure Operated Type (4-Spools + 5-Spools)
2
Main Relief Set-Pressure ................ Normal: 34.3 MPa (350 kgf/cm , 4980 psi) at
140 L/min (37.0 US gpm)
2
Power Digging: 36.3 MPa (370 kgf/cm ) at
140 L/min (37.0 US gpm)
2
Overload Relief Set-Pressure............. 37.2 MPa (379 kgf/cm , 5390 psi) at 50 L/min (13.2 US gpm)
(Boom, Arm Roll-In, Bucket Roll-In)
2
39.2 MPa (400 kgf / cm , 5690 psi) at 50 L/min (13.2 US gpm)
(Arm Roll-Out, Bucket Roll-Out)

POSITIONING CONTROL VALVE (2-Piece Boom Only)


Type .................................. Pilot Pressure Operated Type
2
Overload Relief Set-Pressure............. 39.2 MPa (400 kgf/cm ) at 50 L/min

T1-3-10
GENERAL / Component Specifications

SWING DEVICE
ZX200 class, ZX225 class:
Type .................................. Two-Stage Reduction Planetary Gear
Reduction Gear Ratio ................... 13.385

ZX230 class:
Type .................................. Two-Stage Reduction Planetary Gear
Reduction Gear Ratio ................... 21.75

ZX270 class:
Type .................................. Two-Stage Reduction Planetary Gear
Reduction Gear Ratio ................... 17.022

SWING MOTOR
ZX200 class, ZX225 class:
Model ................................. M5X130C
Type .................................. Swash-Plate Type, Fixed Displacement Axial Plunger Motor

ZX230 class:
Model ................................. M5X130CHB
Type .................................. Swash-Plate Type, Fixed Displacement Axial Plunger Motor

ZX270 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
ZX200 class, ZX225 class:
Type .................................. Non Counterbalance Valve Type
2
Relief Set-Pressure ..................... 30.9 MPa (315 kgf/cm , 4480 psi) at 140 L/min

ZX230 class:
Type .................................. Non Counterbalance Valve Type
2
Relief Set-Pressure ..................... 29.4+1−0 MPa (300+10−0 kgf/cm , 4270+142−0 psi) at 170 L/min

ZX270 class:
Type .................................. Non Counterbalance Valve Type
2
Relief Set-Pressure ..................... 30.2+1.40 MPa (308+14 kgf/cm , 4380+200 psi) at 140 L/min
(Serial No. 020038 and up)
2
27.7±0.3 MPa (282±3 kgf/cm , 4010±43 psi) at 140 L/min
(Up to Serial No. 020037)
SWING PARKING BRAKE
ZX200 class, ZX225 class:
Type .................................. Multi-Disc-Wet Negative Type
2
Release Pressure ...................... 1.96 to 2.64 MPa (20 to 27 kgf/cm , 284 to 384 psi)

ZX230 class:
Type .................................. Multi-Disc-Wet Negative Type
2
Release Pressure ...................... 1.57 to 2.35 MPa (16 to 24 kgf/cm , 228 to 341 psi)

ZX270 class:
Type .................................. Multi-Disc-Wet Negative Type
2
Release Pressure ...................... 2.25 to 2.84 MPa (23 to 29 kgf/cm , 327 to 412 psi)

TRAVEL DEVICE
ZX200 class:
Type .................................. Three-Stage Reduction Planetary Gear
Reduction Gear Ratio ................... 53.289 (ZAXIS210N only: 53.234)

ZX225 class, ZX230 class:


Type .................................. Three-Stage Reduction Planetary Gear
Reduction Gear Ratio ................... 58.623

ZX270 class:
Type .................................. Three-Stage Reduction Planetary Gear
Reduction Gear Ratio ................... 70.842

T1-3-12
GENERAL / Component Specifications

TRAVEL MOTOR
ZX200 class, ZX225 class, ZX230 class:
Type .............................. Swash-Plate Type Variable Displacement Axial Plunger Motor

ZX270 class:
Type .............................. Bent-Axis Type Variable Displacement Axial Plunger Motor

TRAVEL BRAKE VALVE


Type .............................. Counter Balance Valve Type
2
Relief Set Pressure ................. 34.8 MPa (355 kgf/cm , 5050 psi)

TRAVEL PARKING BRAKE


Type .............................. Multi-Disc-Wet Negative Type
2
Cracking Pressure for Release ...... 0.95 to 1.02 MPa (9.7 to 10.4 kgf/cm , 138 to 148 psi)

T1-3-13
GENERAL / Component Specifications

CYLINDER
ZX200 class, ZX225 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)

Bucket Positioning (2-Piece Boom)


Rod Diameter ...................... 80 mm (3.15”) 100 mm (3.94”)
Cylinder Bore ...................... 115 mm (4.53”) 150 mm (5.91”)
Stroke............................. 1060 mm (3’6”) 1255 mm (4’10”)
Fully Retracted Length............... 1590 mm (5’3”) 1875 mm (6’2”))
Plating Thickness ................... 30 µm (1.18 µm) 30 µm (1.18 µm)

ZX230 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)

Bucket
Rod Diameter ...................... 90 mm (3.54”)
Cylinder Bore ...................... 130 mm (5.12”)
Stroke............................. 1075±3 mm (3’6±0.1”)
Fully Retracted Length............... 1665±2.2 mm (5’5±0.1”)
Plating Thickness ................... 30 µm (1.18 µm)

ZX270 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)

Bucket
Rod Diameter ...................... 96 mm (3.78”)
Cylinder Bore ...................... 135 mm (5.32”)
Stroke............................. 1070±3 mm (3’6±0.1”)
Fully Retracted Length............... 1660±2 mm (5’5±0.1”)
Plating Thickness ................... 30 µm (1.18 µm)

T1-3-14
GENERAL / Component Specifications
FRONT ATTACHMENT PILOT VALVE
Model ................................. HVP06A-040-101

TRAVEL PILOT VALVE


Model ................................. HVP05F-040-101

SOLENOID VALVE UNIT


Function ............................... ⋅ SC : Arm Regenerative Control
⋅ SE* : Arm Flow Rate Control
⋅ SG : Power Digging Control
⋅ SI : Travel Motor Swash Angle Control
NOTE: * Up to serial No.104678 (ZX200 class and 225 class)
Up to serial No.010326 (ZX230 class)
Up to serial No.020042 (ZX270 class)

PILOT PRESSURE SIGNAL CONTROL VALVE


Function ............................... ⋅ Shock Reducing (Boom Lower)
⋅ Pump Flow Rate Control
⋅ Bucket Flow Rate Control
⋅ Swing Parking Brake Release
⋅ Flow Combiner Valve Control
⋅ Arm Flow Rate Control**
NOTE:** Serial No.104679 and up (ZX200 class and 225 class)
Serial No.010327 and up (ZX230 class)
Serial No.020043 and up (ZX270 class)

PILOT SHUT-OFF VALVE


Type .................................. Rotary Type

OIL COOLER BYPASS CHECK VALVE


2
Cracking Pressure ...................... 490 kPa (5 kgf/cm ) at 5 L/min

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 : ZX200 class, ZAXIS225USR,
ZX230 class, ZX270 class
24 V, 12 W
ZAXIS225US,
24 V, 12 W

T1-3-15
GENERAL / Component Specifications
AIR CONDITIONER
ZX200 class, ZAXIS225USR, ZX230 class, ZX270 class:
Refrigerant ............................ 134 a
Cooling Ability .......................... 19.3 MJ/h (4600 kcal/h)
3
Cool Air Volume ........................ 550 m /h or More
Heating Ability .......................... 21.0 MJ/h (5000 kcal/h) or More
3
Warm Air Volume ....................... 500 m /h or More
Temperature Adjusting System ........... Electronic Type
Refrigerant Quantity..................... 850±50 g
3
Compressor Oil Quantity................. 210 cm

ZAXIS225US:
Refrigerant ............................ 134 a
Cooling Ability .......................... 16.0 MJ/h (3830 kcal/h)
3
Cool Air Volume ........................ 395 m /h or More
Heating Ability .......................... 14.9 MJ/h (3570 kcal/h) or More
3
Warm Air Volume ....................... 365 m /h or More
Temperature Adjusting System ........... Electronic Type
Refrigerant Quantity..................... 900±50 g
3
Compressor Oil Quantity................. 210 cm

T1-3-16
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

Group 2 Hydraulic System


Outline..................................................... T2-2-1
Pilot Circuit .............................................. T2-2-2
Main Circuit ........................................... T2-2-12

Group 3 Electrical System


Outline..................................................... T2-3-1
Main Circuit ............................................. T2-3-2
Electric Power Circuit .............................. T2-3-3
Indicator Light Check Circuit .................... T2-3-4
Accessory Circuit..................................... T2-3-5
Preheat Circuit......................................... T2-3-6
Starting Circuit ......................................... T2-3-8
Charging Circuit......................................T2-3-11
Serge Voltage Prevention Circuit ........... T2-3-14
Engine Stop Circuit ................................ T2-3-16

178T-2-1
(Blank)

178T-2-2
SYSTEM / Control System
OUTLINE
The main controller (MC) is used to control machine After processing the received signals in the logic cir-
operations. Electronic signals from the engine control cuit, 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.

Input Signals Output Signals


• EC Sensor → Engine Control (EC Motor)
• Engine Control Dial → Engine Control Dial
• Pump 1 Control Pressure Sensor → HP Mode Control
• Pump 2 Control Pressure Sensor → E Mode Control
• Pump 1 Delivery Pressure Sensor → Auto-Idle Control
• Pump 2 Delivery Pressure Sensor → Auto-Acceleration Control
• Pump 3 Delivery Pressure Sensor Auto-Warming Up Control
(Oprtional) → Idle Speed-Up Control
• N sensor → Engine Speed Automatic Increase Control at Travel
(ZX270 class only)

• Pressure Sensor (Travel) → Attachment Operation Speed Increase Control

• Pressure Sensor (Front Attachment) → Attachment Operation Speed Limit Control
• Pressure Sensor (Swing) → Engine Learning Control
• Pressure Sensor (Boom Raise) →
• Pressure Sensor (Arm Roll-In) → Pump Control (Torque Control Solenoid Valve)
• Pressure Sensor (Auxiliary) MC Speed Sensing Control
(Optional) → Slow Speed Torque Increase Control

Pump 1 Flow Rate Limit Control

• Hydraulic Oil Temperature Sensor → Pump 2 Flow Rate Limit Control

• Auto-Idle/Acceleration Selector → Pump 3 Torque Decrease Control
• Power Digging Switch →
• Power Mode Switch (HP/E/P) → Valve Control (Solenoid Valve Unit)
• Travel Mode Switch (Fast/Slow) → Power Digging Control
• Work Mode Switch Arm Flow Rate Control
(Digging/Attachment) → Arm Regenerative Control
• Learning Switch → Travel Motor Swash Angle Control
• Key Switch → Auto-Power Lift Control

• Boom Angle Sensor Auxiliary Flow Rate Control
(Up to serial No.104908 (ZAXIS225US))
• Auxiliary Mode Switch (Optional) →
Other Controls
Boom Electronic Cushion Control
(Up to serial No.104908 (ZAXIS225US))
Work Mode Control

Travel Alarm Control

Load Alarm Control


NOTE: Only on the machines equipped with the
corresponding optional parts.

T2-1-1
SYSTEM / Control System
ENGINE CONTROL
The engine control system is grouped as follows:

• Engine Control Dial Control • Idle Speed-Up Control


• HP Mode Control • Engine Speed Automatic Increase Control at
• E Mode Control Travel (ZX270 class only)
• Auto-Idle Control • ∗Attachment Operation Speed Increase Control

• Auto-Acceleration Control • Attachment Operation Speed Limit Control
• Auto-Warming Up Control • Engine Learning Control


NOTE: Only on the machines with the corre-
sponding optional parts.

Engine Control System Layout

Learning Switch Pressure Sensor

Travel
Front Attachment Pump 2 De- Pump 1 De-
Swing livery Pres- livery 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

Power Mode Switch

HP Mode Pump 2 Con- Pump 1 Con-


trol Pressure trol Pressure
Sensor Sensor
E Mode Work Mode
Switch
Auxiliary Hydraulic Oil
P Mode
Digging Attachment Mode Switch Temperature
Mode Mode (Optional) Sensor
T178-02-01-027

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
-1
and reduces the engine speed by 100 min
to reduce fuel consumption and noise level Engine speed is
when all control levers are in neutral. Control Range reduced by 100
min-1 when the
control levers are
Operation: The MC drives the governor lever in re- in neutral.
sponse to the rotation angle of the engine
control dial to regulate the engine speed.
Engine Con-
trol Dial Po-
NOTE: Even if the control dial is rotated to the full sition
Slow Fast
speed position, the governor lever doesn’t Idle Idle
come in contact with the full speed stopper.
(Refer to the HP mode control.)

When all control levers are turned to neutral (the travel


and front attachment sensors are OFF), the MC drives NOTE: The engine speed is reduced from the
the EC motor so that the engine speed is reduced -1
maximum speed by 100 min . Therefore,
-1
from the maximum speed by 100 min . when the engine speed set by the engine
control dial is already slower than the
-1
maximum speed by 100 min , 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
ANIMATION

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

Function: Slightly increases digging power such as


arm roll-in operation while excavating Engine
Speed Maximum speed
deeply. 1650 min-1 increases by 200
min-1 except
ZX230 class and
Operation: The MC drives the EC motor to slightly in- 1500 min-1 270 class (by 100
crease the engine speed set by the engine min-1 )
control dial when all the following condi-
tions exist with the power mode switch is in
the HP position.

-1
• Engine Control Dial: Set at 1500 min or faster. Engine Con-
• Boom Raise and/or Arm Roll-In Control: In Op- trol Dial Posi-
eration Slow Fast tion
• Average Delivery Pressure of Pumps 1 and 2: Idle Idle
High

NOTE: The engine governor stopper position is


adjusted in the HP mode. Accordingly, the
governor lever doesn’t come in contact with
the stopper in the normal mode.

T2-1-6
ANIMATION

SYSTEM / Control System

Pressure Sensor

Pump 2 De- Pump 1 Deliv-


livery Pres- ery Pressure
sure Sensor Sensor
Boom Raise
Arm Roll-In

Engine Con-
trol Dial

EC Motor

Power Mode Switch

HP Mode

T178-02-01-005

T2-1-7
ANIMATION

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

Power Mode Switch

E Mode

T178-02-01-006

T2-1-8
SYSTEM / Control System
(Blank)

T2-1-9
SYSTEM / Control System
Auto-Idle Control

Function: Reduces the engine speed when all control


levers are in neutral to reduce fuel con-
sumption and noise level.

Operation: Approx. 3.5 seconds after all control levers


are return to neutral, the MC drives the EC Engine speed is
motor so that the engine speed is reduced Engine reduced to the
to the auto-idle speed. As soon as a control Speed auto-idle speed
3.5 seconds later.
lever is operated (the travel and/or front
attachment pressure sensor is turned ON), Fast
the MC drives the EC motor so that the Speed
engine speed is increased to the original
engine speed (set by the engine control Auto-Idle
dial). Speed

Auto-Idle System Deactivation Requirements:


• Control Levers: Being operated (either travel or Engine Con-
front attachment control levers with pilot sensor trol Dial Posi-
ON) Slow Fast tion
Idle Idle
• Power Mode Switch: When the E mode is
changed to P mode or the P mode is changed to
the E mode.
• Engine Control Dial: When engine speed is
changed.

T2-1-10
ANIMATION

SYSTEM / Control System

Pressure Sensor

Travel
Front Attachment

Engine Con-
trol Dial

Auto-Idle

Auto-Idle/
Acceleration
Selector EC Motor

Power Mode Switch

E Mode

T178-02-01-007

T2-1-11
SYSTEM / Control System
Auto Acceleration Control

Function: Automatically regulates the engine speed to Engine Speed VS. Control Lever Operations:
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
Operation: When a control lever is operated with the speed by 400 min-1 .
auto-idle / acceleration selector in auto ac- Auto-
celeration position, the MC calculates the Acceleration
most proper engine operating speed cor- Speed
Engine speed is reduced
responding to the signals from pressure Auto-Idle to the auto-idle speed
sensors (travel, swing, boom raise, and Speed 3.5 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
-1
400 min 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

NOTE: When all control levers are returned to Full Stroke


neutral, the engine speed is reduced by
-1
400 min from the maximum speed. In
case the engine speed is set by the engine Neutral
control dial and is running at a speed Position
slower than the maximum speed by 100
-1
min , the engine speed will be reduced by Time
-1
300 min .
In response to the control
lever stroke and the pump
delivery pressure, the
optimum engine speed is
Engine Speed selected.

Fast Idle Speed


(P Mode)
Auto Accel-
eration Con-
trol
Auto-Idle En-
gine Speed

Time

T2-1-12
ANIMATION

SYSTEM / Control System

Pressure Sensor

Travel
Pump 2 De- Pump 1 De-
Swing livery Pres- livery Pres-
Boom Raise sure Sensor sure Sensor
Engine Con-
trol Dial Arm Roll-In

Auto-Idle/
Acceleration EC Motor
Selector

Auto-
Acceleration

Pump 2 Con- Pump 1 Con-


trol Pressure trol Pressure
Sensor Sensor

T178-02-01-008

T2-1-13
ANIMATION

SYSTEM / Control System


Auto Warming Up Control

Function: Automatically warms up the hydraulic sys-


tem (similar to the auto choke on automo- Engine
Speed
biles).

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 Con-
trol Dial

EC Motor

Hydraulic Oil
Temperature
Sensor
T178-02-01-009

T2-1-14
ANIMATION

SYSTEM / Control System


Idle Speed-Up Control

Engine
Function: Prevents the engine from hunting when Speed
running the engine at slow speed.

Operation: When the travel or front attachment func-


tion is operated while the engine is running
at a speed between the minimum speed
Idle
and the Idle Speed-Up Speed, the MC Speed-Up
drives the EC motor so that the engine Speed
speed is increased to the Idle Speed-Up Increasing
Speed
Speed. Engine Con-
trol Dial Posi-
Slow Fast tion
Idle Idle

Pressure Sensor

Travel
Front Attachment

Engine Con-
trol Dial

EC Motor

T178-02-01-010

T2-1-15
ANIMATION

SYSTEM / Control System


Engine Speed Automatic Increase Control at
Travel (ZX270 class only)

Function: Increases the engine speed at travel single


operation to increase the travel speed.

Operation: MC drives EC motor to increase the engine


speed by 100 min−1 (rpm) when the power
mode switch is turned to P or HP and the
following conditions exist.
Consequently, the pump delivery flow rate
increases, so that the travel speed in-
creases.

Condition: Engine Control Dial: The speed is set to


maximum.
Travel Operation: Operated
Front Attachment Operation: Not operated

Pressure Sensor
Travel
Front At-
tachment

Engine Con-
trol 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.

Operation: When the following conditions exist, the


MC drives the EC motor so that the engine
maximum speed is increased to the at-
tachment operating speed set by Dr. ZX
when the attachment is operated. Engine Con-
trol Dial Posi-
Slow Fast tion
Operating Conditions: Idle Idle
Dr. ZX: Resets the maximum engine speed to a faster
(+) attachment (hydraulic breaker, secondary crusher,
primary crusher, or vibrating hammer) operating speed
in the service mode.
Engine Control Dial: Maximum Speed Position NOTE: When the P mode engine speed is preset
Power Mode Switch: HP Mode to a slower speed in the Dr. ZX service
Auxiliary: In Operation mode, the maximum engine speed won’t
Work Mode Switch: Attachment Mode be increased when operating the attach-
Auxiliary Mode Switch (Optional): Attachment position ment.
(hydraulic breaker, secondary crusher, primary crusher,
or vibrating hammer) reset by Dr. ZX.

T2-1-18
ANIMATION

SYSTEM / Control System

Pressure Sensor

Auxiliary(Optional)
Engine Con-
trol Dial

EC Motor

Power Mode Switch

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).)

Function: Decreases the maximum engine speed to Engine


the attachment (hydraulic breaker, secon- Speed
When all condi-
dary crusher, primary crusher or vibrating 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
Operation: When the following conditions exists, the Dr. 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.

Operating Conditions: Slow Fast


Idle Idle
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.
Work Mode Switch: Attachment Mode
Auxiliary Mode Switch (Optional): Attachment position
(hydraulic breaker, secondary crusher, primary crusher,
or vibrating hammer) set by Dr. ZX.

T2-1-20
ANIMATION

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
governor lever from the IDLE to FULL and cable, or EC motor has been
to STOP positions in this order. The EC removed 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 position NOTE: The engine learning is not required when
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

The pump control system has the following functions:

• Speed Sensing Control


• *Pump 1 Flow Rate Limit Control
• *Pump 2 Flow Rate Limit Control
• *Pump 3 Flow Torque Decrease Control
NOTE: *Only on the machines equipped with the
corresponding optional parts.

Pump Control System Layout

Pressure Sensor
Travel
Pump 3 De-
Pump 2 De- Pump 1 De- livery Pres-
livery Pres- livery Pres- sure Sensor
sure Sensor sure Sensor (Optional)

Auxiliary(Optional)
Engine Con-
trol Dial

Torque Control
Solenoid Valve

Max. Pump 2 Flow Rate


Limit Solenoid Valve

Max. Pump 1 Flow Rate Limit T178-02-01-002


Solenoid Valve (Optional)

T2-1-23
SYSTEM / Control System
Speed Sensing Control

Function: Controls the pump flow rate in response to


engine speed changes due to variations in
load so that the engine output can be utilized
more efficiently. (Engine stall is prevented
when the machine operates under adverse
conditions such as operating at high
altitude.)
Q
Operation: Flow Rate
1. The target engine operating speed is set by con-
trolling the engine control dial. Normal Pump P-Q Curve
2. The MC calculates the difference in speed be-
tween the target operating speed and the actual
operating speed monitored by the N sensor. Then,
the MC sends signals to the torque control sole-
noid valve.
3. The torque control solenoid valve delivers pilot
pressure oil in response to the signals received
from the MC to the pump regulator, controlling the
pump flow rate.
4. If the engine load increases and the actual en-
gine operating speed becomes slower than the Pressure P
target operating speed, the pump swash angle is
reduced so that pump flow rate will be reduced.
Therefore, the engine load is reduced, preventing
engine stall.
5. If the actual engine operating speed becomes
faster than the target operating speed, the pump
swash angle is increased so that the pump flow
rate will increase, by which the engine output can
be utilized more efficiently.

T2-1-24
ANIMATION

SYSTEM / Control System

N Sensor

Engine Con-
trol 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 maximum Flow Rate B
pump flow rate when the engine is running at
slow speed. When travel operation is made Increased Torque
P-Q Curve
with the engine running at slow speed, nor- A
mally, 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 between
pump 1 and pump 2 flow rate, the machine
will mistrack. To prevent mistracking, the
Normal P-Q Curve
pump P-Q curve is raised so that, when
traveling the machine with the engine run-
ning at slow speed, the pump delivers pres-
sure 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.

NOTE: If the MC stops the slow speed torque in-


crease control when the front attachment is
operated while traveling, the pump flow
rate will be reduced quickly, developing a
shock load to the machine. Therefore, the
MC maintains the slow speed torque in-
crease control even if the front attachment
is simultaneously operated while traveling.

T2-1-26
ANIMATION

SYSTEM / Control System

Pressure Sensor
Travel Pump 2 De- Pump 1 De-
livery Pres- livery Pres-
sure Sensor sure Sensor

Engine
Control Dial

Torque Control Solenoid Valve

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.

Normal Pump P-Q Curve

Pressure

T2-1-28
ANIMATION

SYSTEM / Control System

Pressure Sensor

Auxiliary (Optional)

T178-02-01-017

Maximum Pump 2 Flow Maximum Pump 1 Flow Rate


Rate Limit Control Solenoid Limit Control Solenoid
Valve Valve (Optional)

T2-1-29
ANIMATION

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 ex-
ceed the engine output, utilizing the engine
output efficiently.
Pressure P

Pump 3 De-
livery 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:

• Power Digging Control


• Auto-Power Lift Control
• **Arm Flow Rate Control
• Arm Regenerative Control
• Travel Motor Swash Angle Control

• Auxiliary Flow Rate Control


NOTE: Only on the machines equipped with the
corresponding optional parts.
** Up to serial No.104678
(ZX200 class and 225 class)
Up to serial No.010326 (ZX230 class)
Up to serial No.020042 (ZX270 class)

T2-1-32
ANIMATION

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
Control Dial

Power
Digging
Switch Hydraulic Oil
Temperature Sensor

Fast

Slow Pump 2 Control


Pressure Sensor

Travel Mode Switch


Pump 1 Control
Pressure
Solenoid Valve Unit Sensor
Main Relief Valve
SG
SC
Up to serial No.104678 SE
(ZX200 class and 225 SI
class)
Up to serial No.010326
(ZX230 class)
Up to serial No.020042 Auxiliary Flow
(ZX270 class) Rate Control
Solenoid Valve
(Optional)

Auxiliary Flow Rate


Control Valve

Travel Motor

Swash Angle Arm Regenerative


Control Valve Valve T178-02-01-003
Arm Flow Rate Control
Valve

T2-1-33
SYSTEM / Control System
Power Digging Control

Function: Increases digging force by temporarily


increasing relief pressure.

Operation: For maximum 8 seconds after the power


digging switch is turned ON, the MC
continuously activates solenoid valve unit
(SG). Solenoid valve unit (SG) delivers the
pilot oil pressure to the relief valve,
increasing the relief set-pressure. (Refer to
the COMPONENT OPERATION / Control
Valve group.)

T2-1-34
ANIMATION

SYSTEM / Control System

Power
Digging
Switch

Solenoid Valve Unit Main Relief Valve

SG

T178-02-01-019

T2-1-35
SYSTEM / Control System
Auto-Power Lift Control

Function: Increases oil pressure when raising the


boom.

Operation: The MC activates solenoid valve unit (SG)


when signals from pressure sensor (boom
raise) and pump 1 delivery pressure
sensor meet the following conditions.
Solenoid valve (SG) delivers the pilot
pressure oil to the relief valve, increasing
the relief set- pressure. (Refer to the
COMPONENT OPERATION / Control
Valve group.)

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
control lever is in neutral.)

NOTE: This control system is activated during


combined operations (except for the arm
roll-in combined operation).

T2-1-36
ANIMATION

SYSTEM / Control System

Pressure Sensor

Pump 1 Delivery
Boom Raise Pressure Sensor
Arm Roll-In

Main Relief Valve


Solenoid Valve Unit
SG

T178-02-01-020

T2-1-37
SYSTEM / Control System
Arm Flow Rate Control
Up to serial No.104678 and up(ZX200 and 225 class)
Up to serial No.010326 and up (ZX230 class)
Up to serial No.020042 and up (ZX270 class)

Function: Gives pressure oil from pump 2 priority to


flow to the swing motor spool over the arm
1 spool to ensure swing power.

Operation: The MC activates solenoid valve unit (SE)


when signals from the pump 2 delivery
pressure sensor and pressure sensors
(swing and arm roll-in) meet the following
conditions. Solenoid valve unit (SE)
delivers the pilot pressure oil to the arm
flow rate control so that the parallel oil
passage to the arm 1 spool is restricted.
Thereby, the swing spool has priority,
ensuring swing motor power, preventing
the upperstructure from being rotated by
the arm reaction force when the arm is
rolled in. (Refer to the COMPONENT
OPERATION/Control Valve group.)

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
ANIMATION

SYSTEM / Control System

Pressure Sensor

Pump 2
Swing Delivery
Pressure
Sensor
Arm Roll-In

Solenoid Valve Unit

SE

T178-02-01-021
Arm Flow Rate Control Valve

T2-1-39
SYSTEM / Control System
Arm Regenerative Control

Function: Accelerates the arm roll-in speed to


prevent arm hesitation during arm roll-in
operation.

Operation: The MC activates the solenoid valve unit


(SC) so that solenoid valve delivers the
pilot pressure oil to shift the arm
regenerative valve when signals from the
pump 2 delivery pressure sensor, swing
pressure sensor, arm roll-in pressure
sensor, and boom raise pressure sensor
meet the following conditions. When the
arm regenerative valve is shifted, the return
circuit from the arm cylinder rod side to the
hydraulic oil tank is closed. Then, the
return oil from the cylinder rod side is
combined with the pressure oil from the
pump and is routed to the cylinder bottom,
accelerating the arm roll-in speed and
preventing arm hesitation. (Refer to the
COMPONENT OPERATION / Control
Valve group.)

Operating Conditions:
Pump 2 Delivery Pressure Sensor: Low pressure.
(The arm doesn’t need much power.)
Arm Roll-In Pressure Sensor: High output. (The arm
control lever stroke is large.)
Swing or Boom Raise Pressure Sensor: Outputting
signal.

NOTE: To improve arm leveling performance, the


MC gradually activates solenoid valve unit
(SC) when the hydraulic oil temperature is
at 0 to 10 °C (32 to 50 °F).

T2-1-40
ANIMATION

SYSTEM / Control System

Pressure Sensor

Pump 2
Swing Delivery
Boom Raise Pressure
Sensor
Arm Roll-In

Hydraulic Oil
Temperature Sensor

Solenoid Valve Unit

SC

Arm Regenerative Valve T178-02-01-022

T2-1-41
SYSTEM / Control System
Travel Motor Swash Angle Control

Function: Controls the travel mode.

Operation: When the travel mode switch is in the


SLOW position, the travel motor swash
angle is kept in the maximum angle so that
the travel speed is slow.
When the MC receives the signals from the
travel pressure sensor, pump 1 and 2
delivery pressure sensors, pump 1 and 2
control pressure sensors under the
following conditions with the travel mode
switch in the FAST position, the MC
activates the solenoid valve unit (SI). Then,
the solenoid valve (SI) delivers the pilot
pressure oil to the travel motor swash
angle control valve, reducing the swash
angle to the minimum so that the travel
speed increases.

• ZX200 class, 225 class, 230 class • ZX270 class


Operating Conditions: Operating Conditions:
Travel Pressure Sensor: ON Travel Pressure Sensor: ON
Front Attachment Pressure Sensor: OFF Front Attachment Pressure Sensor: OFF
Pump 1 and 2 Delivery Pressure Sensor: Either pump Pump 1 and 2 Delivery Pressure sensor: Both of pump
delivery pressures are low. 1 and 2 delivery pressure are low.
Pump 1 and 2 Control Pressure Sensor: Either pump Pump 1 and 2 Control Pressure Sensor: Both of pump
control pressures are high. 1 and 2 control pressures are high.

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 the one side pump displacement target
increases, allowing the raised track to angle remains small so that the travel
rotate at fast speed. motor speed does not increase.
When the machine is traveling in the fast
mode, even if the front attachment is
operated (the front attachment pressure
sensor is turned ON), the travel mode is
kept unchanged in the fast mode.

T2-1-42
ANIMATION

SYSTEM / Control System

Pressure Sensor
Travel

Pump 2 Pump 1
Delivery Delivery
Pressure Pressure
Sensor Sensor

Travel Mode Switch

Fast
Mode
Pump 2 Control
Pressure Sensor

Pump 1 Control
Pressure Sensor
Solenoid Valve Unit

SI

Travel Motor

Swash Angle Control Valve

T178-02-01-023

T2-1-43
SYSTEM / Control System
Auxiliary Flow Rate Control (Only on the
machines equipped with the auxiliary pressure
sensor and auxiliary flow rate control solenoid
valve)

Function: Restricts the oil flow to the auxiliary spool


when the combined operation of the swing,
boom raise, and arm roll-in is made while
operating a front attachment using the
auxiliary spool to maintain controllability of
the combined operation.

Operation: The MC activates the auxiliary flow rate


control solenoid valve (optional) so that the
oil flow to the auxiliary spool is restricted
under the following conditions.

Operating Conditions:
Auxiliary Pressure Sensor: ON
Swing, Boom Raise, Arm Roll-In Pressure Sensors:
ON

T2-1-44
ANIMATION

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))

Function: Reduces the shock which may occur when


the boom reaches to its full stroke position
at boom raise operation by functioning the
electronic cushion in the speed reduction
area.

Operation:The signal from the boom angle sensor


comes into MC at boom raise operation.
MC calculates the boom angle by this
signal. When the boom angle reaches to
the speed reduction area, MC controls the
boom electronic cushion solenoid valve to
decrease the boom raise pilot pressure.
NOTE: Boom angle sensor and boom electronic
cushion solenoid valve are provided on the
ZAXIS225US (Up to serial No.104908).

Speed Reduction Area

Position where speed


reduction begins
Boom Full Stroke Position

T1GF-02-01-001

T2-1-46
ANIMATION

SYSTEM / Control System

Boom Angle Sensor

Boom Raise

Boom Electronic
Cushion Solenoid
Valve

Signal Control Valve


1
Control 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.

• Front Attachment Mode:


Functions only when a front attachment in the
optional kit is operated. The engine speed (see
T2-1-18 and 20) and pump flow rate (see
T2-1-28) are controlled so as to match the
installed front attachment operation in response
to the movement of the auxiliary valve spool. The
engine speed and pump flow rate control settings
are made by using Dr. ZX.

T2-1-48
ANIMATION

SYSTEM / Control System


Travel Alarm Control (Only on the machines
equipped with the travel alarm device (Optional))

Function: Sounds the buzzer while traveling.

Operation: As long as the MC receives signals from


the travel pressure sensor when travel
operation is made, the MC sends out
signals to the travel alarm device to sound
the buzzer (optional).

NOTE: After traveling continuously for more than


13 seconds, the buzzer can be stopped
with the buzzer deactivation switch
(Optional).

Pressure Sensor

Travel

Travel Alarm
Device (Optional)
Buzzer Deactivation
Switch (Optional)

Buzzer (Optional) T178-02-01-025

T2-1-49
SYSTEM / Control System
Overload Alarm Control (only on the machine
fitted with options)

Function: Sounds the buzzer when the front


attachment is operated.

Operation: MC receives a signal from a pressure


sensor provided at the bottom side of the
boom cylinder. MC determines the load,
and sends a signal to the overload alarm
device and sounds the buzzer when the
pressure exceeds the specified level
(load).
NOTE: Alarm may be turned on and off with the
buzzer on/off switch (optional).

Pressure Sensor

Boom Cylinder
Bottom

Overload Alarm Device


(Optional)
Buzzer on/off
Switch (Optional)

Buzzer

T178-02-01-038

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:

Power Source Controller Actuator


Main Pumps → Control Valves → Motors
Cylinders
Front Attachmens (Optional)

Pilot Circuit:

Power Source Controller Pilot Circuit


Pilot Pumps → Pilot Valves → Operation Control Circuit
Pump Regulator Pump Control Circuit
Solenoid Valve Unit Valve Control Circuit
Signal Control Valve Swing Parking Brake Release Circuit
Boom Electronic Cushion Travel Motor Swash Angle Control Circuit
Solenoid Valve Hydraulic Oil Heat Circuit
(Up to serial No.104908 Positining Circuit(2-Piece Boom only)
(ZAXIS225US))

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
**Positioning Left Pilot Travel Pilot Right Pilot Auxiliary Pilot
Pilot Valve Valve Valve Valve Valve Swing Motor

*Boom Electronic
Pump
To
Positoning Cushion Solenoid Control Circuit
control Valve
Valve**
Maximum Pump 2 Torque
Flow Rate Control Control So-
Solenoid Valve lenoid Valve
Pilot Shut-
Off Valve
Signal Control Valve SB ST

Hydraulic Oil
Heat Circuit SA

Maximum Pump 1
Flow Rate Control So-
To Control Valve lenoid Valve (Optional)
2 1
Spools
Boom

Flow Bucket Flow


Arm
Auxiliary Flow Combining Combiner Rate Control
Solenoid Valve (When Valve Valve Regulator
Posi- the auxiliary spool is
tioning used.)
Boom Anti-Drift Valve
Holding
Valve (Op-
tional) Arm Anti-Drift Valve
Auxiliary Flow Rate Control
Solenoid Valve (When the
auxiliary spool is used.) Auxiliary Flow Combiner Valve

Bypass Cut Valve

Auxiliary Flow Control Valve

SG Main Relief Valve


Valve
Control SC Arm Regenerative Valve
Circuit Hydraulic
Oil Tank
SE Arm Flow Rate Control Valve

SI
Control Valve
Serial No.104679 and up ((ZX200 class and Suction
VC Solenoid 225 class), Filter
Valve Unit Serial No.010327 and up (ZX230 class),
Up to serial No.104678 (ZX200 class Serial No.020043 and up (ZX270 class)
and 225 class), Up to serial Travel Motor Swash
No.010326 (ZX230 class), Up to Angle Control Circuit
serial No.020042 (ZX270 class) Relief Valve
Pilot Pump
Travel Motor Travel Motor

NOTE: *Boom Electronic Cushion Solenoid Valve


is provide on the ZAXIS225US (Up to serial Pilot Filter
No104908).
**2-Piece boom only.

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 lower 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

Signal Control Valve


T1GF-02-02-001

T2-2-4
SYSTEM / Hydraulic System
ZX200 class, ZAXIS225USR, 230 class, 270 class,
ZAXIS225US (Serial No.104909 and up)
Positioning Pilot Valve
(2-piece boom only)

Travel Pilot Valve Pilot Valve (Left) Pilot Valve (Right)

Shockless Valve

13 14

9 10 11 12 4
3 2 1 8 7 6 5
Signal Control Valve

10 11
9

8
7

2 1
1
13 14

4
3 3
Positioning Control
Valve

6
5

Pilot Control Valve


Pump

T178-02-02-012
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.)

• Pump Flow Rate Control by Flow Rate Control Pres-


sure Pi
• Pressure oil from the pilot valve is selected by the
shuttle valves in the signal control valve. Then,
the selected pressure oil is routed further to either
the pump 1 flow rate control valve or the pump 2
flow rate control valve in the same signal control
valve, shifting either of the flow rate control
valves.

• When either the pump 1 flow rate control valve or


the pump 2 flow rate control valve is shifted, the
pilot pressure oil from the pilot pump is routed to
either main pump 1 or main pump 2 as flow rate
control pressure Pi.

NOTE: When the boom (raise/lower), arm


(roll-in/out), bucket (roll-in/out), auxiliary,
and/or travel (right) function is operated,
flow rate control pressure Pi is routed to
main pump 1. When the boom (raise/lower),
arm (roll-in/out), swing (right/left), and/or
travel (left) function is operated, flow rate
control pressure Pi is routed to main pump
2.

• Torque Control (Speed Sensing) by Torque Control


Solenoid Valve
• After the pilot oil pressure from the pilot pump is
regulated by the torque control solenoid valve, the
regulated pilot oil pressure is routed to main
pump 1 and 2 as speed sensing pressure Ppc.

T2-2-6
ANIMATION

SYSTEM / Hydraulic System

Travel (Left) Travel (Right) Swing Arm Boom Bucket

Signal
control
Valve

Pump 1 Flow Rate


Control Valve
Pump 2 Flow Rate
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 Valve, • Auxiliary Flow Rate Control Solenoid Valve: Aux-
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 auxiliary • Flow Combiner Valve Control Spool: Flow Com-
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 (ZX200 class and
• Solenoid Valve SC: Arm Regenerative Valve 225 class)
Up to serial No.010326 (ZX230 class)
• Solenoid Valve SE*: Arm Flow Rate Control Valve Up to serial No.020042 (ZX270 class)

• Solenoid Valve SG: Main Relief Valve (increasing


the set-pressure)
NOTE: **Serial No.104679 and up 104678 (ZX200
class and 225 class)
Serial No.010327 and up (ZX230 class)
Serial No.020043 and up (ZX270 class)

T2-2-8
SYSTEM / Hydraulic System

Positioning Travel (Right) Arm Roll-In Boom Lower

**Arm Flow
Control Valve
Control Spool

Auxiliary

13

Signal 4
Control Main Relief Valve Auxiliary Flow
Valve 2
Combining
Solenoid Valve

Auxiliary
Flow Combiner
Flow
Valve 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
Arm Anti-Drift Valve
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)

Arm Arm Flow


Regenerative Rate Control
Valve Valve

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.

• Consequently, the release signal oil pressure is


routed to the swing motor, releasing the swing
parking brake.

Travel Motor Swash Angle Control Circuit (Refer


to the COMPONENTS OPERATION / Travel Device
group.)
• The pilot oil pressure from solenoid valve SI regu-
lates the travel motor swash angle control valve.

Hydraulic Oil Heat Circuit (Refer to the COMPO-


NENTS OPERATION / Others (Upperstructure)
group.)
• When the pilot shut-off valve is closed, the pilot
oil pressure is routed to the signal control valve
so that hydraulic oil is warmed while passing
through the orifice in the signal control valve.

• The warmed pilot pressure oil flows to the signal


control valve and pilot valves so that the pilot sys-
tem components are warmed.

Positioning Circuit (2-Piece Boom Only)


(Refer to the COMPONENTS OPERATION / Con-
trol Valve group.)
• When the positioning function is operated, the pi-
lot pressure shifts the bypass shut-out valve and
positioning control valve spool.

T2-2-10
SYSTEM / Hydraulic System

Swing Arm Boom Bucket

Orifice

Signal
Control Swing Parking Brake
Valve Release Spool

Solenoid
Valve Unit Swing Motor
Control Valve

SI
Travel Motor

T178-02-02-008
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.

• Delivered pressure oil is routed to the motor(s) or


cylinder(s) in response to operation(s) of the
spool(s) in the control valve(s).

• The return oil from the motor(s) and/or cylinder(s)


flows back to the hydraulic oil tank via the control
valve and/or the oil cooler.

• When the oil temperature is low (high viscosity),


the oil flow resistance increases in the oil cooler,
which opens the bypass check valve, allowing
hydraulic oil to return directly to the hydraulic oil
tank without passing through the oil cooler.

T2-2-12
SYSTEM / Hydraulic System

Travel Motor (Left) Travel Motor (Right)

Bucket Cylinder

Front Attachment (s)

Control Valve Boom Cylinder

4-Spool
Arm Cylinder Side

Travel (Left) Travel (Right)

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.

Single Operation Circuit


• Pressure oil from main pump 1 is routed to the
4-spool control valve and is further routed to each
spool of the travel (right), bucket, boom 1, and
arm 2.

• Pressure oil from main pump 2 is routed to the


5-spool control valve and is further routed to each
spool of the swing, arm 1, boom 2, and travel
(left).

• The boom and arm are actuated by pressure oil


from two main pumps. Pressure oil from each
main pump is combined and supplied together.

T2-2-14
ANIMATION

SYSTEM / Hydraulic System

Travel Motor (Left) Travel Motor (Right)

Control Valve

Front Attachment Travel Travel


(Left) (Right)

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.

• Pressure oil from pump 1 flows into the boom cyl-


inders via the parallel circuit and the boom 1
spool, raising the boom.

• Pressure oil from pump 2 flows into the swing


motor via the swing spool.

• At the same time, pressure oil from pump 2 flows


through the parallel circuit and after being com-
bined with pressure oil from pump 1, flows into
the boom cylinders, raising the boom together
with pressure oil from pump 1.

T2-2-16
ANIMATION

SYSTEM / Hydraulic System

Parallel Circuit

Boom 2
Boom 1 Boom Cylinder

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.

• At the same time, the right travel pilot oil pressure


shifts the flow combiner valve control spool in the
signal control valve. Pressure oil from the flow
combiner valve control spool is routed to the flow
combiner valve, shifting the flow combiner valve.

• Pressure oil from pump 1 drives the right travel


motor via the right travel spool.

• At the same time, pressure oil from pump 1


passes through the flow combiner valve and the
left travel spool and drives the left travel motor.

• Pressure oil from pump 2 flows into the arm cyl-


inder via the arm 1 spool, moving the arm.

• Consequently, pressure oil from pump 2 is used


only to operate the arm. Pressure oil pump 1 is
equally routed to both the right and left travel mo-
tors, ensuring that the machine can travel
straight.

T2-2-18
ANIMATION

SYSTEM / Hydraulic System

Travel Motor (Left) Pilot Pressure 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.

Combined Operation Circuit T178-02-02-014

• In combined operations, the pressurized oil from


pump 1 flows into the positioning control valve
through the parallel circuit.
• Even in combined operations, the parallel circuit
allows positioning operation.

T2-2-20
SYSTEM / Hydraulic System

4 Spool Side
Parallel Circuit

Positioning
Pilot Pressure Cylinder
from Position-
ing Pilot Valve

Bypass Shut-Out
Valve

Pump 1

Positioning
Control Valve

T178-03-03-057

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 or
breaker is operated, the pilot pressure oil from the roll–out), bucket (roll-in or roll–out), and/or
hydraulic breaker pilot valve shifts the auxiliary right travel operation, pilot pressure oil is
flow combiner valve and bypass shut-out valve. routed to port SN from the signal pilot pres-
sure control valve so that the aux. flow
• Therefore, the neutral circuit in the 4-spool control combiner valve is not shifted. (Refer to the
valve is blocked so that pressure oil from pump1 SYSTEM / Control System group.)
is routed to the auxiliary spool via the auxiliary
flow combiner valve.

T2-2-22
ANIMATION

SYSTEM / Hydraulic System

Pilot Oil Pressure


from Hydraulic
Breaker Pilot Valve

Auxiliary Flow Com-


bining Solenoid Valve

Pilot Pressure from


Auxiliary Flow Signal Control Valve
Combiner Valve
SN SM

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.

• Control Circuit (Refer to the SYSTEM / Control


System group.)
The control circuit is categorized into the engine,
pump, and valve control circuits. Each circuit
consists of the actuators such as solenoid valves,
MC (main controller), switch boxes, sensors and
pressure switches.

T2-3-1
SYSTEM / Electrical System
MAIN CIRCUIT
The major functions and circuits in the main circuit are
as follows.

• Electric Power Circuit: Supplies all electric power • Starting Circuit


to all electrical systems on this machine. [Key Starts the engine. [ Key Switch, Starter, Starter
Switch, Batteries, Fuses (Fuse Boxes, Fusible Relay]
Links), Battery Relay]
• Charging Circuit
• Indicator Light Check Circuit Charges the batteries. [Alternator, Regulator]
Checks all indicator bulbs for burning.
• Serge Voltage Prevention Circuit
• Accessory Circuit Prevents the occurrence of serge voltage
Becomes operative when the key switch is turned developed when stopping the engine. [ Load
to the ACC position. Damp Relay]

• Preheat Circuit • Engine Stop Circuit


Assists the engine to start in cold weather. [Key Stops the engine using the EC motor. [MC, EC
Switch, QOS Controller, Coolant Switch, Glow Motor]
Plug Relay, Glow Plugs]

T2-3-2
ANIMATION

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
ANIMATION

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.

• Current from key switch terminal M excites the


battery relay.

• Therefore, the battery current enters the monitor


controller via the battery relay and fuse #6 and
checks the indicator bulbs.

Key Switch

Battery

Battery
Relay
Fuse
Box

Monitor
Controller

T178-02-03-002

T2-3-4
ANIMATION

SYSTEM / Electrical System


ACCESSORY CIRCUIT

• When the key switch is turned to the ACC


position, terminal B is connected to terminal ACC
in the key switch.

• Current from key switch terminal ACC flows to


horn (fuse #14), radio (fuse #15), lighter (fuse
#16), cab light (fuse #17) and auxiliary (fuse #18)
through the fuse box, making each accessory
operable.

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 #1 preheating is not performed, the preheat indicator
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
NOTE: After preheating has been performed,
coolant temperature is 10 °C (50 °F) or below),
heating will continue for approx. 30
QOS controller terminal #4 is connected to
seconds after the engine starts.
terminal #5 (ground).

• Accordingly, the glow plug relay is turned ON,


routing current to the glow plugs so that
preheating begins.

T2-3-6
ANIMATION

SYSTEM / Electrical System

Monitor

Coolant Temperature Switch


Preheat Indicator
QOS Key Switch
Controller

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 ON
position, terminal B is connected to terminals M 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 signal
relay, battery current is routed to starter terminal indicating that the key switch is in the ON or
B and starter relay terminal B via the battery relay. START position.

• Key switch terminal ST is connected to starter • As soon as the MC receives this signal, the MC
relay terminal S so that current flows through the drives the EC motor, moving the governor lever to
starter relay coil. the engine start position.

• Then, the starter relay is turned ON, allowing


current to flow from starter relay terminal C to
starter terminal C.

T2-3-8
ANIMATION

SYSTEM / Electrical System

Key Switch

Battery

Battery
Relay
Starter Fuse
Box

Starter Relay

EC Motor

MC

T178-02-03-005

T2-3-9
ANIMATION

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

Key Switch 12V

Battery

T107-04-04-003

T2-3-10
ANIMATION

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
ANIMATION

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
ANIMATION

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 is
routed to base B of transistor T2, connecting 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 force ground.
just after the key switch is turned OFF so that the
alternator continues to generate electricity. • Then, current flows through the load damp relay
exciting circuit, turning the load damp relay ON.
• As the generating current cannot flow to the
battery, surge voltage arises in the circuit, • Accordingly, even if the key switch is turned OFF
possibly causing failures of the electronic while the engine is rotating, the battery current
components, such as the controller. To prevent continues to excite the battery relay via the load
the occurrence of surge voltage, the surge damp relay until the alternator stops generating.
voltage prevention circuit is provided. Therefore, the battery relay is kept ON, allowing
the generating current to flow to the batteries.

T2-3-14
ANIMATION

SYSTEM / Electrical System

Key Switch

Battery

Battery
Relay
Load
Damp
Relay

Alternator

Monitor Controller

T178-02-03-007

T2-3-15
ANIMATION

SYSTEM / Electrical System


ENGINE STOP CIRCUIT

• When the key switch is turned from the ON


position to the OFF position, the signal current
indicating that the key switch is ON stops flowing
from terminal M to MC terminal C-31.

• Then, the MC drives the EC motor to the engine


stop position.

Key Switch

EC Motor

MC

T178-02-03-008

T2-3-16
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 ............................. T3-5-2
Regulator................................................. T3-1-6 Travel Motor ............................................ T3-5-4
Solenoid Valve ....................................... T3-1-22 Parking Brake .......................................... T3-5-6
Pilot Pump ............................................. T3-1-24 Travel Mode Change................................ T3-5-8
N Sensor (Engine Speed Sensor) .......... T3-1-24 Travel Brake Valve................................. T3-5-14
Pump Delivery Pressure Sensor ............ T3-1-24
Group 6 Signal Control Valve
Pump Control Pressure Sensor ............. T3-1-25
Outline ..................................................... T3-6-1

Group 2 Swing Device Pilot Port.................................................. T3-6-2


Outline..................................................... T3-2-1 Shuttle Valve............................................ T3-6-6
Swing Reduction Gear ............................. T3-2-2 Shockless Valve..................................... T3-6-10
Swing Motor ............................................ T3-2-4 Pump 1 and Pump 2 Flow Rate
Swing Parking Brake ............................... T3-2-6 Control Valves...................................... T3-6-12
Valve Unit ................................................ T3-2-8 Bucket Flow Rate Control Valve,
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 ............................. T3-3-21
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 ................................................T3-7-11
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
Outline..................................................... T3-4-1 Track Adjuster ......................................... T3-8-3
Operation ................................................ T3-4-2

178T-3-1
(Blank)

178T-3-2
ANIMATION

COMPONENT OPERATION / Pump Device


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

6
7

8
10
3 2 1
11 T178-03-01-001

12

5 4 T178-03-01-003

T178-03-01-002

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


Sensor
2 - Pump 2 5 - Pump 2 Delivery Pressure 8 - Pump 1 Control Pressure Sensor 11 - Transmission
Sensor
3 - Pilot Pump 6 - Pump 1 Flow Rate Control 9 - Pump 2 Control Pressure Sensor 12 - Coupling
Solenoid Valve

T3-1-1
COMPOMRNT OPERATION / Pump Device
MAIN PUMP
The main pump supplies pressure oil to actuate the
hydraulic components such as motors or cylinders.
The main pump consists of pump 1 and pump 2. Shaft
(3) is connected to each pump cylinder block (6) via
seven plungers (4) so that the shaft and cylinder block
rotate together. When cylinder block (6) is rotated,
plungers (4) oscillate in the cylinder block, suctioning
and delivering hydraulic oil. Each main pump is
equipped with a regulator which controls the flow rate.

1 2

4
T178-03-01-005

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


2 - Housing 4 - Plunger

T3-1-2
COMPOMRNT OPERATION / Pump Device
Operational Principle
Engine torque is transferred to the shaft and the
seven plungers, causing the cylinder block to rotate
while sliding along the valve plate surface. The
plungers oscillate in the cylinder block bores to
alternately draw and deliver hydraulic oil.

Plunger

Valve Plate

Shaft

Cylinder Block

T105-02-03-002

T3-1-3
COMPOMRNT OPERATION / Pump Device
Increasing and Decreasing Flow Rate
Changing inclination of cylinder block (3), causes
plunger (2) stroke to increase or decrease depending
on the slant angle which in turn controls the main
pump flow rate. Up-down movement of servo piston
(6) changes inclination of cylinder block (3). Servo
piston (6) is interlocked with valve plate (4) via pin (5).
The one end of cylinder block (3) is kept in contact
with the surface of valve plate (4) and slides along it.

Maximum Displacement Angle:


2

T105-02-03-021

Minimum Displacement Angle (Operable Limit Angle): 5

6
T178-03-01-005

4 2

T105-02-03-022

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


3 - Cylinder Block

T3-1-4
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
response to the various command signal pressures so Dr
that the pump driving power doesn’t exceed the
engine power. Pump 1 and pump 2 are provided with
one regulator each. The major parts of the regulator
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 Bleeding
Circuit
command signal pressures, the regulator opens or Pps
Dr
closes the circuit to servo piston (10), causing the
inclination of cylinder block (11) to change, by which Pd1
the pump flow rate is controlled.

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


the smaller side chamber of servo piston Pg
(10). 10 12 8, 9
Increase Decrease
T176-03-01-009
Cylinder Block Inclination

Pd1 -Pump 1 Delivery Pi - Pump Control Pressure


Pressure
Pd2 -Pump 2 Delivery Pps -Torque Control Pressure
Pressure
Dr - Returning to Hydraulic Pg - Primary Pilot Pressure
Oil Tank (From Pilot Pump)

T3-1-6
COMPOMRNT OPERATION / Pump Device

1 2 3 4

T178-03-01-006
5 6 7 8 9

12

11

10

T178-03-01-005

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


2 - Sleeve A 5 - Load Piston 8 - Outer Spring 11 - Cylinder Block
3 - Spool A 6 - Spool B 9 - Inner Spring 12 - Link

T3-1-7
COMPOMRNT OPERATION / Pump Device
Regulator Control Function
The regulator has the following four control
functions.

• Control by Pump Control Pressure


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

• Control by Own or Opponent Pump Delivery


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

T3-1-8
COMPOMRNT OPERATION / Pump Device
• Control by Pilot Pressure from Torque Control
Solenoid Valve
The main controller (MC) operates based on both
the engine target speed input data and actual speed Flow
Rate (Q)
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)

• Control by Pilot Pressure from Flow Rate Control


Solenoid Valve Flow
(Pump 2 Side Only) Rate (Q)
When the MC receives signals from the work mode
switch, pressure sensor (optional) [auxiliary] or
attachment mode switch (optional), the MC send
signals to the maximum pump flow rate control
solenoid valve. Then, in response to the signals
from the MC, the maximum pump flow rate control
solenoid valve reduces pump control pressure Pi,
limiting the maximum pump flow rate. (Pump Flow
0 Pressure (P)
Rate Limit Control)
(Refer to the CONTROL SYSTEM section.) Dr

Pi

Pd2 Air
Bleeding
Circuit
Pps
Dr

Pd1

Pg

Increase Decrease
Cylinder Block Inclination T176-03-01-009

Pd1 -Pump 1 Delivery Pi - Pump Control Pressure


Pressure
Pd2 - Pump 2 Delivery Pps -Torque Control Pressure
Pressure
Dr - Returning to Hydraulic Pg - Primary Pilot Pressure
Oil Tank (From Pilot Pump)

T3-1-9
COMPOMRNT OPERATION / Pump Device
Control by Pump Control Pressure

• Increasing Flow Rate


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

Pd1

Pg
10 12
Increase Decrease
Cylinder Block Inclination T176-03-01-009

1 - Spring 4 - Piston
2 - Sleeve A 10 - Servo Piston
3 - Spool A 12 - Link

Pd1 -Pump 1 Delivery Pi - Pump Control Pressure


Pressure
Pd2 - Pump 2 Delivery Pps -Torque Control Pressure
Pressure
Dr - Returning to Hydraulic Pg - Primary Pilot Pressure
Oil Tank (From Pilot Pump)

T3-1-10
ANIMATION

COMPOMRNT OPERATION / Pump Device

To Hydraulic Primary Pilot Oil


1 Oil Tank Pressure 2 3 4 Pump Control
Pressure Pi

Torque
Control
Pressure
Pps

Pump 2
Delivery
Pressure
Pd2
Pump 1 12
Delivery
Pressure
Pd1

10
T178-03-01-008

To Hydraulic Primary Pilot Oil


1 Oil Tank Pressure 2 3 4 Pump Control
Pressure Pi

Torque
Control
Pressure
Pps

Pump 2
Delivery
Pressure
Pd2

Pump 1 12
Delivery
Pressure
Pd1

10
T178-03-01-009

T3-1-11
COMPOMRNT OPERATION / Pump Device

• Decreasing Flow Rate


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

Pg
10 12
Increase Decrease
Cylinder Block Inclination T176-03-01-009

1 - Spring 4 - Piston
2 - Sleeve A 10 - Servo Piston
3 - Spool A 12 - Link

Pd1 -Pump 1 Delivery Pi - Pump Control Pressure


Pressure
Pd2 -Pump 2 Delivery Pps -Torque Control Pressure
Pressure
Dr - Returning to Hydraulic Pg - Primary Pilot Pressure
Oil Tank (From Pilot Pump)

T3-1-12
ANIMATION

COMPOMRNT OPERATION / Pump Device

To Hydraulic Primary Pilot


1 Oil Tank Pressure 2 3 4 Pump Control
Pressure Pi

Torque
Control
Pressure
Pps

Pump 2
Delivery
Pressure
Pd2

Pump 1
Delivery
12
Pressure
Pd1

10
T178-03-01-010

To Hydraulic Primary Pilot


1 Oil Tank Pressure 2 3 4 Pump Control
Pressure Pi

Torque
Control
Pressure
Pps

Pump 2
Delivery
Pressure
Pd2

Pump 1 12
Delivery
Pressure
Pd1

10
T178-03-01-011

T3-1-13
COMPOMRNT OPERATION / Pump Device
Control by Own or Opponent Pump Delivery
Pressure

• Decreasing Flow Rate


1. When the pump is loaded by operating any of the
control levers, either pump 1 delivery pressure Flow
Rate (Q)
Pd1 or pump 2 delivery pressure Pd2 increases.
(During operation, pump control pressure Pi is
increased.)
2. Load piston (5) moves spool B (6) and inner and
outer springs (8 and 9) toward the direction of the
arrow.
3. Due to the movement of spool B (6), the pilot oil
pressure is routed into the large chamber of servo
piston (10). 0 Pressure (P)
4. Due to the difference in diameter between the
large and small chambers, servo piston (10) Dr
moved toward the direction of the arrow so that
the cylinder block is rotated in the minimum
inclination direction, decreasing the pump flow
rate. Pi
5. The movement of the cylinder block is transmitted Pd1 Air
to sleeve B (7) via link (12). Then, sleeve B (7) is Bleeding
moved in the same direction as spool B (6). Pps
Circuit
6. When sleeve B (7) is moved by the same stroke Dr
as spool B (6), the pilot oil pressure circuit to Pd2
servo piston (10) through sleeve B (7) and spool
B (6) is closed so that servo piston (10) is
stopped, completing flow rate decrease
operation. 5 7 6 Pg
10 12 8, 9
Increase Decrease
Cylinder Block Inclination T176-03-01-009

5- Load Piston 9 - Outer Spring


6- Spool B 10 - Servo Piston
7- Sleeve B 12 - Link
8- Inner Spring

Pd1 - Pump 1 Delivery Pi - Pump Control Pressure


Pressure
Pd2 - Pump 2 Delivery Pps -Torque Control Pressure
Pressure
Dr - Returning to Hydraulic Pg - Primary Pilot Pressure
Oil Tank (From Pilot Pump)

T3-1-14
ANIMATION

COMPOMRNT OPERATION / Pump Device

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
T178-03-01-012
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

• Increasing Flow Rate


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

5 7 6 Pg
10 12 8, 9
Increase Decrease
Cylinder Block Inclination T176-03-01-009

5- Load Piston 9 - Outer Spring


6- Spool B 10 - Servo Piston
7- Sleeve B 12 - Link
8- Inner Spring

Pd1 -Pump 1 Delivery Pi - Pump Control Pressure


Pressure
Pd2 -Pump 2 Delivery Pps -Torque Control Pressure
Pressure
Dr - Returning to Hydraulic Pg - Primary Pilot Pressure
Oil Tank (From Pilot Pump)

T3-1-16
ANIMATION

COMPOMRNT OPERATION / Pump Device

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
T178-03-01-014

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
T178-03-01-015

T3-1-17
COMPOMRNT OPERATION / Pump Device
Control by Pilot Pressure from Torque Control
Solenoid Valve

• Decreasing Flow Rate


1. When the torque control solenoid valve is
activated by the signals from the MC, torque Flow
control pressure Pps increases. Rate (Q)
2. Torque control pressure Pps and either own
pump delivery pressure Pd1 or opponent pump
delivery pressure Pd2 are combined and applied
to load piston (5).
3. Load piston (5) pushes spool B (6) and inner and
outer springs (8 and 9) toward the direction of the
arrow.
4. Due to the movement of spool B (6), the pilot oil 0 Pressure (P)
pressure is routed into the large chamber of servo
piston (10). Dr
5. Due to the difference in diameter between the
large and small chambers, servo piston (10) is
moved toward the direction of the arrow. Then,
the cylinder block is rotated in the minimum Pi
inclination direction, decreasing the pump flow Pd2 Air
rate. Bleeding
6. The movement of the cylinder block is transmitted Pps
Circuit
to sleeve B (7) via link (12). Then, sleeve B (7) is Dr
moved in the same direction as spool B (6). Pd1
7. When sleeve B (7) is moved by the same stroke
as spool B (6), the pilot oil pressure circuit to the
large chamber of servo piston (10) through sleeve
B (7) and spool B (6) is closed so that servo 5 7 6 Pg
piston (10) is stopped, completing flow rate
10 12 8, 9
decrease operation. Increase Decrease
Cylinder Block Inclination T176-03-01-009

5- Load Piston 9 - Outer Spring


6- Spool B 10 - Servo Piston
7- Sleeve B 12 - Link
8- Inner Spring

Pd1 -Pump 1 Delivery Pi - Pump Control Pressure


Pressure
Pd2 - Pump 2 Delivery Pps -Torque Control Pressure
Pressure
Dr - Returning to Hydraulic Pg - Primary Pilot Pressure
Oil Tank (From Pilot Pump)

T3-1-18
ANIMATION

COMPOMRNT OPERATION / Pump Device

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
T178-03-01-016

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
T178-03-01-017

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, limiting pump
control pressure Pi.
3. Piston (4) pushes spool A (3) and spring (1)
0 Pressure (P)
toward the direction of the arrow.
4. Due to the movement of spool A (3), the circuit
from the large chamber of servo piston (10) is 1 3 2 4
opened to the hydraulic oil tank.
5. Since the pilot oil pressure is constantly routed Dr
into the small chamber of servo piston (10), servo
piston (10) is moved toward the direction of the
arrow so that the cylinder block is rotated in the
Pi
maximum inclination direction, increasing the
pump flow rate. Pd2 Air
Bleeding
6. The movement of the cylinder block is transmitted Circuit
to sleeve A (2) via link (12). Then, sleeve A (2) is Pps
Dr
moved in the same direction as spool A (3).
7. When sleeve A (2) is moved by the same stroke Pd1
as spool A (3), the pilot oil pressure circuit to the
large chamber of servo piston (10) is closed so
that servo piston (10) is stopped, completing flow
rate increase operation. Pg
8. As the pump control pressure is restricted, the 10 12
maximum flow rate is reduced more than normal. Increase Decrease
Cylinder Block Inclination T176-03-01-009

1 - Spring 4 - Piston
2 - Sleeve A 10 - Servo Piston
3 - Spool A 12 - Link

Pd1 - Pump 1 Delivery Pi - Pump Control Pressure


Pressure
Pd2 - Pump 2 Delivery Pps -Torque Control Pressure
Pressure
Dr - Returning to Hydraulic Pg - Primary Pilot Pressure
Oil Tank (From Pilot Pump)

T3-1-20
ANIMATION

COMPOMRNT OPERATION / Pump Device

To Hydraulic Primary Pilot Oil


Pump Control
1 Oil Tank Pressure 2 3 4
Pressure Pi
Regulated by
Maximum Pump
Flow Rate Control
Solenoid Valve

Torque
Control
Pressure
Pps

Pump 2
Delivery
Pressure
Pd2

Pump 1 12
Delivery
Pressure
Pd1

10
T178-03-01-018

To Hydraulic Primary Pilot Oil


Oil Tank Pressure 2 3 4 Pump Control
1 Pressure Pi
Regulated by
Maximum Pump
Flow Rate Control
Solenoid Valve

Torque
Control
Pressure
Pps

Pump 2
Delivery
Pressure
Pd2
Pump 1 12
Delivery
Pressure
Pd1

10
T178-03-01-019

T3-1-21
COMPOMRNT OPERATION / Pump Device
SOLENOID VALVE

The torque control solenoid valve and the pump 2 flow


rate limit solenoid valve are provided on the pump 1
regulator. The torque control solenoid valve supplies
the torque control pressure Pps to both the pump 1
and pump 2 regulators to reduce the pump flow rate.
The pump 2 flow rate limit solenoid valve reduces the
pump control pressure to the pump 2 regulator so that
the maximum pump flow rate is limited.

Operation
1. When neutral, port P is connected to the output
port through the notch on the spool.
2. When the current flows to the solenoid from the
MC, the solenoid is magnetized, pushing spring 1.
3. Then, spring 1 pushes the spool so that the
output port is connected to port T through the
notch on the spool.
4. Thereby, pressure at the output port begins to
decrease.
5. Since the left side spool diameter (A) is larger
than the right side spool diameter (B), the spool is
returned to the left side.

T3-1-22
ANIMATION

COMPOMRNT OPERATION / Pump Device


When Neutral:

Solenoid Spring 1 Spring 2 Sleeve Spool

T176-03-01-030

A Port P Port T B

Output Port

When in Operation:

Solenoid Spring 1 Spring 2 Sleeve Spool

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
transmission which in turn rotates driven gear (2) as 2
they are meshed together.

1 - Drive Gear 2 - Driven Gear

Outlet Port

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

The N sensor detects the engine speed, which is used


to control various operations. The N sensor is located
close to the transmission teeth so that the sensor
converts the number of teeth passing by the sensor
into pulse signals, effectively sensing the engine
speed. 4 5

3 - Tooth 5 - Output 3
4 - Output

T178-03-01-020

PUMP DELIVERY PRESSURE SENSOR


This sensor detects the pump delivery pressures,
which are used to control various operations. When oil
pressure is applied onto diaphragm (9), the diaphragm
is deformed. The deformation of the diaphragm is
detected as electrical signals.

T157-02-03-010
6 - Ground 8 - Power Source (5V)
6 7 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
diaphragm is deformed. The deformation of the
diaphragm is detected as electrical signals.

10 - Pressure Receiving Area 12 - Output


T176-03-01-023
(Diaphragm)
10 11 12 13
11 - Ground 13 - Power Source (5V)

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.

ZX200 class, 225 class, 230class ZX270 class

Valve Unit
Valve Unit

Swing Motor
Swing Motor

Swing Reduction Swing Reduction


Gear Gear

T178-03-02-001

T1HG-03-02-003

T3-2-1
ANIMATION

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 in- secured to the undercarriage, causing the upperstruc-
ternal surface of the housing so that they are inte- ture to rotate.
grated. As the housing is bolted on the upperstructure,
the ring gear doesn’t rotate. The swing motor shaft ro-
tates 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.

ZX200 class, 225 class, 230class

Swing Motor Shaft

First Stage Sun Gear


First Stage Planetary Gear
First Stage Carrier
Ring Gear
Second Stage Sun Gear
Second Stage Planetary Gear
Second Stage Carrier

Shaft

T178-03-02-006

T3-2-2
COMPONENT OPERATION / Swing Device

ZX270 class

First Stage Sun Gear Swing Motor Shaft

First Stage Carrier First Stage Planetary Gear

First Stage Ring Gear

Second Stage Planetary


Second Stage Sun Gear

Second Stage Ring Gear

Second Stage Carrier

Shaft

T164-03-02-003

T3-2-3
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 rota-
tion is transmitted to the swing reduction gear.

ZX200 class, 225 class, 230class

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

ZX270 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
ANIMATION

COMPONENT OPERATION / Swing Device


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

ZX200 class, 225 class, 230class

Releasing Brake: Applying Brake:


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

Spring

Brake Piston

Orifice

Friction Plate Check Valve


Port SH
(Brake Release
Pressure)
Plate

Brake Piston Chamber

T178-03-02-003

T3-2-6
COMPONENT OPERATION / Swing Device
ZX270 class

Releasing Brake: Applying Brake:


1. When the swing and/or front attachment control 1. When the swing and/or front attachment control
levers are operated, the swing parking brake re- levers are released, the swing parking brake re-
lease spool in the signal pilot pressure control lease spool in the signal pilot pressure control
valve is shifted. Thereby, the pilot pressure oil valve is returned to neutral so that the pilot pres-
from the pilot pump is routed to port SH. sure routed to port SH is reduced.
2. The spool is shifted to the right side by the pilot 2. Thereby, the spool returns to the original position.
pressure supplied to port SH. The pilot pressure from port PG is blocked, open-
The pilot pressure supplied to port PG is routed to ing the check valve.
the brake piston chamber via the spool. 3. The pressure oil in the brake piston chamber is
3. At the same time, the pressure oil in port PG is released to the swing motor housing through the
routed to the check valve via the spool. The pres- orifice of the check valve.
sure difference is developed between the front 4. Consequently spring 1 force is applied to plates
and the rear of the check valve caused by the ori- and friction plates which are meshed with the
fice, moving the check valve to the right when the outer diameter of the rotor and inner diameter of
pressure difference is increased more than the the housing respectively via the brake piston.
force of spring 2. Thereby, the drain circuit to the Then, the rotor outer diameter is held with friction
housing is blocked. force. While the engine is stopped, no pilot pres-
4. Then, the brake piston is raised, breaking contact sure is routed to port SH, allowing the brake to be
between the plates and friction plates so that the automatically applied.
brake is released.

Spring 1

Check Valve Spring 2 Brake Piston

Rotor

Port PG
(Brake Release Plate
Pressure)

Friction Plate

Spool

Port SH
(Brake Release
Pressure) T1HG-03-02-004

Orifice Brake Piston Chamber

T3-2-7
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 lack
T107-02-04-013
of oil in the circuit.

Control Valve
ZX200 class, 225 class, 230class

Poppet

Make-Up Valve Make-Up Valve

Port C

T178-03-02-004
Relief Valve

T3-2-8
COMPONENT OPERATION / Swing Device

ZX270 class

Relief Valve

Poppet

Make-Up Valve
Make-Up Valve

T1HH-03-02-003

T3-2-9
ANIMATION

COMPONENT OPERATION / Swing Device


Relief Valve
During starting or stopping swing operation, oil
pressure in the swing circuit becomes high. The re-
lief valve prevents the circuit pressure from rising
higher than the set-pressure.

ZX200 class, 225 class, 230class

Low Pressure Relief Operation (Shock Reducing High Pressure Relief Operation (Overload Prevention):
Function): 1. After the piston is moved full stroke, the spring is
1. Pressure at port HP (swing circuit) is routed into compressed so that the circuit pressure is in-
oil chamber C through the poppet orifice. creased to the set-pressure.
2. Pressure oil in oil chamber C is further routed into 2. If pressure in port HP increases more than the
oil chambers A and B via passages A and B re- spring set-pressure, the poppet is unseated,
spectively. causing pressure oil to flow to port LP from port
3. The pressure receiving area in oil chamber B is HP.
larger than oil chamber A so that the piston 3. When pressure in port HP is reduced to the
moves to the left. specified level, the poppet is seated by spring
4. As long as the piston keeps moving, a pressure force.
difference is developed between the front and the
rear of the poppet. When this pressure difference
is increased more than spring force, the poppet is
unseated, allowing pressure oil to flow to port LP.
5. When the piston is moved full stroke, the pres-
sure difference between the front and the rear of
the poppet disappears, causing the poppet to be
seated.

Poppet Orifice Spring Passage A Passage B Piston

HP

LP

Oil Chamber C Oil Chamber B T178-03-02-005

Oil Chamber A

T3-2-10
COMPONENT OPERATION / Swing Device
ZX270 class

Low Pressure Relief Operation (Shock Reducing High Pressure Relief Operation (Overload Preven-
Function): tion):
1. Pressure at port HP (swing circuit) is routed into 1. After the piston is moved full stroke, so that the
oil chamber through the poppet orifice. circuit pressure is increased to the set-pressure.
2. When the pressure in the oil chamber is in- 2. If pressure in port HP increases more than the
creased more than the force of spring 2, the pis- spring 1 set-pressure, the poppet is unseated,
ton moves to the left side. causing pressure oil to flow to port C (Serial
3. As long as the piston keeps moving, a pressure No.020038 and up) (Up to serial No. 020037: port
difference is developed between the front and the LP) from port HP.
rear of the poppet. When this pressure difference 3. When pressure in port HP is reduced to the
is increased more than spring force, the poppet is specified level, the poppet is seated by spring 1
unseated, allowing pressure oil to flow to port C force.
(Serial No.020038 and up) (Up to serial No.
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.

Serial No.020038 and up

Spring 2 Piston Oil Chamber Spring 1 Orifice


Return Circuit
(Port C)

Hp

Poppet T107-02-04-020
Up to serial No.020037
Spring 2 Piston Spring 1 Poppet

Orifice

LP

HP

Oil Chamber
T157-02-04-006

T3-2-11
COMPONENT OPERATION / Swing Device
(Blank)

T3-2-12
COMPONENT OPERATION / Control Valve
OUTLINE
The control valve controls oil pressure, flow rate, and 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 as
of the control valve are the main relief valve, overload viewed from the machine front (ZX200 class, 230
relief valve, flow combiner valve, anti-drift valve, flow class and 270 class) [as viewed from the machine
rate control valve, regenerative valve, auxiliary flow right on ZX225 class].
combiner valve, bypass shut-out valve, and spools. In the 5-spool section, the left travel, auxiliary, boom 2,
The spools are operated by pilot oil pressure. arm 1, and swing spool sections are arranged in that
order as viewed from the machine front (ZX200 class,
230 class and 270 class) [as viewed from the machine
right on ZX225 class].

Front
ZX200 class
ZX230 class Right Travel
ZX270 class Bucket
Boom 1
Left Travel Arm 2

Main Relief Valve

4-Spool Section

Auxiliary

Boom 2

Arm 1

Swing

5-Spool Section

Front
M178-05-003
ZX225 class

Positioning Control Valve


(2-Piece Boom only)

Front

T1SM-01-02-007

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 ZX225 class
29

18

22 3

35

2
20

14 4

9,10
Front
36
ZX200 class
ZX230 class W178-02-05-017
ZX270 class

1 - Load Check Valve (Travel 10 - Bucket Flow Rate Control 19 - Boom Anti-Drift Valve 28 - Overload Relief Valve
Parallel Circuit) Valve (Poppet Valve) (Switch Valve) (Arm: Bottom Side)
2 - Check Valve 11 - Bucket Regenerative Valve 20 - Load Check Valve (Arm 29 - Overload Relief Valve
(Main Relief Circuit) Tandem Circuit) (Arm: Rod Side)
3 - Main Relief Valve 12 - Overload Relief Valve 21 - Check Valve (Orifice) 30 - Arm Anti-Drift Valve (Check
(Bucket: Rod Side) (4-Spool Side Parallel Valve)
Circuit)
4 - Check Valve 13 - Overload Relief Valve 22 - Bypass Shut-Out Valve 31 - Arm Anti-Drift Valve
(Main Relief Circuit) (Bucket: Bottom Side) (Switch Valve)
5 - Check Valve 14 - Load Check Valve (Boom 1 23 - Arm Flow Rate Control 32 - Load Check Valve (Boom 2
(Flow Combiner Valve Parallel Circuit) Valve (Poppet Valve) Parallel Circuit)
Circuit)
6 - Flow Combiner Valve 15 - Boom Regenerative Valve 24 - Arm Flow Rate Control 33 - Auxiliary Flow Rate Control
Valve (Switch Valve) Valve (Switch Valve)
7 - Auxiliary Flow Combiner 16 - Overload Relief Valve 25 - Load Check Valve (Swing 34 - Auxiliary Flow Rate Control
Valve (Boom: Bottom Side) Circuit) Valve (Poppet Valve)
8 - Check Valve 17 - Overload Relief Valve 26 - Check Valve 35 - Load Check Valve (Travel
(Aux. Flow Combiner (Boom: Rod Side) (Arm Regenerative Circuit) Tandem Circuit)
Valve Circuit)
9 - Bucket Flow Rate Control 18 - Boom Anti-Drift Valve 27 - Arm Regenerative Valve 36 - Load Check Valve (Orifice)
Valve (Switch Valve) (Check Valve) (Bucket)

T3-3-3
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
ZX225
l
25
31
16
30
23,24

32

33,34

26
Front
ZX200 class
ZX230 class 28
ZX270 class 17
W178-02-05-018
13
6

1 - Load Check Valve (Travel 10 - Bucket Flow Rate Control 19 - Boom Anti-Drift Valve 28 - Overload Relief Valve
Parallel Circuit) Valve (Poppet Valve) (Switch Valve) (Arm: Bottom Side)
2 - Check Valve 11 - Bucket Regenerative Valve 20 - Load Check Valve (Arm 29 - Overload Relief Valve
(Main Relief Circuit) Tandem Circuit) (Arm: Rod Side)
3 - Main Relief Valve 12 - Overload Relief Valve 21 - Check Valve (Orifice) 30 - Arm Anti-Drift Valve (Check
(Bucket: Rod Side) (4-Spool Side Parallel Valve)
Circuit)
4 - Check Valve 13 - Overload Relief Valve 22 - Bypass Shut-Out Valve 31 - Arm Anti-Drift Valve
(Main Relief Circuit) (Bucket: Bottom Side) (Switch Valve)
5 - Check Valve 14 - Load Check Valve (Boom 1 23 - Arm Flow Rate Control 32 - Load Check Valve (Boom 2
(Flow Combiner Valve Parallel Circuit) Valve (Poppet Valve) Parallel Circuit)
Circuit)
6 - Flow Combiner Valve 15 - Boom Regenerative Valve 24 - Arm Flow Rate Control 33 - Auxiliary Flow Rate Control
Valve (Switch Valve) Valve (Switch Valve)
7 - Auxiliary Flow Combiner 16 - Overload Relief Valve 25 - Load Check Valve (Swing 34 - Auxiliary Flow Rate Control
Valve (Boom: Bottom Side) Circuit) Valve (Poppet Valve)
8 - Check Valve 17 - Overload Relief Valve 26 - Check Valve 35 - Load Check Valve (Travel
(Aux. Flow Combiner (Boom: Rod Side) (Arm Regenerative Circuit) Tandem Circuit)
Valve Circuit)
9 - Bucket Flow Rate Control 18 - Boom Anti-Drift Valve 27 - Arm Regenerative Valve 36 - Load Check Valve (Orifice)
Valve (Switch Valve) (Check Valve) (Bucket)

T3-3-5
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 (Travel 10 - Bucket Flow Rate Control 19 - Boom Anti-Drift Valve 28 - Overload Relief Valve
Parallel Circuit) Valve (Poppet Valve) (Switch Valve) (Arm: Bottom Side)
2 - Check Valve 11 - Bucket Regenerative Valve 20 - Load Check Valve (Arm 29 - Overload Relief Valve
(Main Relief Circuit) Tandem Circuit) (Arm: Rod Side)
3 - Main Relief Valve 12 - Overload Relief Valve 21 - Check Valve (Orifice) 30 - Arm Anti-Drift Valve
(Bucket: Rod Side) (4-Spool Side Parallel (Check Valve)
Circuit)
4- Check Valve 13 - Overload Relief Valve 22 - Bypass Shut-Out Valve 31 - Arm Anti-Drift Valve
(Main Relief Circuit) (Bucket: Bottom Side) (Switch Valve)
5 - Check Valve 14 - Load Check Valve (Boom 1 23 - Arm Flow Rate Control 32 - Load Check Valve (Boom
(Flow Combiner Valve Parallel Circuit) Valve (Poppet Valve) 2 Parallel Circuit)
Circuit)
6 - Flow Combiner Valve 15 - Boom Regenerative Valve 24 - Arm Flow Rate Control 33 - Auxiliary Flow Rate Control
Valve (Switch Valve) Valve (Switch Valve)
7- Auxiliary Flow Combiner 16 - Overload Relief Valve 25 - Load Check Valve (Swing 34 - Auxiliary Flow Rate Control
Valve (Boom: Bottom Side) Circuit) Valve (Poppet Valve)
8 - Check Valve 17 - Overload Relief Valve 26 - Check Valve 35 - Load Check Valve (Travel
(Aux. Flow Combiner (Boom: Rod Side) (Arm Regenerative Circuit) Tandem Circuit)
Valve Circuit)
9 - Bucket Flow Rate Control 18 - Boom Anti-Drift Valve 27 - Arm Regenerative Valve 36 - Load Check Valve (Orifice)
Valve (Switch Valve) (Check Valve) (Bucket)

NOTE: There are only spools but no valves in


Cross Section B.

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
Cross Section D Cross Section F
Swing
Boom 2 Boom 1

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 (Travel 10 - Bucket Flow Rate Control 19 - Boom Anti-Drift Valve 28 - Overload Relief Valve
Parallel Circuit) Valve (Poppet Valve) (Switch Valve) (Arm: Bottom Side)
2 - Check Valve 11 - Bucket Regenerative Valve 20 - Load Check Valve (Arm 29 - Overload Relief Valve
(Main Relief Circuit) Tandem Circuit) (Arm: Rod Side)
3 - Main Relief Valve 12 - Overload Relief Valve 21 - Check Valve (Orifice) 30 - Arm Anti-Drift Valve
(Bucket: Rod Side) (4-Spool Side Parallel (Check Valve)
Circuit)
4- Check Valve 13 - Overload Relief Valve 22 - Bypass Shut-Out Valve 31 - Arm Anti-Drift Valve
(Main Relief Circuit) (Bucket: Bottom Side) (Switch Valve)
5 - Check Valve 14 - Load Check Valve (Boom 1 23 - Arm Flow Rate Control 32 - Load Check Valve (Boom
(Flow Combiner Valve Parallel Circuit) Valve (Poppet Valve) 2 Parallel Circuit)
Circuit)
6 - Flow Combiner Valve 15 - Boom Regenerative Valve 24 - Arm Flow Rate Control 33 - Auxiliary Flow Rate Control
Valve (Switch Valve) Valve (Switch Valve)
7- Auxiliary Flow Combiner 16 - Overload Relief Valve 25 - Load Check Valve (Swing 34 - Auxiliary Flow Rate Control
Valve (Boom: Bottom Side) Circuit) Valve (Poppet Valve)
8 - Check Valve 17 - Overload Relief Valve 26 - Check Valve 35 - Load Check Valve (Travel
(Aux. Flow Combiner (Boom: Rod Side) (Arm Regenerative Circuit) Tandem Circuit)
Valve Circuit)
9 - Bucket Flow Rate Control 18 - Boom Anti-Drift Valve 27 - Arm Regenerative Valve 36 - Load Check Valve (Orifice)
Valve (Switch Valve) (Check Valve) (Bucket)

T3-3-9
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
Cross Section H Cross Section I

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 (Travel 10 - Bucket Flow Rate Control 19 - Boom Anti-Drift Valve 28 - Overload Relief Valve
Parallel Circuit) Valve (Poppet Valve) (Switch Valve) (Arm: Bottom Side)
2 - Check Valve 11 - Bucket Regenerative Valve 20 - Load Check Valve (Arm 29 - Overload Relief Valve
(Main Relief Circuit) Tandem Circuit) (Arm: Rod Side)
3 - Main Relief Valve 12 - Overload Relief Valve 21 - Check Valve (Orifice) 30 - Arm Anti-Drift Valve (Check
(Bucket: Rod Side) (4-Spool Side Parallel Valve)
Circuit)
4 - Check Valve 13 - Overload Relief Valve 22 - Bypass Shut-Out Valve 31 - Arm Anti-Drift Valve
(Main Relief Circuit) (Bucket: Bottom Side) (Switch Valve)
5 - Check Valve 14 - Load Check Valve (Boom 1 23 - Arm Flow Rate Control 32 - Load Check Valve (Boom 2
(Flow Combiner Valve Parallel Circuit) Valve (Poppet Valve) Parallel Circuit)
Circuit)
6 - Flow Combiner Valve 15 - Boom Regenerative Valve 24 - Arm Flow Rate Control 33 - Auxiliary Flow Rate Control
Valve (Switch Valve) Valve (Switch Valve)
7 - Auxiliary Flow Combiner 16 - Overload Relief Valve 25 - Load Check Valve (Swing 34 - Auxiliary Flow Rate Control
Valve (Boom: Bottom Side) Circuit) Valve (Poppet Valve)
8 - Check Valve 17 - Overload Relief Valve 26 - Check Valve 35 - Load Check Valve (Travel
(Aux. Flow Combiner (Boom: Rod Side) (Arm Regenerative Circuit) Tandem Circuit)
Valve Circuit)
9 - Bucket Flow Rate Control 18 - Boom Anti-Drift Valve 27 - Arm Regenerative Valve 36 - Load Check Valve (Orifice)
Valve (Switch Valve) (Check Valve) (Bucket)

T3-3-11
COMPONENT OPERATION / Control Valve
2-Piese Boom (Optional)

T178-03-03-056

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
Positioning Control Valve
(2-Piece Boom Only)

X
2

X
3
T198-03-03-002

Section X-X

T198-03-03-003

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
provided in both right and left main circuits, making
combined operations possible. An oil flow combiner
circuit is provided in both the boom and arm circuits
so that when a single operation is made, pressure oil
from both pumps 1 and 2 is supplied to the boom or
arm cylinders.

The main relief valve is located in the main circuit


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

T3-3-14
COMPONENT OPERATION / Control Valve

Left Travel Motor Main 4-Spool Section Right Travel Motor


Relief Valve Parallel Passage

5-Spool Section 4-Spool Section

Auxiliary

Bucket
Cylinder

Overload
Relief Valve

Arm
Cylinder Overload
Relief Valve

Swing Motor

Boom
Cylinder

Oil Flow
Combiner Circuit

5-Spool Section
Parallel Circuit

Pump 2 Pump 1

T178-02-02-001

T3-3-15
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.

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
cylinder.

Combined Operation Circuit


• In combined operations, the pressurized oil from
pump 1 flows into the positioning control valve
through the parallel circuit.
• Even in combined operations, the parallel circuit
allows positioning operation.

T3-3-16
COMPONENT OPERATION / Control Valve

4-Spool Side
Parallel Circuit

Positioning
Cylinder
Pilot Pressure
from
Positioning
Pilot Valve

Bypass Shut-Out
Valve

Positioning
Control Valve

T178-03-03-057

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 (ZX200 class
(2) shifts the switch valve in the boom anti-drift and 225 class),
valve while exerting onto the boom spool end. Serial No.010326 and earlier (ZX230 class),
As the air bleed circuit is provided in the upper Serial No.020042 and earlier (ZX270 class))
section of the control valve so that any air trapped in • The arm flow rate control valve is shifted by the
the control valve will automatically be bled. pilot pressure oil delivered from the arm flow rate
control valve control spool in the signal control
valve. (Serial No.104679 and later (ZX200 class
and 225 class),
Serial No.010327 and later (ZX230 class),
Serial No.020043 and later (ZX270 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 combiner valve and the bypass
shut-out valve are shifted by the pilot pressure oil
from auxiliary pilot valve.
• The auxiliary flow rate control valve is shifted by
the pilot pressure oil from the auxiliary flow rate
control solenoid valve.
• 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
Auxiliary Flow 7
Rate Control
Solenoid
Valve

Auxiliary Flow
Rate Control 2
1
Solenoid 1
Valve
Arm Anti-Drift
Valve

Pilot
Pressure Oil
from Boom
Solenoid 4 Anti-Drift
Valve Unit 3 Valve
3
Arm
Regenerative
Valve

Pilot Pressure Oil


from Pilot Pressure
Arm Flow Rate 6 Air Bleeding Oil from Aux.
Control Valve 5 Circuit Pilot Valve
Control Spool in
the signal Control
Valve

(Up to serial
No.104678
(ZX200 and 225 Arm Flow Rate
class), Up to Control Valve
Bypass Shut-Out Valve
serial No.010326
(ZX230 class),
Up to serial
No.020042
(ZX270 class)) T178-03-03-040
Pilot Pressure Oil
from SE

1 - Boom Raise 4 - Arm Roll-In 7 - Bucket Roll-In 10 - Left Travel Reverse


2 - Boom Lower 5 - Left Swing 8 - Bucket Roll-Out 11 - Right Travel Forward
3 - Arm Roll-Out 6 - Right Swing 9 - Left Travel Forward 12 - Right Travel Reverse

T3-3-19
COMPONENT OPERATION / Control Valve
(Blank)

T3-3-20
ANIMATION

COMPONENT OPERATION / Control Valve


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

T178-03-03-010

Pilot Pressure Oil from Flow


Combiner Valve Control Spool

Left Travel Motor Right Travel Motor

Flow Combiner Valve


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

Pump 1 T176-03-03-026

T3-3-21
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.

Relief Operation Set-Pressure Increase Operation


1. Pressure in port HP (main circuit) exerts on the 1. The pilot pressure from solenoid valve unit (SG)
pilot poppet via orifice A in the main poppet and is delivered to port SG, the piston compresses
orifice B in the seat. spring B.
2. When pressure in port HP increases more than 2. Then, spring B force is increased.
set-force of spring B, the pilot poppet is unseated, 3. Accordingly, pressure required to unseat the pilot
allowing pressure oil to flow to port LP (hydraulic poppet is increased, causing the relief valve
oil tank) through the passage and clearance set-pressure to increase.
around the sleeve.
3. At this time a pressure difference arises between
port HP and the spring chamber due to orifice A.
4. If this pressure difference increases more than
set-force of spring A, the main poppet is unseated
so that pressure oil at port HP flows to port LP.
5. Thereby, the main circuit pressure decreases.
6. When the main circuit pressure decreases more
than the specified pressure, the main poppet is
seated by spring A.

T3-3-22
ANIMATION

COMPONENT OPERATION / Control Valve


During Normal Operation:
Main Poppet Orifice A Orifice B Seat Passage Spring B

HP SG

LP

Sleeve Spring Sprind A Pilot Poppet Piston T157-02-05-003


Chamber

During Relief Operation:


Main Poppet Orifice A Orifice B Seat Passage Spring B

HP

LP

Sleeve Spring Spring A Pilot Poppet T157-02-05-003


Chamber

During Set-Pressure Increase Operation:


Spring B

HP SG

LP

Pilot Poppet Piston T157-02-05-004

T3-3-23
COMPONENT OPERATION / Control Valve
OVERLOAD RELIEF VALVE
(with Make-Up Function)

The overload relief valves are located in the boom,


arm, bucket, and positioning (2-piece boom only)
circuits. The overload relief valve prevents each
actuator circuit pressure from rising excessively when
the actuators are moved by external loads. In addition,
when the actuator circuit pressure is reduced, draws
the hydraulic oil from the hydraulic oil tank to prevent
the occurrence of cavitation (make-up function).

NOTE: The operations of overload relief valves in


boom, arm, bucket, and positioning
(2-piece boom) are same.

Relief Operation Make-Up Operation


1. Pressure in port HP (actuator circuit) exerts on 1. When pressure at port HP (actuator circuit) is
the pilot poppet via an orifice in the piston reduced more than port LP (hydraulic oil tank),
(positioning: valve). the sleeve is moved to the right (positioning: left).
2. When pressure in port HP increases more than 2. Then, hydraulic oil flows in port HP from port LP,
set-force of spring B, the pilot poppet is unseated, preventing cavitation.
allowing pressure oil to flow to port LP (hydraulic 3. When pressure in port HP increases more than
oil tank) through passage A and clearance around the specified pressure, the sleeve is closed by
the sleeve. spring C .
3. At this time a pressure difference arises between
port HP and the spring chamber due to the
orifice.
4. If this pressure difference increases more than
set-force of spring A, the main poppet is unseated Positioning Circuit (2-piece boom only)
so that pressure oil at port HP flows to port LP.
5. Thereby, the actuator circuit pressure decreases. Spring A Main Poppet
Spring C Sleeve
6. When the actuator circuit pressure decreases
more than the specified pressure, the main Seat
Orifice A
poppet is seated by spring A.
HP

Passage A Valve
Pilot
Spring B Spring
Poppet
Chamber LP T198-03-03-006

T3-3-24
ANIMATION

COMPONENT OPERATION / Control Valve


Boom, Arm and Bucket

During Normal Operation:


Make-Up Valve Sleeve Spring A Passage A Spring B
Main Poppet

HP

LP
Orifice Piston Spring Pilot Spring C T107-02-05-019

Chamber Poppet
During Relief Operation:
Sleeve Spring A Passage A Spring B
Main Poppet

HP

LP
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
ANIMATION

COMPONENT OPERATION / Control Valve


REGENERATIVE VALVE
The regenerative valves are provided in the boom
lower, arm roll-in, and bucket roll-in circuits to increase
cylinder speeds and to prevent cylinder hesitation,
improving machine controllability.

Boom Regenerative Valve and Bucket Regener-


ative Valve

NOTE: Operational principle of the boom


regen-erative valve is identical to that of
the bucket regenerative valve. Therefore,
the bucket generative valve is explained as Pressure Oil from Pump 1
an example.

Operation
1. When the bucket is rolled in, the return oil from
the cylinder rod side (bottom side of the boom
cylinder) enters hole A in the spool and acts on Bucket
the check valve. Cylinder
2. At this time, if pressure in the cylinder bottom side
(rod side of the boom cylinder ) is lower than the
rod side, the check valve is opened.
3. Then, the return oil from the cylinder rod side
flows into the bottom side together with oil
delivered from the pump, increasing the cylinder Check Valve
speed.
4. When the cylinder is moved full stroke or the T176-03-03-027

digging load increases, pressure in the cylinder


bottom side circuit will increases more than the
rode side, causing the check valve to close and
stopping regenerative operation.

T3-3-26
COMPONENT OPERATION / Control Valve

Orifice

Return Oil from


Cylinder Rod
Hole A Side

Spool
Pressure Oil to
Cylinder Bottom
Check Side
Valve

T178-03-03-052

T3-3-27
COMPONENT OPERATION / Control Valve
ARM REGENERATIVE VALVE
Operation
1. Normally, during arm rolled-in operation, the
return oil from the cylinder rod side flows back to
the hydraulic oil tank through the hole (orifice) in
the arm regenerative valve spool.
2. When solenoid valve unit (SC) is activated by a
signal from the MC (main controller), pilot
pressure oil delivered from solenoid valve unit
(SC) shifts the arm regenerative valve spool,
blocking the return oil circuit from the cylinder rod
side. (Refer to the SYSTEM /Control System
group.)
3. Thereby, the return oil from the cylinder rod side
flows to the bottom side together with oil delivered
from the pump, increasing the cylinder speed.

T3-3-28
COMPONENT OPERATION / Control Valve

Arm Regenerative
Valve
Arm 1 Arm 2

Return Oil from Arm


Cylinder Rod Side To Arm
Regenerative
Valve
Spool
Spool
To Hydraulic
Oil Tank Hole

From Arm 1
Spool Pilot Pressure
Oil from
Solenoid Valve
Unit (SC)

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

T3-3-29
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 circuit,
preventing the cylinders from drifting.

NOTE: Both the boom and arm anti-drift valves are


identical in construction.

Holding Operation
1. When the control lever is in the neutral position
(neutral spool position), the switch valve in the Boom Cylinder
anti-drift valve is not shifted.
2. Thus, pressure oil from the boom cylinder bottom
side (arm cylinder rod side) exerts on the check
valve (spring side) in the anti-drift valve though
the switch valve.
3. Consequently, the check valve is closed so that
the return circuit from the cylinder is blocked,
reducing cylinder drift.

Releasing Operation
1. When the arm is rolled in or the boom is lowered,
pilot pressure oil from the pilot valve pushes the
T176-03-03-028
piston in the anti-drift valve so that the switch Anti-Drift Valve Anti-Drift Valve
valve is shifted. (Switch Valve) (Check Valve)
2. Then, oil in the check valve spring chamber flows To
back to the hydraulic oil tank through the switch Pressure Oil Hydraulic
from Pump 1 Oil Tank Boom Cylinder
valve.
3. Thereby, the check valve is opened, allowing the
return oil from the boom cylinder bottom side
(arm cylinder rod side) to flow to the spool.
From Pilot
Valve

To
Hydraulic
Oil Tank

T176-03-03-029
Anti-Drift Valve Anti-Drift Valve
(Switch Valve) (Check Valve)

T3-3-30
COMPONENT OPERATION / Control Valve

Pilot Pressure Oil


Piston
from Pilot Valve

To Hydraulic Oil Tank


Switch Valve

To Main Spool

T178-03-03-051
Check Valve
Cylinder
Bottom Side
Circuit

T3-3-31
ANIMATION

COMPONENT OPERATION / Control Valve


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

NOTE: Each flow rate control valve functions in To Hydraulic


Oil Tank
respective combined operation as shown
below. As an example, the arm flow rate
control valve operation is explained in this
section.
Flow Rate
Combined Operation
Control Valve
Switch
Arm Swing and Arm Roll-In Valve
Bucket Boom Raise and Arm Roll-In
Poppet
Auxiliary Front Attachment and Auxiliary Valve

Normal Operation
1. Pressure oil from pump 2 exerts on the check
valve in the poppet valve. Pressure Oil
2. Normally, the switch valve is kept opened. Then, from Pump 2
pressure oil from pump 2 opens the check valve
and flows to the main spool through the switch T178-03-03-030

valve. Arm
Cylinder
3. Thereby, the poppet valve is opened so that
pressure oil from pump 2 flows to the main spool.
To Hydraulic
Flow Rate Control Operation Oil Tank
1. Pilot pressure oil from *arm flow rate control valve
control spool shifts the switch valve in the arm
flow rate control valve.
2. When the switch valve is shifted, oil pressure is
enclosed behind the poppet valve, limiting the
poppet valve to open.
3. Thereby, the poppet valve restricts the oil flow
Switch
rate to the main spool, allowing pressure oil to be Valve
supplied to the swing motor which is loaded more
than the arm. Poppet
Valve
NOTE: * SE (Up to serial No. (ZX200 class and
225 class), Up to serial No.010326 *Arm Flow
Rate Control
(ZX230 class), Up to serial No.020042 Valve Control Pressure Oil
(ZX270 class)) Spool from Pump 2

T178-03-03-031

T3-3-32
COMPONENT OPERATION / Control Valve

Spring A Check Valve Poppet

Spring B
To Main Spool

To Hydraulic Oil Tank


Pressure Oil from
Switch Valve Main Pump 2

Pilot Pressure from Am


Flow Rate Control Valve
Control Spool in the Signal
Control Valve*

Pilot Pressure from Solenoid


Valve Unit (SE)** To Main Spool

T178-03-03-013

NOTE: *Serial No.104679 and Up (ZX200 class


and 225 class)
Serial No.010327 and Up (ZX230 class)
Serial No.020043 and Up (ZX270 class)

NOTE: **Up to Serial No.104678


(ZX200 class and 225 class)
Up to Serial No.010326 (ZXS230 class)
Up to Serial No.020042 (ZX270 class)

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
bypass shut-out valve spool. supplied together to the attachment, increasing
attachment 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
attachment 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

Bypass Shut-Out Valve

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

Bypass Shut-Out Valve

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
attachment pilot pressure is routed to port SM of
the auxiliary flow combiner valve.
2. Then when the boom, arm, bucket, or travel Pressure Oil
function is operated at the same time, pilot From Pump 1
pressure from the signal pilot pressure control
valve is routed to port SN. Spool
3. The auxiliary flow combiner valve spool receives
pressure from port SM in the opening direction Check Valve
and pressure from port SN in the closing direction.
In addition, spring force acts on the spool in the Spring
closing direction.
4. Therefore, spool closing direction force is larger
than opening direction force, holding the spool
closed.

Port SN T178-03-03-053

T3-3-36
COMPONENT OPERATION / Pilot Valve
OUTLINE
The pilot valve controls the pilot oil pressure by which The reducing valves in both the front attachment /
the control valve spools are operated. swing and travel pilot valves are identical construction
Two types of the standard pilot valves are located on except for the pusher moving cam.
this machine. Both have four oil ports. One type is
used for the front attachment / swing function control.
Another is used for the travel function control. Optional
type has two oil ports.
• Travel Pilot Valve
4 Oil Ports Pilot Valve 1 Right Travel Reverse
• Front Attachment / Swing Pilot Valve 2 Right Travel Forward
Port ISO Control 3 Left Travel Forward
Hitachi Pattern 4 Left Travel Reverse
No. Pattern
1 Bucket Roll-Out ←
2 Boom Lower ← Hydraulic P T
Right Symbol
3 Bucket Roll-In ←
4 Boom Raise ←
1 Right Swing Arm Roll-In
2 Arm Roll-Out Right Swing
Left 1 4
3 Left Swing Arm Roll-Out 3 2
4 Arm Roll-In Left Swing T105-02-07-020

Hydraulic P T
Symbol

1 3 2 4
T105-02-07-020
T

3 4

2 1
T178-03-04-002
1

P
T178-03-04-001

T3-4-1
COMPONENT OPERATION / Pilot Valve
OPERATION
Spool (6) head comes in contact with the upper face of
spring guide (3) which is kept raised by return spring
(5).

Neutral (Output Diagram: A to B):


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

3. This status continues until hole (7) on spool (6) is


opened to port P.

T3-4-2
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

Output Port T178-03-04-005


Output Port T178-03-04-007

Travel Pilot Valve


1 1

2 2 Port T

7
Port P
3 3 6

4 4
5 Output Port
5
6
Port T Port T

6
Port P Port P
7 7

Output Port T178-03-04-006


Output Port T178-03-04-011

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


2 - Pusher 4 - Balance Spring 6 - Spool

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

4. As oil pressure in the output port increases, force


to push spool (6) upward increases. When, this
force overcomes balance spring (4) force,
balance spring (4) is compressed so that spool
(6) is moved upward.
5. As spool (6) is moved upward, hole (7) is closed
so that pressure oil from port P stops flowing into
the output port, stopping pressure oil in the output
port to increase.
6. As spool (6) is moved downward, balance spring
(4) is compressed, increasing the spring force.
Therefore, oil pressure in the output port
becomes equal to the oil pressure acting on the
bottom face of spool (6) being balanced in
position with the spring force.

T3-4-4
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

Output Port T178-03-04-008 Output Port T178-03-04-009

Travel Pilot Valve


1 1

2 2

3 3

4 4
5 5
6 6
Port T Port T

Port P Port P
7 7

Output Port T178-03-04-012 Output Port T178-03-04-013

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


2 - Pusher 4 - Balance Spring 6 - Spool

T3-4-5
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
2. At this moment, the bottom of pusher (2) directly Pressure
pushes spool (6). Therefore, even if oil pressure
in the output port increases further, hole (7) on
C
spool (6) is kept open.
3. Consequently, oil pressure in the output port is
equal to oil pressure in port P. A B
Lever Stroke
T522-02-05-001
NOTE: Total lever strokes for the front attachment
and swing controls are determined by
stroke dimension (E) of pusher (2). Total
lever stroke for the travel control is
determined by stroke dimension (E) of cam
(1).

T3-4-6
COMPONENT OPERATION / Pilot Valve

Front Attachment / Swing Pilot Valve

2 2

4
5

6
Port T

7 Port P

T178-03-04-010
Output Port T178-03-04-005

Travel Pilot Valve


1
1

E
2

4
5
6
Port T

Port P
7

T178-03-04-006
Output Port T178-03-04-014

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


2 - Pusher 4 - Balance Spring 6 - Spool

T3-4-7
COMPONENT OPERATION / Pilot Valve
(Blank)

T3-4-8
COMPONENT OPERATION / Travel Device
OUTLINE
The travel device consists of the travel motor, travel The travel reduction gear is a three stage reduction
reduction gear, and travel brake valve. The travel mo- planetary gear type, converting rotary power transmit-
tor is a swash plate type variable displacement axial ted from the travel motor to slow large torque causing
plunger motor, equipped with parking brake (wet-type the sprocket and track to rotate. The travel brake valve
negative multi-disc brake). The travel motor is driven protects the travel circuit from being overloaded and
by pressure oil from the pump and transmits its rotary prevents the occurrence of cavitation.
power to the travel reduction gear.
NOTE: The structure and theory of operation of the
travel device for ZX200 class, ZX225 class
and ZX230 class can be thought as identi-
cal. Only some parts differs. This section
describes the operation of ZX200 class and
ZX270 class.

ZX200 class, 225 class, 230 class ZX270 class

Travel Brake Valve Travel Reduction Gear Travel Brake Valve Travel Reduction Gear

T1HG-03-05-001
T178-03-05-001
Travel Motor Travel Motor

T3-5-1
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).

ZX200 class, 225 class, 230 class

1 2 3 4 5 6

14 13 11 10 9 8

12
T178-03-05-001
1 - Ring Gear 5 - First Stage Sun Gear 9 - Second Stage Planetary 12 - Sprocket
Gear
2 - Third Stage Carrier 6 - First Stage Carrier 10 - Third Stage Planetary Gear 13 - Drum
3 - Second Stage Sun Gear 7 - Propel Shaft 11 - Hub 14 - Housing
4 - Second Stage Carrier 8 - First Stage Planetary Gear

T3-5-2
COMPONENT OPERATION / Travel Device

ZX270 class

1 2 3 4 5 6

11 10 9

14 13

12 T1HG-03-05-001

T3-5-3
COMPONENT OPERATION / Travel Device
TRAVEL MOTOR
ZX200 class, 225 class, 230 class

The travel motor is a variable-displacement swash Shoes (3) on the tips of plungers (5) slide along swash
plate axial plunger motor. The travel motor consists of plate (4) surface due to the inclination of swash plate
valve plate (6), swash plate (4), rotor (2), plungers (5), (4), causing rotor (2) to rotate.
and shaft (1). Shaft (1) is splined to rotor (2), in which
plungers (5) are inserted. When pressure oil is sup-
plied from the pump, the plungers (5) are pushed.

1 2 3 4

6 5

T178-03-05-002

1 - Shaft 3 - Shoe 5 - Plunger 6 - Valve Plate


2 - Rotor 4 - Swash Plate

T3-5-4
COMPONENT OPERATION / Travel Device
ZX270 class

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

1- Plate 5- Center Shaft 9- Roller Bearing 13 - Plunger


2- Valve Plate 6- Housing 10 - Plate 14 - Rotor
3- Disc Spring 7- Drive Disc 11 - Friction Plate 15 - Link
4- Spring 8- Roller Bearing 12 - Brake Piston 16 - Servo Piston

T3-5-5
COMPONENT OPERATION / Travel Device
PARKING BRAKE
The parking brake is a wet-type multi disc brake. The
brake is a negative type so that it is released only
when the brake release pressure oil is routed into the
brake piston chamber. The parking brake is auto-
matically applied unless the travel function is operated.
The friction plates and the plates are splined to the
rotor and the housing, respectively.

Releasing Brake Applying Brake


1. When the travel lever is operated, pressure oil 1. When the travel lever is returned to neutral, the
from the main pump is routed to port AM or BM counterbalance spool in the travel brake valve is
through the control valve. returned to neutral.
2. ZX200 class, 225 class, 230 class: 2. ZX200 class, 225 class, 230 class:
This pressure oil shifts the counterbalance valve Then, pressure oil acting on the brake piston is
spool and acts on the brake piston via the notch returned to the drain circuit via the orifice of brake
on the spool. piston. Therefore, the brake piston is slowly
ZX270 class: pushed back by the disc spring.
This pressure oil shifts the counterbalance valve ZX270 class:
spool and acts on the brake piston via notch (I) Then, pressure oil acting on the brake piston is
reducing valve on the spool. returned to the drain circuit via the orifice of re-
3. Then, the brake piston is pushed against the disc ducing valve. Therefore, the brake piston is slowly
spring, allowing the plates and friction plates to be pushed back by the disc spring.
freed each other so that the brake is released. 3. Consequently, spring force is applied to the plates
engaging on the outer diameter of the rotor and
the friction plates engaging on the inner diameter
of the housing via the brake piston, securing the
rotor outer diameter by friction between the fric-
tion plates and the plates.

T3-5-6
ANIMATION

COMPONENT OPERATION / Travel Device

Friction Plate Plate Friction Plate Plate


When Applying Brake When Releasing Brake

Disk Spring Orifice Brake Piston Disk Spring Brake Piston

ZX200 class, 225 class, 230 class

To Brake
Piston
BM AM

Counterbalance
Spool

ZX270 class
To Breke Piston T178-03-05-008

Reducing Valve

Drain
I

Counterbalance Spool

BM T137-03-02-009
AM

T3-5-7
COMPONENT OPERATION / Travel Device
TRAVEL MODE CHANGE
ZX200 class, 225 class, 230 class
The tilt angle of swash plate (8) is changed by piston
(9) and (10) movement to select the travel mode.

• Slow Speed Mode


1. When the travel mode switch is in the SLOW po-
sition, the MC (main controller) doesn’t send sig-
nals to solenoid valve unit (SI) so that the pilot
pressure oil is not routed to pilot port (1). There-
fore, spool (2) is kept raised by spring (3).
2. Pressure oil in high pressure motor port (AM or
BM) acts on slow-speed piston (8) through piston
operating shuttle valve (4) and slow-speed orifice
(5).
3. Slow-speed piston (8) moves swash plate (7) so
that swash plate (7) angle is increased. Thereby,
plunger (6) stroke is increased, causing the travel
motor to rotate at slow speed.

T3-5-8
ANIMATION

COMPONENT OPERATION / Travel Device

6 7 8
1
Motor Port
(AM, BM)

To Drain

4 10 9

T178-03-05-004

1 - Pilot Port 4 - Piston Operating Shuttle 7 - Swash Plate 9 - Fast-Speed Piston


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

T3-5-9
COMPONENT OPERATION / Travel Device

• Fast Speed Mode


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

T3-5-10
ANIMATION

COMPONENT OPERATION / Travel Device

6 7 8
1
Motor Port
(AM, BM)

4 10 9

T178-03-05-005

1 - Pilot Port 4 - Piston Operating Shuttle 7 - Swash Plate 9 - Fast-Speed Piston


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

T3-5-11
COMPONENT OPERATION / Travel Device
ZX270 class

Servo piston (1) is interconnected to valve plate (6)


via link (5) so that when servo piston (1) is moved,
swash angle of rotor (7) is shifted through valve plate
(6), leading to travel speed change.

• Slow Speed

1. When the slow speed travel mode is selected, the 3. Accordingly, as the stroke of the plungers in the
MC (Main Controller) does not send out an motor is increased, slower revolution of the travel
electronic control signal to solenoid valve unit (SI). motor for low speed mode is obtained.
Therefore, speed change pilot pressure is not
routed to servo piston (1). Thus, spool (3) is held
down by spring (2).
2. Then, pressure oil P from the motor port is led to
both chambers “B” and “C”.
Since the pressure-receiving area in chamber “C”
is larger than that in chamber “B”, servo piston (1)
moves upward, increasing swash angle to the
maximum.

6 7

2 Drain

Pilot Pressure

T157-03-02-001

1 - Servo Piston 3 - Spool 5 - Link 7 - Rotor


2 - Spring 4 - Orifice 6 - Valve Plate

T3-5-12
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

Position of servo piston at initial


stage of fast speed travel operation:

Pilot Pressure

Position of servo piston at during


stage of fast speed travel operation:

T157-03-02-002

1 - Servo Piston 3 - Spool 5 - Link 7 - Rotor


2 - Spring 4 - Orifice 6 - Valve Plate

T3-5-13
COMPONENT OPERATION / Travel Device
TRAVEL BRAKE VALVE
The travel brake valve is located on the travel motor
head, consisting of the following valves.

ZX200 class, 225 class, 230 class


Counterbalance Valve:
Makes starting and stopping travel operations smooth,
prevents the machine from running away while de-
scending slopes, and routes the travel motor operating
pressure oil in high pressure port (AV or BV) to the
parking brake.

Check Valve:
Assists the counterbalance valve operation and pre-
vents cavitation in the motor circuit.

Overload Relief Valve:


Prevents the occurrence of overload and surge pres-
sure in the motor circuit and reduces shock loads de-
veloped when stopping travel operation.

Shuttle Valve:
Routes the travel motor operating high pressure oil in
high pressure port (AM or BM) to the slow or fast side
piston so that the piston is controlled.

Travel Motor Swash Plate Angle Control Valve:


Delivers pressure oil routed by the piston control shut-
tle valve to the slow or fast side piston.

Slow-Speed Orifice, Fast-Speed Orifice:


Makes the travel mode change (swash plate angle
control) smooth.

T3-5-14
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

T3-5-15
COMPONENT OPERATION / Travel Device
ZX270 class

Check Valve:
ensures smooth starts and stops, and prevents
cavitation from occurring in the motor circuit by
functioning together with counterbalance valve.

Reducing Valve:
reduces parking brake release pressure and prevents
sudden operation of the brake.

Parking Brake Release Shuttle Valve:


leads travel motor drive pressure to the parking brake.

Overload Relief Valve:


prevents overloads and surge pressure in the motor
circuit.

Counterbalance Valve:
ensures smooth starts and stops and prevents
overrunning when traveling down slopes.

Servo-Piston Operating Shuttle Valve:


leads divided hydraulic oil flow for travel motor
operation to the servo-piston.

T3-5-16
COMPONENT OPERATION / Travel Device

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

T3-5-17
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
(9) is returned to the original position by spring the 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.

T3-5-18
ANIMATION

COMPONENT OPERATION / Travel Device


ZX200 class, 225 class, 230 class

10 8 9 1 2
BV AV

6
4
7
3

T178-03-05-006

4 6
ZX270 class

h
f

AV BV

T140-03-02-005

10 1 8 2

1 - Port AV 4 - Motor Port AM 7 - Check Valve BC 9 - Spool (Counterbalance


Valve)
2 - Chamber A 5 - Overload Relief Valve 8 - Port BV 10 - Chamber B
3 - Check Valve AC 6 - Motor Port BM

T3-5-19
COMPONENT OPERATION / Travel Device
(Blank)

T3-5-20
COMPONENT OPERATION / Signal Control Valve
OUTLINE
The signal control valve is provided in the pilot circuit
between the pilot valve and the control valve and 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.

Pilot Valve Side

T178-03-06-016
Cross Section A-A

Shockless Valve

*Arm Flow Rate Control Valve


Control spool Bucket Flow Rate Control Valve
**Auxiliary

Pump 1 Flow Rate Control Valve Pump 2 Flow Rate Control Valve

Swing Parking Brake Flow Combiner Valve Control Spool


Release Spool

T178-03-06-002

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

Pilot Valve Side


Port Name Connecting to Note
Port A Right Pilot Valve Boom Raise Pilot Pressure
Boom Electronic Cushion Solenoid Valve (Up
to serial No.104908 (ZAXIS225US))
Port B Right Pilot Valve Boom Lower Pilot Pressure
Port C Left Pilot Valve Arm Roll-Out Pilot Pressure
Port D Left Pilot Valve Arm Roll-In Pilot Pressure
Port E Left Pilot Valve Left Swing Pilot Pressure
Port F Left Pilot Valve Right Swing Pilot Pressure
Port G Right Pilot Valve Bucket Roll-In Pilot Pressure
Port H Right Pilot Valve Bucket Roll-Out Pilot Pressure
Port I Travel Pilot Valve Left Travel Forward Pilot Pressure
Port J Travel Pilot Valve Left Travel Reverse Pilot Pressure
Port K Travel Pilot Valve Right Travel Forward Pilot Pressure
Port L Travel Pilot Valve Right Travel Reverse Pilot Pressure
Port M Auxiliary Pilot Valve Auxiliary Open Pilot Pressure
Port N Auxiliary Pilot Valve Auxiliary Close Pilot Pressure
Port SA Pump 1 Regulator Pump 1 Control Pressure
Port SB Pump 2 Regulator Pump 2 Control Pressure
Port PI Pilot Shut-Off Valve Primary Pilot Pressure
Port PH Pilot Shut-Off Valve Primary Pilot Pressure (Heating Circuit)
Port SH Swing Parking Brake Brake Release Pressure
Port DF Hydraulic Oil Tank Returning to Hydraulic Oil Tank

T3-6-2
COMPONENT OPERATION / Signal Control Valve

Pilot Valve Side


PH
C
A

E
M
D
H
B
F
SB
PI G

Pilot Valve Side

K N

I
SH
J

DF

SA L
T178-03-06-016

Control Valve Side


SM
3

1 5

13
2 4
SK
SE

Pressure Sensor (Swing)


8

14
Control Valve Side
7
9
6
10

SN
SL
11

Pressure Sensor (Travel) 12 SP T178-03-06-015

T3-6-3
COMPONENT OPERATION / Signal Control Valve

Control Valve Side


Port Name Connecting to Note
Port 1 Control Valve Boom Raise Pilot Pressure
Port 2 Control Valve Boom Lower Pilot Pressure
Port 3 Control Valve Arm Roll-Out Pilot Pressure
Port 4 Control Valve Arm Roll-In Pilot Pressure
Port 5 Control Valve Left Swing Pilot Pressure
Port 6 Control Valve Right Swing Pilot Pressure
Port 7 Control Valve Bucket Roll-In Pilot Pressure
Port 8 Control Valve Bucket Roll-Out Pilot Pressure
Port 9 Control Valve Left Travel Forward Pilot Pressure
Port 10 Control Valve Left Travel Reverse Pilot Pressure
Port 11 Control Valve Right Travel Forward Pilot Pressure
Port 12 Control Valve Right Travel Reverse Pilot Pressure
Port 13 Control Valve Auxiliary Open Pilot Pressure
Port 14 Control Valve Auxiliary Close Pilot Pressure
Port SE  Plug
(Up to serial No.104678 (ZX200 class and (Up to serial No.104678 (ZX200 class and 225
225 class), Up to serial No.010326 (ZX230 class), Up to serial No.010326 (ZX230 class), Up
class), Up to serial No.020042 (ZX270 to serial No.020042 (ZX270 class))
class))
Control Valve
(Serial No.104679 and up (ZX200 class and Arm Flow Rate Control Valve Control Pressure
225 class), Serial No.010327 and up (ZX230 (Serial No.104679 and up (ZX200 class and 225
class) Serial No.020043 and up (ZX270 class), Serial No.010327 and up (ZX230 class)
class)) Serial No.020043 and up (ZX270 class))
Port SM Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Port SN  Plug
Port SP Hydraulic Oil Tank Returning to Hydraulic Oil Tank
Port SL Control Valve Flow Combiner Valve Control Pressure
Port SK Control Valve Bucket Flow Rate Control Valve Control Pressure

T3-6-4
COMPONENT OPERATION / Signal Control Valve
Pilot Valve Side
PH
C
A

E
M
D
H
B
F
SB
PI G

Pilot Valve Side

K N

I
SH
J

DF

SA L
T178-03-06-016

Control Valve Side


SM
3

1 5

13
2 4
SK
SE

Pressure Sensor (Swing)


8

14
Control Valve Side
7
9
6
10

SN
SL
11

Pressure Sensor (Travel) 12 SP T178-03-06-015

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 (ZX200 class and 225 class)


Serial No.010327 and up (ZX230 class)
Serial No.020043 and up (ZX270 class)

T3-6-6
ANIMATION

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 Control Rate Control Rate Control Valve Control Brake Release Rate Control
Valve Valve Valve Control Spool Spool Valve Control
Spool Spool

T178-03-06-018

T3-6-7
COMPONENT OPERATION / Signal Control Valve

Pilot Valve Side

T178-03-06-016

Cross Section B-B

9
5
8
7
16

17

15
13
11
14

6 10
12
3
1
4

2
T178-03-06-009

1- Left Travel 6- Boom/Arm/Bucket/Right Travel 11- Boom/Arm/Bucket 16- Swing/Auxiliary


2- Left Travel/Right Travel 7- Boom/Arm 12- Boom/Arm/Bucket/ 17- Auxiliary
Swing/Auxiliary
3- Right Travel 8- Boom 13- Arm/Boom Raise/Swing/Auxiliary
4- Boom/Arm/Bucket/ Right Travel 9- Arm/Boom Raise 14- Bucket
5- Arm 10- Boom Raise/Arm/Bucket/Left 15- Swing
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.

During Boom Raising Operation: During Boom Lowering Operation (Shock Re-
1. Boom raise pilot pressure oil is routed into port A ducing Operation)
and acts on the spool. 1. When the boom is lowered, the return oil from the
2. Immediately after operation is started, the low pi- boom raise spool in the control valve is routed to
lot pressure oil flows to port 1 via clearance C port 1.
between the spool and the housing, and inner 2. Since the spool blocks the oil passage between
passage 2. port 1 and port A, the return oil cannot flow di-
3. The set-force of spring A is weaker than that of rectly to port A.
spring B. Therefore, when the pilot pressure in- 3. Port 1 is connected to spring A side via inner
creases, the spool is moved to the left. passage 1 and to the oil chamber via inner pas-
4. As the spool is moved to the right, port A is con- sage 2.
nected to port 1, increasing pressure in port 1 so 4. Pressure oil in the oil chamber flows out from
that the spool in the control valve is moved. clearance C between the spool and the housing,
reducing pressure in the oil chamber. Then, the
spool is moved to the right by pressure in the
spring A side. Thereby, clearance C between the
spool and the housing is closed, blocking pres-
sure oil flow.
5. When clearance C is closed, pressure in the oil
chamber increases, moving the spool to the left.
Therefore, clearance C is opened again, allowing
pressure oil to flow to port A.
6. As operations in steps (4 and 5) are repeated,
pressure oil is gradually returned to port A so that
the control spool returns slowly.

T3-6-10
COMPONENT OPERATION / Signal Control Valve

Pilot Valve Side

Port A
Inner Passage 1 C Spool Spring B

Spring A Inner Passage 2 Oil Chamber

Port 1
T178-03-06-013
Control Valve Side

T3-6-11
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.

1. The pilot oil pressure from the pilot valve is routed


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

NOTE: The pump 1 flow rate control valve oper-


ates when the boom (raise or lower), arm
(roll-in or out), bucket (roll-in or out), auxil-
iary, and travel (right) functions are oper-
ated. The pump 2 flow rate control valve
operates when the boom (raise), arm
(roll-in or out), swing (right or left), and
travel (left) functions are operated.

T3-6-12
ANIMATION

COMPONENT OPERATION / Signal Control Valve

Port SA, SB
Spring Spool

Primary Pilot Pressure

Pilot Pressure

Shuttle Valve

T178-03-06-017

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 CON- Bucket Flow Rate Control Valve Control Spool:
TROL SPOOL To Hydraulic Boom Raise Control
Oil Tank Pilot Pressure
Spool Spring
NOTE: The three captioned spools are identical in
operational principle.

The bucket flow rate control valve control spool is


shifted by the arm roll-in control pilot pressure, allow-
ing the boom raise control pilot pressure to flow to the T178-03-06-014
bucket flow rate control valve in the control valve. Arm Roll-In To Bucket Flow Rate
The flow combiner valve control spool is shifted by the Control Pilot Control Valve
Pressure
right travel control pilot pressure, allowing the primary
pilot pressure to flow to the flow combiner valve in the Flow Combiner Valve Control Spool:
To Hydraulic Primary Pilot
control valve. Oil Tank Pressure
The swing parking brake release spool is shifted by Spool Spring
the boom, arm, bucket, or auxiliary control pilot pres-
sure, allowing the primary pilot pressure to flow to the
swing motor.
The arm flow rate control valve control spool is shifted
by the arm roll-in control pilot pressure, allowing the
swing control pilot pressure to flow to the arm flow rate T178-03-06-014
control valve in the control valve. Right Travel To Flow Combiner
Control Pilot Valve
Pressure
NOTE: *Serial No.104679 and up
Swing Parking Brake Release Spool:
(ZX200 class and 225 class) Primary Pilot
To Hydraulic
Serial No.010327 and up (ZX230 class) Oil Tank Pressure
Serial No.020043 and up (ZX270 class). Spool Spring

T178-03-06-014
Boom, Arm, To Swing
Bucket and Motor
Auxiliary Pilot
Pressure

Arm Flow Rate Control Valve Control Spool:


To Hydraulic Swing Pilot
Oil Tank Pressure
Spool Spring

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
The pilot shut-off valve is a manual-operated switch • When Pilot Control Shut-Off Lever is in UNLOCK
valve. The spool in the pilot shut-off valve is rotated by Position
moving the pilot control shut-off lever to turn on or off The pilot shut-off valve is set in the ON position. The
the pilot oil flow to the pilot valves. pressure oil from the pilot pump to flow into the pilot
valves as the drain circuit is blocked. If the control
• When Pilot Control Shut-Off Lever is in LOCK lever is operated, the pilot valve works.
Position.
The pilot shut-off valve is set in the OFF position.
The pressure oil from the pilot pump does not flow
into the pilot valves, but it is routed to the signal
control valve. The pilot oil on the pilot valve side is Section Z-Z
routed to the hydraulic tank. The pilot valve are
operated, as the control levers are operated.

To Signal From Pilot


Control Valve Valve T178-03-07-002

A2 A1 Z

T1 T2 A3 A4 T4

T3 P

A5 T178-03-07-003

A1 - Right Pilot Valve A4 - Signal Control Valve T1 - Travel Pilot Valve T - Hydraulic Oil Tank
(Port 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
Serial No.104679 and up (ZX200 class and 225 class)
Two kinds of solenoid valve are provided: the solenoid Serial No.010327 and up (ZX230 class)
valve unit to control pumps and valves, and the boom Serial No.020043 and up (ZX270 class)
electronic cushion solenoid valve (ZAXIS225US: Up to
serial No.104908) to control the boom electronic
cushion.

Solenoid Valve Unit


The solenoid valve unit functions to control the pump
regulator, control valve and travel motor servo piston
upon receiving signals from the main controller (MC).
The solenoid valve unit consists of four solenoid
valves (SE)* (SC), (SI), and (SG). (Refer to the Control
System Group in the SYSTEM Section.)

SE*: Controls the arm flow rate control valve located in


the control valve T178-03-07-005
7 8 9
SC : Controls the arm regenerative valve located in the
control valve.
SI : Controls the travel motor servo piston.
(Travel Speed Selection)
SG : Functions to increase the main relief valve Up to serial No.104678 (ZX200 class and 225 class)
pressure setting. Up to serial No.010326 (ZX230 class)
Up to serial No.020042 (ZX270 class)
NOTE:* Up to serial No.104678 (ZX200 class and
225 class)
Up to serial No.010326 (ZX230 class)
Up to serial No.020042 (ZX270 class)

6 7 8 9 T178-01-02-003

T3-7-2
ANIMATION

COMPONENT OPERATION / Others (Upperstructure)


Proportional Solenoid Valve

Upon receiving an electric current signal from the MC,


the proportional solenoid valve outputs hydraulic
pressure proportional to the degree of the electric
current.

• When not energized (In neutral): 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.”)

Spool Spring Solenoid


T S P

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. As the left (A) diameter of the spool is larger than
the right (B), the spool returns to the left side.
5. The spool stops when the spool and sleeve notch
close. Therefore, the pressure in the output port
stops to decrease.

T3-7-4
COMPONENT OPERATION / Others (Upperstructure)
When Neutral:

Solenoid Spring 1 Spring 2 Sleeve Spool

T176-03-01-030

A Port P Port T B

Output Port

When in Operation:

Solenoid Spring 1 Spring 2 Sleeve Spool

T176-03-01-031

A Port P Port T B

Output Port

NOTE: The theory of operation of this solenoid


valve is similar to that of the solenoid valve
to control the pump. Refer to T3-1-23 also
for the illustration.

T3-7-5
COMPONENT OPERATION / Others (Upperstructure)
HOLDING VALVE
(Only on the machines equipped with the
corresponding optional parts.)

The holding valves function to hold the front


attachment in position if any hose for the front
attachment is punctured accidentally. The holding
Chamber a Passage c Passage b
valves are attached to the bottom side of the boom
cylinder, the rod side of the arm cylinder, and the rod
side of the positioning cylinder.
NOTE: The following explanation will be made
about the holding valve for the boom
cylinder as an instance.

• Holding valve operation when the control lever is in


neutral. Pressure
Pi
Because the pilot pressure Pi does not act on the
Port B Spool
spool, the spool remains in neutral.
The cylinder-holding pressure at the cylinder port B is Poppet Passage a
Port A To the Spool
applied to the poppet and to the spool through
in the Control T178-03-07-006
passage c. The cylinder-holding pressure, after Valve
passing 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 passage a
by blocking with the spool. 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 unintended lowering.

T3-7-6
COMPONENT OPERATION / Others (Upperstructure)

X Section X-X Passage a

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
control lever is operated The Boom Lower Control Lever: Half Stroke or less

When moving the boom lower control lever at half Chamber a Passage c Passage b Relief
Valve
stroke or less, the pilot pressure Pi acts on the spool,
and makes the spool move to the orifice B position. At
this time, the spool blocks passage B, so that the
poppet is pushed against the seat. As a result, the
pressurized oil from the port B flows through passages Orifice A
c and a in order to lower the boom.

When moving the boom lower control lever at half


stroke or more, the pilot pressure Pi acts on the spool, Pressure
and makes the spool shift to the orifice C position. Pi
Then, passages b and a are connected through orifice Port B
C. At this time, an oil passage, from port B to orifice A Spool
to chamber a to passage b to orifice C to passage a to Port A
port A, is opened. The oil from passage c is blocked by To the Spool
in the Control Poppet Passage a Orifice B
the spool, so that the oil does not flow into passage a. Valve T178-03-07-009
The pressure in the chamber a lowers, and the poppet
rises accordingly, so that the return oil from the
cylinder port B flows into port A through the poppet to
lower the boom.

The Boom Lower Control Lever: Half Stroke or More


Chamber a Passage c Passage b Relief
Valve

Passage A

Orifice C

Pressure
Pi
Port B
Spool

Port A To the Spool Poppet Passage a


in the Control
Valve T178-03-07-007

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

Orifice A

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

Output Output Worm


EC MOTOR Gear Shaft Gear

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


gear is incorporated into the EC motor to prevent a
loss of synchronism from occurring. The EC sensor is
provided to detect the degrees of the EC motor
rotation to calculate the governor lever position. (Refer
to the Control System Group in SYSTEM Section.)

Motor

Sensor EC Worm
Gear Sensor Wheel

T157-02-05-018

T3-7-10
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

1 - Outer Race 3 - Inner Race 5 - Support 6 - Ball


2 - Seal 4 - Seal

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.

To Left Travel To Right Travel To Left Travel To Right Travel


Motor (Reverse) Motor (Forward) Motor (Forward) Motor (Forward)

To Left Travel To Left Travel To Right Travel


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

1
Pilot Pressure Pilot Pressure
for Travel Speed Selection Drain for Travel Speed
Selection

Drain

Drain 3

Drain

: Forward
: Reverse
: Pilot Pressure
for Travel Speed Selection

T157-03-02-004

1 - Spindle 2 - Body 3 - Seal

T3-8-2
COMPONENT OPERATION / Others (Undercarriage)
TRACK ADJUSTER
CAUTION: Do not loosen valve (1) quickly
The track adjuster located on the side frame is
or loosen too much since high-pressure
composed of spring (5) and adjuster cylinder (6).
grease in the adjusting cylinder may spout
Spring (5) absorbs loads applied to the front idler.
out.
Adjuster cylinder (6) adjusts track sag.
Loosen carefully, keeping body parts and
face away from valve (1).
• Grease is applied through grease fitting into
Never loosen grease fitting.
chamber A of adjuster cylinder (6) as illustrated
below. The pressure of the grease pushes
piston rod (8) out and decreases track sag.

• To increases track sag, loosen valve (1) 1 to 1.5


turns counterclockwise to release grease from
the track adjuster cylinder through the grease
discharge hole. 1
Grease Fitting

Grease Discharge Hole

M104-07-119

1 2 3 4 a
5 6 7 8

W178-03-04-002

1 - Valve 3 - Washer 5 - Spring 7 - Flange


2 - Nut 4 - Spacer 6 - Adjuster Cylinder 8 - Piston Rod

T3-8-3
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: 81-298-31-1162

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