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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 man-
Be sure to thoroughly read this manual for cor- ual.
rect product information and service procedures. (Note: Do not tear off the form. Copy it for us-
age.):
Publications Marketing & Product Support
Hitachi Construction Machinery Co. Ltd.
TEL: 81-298-32-7173
FAX: 81-298-31-1162
ADDITIONAL REFERENCES
Please refer to the materials listed below in addition Operation Manual of the Engine
to this manual. Parts Catalog of the Engine
Hitachi Training Material
The Operators 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
signal words are used to alert the reader to the could, if not avoided, result in personal injury or
potential for personal injury of machine damage. death.
This is the safety alert symbol. When you see this IMPORTANT:
symbol, be alert to the potential for personal injury. Indicates a situation which, if not conformed to the
Never fail to follow the safety instructions prescribed instructions, could result in damage to the machine.
along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to component/part weights. NOTE:
To avoid injury and damage, be sure to use appropri- Indicates supplementary technical information or
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
m3 yd3 1.308 Temperature pC pF pCI1.8+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 Nm kgf m 1.0197 mL/rev cc/rev 1.0
Nm 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 ta-
ble.
Class
ZX200 Class ZAXIS200, 200LC, 210H, 210LCH, 210, 210LC, 210N, 240
ZX225 Class ZAXIS225USR, 225USRLC, 225US, 225USLC
ZX230 Class ZAXIS230, 230LC, 240H, 240LCH, 250, 250LC, 250LCN
ZX270 Class ZAXIS270, 270LC, 280LC, 280LCN
Model
Std. Model 200, 200LC, 210, 210LC, 210H, 210LCH, 210N, 225USR, 225USRLC,
225US, 225USLC, 230, 230LC, 240, 240H, 240LCH, 250, 250LC, 250LCN, 270,
270LC, 280LC, 280LCN
IN-04

SECTION AND GROUP
SECTION 1 GENERAL
CONTENTS Group 1 Specification
Group 2 Component Layout
Group 3 Component Specifications
SECTION 2 SYSTEM
Group 1 Control System
TECHNICAL MANUAL Group 2 Hydraulic System
Group 3 Electrical System
(Operational Principle)
SECTION 3 COMPONENT OPERATION
Group 1 Pump Device
Group 2 Swing Device
Group 3 Control Valve
Group 4 Pilot Valve
Group 5 Travel Device
Group 6 Signal Control Valve
Group 7 Others(Upperstructure)
Group 8 Others(Undercarriage)
TECHNICAL MANUAL (Troubleshooting)
SECTION 4 OPERATIONAL PER- SECTION 5 TROUBLESHOOTING
FORMANCE TEST Group 1 Diagnosing Procedure
Group 1 Introduction Group 2 Component Layout
Group 2 Standard Group 3 Troubleshooting A
Group 3 Engine Test Group 4 Troubleshooting B
Group 4 Excavator Test Group 5 Troubleshooting C
All information, illustrations and speci- Group 5 Component Test Group 6 Electrical System Inspection
fications in this manual are based on Group 6 Adjustment Group 7 ICX
the latest product information available
at the time of publication. The right is WORKSHOP MANUAL
reserved to make changes at any time
without notice. SECTION 1 GENERAL INFORMA- SECTION 3 UNDERCARRIAGE
TION Group 1 Swing Bearing
Group 1 Precautions for Disassem- Group 2 Travel Device
bling and Assembling Group 3 Center Joint
Group 2 Tightening Torque Group 4 Track Adjuster
Group 3 Painting Group 5 Front Idler
Group 4 Bleeding Air from Hydrau- Group 6 Upper and Lower Roller
COPYRIGHT(C)2005 lic Oil Tank Group 7 Track
Hitachi Construction Machinery Co., Ltd. SECTION 2 UPPERSTRUCTURE SECTION 4 FRONT ATTACHMENT
Tokyo, Japan Group 1 Cab Group 1 Front Attachment
All rights reserved Group 2 Counterweight Group 2 Cylinder
Group 3 Main Frame SECTION 5 ENGINE
Group 4 Pump Device
Group 5 Control Valve
Group 6 Swing Device
Group 7 Pilot Valve
Group 8 Pilot Shut-Off Valve
Group 10 Solenoid Valve
SECTION 1
GENERAL
CONTENTS
Group 1 Specifications
Specifications............................................ T1-1-1
Working Ranges ..................................... T1-1-14
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 ........................ T1-2-13
Group 3 Component Specifications

Engine ...................................................... T1-3-1
Engine Accessories .................................. T1-3-8
Hydraulic Component ............................... T1-3-9
Electrical Component.............................. T1-3-16
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 min1 (140 PS/1900 rpm)
Engine
110 kW / 2100 min1 (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)
E: Counterweight Clearance * 1030 mm (3 ft 5 in)
F: Engine Cover Height * 2220 mm (7 ft 3 in)
G: Overall Width of Upperstructure 2710 mm (8 ft 11 in) 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 min1 (rpm) 13.3 min1 (rpm) 13.3 min1 (rpm) 13.3 min1 (rpm)
Travel Speed (fast/slow) 5.5/3.6 km/h (3.4/2.2 mph)
Gradeability 35° (tan = 0.70)
NOTE: H/P mode

* The dimensions do not include the height of the shoe lug.
T1-1-1

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
Engine
110 kW / 2100 min1 (150 PS /2100 rpm)
A: Overall Width
B: Cab Height 2950 mm (9 ft 8 in)
C: Rear End Swing Radius 2750 mm (9 ft 0 in)
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)
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)
(Grouser shoe) (Grouser shoe)
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 min1 (rpm)
NOTE: H/P mode
T1-1-2

ZAXIS225USR, ZAXIS225USRLC
A,G C
B
F
E
D
K J
I
H
M178-12-007
Model ZAXIS225USR ZAXIS225USRLC

Operating Weight 22000 kg (48500 lb) 22500 kg (49600 lb)
Basic Machine Weight 17800 kg (39240 lb) 18300 kg (40340 lb)
Engine
110 kW/2100 min1 (150 PS/2100 rpm)
A: Overall Width
2860 mm (9 ft 5 in) 2990 mm (9 ft 10 in)
D: Minimum Ground Clearance *450 mm (18 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)
Ground Pressure 49 kPa (0.50 kgf/cm2, 7.1 psi) 47 kPa (0.48 kgf/cm2, 6.8 psi)
NOTE: H/P mode

T1-1-3

ZAXIS225US, ZAXIS225USLC
A C
B
F
E
D
K J
I H
M1GF-12-001
Model ZAXIS225US ZAXIS225USLC

3 3 3
Bucket Capacity (Heaped) PCSA 0.8 m (1.05 yd ), CECE 0.7 m
Engine
110 kW/2100 min1 (150 PS/2100 rpm)
A: Overall Width
2810 mm (9 ft 3 in) 2990 mm (9 ft 10 in)
J: Sprocket Center to Idler Center 3370 mm (11 ft 1 in) 3660 mm (12 ft)
1
Swing Speed 13.3 min (rpm)
NOTE: H/P mode

T1-1-4

ZAXIS240
A C
E
D
K J
I H
M178-12-001
Model ZAXIS240
Operating Weight 22400 kg (49400 lb)
Basic Machine Weight 17900 kg (39500 lb)
Engine
110 kW / 2100 min1 (150 PS /2100 rpm)
A: Overall Width (Excluding back mirrors) 2500 mm (8 ft 2 in)
H: Undercarriage Length 4260 mm (13 ft 12 in)
I: Undercarriage Width 2480 mm (8 ft 2 in)
J: Sprocket Center to Idler Center 3460 mm (11 ft 4 in)
53 kPa
Ground Pressure
(0.54 kgf/cm2, 7.7 psi)
NOTE: H/P mode
T1-1-5

ZAXIS230, 230LC, 240H, 240LCH

A C
E
D
K J
I H
M178-12-001
ZX230 Hydraulic ZX230LC Hydraulic ZX240H Hydraulic ZX240LCH Hydraulic

Model
Excavator Excavator Excavator Excavator
Type of Front-End Attachment 2.96 m (9 ft 9 in) 2.96 m (9 ft 9 in) H Arm
Isuzu CC-6BG1T 118 kW/2000 min1 (160 PS/2000 rpm)
Engine
125 kW/2100 min1 (170 PS/2100 rpm)
A: Overall Width
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)
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)
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)
NOTE: H/P mode

T1-1-6

ZAXIS250, 250LC, 250LCN

A C
E
D
K J
I H
M178-12-001
Model ZAXIS250 ZAXIS250LC ZAXIS250LCN

Engine
125 kW/2100 min1 (170 PS/2100 rpm)
A: Overall Width
2990 mm (9 ft 10 in) 3190 mm (10 ft 6 in) 2990 mm (9 ft 10 in)
I: Undercarriage Width 2990 mm (9 ft 10 in) 3190 mm (10 ft 6 in) 2990 mm (9 ft 10 in)
J: Sprocket Center to Idler Center 3460 mm (11 ft 4 in) 3840 mm (12 ft 7 in)
1
NOTE: H/P mode

T1-1-7

ZAXIS270, ZAXIS270LC
A C
B
F
E
D
K J
I H
M178-12-001
Model ZAXIS270 ZAXIS270LC

Engine
132 kW/2150 min1 (180 PS/2150 rpm)
A: Overall Width
3190 mm (10 ft 6 in)
J: Sprocket Center to Idler Center 3730 mm (12 ft 3 in) 4050 mm (13 ft 3in)
1
NOTE: H/P mode

T1-1-8

ZAXIS280LC, 280LCN
A C
E
D
K J
I
H
M178-12-001
Model ZAXIS280LC ZAXIS280LCN

Engine
132 kW/2150 min1 (180 PS/2150 rpm)
A: Overall Width
3190 mm (10 ft 6 in) 3000 mm (9 ft 10 in)
C Rear End Swing Radius 2940 mm (9 ft 8 in)
Ground Pressure 52 kPa (0.53 kgf/cm2, 7.5 psi)
NOTE: H/P mode

T1-1-9

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
Engine
110 kW / 2100 min1 (150 PS /2100 rpm)
A: Overall Width
G: Overall Width of Upperstructure 2710 mm (8 ft 11 in) 2500 mm (8 ft 2 in)
H: Undercarriage Length 4170 mm (13 ft 8 in) 4460 mm (14 ft 8 in) 4170 mm (13 ft 8 in)
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)
(Grouser shoe) (Grouser shoe)
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
NOTE: H/P mode
T1-1-10

ZAXIS240 (2-piece Boom)

A C
E
D
K J
I H
M178-12-001
Model ZAXIS240 2-piece Boom

Operating Weight 23000 kg (50700 lb)
Basic Machine Weight 17900 kg (39500 lb)
Engine
110 kW / 2100 min1 (150 PS /2100 rpm)
A: Overall Width (Excluding back mirrors) 2500 mm (8 ft 2 in)
55 kPa
Ground Pressure
(0.56 kgf/cm2, 8.0 psi)
NOTE: H/P mode
T1-1-11

ZAXIS250, 250LC, 250LCN (2-piece Boom)

A C
E
D
K J
I H
M178-12-001
ZAXIS250 ZAXIS250LC ZAXIS250LCN

Model
2-piece Boom 2-piece Boom 2-piece Boom
Engine
125 kW/2100 min1 (170 PS/2100 rpm)
A: Overall Width
2990 mm (9 ft 10 in) 3190 mm (10 ft 6 in) 2990 mm (9 ft 10 in)
B: Cab Height 2290 mm (7 ft 6 in) 3020 mm (9 ft 11 in)
I: Undercarriage Width 2990 mm (9 ft 10 in) 3190 mm (10 ft 6 in) 2990 mm (9 ft 10 in)
J: Sprocket Center to Idler Center 3460 mm (11 ft 4 in) 3840 mm (12 ft 7 in)
NOTE: H/P mode

T1-1-12

ZAXIS280LC, 280LCN (2-piece Boom)

A C
E
D
K J
I
H
M178-12-001
Model ZAXIS280LC 2-piece Boom ZAXIS280LCN 2-piece Boom

Engine
132 kW/2150 min1 (180 PS/2150 rpm)
A: Overall Width
3190 mm (10 ft 6 in) 3000 mm (9 ft 10 in)
C Rear End Swing Radius 2940 mm (9 ft 8 in)
1
NOTE: H/P mode

T1-1-13

WORKING RANGES
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) Arm 2.91 m (9 ft 7 in) H Arm
Category
Backhoe Shovel Backhoe Shovel Backhoe Shovel
Item
mm ft in mm ft in mm ft in mm ft in mm ft in mm ft in
A: Maximum Digging Reach 9250 304 9390 3010 9910 326 10060 330 9910 326 10060 330
B: Maximum Digging Depth *5980 *197 *6120 *200 *6670 *2111 *6820 *225 *6670 *2111 *6820 *225
C: Maximum Cutting Height *9170 *301 *9450 *310 *9600 *316 *9850 *324 *9600 *316 *9850 *324
D: Maximum Dumping Height *6390 *210 *6290 *208 *6780 *223 *6720 *221 *6780 *223 *6720 *221
E: Transport Height 3130 103 3130 103 2970 99 2970 99 2970 99 2970 99
F: Overall Transport Length 9620 317 9620 317 9500 312 9500 312 9500 312 9500 312
G: Minimum Swing Radius 3530 117 3530 117 3540 117 3540 117 3540 117 3540 117
NOTE: * The dimensions do not include the height of the shoe lug.
T1-1-14

ZAXIS210, ZAXIS210LC, ZAXIS210N

G
E E
A
B
Backhoe M178-12-002
Model ZAXIS210, 210LC, 210N, 240

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 ft in mm ft in mm ft in mm ft in
A: Maximum Digging Reach 9215 303 9415 3011 9910 326 10445 343
B: Maximum Digging Depth *5790 *1812 *6175 *203 *6670 *2111 *7265 *2310
C: Maximum Cutting Height *9475 *311 *9245 *304 *9600 *316 *9855 *324
D: Maximum Dumping Height *6610 *218 *6460 *212 *6780 *223 *7035 *231
E: Transport Height 3120 103 3150 104 2970 99 3110 102
F: Overall Transport Length 9620 317 9610 316 9500 312 9560 314
G: Minimum Swing Radius 3605 1110 3525 117 3540 117 3555 118
T1-1-15

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
Model ZAXIS225USR, 225USRLC
2.22 m (7 ft 3 in) Arm 2.91 m (9 ft 7 in) Standard Arm

Category
Backhoe Shovel Backhoe Shovel
Item
B: Maximum Digging Depth *5980 *19 7 *6120 *20 1 *6670 *21 11 *6820 *22 5
C: Maximum Cutting Height *9170 *30 1 *9450 *31 0 *9600 *31 6 *9850 *32 4
D: Maximum Dumping Height *6390 *21 0 *6290 *20 8 *6780 *22 3 *6720 *22 1
Std *8985 *29 6 *8985 *29 6 *8865 *29 1 *8865 *29 1

F: Overall Transport Length
LC *9130 *29 11 *9130 *29 11 *9010 *29 7 *9010 *29 7
T1-1-16

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
Model ZAXIS225US, 225USLC

2.22 m (7 ft 3 in) Arm 2.91 m (9 ft 7 in) Arm
Category
Item
Std 9040 298 9030 298 8920 293 8910 293
F: Overall Transport Length
LC 9180 301 9170 301 9060 299 9050 298
*NOTE: *The dimensions do not include the height of the shoe lug.
T1-1-17

G G
C C
D
D
E E
F F
A A
B B
Model ZAXIS230, 230LC

2.32 m (7 ft 7 in) Arm 2.96 m (9 ft 9 in) Arm 3.61m (11 ft 10 in) Arm
Category
Backhoe Shovel Backhoe Shovel Backhoe Shovel
Item
mm ft in mm ft in mm ft in mm ft in mm ft in mm ft in
*2210
B: Maximum Digging Depth *6300 *208 *6490 *214 *6950 *7130 *235 7590 2411 7780 256

*3010
C: Maximum Cutting Height *9410 *9810 *322 *9630 *317 *10040 *3211 9990 329 10380 341

D: Maximum Dumping Height *6540 *215 *6420 *211 *6760 *222 *6640 *219 7100 234 6980 2211
Model ZAXIS240H, 240LCH

2.96 m (9 ft 9 in) H Arm
Category
Backhoe Shovel
Item
mm ft in mm ft in
A: Maximum Digging Reach 10270 338 10460 345
B: Maximum Digging Depth *6950 *2210 *7130 *235
C: Maximum Cutting Height *9630 *317 *10040 *3211
D: Maximum Dumping Height *6760 *222 *6640 *219
E: Transport Height 3100 102 3100 *102
F: Overall Transport Length 10140 333 10140 333
G: Minimum Swing Radius 3870 128 3870 128
T1-1-18

ZAXIS250, 250LC, 250LCN

G
A
B
Backhoe M178-12-002
Model ZAXIS250, 250LC, 250LCN

2.19 m (9 ft 9 in) Arm 2.50 m (8 ft 2 in) Arm 2.96 m (9 ft 9 in) Arm
Category
Backhoe Backhoe Backhoe
Item
mm ft in mm ft in mm ft in
A: Maximum Digging Reach 9650 318 9870 325 10270 338
B: Maximum Digging Depth *6170 203 *6490 214 *6950 *2210
C: Maximum Cutting Height *9550 314 *9460 310 *9630 *317
D: Maximum Dumping Height *6590 217 *6580 217 *6760 *222
E: Transport Height 3240 108 3270 109 3100 102
F: Overall Transport Length 10230 337 10260 338 10140 333
G: Minimum Swing Radius 3850 127 3950 1212 3870 128
3.61m (11 ft 10 in) Arm

Category
Backhoe
Item
mm ft in
A: Maximum Digging Reach 10900 359
B: Maximum Digging Depth *7590 *2411
C: Maximum Cutting Height *9990 *329
D: Maximum Dumping Height *7100 *234
E: Transport Height 3320 1011
F: Overall Transport Length 10200 336
G: Minimum Swing Radius 3890 129
T1-1-19

ZAXIS270, ZAXIS270LC
G G
C C
D D
E E
F F
A A
B B
Model ZAXIS270, 270LC

2.4 m (7 ft 11 in) Arm 3.1 m (10 ft 2 in) Standard Arm
Category
Item
B: Maximum Digging Depth *6540 *21 5 *6720 *22 1 *7230 *23 9 *7410 *24 4
C: Maximum Cutting Height *9640 *31 8 *10050 *33 0 *9980 *32 9 *10360 *34 0
D: Maximum Dumping Height *6750 *22 2 *6670 *21 11 *7070 *23 2 *6990 *22 11
3.75 m (12 ft 4 in) Arm

Category
Backhoe Shovel
Item
mm ft in mm ft in
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
T1-1-20

ZAXIS280LC, 280LCN
E E
A
B
Backhoe M178-12-002
Model ZAXIS280LC, 280LCN

Category
Item
B: Maximum Digging Depth *6540 *215 *7230 *239 *7880 *2510
C: Maximum Cutting Height *9640 *318 *9980 *329 *10150 *334
D: Maximum Dumping Height *6750 *222 *7070 *232 *7250 *239
T1-1-21

ZAXIS210, ZAXIS210LC, ZAXIS210N, ZAXIS240 (2-piece Boom)

G
F
A
Backhoe
M1G6-13-012
Model ZAXIS210, 210LC, 210N, 240 2-piece Boom

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
F: Overall Transport Length 9750 3112 9540 314 9500 312 9490 312
T1-1-22

ZAXIS250, 250LC, 250LCN (2-piece Boom)

G
A
B
M1G6-13-012
Backhoe
Model ZAXIS250, 250LC, 250LCN 2-piece Boom

Category
Item
B: Maximum Digging Depth *5790 *1812 *6070 *1911 *6520 *215
C: Maximum Cutting Height *11100 *365 *11230 *3610 *11580 *3712
D: Maximum Dumping Height *8010 *263 *8140 *269 *8490 *2710
3.61m (11 ft 10 in) Arm

Category
Backhoe
Item
mm ft in
A: Maximum Digging Reach 11060 363
B: Maximum Digging Depth *7170 *236
C: Maximum Cutting Height *12130 *3910
D: Maximum Dumping Height *9030 *298
E: Transport Height 3330 1011
F: Overall Transport Length 10170 334
G: Minimum Swing Radius 2690 810
T1-1-23

ZAXIS280LC, 280LCN (2-piece Boom)

G
A
B
M1G6-13-012
Backhoe
Model ZAXIS280LC, 280LCN 2-piece Boom

Category
Item
B: Maximum Digging Depth *6020 *199 *6700 *2112 7320 24 0
C: Maximum Cutting Height *11370 *374 *11920 *391 12350 406
D: Maximum Dumping Height *8260 *271 *8810 *2811 9240 304
T1-1-24

GENERAL / Component Layout
MAIN COMPONENT LAYOUT
ZAXIS200 class, 230 class, 270 class
1
3
4
5
6
7
8
9
21
10
11
12
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

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

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

ELECTRICAL COMPONENT LAYOUT
(Overview)
ZAXIS200 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 (ZAXIS 200 class)

Up to serial No.010326 (ZAXIS 230 class)
Up to serial No.020042 (ZAXIS 270 class)
T1-2-4

ZAXIS225US
N Sensor 1 2 3 4 5 6
Torque Control Solenoid Valve
Pump 2 Flow Rate Control Solenoid Valve
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.

** Up to serial No.104908.
T1-2-5

ZAXIS225USR
N Sensor 1 2 3 4 5
Pump 2 Flow Rate Control Solenoid Valve
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

ELECTRICAL SYSTEM (Relays and Related Equipment)
Except ZAXIS225US
5
4
3 6
2
Rear Deck
7
8
9
10
T178-01-02-006
15
14
18 13
17 12
16 11
T178-01-02-007
1 - Satellite Terminal ON/OFF 6- Fuse Box 11 - Load Damp Relay (R1) 16 - Wiper Relay A (R6)
Switch (Satellite Navigation
System Equipped Machines
only)
2 - QOS Controller 7- Learning Switch 12 - Washer Relay (R2) 17 - Wiper Relay B (R7)
3 - ICX (Information Controller) 8- Dr. ZX Connector to MC 13 - Work Light Relay 2 (R3) 18 - Wiper Relay C (R8)
4 - MC (Main Controller) 9- Download Connector 14 - Work Light Relay 1 (R4)
(Not connected in Satellite
Terminal equipped machines)
5 - Satellite Terminal (Optional) 10 - Dr. ZX Connector to ICX 15 - Horn Relay (R5)
T1-2-7

ZAXIS225US
15
4
16
14
17
13
12
11 5
10
T1GF-01-02-003
1, 2 3
6
9 8 7
T1SM-01-02-006
1 - ICX (Information Controller) 6 - Fuse Box 11 - Work Light Relay 1 (R4) 16 - Wiper Relay B (R7)
2 - MC (Main Controller) 7 - Dr. ZX Connector to MC 12 - Work Light Relay 2 (R3) 17 - Wiper Relay C (R8)
3 - Satellite Terminal 8 - Dr. ZX Connector to ICX 13 - Washer Relay (R2)
(Optional)
4 - Download Connector 9 - * Learning Switch 14 - Load Dump Relay (R1)
5 - Diode D1, D2, D3, D4 10 - Horn Relay (R5) 15 - Wiper Relay A (R6)
NOTE: It is used for engine learning and the

initialization of the boom electronic cushion
(Up to serial No.104908).
T1-2-8

ELECTRICAL SYSTEM (Monitors and
Switches)
1 2
20
19
21
18
3
17
22
16 4
15
23
5
14 24
6
13 7
12 8
25
11
9
10
T178-01-02-008
T178-01-01-004
1- Coolant Temperature Gauge 8- Alternator Indicator 15- Digging Mode Indicator 22- Power Mode Switch
2- Fuel Gauge 9- Hydraulic Oil Filter Indicator 16- Attachment Mode Indicator 23- Travel Mode Switch
(Optional)
3- Display Selection Switch 10- Coolant Level Indicator * 17- Liquid Crystal Display 24- Work Light Switch
4- SET Switch 11- Engine Oil Level Indicator * 18- Auto-Idle Indicator 25- Wiper/Washer Switch
5- Work Mode Switch 12- Engine Oil Pressure 19- Auto-Acceleration Indicator
Indicator
6- Fuel Level Indicator 13- Preheat Indicator 20- Engine Control Dial
7- Air Filter Restriction Switch 14- Overheat Indicator 21- Auto-Idle/Acceleration
Selector
NOTE: * Up to serial No.104679 (ZAXIS200 class and 225 class)

Up to serial No.010322 (ZAXIS230 class)
T1-2-9

PUMP DEVICE
9
3 2 1
6
7
8
10
T178-03-01-001
5 4 T178-03-01-003
SWING DEVICE
ZAXIS200class, 225 class, 230 class ZAXIS270 class 11
11
12
12
T178-03-02-001 T1HG-03-02-003
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 11 - Swing Relief Valve
Sensor Sensor
3 - Pilot Pump 6 - Pump 2 Flow Rate Control 9 - Pump 2 Control Pressure 12 - Pressure Sensor
Solenoid Valve Sensor (Front Attachment)
T1-2-10

CONTROL VALVE SOLENOID VALVE UNIT
1 Serial No.104679 and up

(ZAXIS200 class and 225 class)
2 Serial No.010327 and up (ZAXIS230 class)
Serial No.020043 and up (ZAXIS270 class)
T178-03-07-005
7 8 9
3
T178-01-02-011
SIGNAL CONTROL VALVE

Up to serial No.104678
7 6 8 9 T178-01-02-003
T178-03-06-015
1 - Main Relief Valve 4 - Pressure Sensor (Swing) 7 - Solenoid Valve Unit (SC) 10 - Solenoid Valve Unit (SG)
2 - Pressure Sensor 5 - Pressure Sensor (Travel) 8 - Solenoid Valve Unit (SI)
(Arm Roll-in)
3 - Pressure Sensor 6 - Solenoid Valve Unit (SE)*
(Boom Raise)

T1-2-11

TRAVEL DEVICE
ZAXIS200 class, 225 class and 230 class
1
T1HD-01-02-001
ZAXIS270 class (Up to serial No. 20226) ZAXIS270 class (Serial No. 20227 and up)
2
1
1 1
T178-01-02-014
T1HG-01-02-002
2
1- Counterbalance Valve 2- Travel Relief Valve 3- Overload Relief Valve

(Positioning)
T1-2-12

POSITIONING CONTROL VALVE
(2-piece Boom Only)
ZAXIS200 class
T178-03-03-071
ZAXIS230 class and ZAXIS270 class
T178-03-03-068
T1-2-13

(Blank)
T1-2-14

GENERAL / Component Specifications
ENGINE
ZAXIS200 class, ZAXIS225 class:

Manufacturer ISUZU
Model AA-6BG1TRA
Type Diesel, 4-Cycle, Water-cooled, Inline, Direct Injection
Cyl. No.- Bore I Stroke 6-105 mmI125 mm (4.13 inI4.92 in)
Piston Displacement 6494 cm3 (396 in3)
-1
Rated Output 103 kW/1900 min (140 PS/1900 rpm)
HP Mode: 110 kW / 2100 min-1 (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)
ZAXIS230 class:
Manufacturer ISUZU
Model CC-6BG1TRA
-1
Rated Output 118 kW/2000 min (160 PS/2000 rpm)
T1-3-1

ZAXIS270 class:
Manufacturer ISUZU
Model CC-6BG1TRA
Rated Output 125 kW/2050 min-1 (170 PS/2050 rpm)
COOLING SYSTEM
Cooling Fan Dia. 650 mm (25.6 in), 7 Blades (N-Type Blade, Unequal Pitch),
Draw-in Type
Fan Pulley Ratio Engine rpm I 0.80
Thermostat Cracking Temperature at Atmospheric Pressure: 82 pC (180 pF)
Full Open (Stroke: 10 mm or more) Temperature: 95 pC (203 pF)
Water Pump Centrifugal Belt Driven Type

Cooling Fan Dia. 650 mm (25.6 in), 7 Blades (N-Type Blade, Unequal Pitch),
Draw-in Type
Fan Pulley Ratio Engine rpm I 0.88
Thermostat Cracking Temperature at Atmospheric Pressure: 82 pC (180 pF)
Full Open (Stroke: 10 mm or more) Temperature: 95 pC (203 pF)
Water Pump Centrifugal Belt Driven Type
T1-3-2

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

PERFORMANCE
IMPORTANT: This list shows design specifications, which are not servicing standards.
Fuel Consumption Ratio Less than 237 g/kW/h (174 g/PS h) at 110 kW / (at Full Load:
2100 min-1)
Less than 227 g/kW/h (166 g/PS h) at 103 kW / (at Working
-1
Load: 1900 min )
Injection Timing 10 p before T.D.C.
Maximum Output Torque More than 550o60 N m (54o6 kgf m) at approx. 1600 min-1
Injection Pressure 18.14 MPa (185 kgf/cm2)
Compression Pressure 3.04 MPa (31 kgf/cm2)
Valve Clearance (Inlet / Exhaust) 0.4 / 0.4 mm (when cool)
No Load Speed Slow: (at Full Load: 900o20 min-1)
+20 -1
Fast: (at Full Load: 2350 -50 min )
(at Working Load: 2100o50 min-1)
ZAXIS230 class:
Fuel Consumption Ratio Less than 237 g/kW/h (174 g/PS h) at 125 kW / (at Full Load:
-1
2100 min )
load: 2000 min-1)
Injection Timing 10p before T.D.C.
2
Injection Pressure 18.14 MPa (185 kgf/cm )
2
Compression Pressure 3.04 MPa (31 kgf/cm )
No Load Speed Slow: (at Full Load: 900o20 min-1)
Fast: (at Full Load: 2420+20-50 min-1)
-1
(at Working Load: 2300o50 min )
ZAXIS270 class:
Fuel Consumption Ratio Less than 243 g/kW/h (179 g/PS h) at 132 kW / (at Full
Load: 2150 min-1)
Load: 2050 min-1)
Injection Timing 10 p before T.D.C.
2
Injection Pressure 18.14 MPa (185 kgf/cm )
2
Compression Pressure 3.04 MPa (31 kgf/cm )
-1
No Load Speed Slow: (at Full Load: 900o20 min )
Fast: (at Full Load: 2470 -50 min-1)
+20
-1
(at Working Load: 2350o50 min )
T1-3-4

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
Nm
Fuel Consumption
Ratio
g/kw h
Engine Speed min-1 (rpm) T178-01-03-002
T1-3-5

ZAXIS230 class:
Engine Performance Curve (CC-6BG1TRA)
Torque
Nm
Output
kw
Fuel Consumption
Ratio
g/kw h
T1HD-01-03-001
Engine Speed min-1 (rpm)
T1-3-6

ZAXIS270 class:
Engine Performance Curve (CC-6BG1TRA)
Torque
Nm
Output
kw
Fuel Consumption
Ratio
g/kw h
Engine Speed min-1 (rpm) T1HG-01-03-001
T1-3-7

ENGINE ACCESSORIES
RADIATOR ASSEMBLY
ZAXIS200 class, ZAXIS225USR:
Type Radiator/Oil Cooler Tandem Type Assembly
Weight 78 kg (172 lb)
Radiator Oil Cooler

Capacity 8.0 L (2.1 US gal) 6.35 L (1.7 US gal)
Air-Tight Test Pressure 98 kPa (1.0 kgf/cm2, 14 psi) 1470 kPa (15 kgf/cm2, 213 psi)
Cap Opening Pressure 49 kPa (0.5 kgf/cm2, 7 psi) –
Intercooler
Capacity 7.9 L (1.7 US gal)
Air-Tight Test Pressure 25 kPa (0.25 kgf/cm2, 4 psi)
Cap Opening Pressure –
ZAXIS225US:
Weight 79.5 kg (176 lb)
Radiator Oil Cooler

Air-Tight Test Pressure 98 kPa (1.0 kgf/cm2, 14 psi) 1470 kPa (15 kgf/cm2, 213 psi)
2
Cap Opening Pressure 49 kPa (0.5 kgf/cm , 7 psi) –
Intercooler
T1-3-8


Weight 83 kg (183 lb)
Radiator Oil Cooler

2 2
Air-Tight Test Pressure 98 kPa (1.0 kgf/cm , 14 psi) 1470 kPa (15 kgf/cm , 213 psi)
Cap Opening Pressure 49 kPa (0.5 kgf/cm2, 7 psi) –
Intercooler
BATTERY
Capacity 96 Ah (5-Hour Rate)
Voltage 12 V
Weight 27.2 kg (60 lb)I2
HYDRAULIC COMPONENT
PUMP DEVICE
Drive Gear Ratio Main Pump: 1, Pilot Pump: 1
MAIN PUMP
Model HPV102GW-RH23A
Type Bent-Axis Type Variable Displacement Axial Plunger Pump
Maximum Flow (Theoretical Value) 193.8 L/min (51.1 US gpm)I2
ZAXIS230 class:
Maximum Flow (Theoretical Value) 204 L/min (54 US gpm)I2
ZAXIS270 class:
Maximum Flow (Theoretical Value) 209.1 L/min (55.24 US gpm)I2
REGULATOR
Type Hydraulic Pressure Operated Type
T1-3-9

PILOT PUMP
Model HY/ZFS 11/16.8
Type Fixed Displacement Type Gear Pump
Maximum Flow (Theoretical Value) 31.9 L/min (8.4 US gpm)
HP Mode: 35.28 L/min (9.32 US gpm)
ZAXIS230 class:
Model HY/ZFS11/16.8
ZAXIS270 class:
Model HY/ZFS11/16.8
CONTROL VALVE
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)
Power Digging: 36.3 MPa (370 kgf/cm2) at
110 L/min (29.0 US gpm)
Overload Relief Set-Pressure 37.2 MPa (379 kgf/cm2, 5390 psi) at 50 L/min (13.2 US gpm)
(Boom, Arm Roll-In, Bucket Roll-In)
39.2 MPa (400 kgf/cm2, 5690 psi) at 50 L/min (13.2 US gpm)
(Arm Roll-Out, Bucket Roll-Out)

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)
Power Digging: 36.3 MPa (370 kgf/cm2) at
140 L/min (37.0 US gpm)
Overload Relief Set-Pressure 37.2 MPa (379 kgf/cm2, 5390 psi) at 50 L/min (13.2 US gpm)
(Boom, Arm Roll-In, Bucket Roll-In)
39.2 MPa (400 kgf / cm2, 5690 psi) at 50 L/min (13.2 US gpm)
(Arm Roll-Out, Bucket Roll-Out)
POSITIONING CONTROL VALVE (2-Piece Boom Only)

Type Pilot Pressure Operated Type
Overload Relief Set-Pressure 39.2 MPa (400 kgf / cm2, 5690 psi) at 50 L/min (13.2 US gpm)
T1-3-10

SWING DEVICE
Type Two-Stage Reduction Planetary Gear
Reduction Gear Ratio 13.385
ZAXIS230 class:
ZAXIS270 class:
SWING MOTOR
Model M5X130C
Type Swash-Plate Type, Fixed Displacement Axial Plunger Motor
ZAXIS230 class:
Model M5X130CHB
ZAXIS270 class:
Serial No. 020038 and up
Model M5X180
Up to serial No. 020037
Model M2X210CHB
T1-3-11

VALVE UNIT
Type Non Counterbalance Valve Type
Relief Set-Pressure 30.9 MPa (315 kgf/cm2, 4480 psi) at 140 L/min
ZAXIS230 class:
Relief Set-Pressure 29.4õ1-0 MPa (300õ10-0 kgf/cm2, 4270õ142-0 psi) at 170 L/min
ZAXIS270 class:
Relief Set-Pressure 30.2+1.40 MPa (308+14 kgf/cm2, 4380+200 psi) at 140 L/min
(Serial No. 020038 and up)
2
27.7o0.3 MPa (282o3 kgf/cm , 4010o43 psi) at 140 L/min
(Up to Serial No. 020037)
SWING PARKING BRAKE
Type Multi-Disc-Wet Negative Type
2
Release Pressure 1.96 to 2.64 MPa (20 to 27 kgf/cm , 284 to 384 psi)
ZAXIS230 class:
Release Pressure 1.57 to 2.35 MPa (16 to 24 kgf/cm2, 228 to 341 psi)
ZAXIS270 class:
Release Pressure 2.25 to 2.84 MPa (23 to 29 kgf/cm2, 327 to 412 psi)
TRAVEL DEVICE
ZAXIS200 class:
Type Three-Stage Reduction Planetary Gear
Reduction Gear Ratio 53.289 (ZAXIS210N and ZAXIS 240: 53.234)

ZAXIS270 class:
T1-3-12

TRAVEL MOTOR
ZAXIS200 class, ZAXIS225 class, ZAXIS230 class:
Type Swash-Plate Type Variable Displacement Axial Plunger Motor
ZAXIS270 class: (Up to serial No. 200226)

Type Bent-Axis Type Variable Displacement Axial Plunger Motor
ZAXIS270 class: (Serial No. 20227 and up)

Type Swash-Plate Type Variable Displacement Axial Plunger Motor
TRAVEL BRAKE VALVE

Type Counter Balance Valve Type
Relief Set Pressure 34.8 MPa (355 kgf/cm2, 5050 psi)
TRAVEL PARKING BRAKE

Cracking Pressure for Release 0.95 to 1.02 MPa (9.7 to 10.4 kgf/cm2, 138 to 148 psi)
T1-3-13

CYLINDER
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 (40) 1475 mm (410)
Fully Retracted Length 1759 mm (59) 2040 mm (68)
Plating Thickness 30 km (1.18 km) 30 km (1.18 km)
Bucket Positioning (2-Piece Boom)

Stroke 1060 mm (36) 1255 mm (41)
Fully Retracted Length 1590 mm (53) 1875 mm (62)
ZAXIS230 class:
Boom Arm
Stroke 1350o3 mm (451o0.1) 1610o3 mm (53o0.1)
Fully Retracted Length 1950o2.2 mm (64o0.1) 2235o2.2 mm (74o0.1)

Stroke 1075o3 mm (36o0.1) 1330 mm (44)
Fully Retracted Length 1665o2.2 mm (55o0.1) 1950 mm (65)
ZAXIS270 class:
Boom Arm
Stroke 1340o3 mm (45o0.1) 1555o3.2 mm (51o0.1)
Fully Retracted Length 1920o2 mm (64o0.1) 2155o2.7 mm (71o0.1)

Stroke 1070o3 mm (36o0.1) 1205 mm (311)
Fully Retracted Length 1660o2 mm (55o0.1) 1825 mm (512)
T1-3-14

FRONT ATTACHMENT PILOT VALVE
Model HVP05P-040-101
TRAVEL PILOT VALVE

Model HVP05F-040-101
POSITIONING PILOT VALVE

(2-piece Boom only)
Model HVP05P-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
PILOT PRESSURE SIGNAL CONTROL VALVE

Function Shock Reducing (Boom Raise)
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 (ZAXIS200 class and 225 class)
PILOT SHUT-OFF VALVE

Type Rotary Type
OIL COOLER BYPASS CHECK VALVE

Cracking Pressure 490 kPa (5 kgf/cm2) at 5 L/min
T1-3-15

ELECTRICAL COMPONENT
BATTERY RELAY
Voltage / Current 24 V / 100 A
GLOW RELAY
Voltage 24 V
HORN
Voltage / Current 24 V 1.5o0.5 A
Sound Pressure 113 dB (A)
ILLUMINATION
Specifications Work Light Halogen 24V, 70 W / 60 W
Cab Light ZAXIS200 class, ZAXIS225USR,
ZAXIS230 class, ZAXIS270 class
24 V, 12 W
ZAXIS225US,
24 V, 12 W
AIR CONDITIONER
ZAXIS200 class, ZAXIS225USR, ZAXIS230 class, ZAXIS270 class:
Refrigerant 134 a
Cooling Ability 19.3 MJ/h (4600 kcal/h)
Cool Air Volume 550 m3/h or More
Heating Ability 21.0 MJ/h (5000 kcal/h) or More
Warm Air Volume 500 m3/h or More
Temperature Adjusting System Electronic Type
Refrigerant Quantity 850o50 g
Compressor Oil Quantity 210 cm3
ZAXIS225US:
Refrigerant 134 a
Cooling Ability 16.0 MJ/h (3830 kcal/h)
Cool Air Volume 395 m3/h or More
Heating Ability 14.9 MJ/h (3570 kcal/h) or More
Warm Air Volume 365 m3/h or More
Temperature Adjusting System Electronic Type
Refrigerant Quantity 900o50 g
Compressor Oil Quantity 210 cm3
T1-3-16

MEMO

MEMO

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(Key Switch:Off) ...... T2-3-3
Indicator Light Check Circuit
(Key Switch:On) ........................................ T2-3-4
Accessory Circuit ...................................... T2-3-5
Preheat Circuit .......................................... T2-3-6
Starting Circuit(Key Switch:Start) .............. T2-3-8
Charging Circuit(Key Switch:On) ............ 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 prcessing the received signals in the logic circuit,
operations. Electronic signals from the engine control the MC sends out control signals to the EC motor,
dial, various sensors and switches are sent to the MC. solenoid valve units, torque control solenoid valve,
and other control circuits to regulate the engine,
pumps, motors and valves.
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
(ZAXIS270 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
Pressure Sensor (Arm Roll-out) Pump 1 Flow Rate Limit Control
(Optional) Pump 2 Flow Rate Limit Control
Hydraulic Oil Temperature Sensor Pump 3 Torque Decrease Control
Auto-Idle/Acceleration Selector
Power Digging Switch Valve Control (Solenoid Valve Unit)
Power Mode Switch (HP/E/P) Power Digging Control
Travel Mode Switch (Fast/Slow) Arm Flow Rate Control
Work Mode Switch Arm Regenerative Control
(Digging/Attachment) Travel Motor Swash Angle Control
Learning Switch Auto-Power Lift Control
Key Switch Auxiliary Flow Rate Control
Boom Angle Sensor
(Up to serial No.104908 (ZAXIS225US))
Auxiliary Mode Switch (Optional) Other Controls
Boom Electronic Cushion Control
Work Mode Control
Travel Alarm Control
Overload Alarm Control
NOTE: Only on the machines equipped with the

corresponding optional parts
Refer to T2-2-2
T2-1-1

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 (ZAXIS270 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 Pump 1
Swing Delivery Pres- Delivery Pres-
Boom Raise sure Sensor sure Sensor
Key Switch
Arm Roll-In
Auxiliary (Optional)
Engine Con- EC Sensor
trol Dial
Auto-Idle /
Acceleration
Selector
Auto-Idle
EC Motor
Auto-Acceleration
Power Mode Switch
HP Mode Pump 2 Pump 1

Control Pres- Control Pres-
sure Sensor sure Sensor
E Mode Work Mode
Switch
P Mode Auxiliary Mode Hydraulic Oil
Digging Attachment Switch Temperature
Mode Mode (Optional) Sensor
T178-02-01-027
T2-1-2

(Blank)
T2-1-3

Engine Control Dial Control
Engine
Function: Controls the engine speed in response to Speed
the rotation angle of the engine control dial
and reduces the engine speed by 100
min-1 to reduce fuel consumption and Engine speed is
noise level when all control levers are in Control Range reduced by 100
-1
neutral. min when the
control levers are
in neutral.
Operation: The MC drives the governor lever in re-
sponse to the rotation angle of the engine
control dial to regulate the engine speed. Engine Con-
trol Dial Posi-
Slow Fast tion
NOTE: Even if the control dial is rotated to the full Idle Idle
speed position, the governor lever doesnt
come in contact with the full speed stopper.
(Refer to the HP mode control.)
When all control levers are turned to neutral (the NOTE: The engine speed is reduced from the
travel and front attachment sensors are OFF), the MC maximum speed by 100 min-1. Therefore,
drives the EC motor so that the engine speed is re- when the engine speed set by the engine
duced from the maximum speed by 100 min-1. control dial is already slower than the
-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

Pressure Sensor
Travel
Front Attachment
Engine Con-
trol Dial
EC Motor
T178-02-01-004
T2-1-5

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
-1
min except
ZAXIS230 class
Operation: The MC drives the EC motor to slightly 1500 min
-1
and 270 class
increase the engine speed set by the en- -1
(by 100 min )
gine control dial when all the following
conditions exist with the power mode
switch is in the HP position.
Engine Control Dial: Set at 1500 min-1 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 doesnt come in contact
with the stopper in the normal mode.

T2-1-6

Pressure Sensor
Pump 2 Pump 1
Delivery Delivery
Pressure Pressure
Boom Raise Sensor Sensor
Arm Roll-In
Engine
Control Dial
EC Motor
Power Mode Switch
HP Mode
T178-02-01-005
T2-1-7

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

(Blank)
T2-1-9

Auto-Idle Control
Function: Reduces the engine speed when all con-

trol levers are in neutral to reduce fuel
consumption 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 con- Speed auto-idle speed
3.5 seconds later.
trol lever is operated (the travel and/or
front attachment pressure sensor is turned Fast
ON), the MC drives the EC motor so that Speed
the engine speed is increased to the origi-
nal engine speed (set by the engine con- Auto-Idle
trol dial). Speed
Auto-Idle System Deactivation Requirements:

Control Levers: Being operated (either travel or Engine
front attachment control levers with pilot sensor Control Dial
ON) Slow Fast Position
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

Pressure Sensor
Travel
Front Attachment
Engine
Control Dial
Auto-Idle
Auto-Idle/
Acceleration
Selector EC Motor
Power Mode Switch
E Mode
T178-02-01-007
T2-1-11

Auto Acceleration Control
Function: Automatically regulates the engine speed Engine Speed VS. Control Lever Operations:
to meet the machine operating conditions.
When all the control levers are in neutral,
the engine speed is reduced to reduce fuel Engine
Speed
consumption and noise level.
Engine speed is reduced
from the maximum speed
Operation: When a control lever is operated with the Fast Speed -1
by 400 min .
auto-idle / acceleration selector in auto Auto-
acceleration position, the MC calculates Acceleration
the most proper engine operating speed Speed
Engine speed is reduced
corresponding to the signals from pressure Auto-Idle to the auto-idle speed 3.5
sensors (travel, swing, boom raise, and Speed seconds later.
arm roll-in), the pump control pressure Slow Speed
sensors, and the pump delivery pressure
Engine Con-
sensors. Then, the MC drives the EC motor trol Dial Posi-
Slow Fast
so that the engine speed is set to the rota- Idle Idle
tion
tion speed calculated by the MC.
When all control levers are returned to
neutral, the engine speed is reduced by
400 min-1 from the maximum speed first.
Then, 3.5 seconds later, the engine speed Operating Time Progress VS. Engine Speed Change
is further reduced to the auto-idle speed. Control Lever Stroke
NOTE: When all control levers are returned to Full Stroke

neutral, the engine speed is reduced by
400 min-1 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
min-1, the engine speed will be reduced by Time
300 min-1.
In response to the control

lever stroke and the pump
delivery pressure, the op-
timum engine speed is
Engine Speed selected.
Fast Idle Speed

(P Mode)
Auto Accel-
eration Con-
trol
Auto-Idle
Engine Speed
Time
T2-1-12

Pressure Sensor
Travel
Pump 2 Pump 1
Delivery Delivery
Swing
Pressure Pressure
Engine Boom Raise Sensor Sensor
Control Dial Arm Roll-In
Auto-Idle/
Acceleration EC Motor
Selector
Auto-
Acceleration
Pump 2 Pump 1
Control Control
Pressure Pressure
Sensor Sensor
T178-02-01-008
T2-1-13

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 pC (32 pF), the MC drives the EC
motor in response to signals from the key
switch and the hydraulic oil temperature Auto
sensor to run the engine at the auto warm Warm Up Increasing
Speed Speed
up speed for 15 minutes after starting the
engine. Slow
Speed Engine
Control Dial
IMPORTANT: When adjusting the auto-idle speed Slow Idle Fast Idle Position
deactivate the auto warming up
control function using Dr. ZX, or
wait to adjust until 15 minutes after
starting the engine.
Key Switch
Engine
Control Dial
EC Motor
Hydraulic Oil
Temperature
Sensor
T178-02-01-009
T2-1-14

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
Control Dial
Slow Fast Position
Idle Idle
Pressure Sensor
Travel
Front Attachment
Engine
Control Dial
EC Motor
T178-02-01-010
T2-1-15

Engine Speed Automatic Increase Control at
Travel (ZAXIS270 class only)
Function: Increases the engine speed at travel single

operation to increase the travel speed.
Operation: MC drives EC motor to increase the en-

gine 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
Control Dial
EC Motor
T1HG-02-01-001
T2-1-16

(Blank)
T2-1-17

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 wont
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

Pressure Sensor
Engine
Control Dial
EC Motor
Power Mode Switch
HP Mode
Work Mode
Switch
Auxiliary Mode
Attachment Switch
Mode (Optional)
T178-02-01-011
T2-1-19

Attachment Operation Speed Limit Control (Only
on the machines equipped with the auxiliary
mode switch (Optional).)
Engine
Function: Decreases the maximum engine speed to Speed
the attachment (hydraulic breaker, secon-
dary crusher, primary crusher or vibrating When all condi-
tions exist, the
hammer) operating engine speed set by Dr. maximum en-
ZX when the attachment mode is selected. gine speed is
reduced to the
speed set by Dr.
Operation: When the following conditions exists, the ZX.
MC drives the EC motor so that the engine
maximum speed is reduced to the attach-
ment operating speed set by Dr. ZX when
the attachment mode is selected.
Slow Idle Fast Idle
Operating Conditions:
Dr. ZX: Resets the maximum engine speed to a
slower (–) attachment (hydraulic breaker, secondary
crusher, primary crusher, or vibrator) operating speed
in the service mode.
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

EC Motor
Work Mode
Switch
Auxiliary Mode
Attachment Switch
Mode (Optional)
T178-02-01-012
T2-1-21

Engine Learning Control
Function: Inputs the governor lever stopper positions IMPORTANT: Be sure to perform the engine
on both the STOP and FULL sides as the learning if the following repair work
standard data to control the engine. is done. (Refer to the Troubleshoot-
ing Section in T/M.) After performing
Operation: When the learning switch in the rear con- the engine learning, check that the
sole is turned to the engine learning posi- engine learning has been performed
tion, the EC motor is driven by the signals correctly using Dr. ZX.
from the MC. The EC motor moves the After the engine, engine control ca-
governor lever from the IDLE to FULL and ble, or EC motor has been removed
to STOP positions in this order. The EC or replaced.
sensor detects the stopper positions of the After the MC has been replaced.
governor lever on both the FULL and
STOP sides and sends each stopper posi- NOTE: The engine learning is not required when
tion signal to the MC. The MC stores these the batteries are replaced.
signals in its memory.
Learning Switch
Key Switch
EC Sensor
EC Motor
T178-02-01-014
T2-1-22

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
Pump 2 Pump 1 Delivery
Delivery Delivery Pressure
Pressure Pressure Sensor
N Sensor Sensor Sensor (Optional)
Auxiliary
Engine (Optional)
Control Dial
Torque Control
Solenoid Valve
Max. Pump 2 Flow Rate

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

Solenoid Valve (Optional)
T2-1-23

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 util-
ized more efficiently. (Engine stall is pre-
vented 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

N Sensor
Engine
Control Dial
Torque Control
Solenoid Valve
T178-02-01-015
T2-1-25

Slow Speed Torque Increase Control
Q
Function: Allows the machine to travel at the maxi- Flow Rate B
mum pump flow rate when the engine is
running at slow speed. When travel opera- Increased Torque
P-Q Curve
tion is made with the engine running at slow A
speed, normally, the hydraulic pump delivers
pressure oil at the flow rate corresponding to
point A on the P-Q curve illustrated to the
right. Therefore, if any difference exists be-
tween pump 1 and pump 2 flow rate, the
machine will mistrack. To prevent mistrack-
Normal P-Q Curve
ing, the pump P-Q curve is raised so that,
when traveling the machine with the engine
running at slow speed, the pump delivers
pressure oil at the flow rate corresponding to
Pressure P
point B (maximum flow rate).
Operation:
1. When the engine speed set by the engine control
dial is slow, the MC processes signals from the
travel pressure sensor, and pump 1 and 2 deliv-
ery pressure sensors and sends control signals
to the torque control solenoid valve.
2. The torque control solenoid valve delivers the pi-
lot pressure oil corresponding to the signals re-
ceived from the MC to the regulator, increasing
the pump flow rate.
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

Pressure Sensor
Travel Pump 2 Pump 1
Delivery Pres-Delivery Pres-
sure Sensor sure Sensor
Engine
Control Dial
T178-02-01-016
T2-1-27

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

Pressure Sensor
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

Pump 3 Torque Decrease Control (Only on the
machines equipped with pump 3 (Optional).) Q
Function: Reduces pump 1 and pump 2 driving Flow Rate P-Q curve is controlled in
proportion to pump 3 delivery
torque to prevent the engine from stalling, pressure.
utilizing the engine output efficiently when
the pump 3 driving torque increases.
Normal P-Q Curve
Operation: When the MC receives signals from pump
3 delivery pressure sensor (optional), the
MC drives the torque control solenoid
valve so that pump 1 and pump 2 flow
rates are reduced. Thereby, the total pump
1, 2, and 3 driving torque is maintained not
to exceed the engine output, utilizing the
engine output efficiently.
Pressure P
Pump 3
Delivery Pres-
sure Sensor
(Optional)
Torque Control
Solenoid Valve
T178-02-01-018
T2-1-30

(Blank)
T2-1-31

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
T2-1-32

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
Engine Con-
trol Dial
Power Dig-
ging Switch
Hydraulic Oil Tem-
perature Sensor
Fast
Slow Pump 2 Control Pres-

sure Sensor
Travel Mode Switch

Pump 1 Control
Pressure Sensor
Solenoid Valve Unit
Main Relief Valve
SG
SC
Up to serial No.104678 SE
(ZAXIS200 class and SI
225 class)
(ZAXIS230 class)
Up to serial No.020042 Auxiliary Flow
(ZAXIS270 class) Rate Control
Solenoid Valve
(Optional)
Auxiliary Flow Rate

Control Valve
Travel Motor
Swash Angle Arm Regenerative

Control Valve Valve T178-02-01-003
Valve
T2-1-33

Power Digging Control
Function: Increases digging force by temporarily in-

creasing relief pressure.
Operation: For maximum 8 seconds after the power

digging switch is turned ON, the MC con-
tinuously 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

Power
Digging
Switch
Solenoid Valve Unit Main Relief Valve
SG
T178-02-01-019
T2-1-35

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 sen-
sor 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.)
Boom Raise Pressure Sensor: Outputting signals.
(The boom must be raised to a certain extent.)
Pump 1 delivery Pressure Sensor: High pressure.
Arm Roll-In Pressure Sensor: Output zero. (The con-
trol lever is in neutral.)
NOTE: This control system is activated during

combined operations (except for the arm
roll-in combined operation).
T2-1-36

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

Up to serial No.104678 and up (ZAXIS200 and 225
class)
Up to serial No.010326 and up (ZAXIS230 class)
Up to serial No.020042 and up (ZAXIS270 class)
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) deliv-
ers 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 upper-
structure from being rotated by the arm
reaction force when the arm is rolled in.
(Refer to the COMPONENT OPERA-
TION/Control Valve group.)
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

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

Arm Regenerative Control
Function: Accelerates the arm roll-in speed to pre-

vent arm hesitation during arm roll-in op-
eration.
Operation: The MC activates the solenoid valve unit

(SC) so that solenoid valve delivers the pi-
lot pressure oil to shift the arm regenera-
tive 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 fol-
lowing conditions. When the arm regen-
erative valve is shifted, the return circuit
from the arm cylinder rod side to the hy-
draulic 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.)
Machines manufactured up to Mar. 2003:
Pump 1 and 2 delivery pressure sensors:
Either pump 1 or 2 delivery pressure is low. (The arm
does not need much power to operate.)
Arm Roll-In Pressure Sensor: High output. (The arm
control lever stroke is large.)
Swing or Boom Raise Pressure Sensor: Outputting
signal.
Machines manufactured in Apr. 2002 and after:

Pump 1 and 2 delivery pressure sensors: Only pump
2 delivery pressure is low.
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

Pressure Sensor
*Pump 2 Pump 1
Swing Delivery Delivery
Boom Raise Pressure Pressure
Sensor Sensor
Arm Roll-In
Hydraulic Oil
Temperature Sensor
Solenoid Valve Unit
SC
Arm Regenerative Valve T178-02-01-037
NOTE: *The arm regenerative valve is activated

only when the pump 2 delivery pressure is
low on the machines manufactured in Apr.
2002 and after.
T2-1-41

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 follow-
ing 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.
ZAXIS200 class, 225 class, 230 class ZAXIS270 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
delivery pressures are low. pump 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 in- the one side pump displacement target
creases, allowing the raised track to rotate angle remains small so that the travel mo-
at fast speed. tor speed does not increase.
When the machine is traveling in the fast
mode, even if the front attachment is oper-
ated (the front attachment pressure sensor
is turned ON), the travel mode is kept un-
changed in the fast mode.
T2-1-42

Pressure Sensor
Travel
Pump 2 Pump 1
Delivery Delivery
Pressure Pressure
Sensor Sensor
Travel Mode Switch
Fast
Mode
Pump 2 Control Pres-
sure Sensor
Pump 1 Control
Pressure Sensor
Solenoid Valve Unit
SI
Travel Motor
Swash Angle Control Valve

T178-02-01-023
T2-1-43

Auxiliary Flow Rate Control (Only on the ma-
chines 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 aux-
iliary 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.
Auxiliary Pressure Sensor: ON
Swing, Boom Raise, Arm Roll-In Pressure Sensors:
ON
T2-1-44

Pressure Sensor
Swing
Boom Raise
Arm Roll-In
Auxiliary Flow
Rate Control
Solenoid Valve
(Optional)
Auxiliary Flow
Rate Control Valve
T178-02-01-024
T2-1-45

OTHER CONTROLS
Boom Electronic Cushion Control
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 sig-
nal. 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

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

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 op-
tional 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 in-
stalled 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

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 op-
eration 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 (Op-
tional).
Pressure Sensor
Travel
Travel Alarm
Device (Optional)
Buzzer Deactivation
Switch (Optional)
Buzzer (Optional) T178-02-01-025
T2-1-49

Overload Alarm Control
(Only on the machine fitted with options)
Function: Sounds the buzzer when lifting the load in

excess of the rated load.
Operation: When lifting the load, the pressure sensor,

provided in the bottom circuit of the boom
cylinder, sends a signal to MC. When a
pressure sensor signal reaches the speci-
fied level, MC sends a signal to the power
transistor, sounding the buzzer.
Overload alarm control can cancel buzzer
warning with an overload alarm switch.
NOTE: For lifting capacities, refer to Operation

Manual.
Pressure Sensor
Boom Bottom (OP)
C16
MC
A28
Power Transistor (OP)
Buzzer
Overload
Relay
Alarm Switch (OP)
(OP) T16R-02-01-001
T2-1-50

SYSTEM / Hydraulic System
OUTLINE
The hydraulic system is broadly divided into two cir-
cuits, the main circuit and the pilot circuit.
Main Circuit:
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

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.
NOTE: Valve control circuit (VC solenoid valve unit (SE))
ZAXIS200, 225 : Up to serial No. 104678.

ZAXIS230 : Up to serial No. 10326.
ZAXIS270 : Up to serial No. 20042.
Valve control circuit (Signal control valve circuit)
ZAXIS200, 225 : Up to serial No. 104679 and up

ZAXIS230 : Up to serial No. 10327 and up
ZAXIS270 : Up to serial No. 20043 and up
T2-2-2

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
To
Positoning *Boom Electronic
Pump
control Cushion Solenoid Control Circuit
Valve** Valve
Maximum Pump 2
Flow Rate Control Torque Control
Solenoid Valve Solenoid Valve
Pilot Shut-
Off Valve
Signal Control Valve SB ST
Hydraulic Oil
Heat Circuit
Maximum Pump 1 Flow
Rate Control Solenoid
Valve (Optional)
To Control Valve
2 1
Boom
Spools
Control Valve
Arm Flow Bucket Flow
Auxiliary Flow Combining Combiner Rate Control
Posi- Solenoid Valve (When Valve Valve Regulator
tioning the auxiliary spool is
used.)
Holding Boom Anti-Drift Valve
Valve
(Optional)
Arm Anti-Drift Valve
Auxiliary Flow Rate Control
Solenoid Valve (When the
auxiliary spool is used.) Auxiliary Flow Combiner Valve
Bypass Cut Valve
Auxiliary Flow Control Valve
Main Relief Valve

Valve
Control Arm Regenerative Valve
Circuit Hydraulic
Oil Tank
Arm Flow Rate Control Valve
Serial No.104679 and up (ZAXIS200 class and 225 class),

Serial No.010327 and up (ZAXIS230 class), Suction
Up to serial No.104678 (ZAXIS200 Serial No.020043 and up (ZAXIS270 class) Filter
class and 225 class), Up to serial
No.010326 (ZAXIS230 class), Up to
serial No.020042 (ZAXIS270 class) Travel Motor Swash
Angle Control Circuit Relief Valve
Pilot Pum
Travel Motor Travel Motor
NOTE: *Boom Electronic Cushion Solenoid Valve

is provide on the ZAXIS225US (Up to se- Pilot Filter
rial No104908).
**2-Piece boom only.
T2-2-3

Operation Control Circuit
The pilot valves control the pressure oil from the The boom electronic cushion solenoid valve is
pilot pump to operate the control valve spools. provided between the pilot valve (right) and the
signal control valve on ZAXIS225US (Up to serial
The signal control valve is provided between the No.104908).
pilot valves and the control valve. The shockless This valve reduces the shock which may occur
valve (in the boom raise circuit) built in the signal when the boom reaches to its full stroke position.
control valve dampens quick spool movement in (Refer to SYSTEM / Control System group.)
the control valve. (Refer to the COMPONENT
OPERATION / Signal Control Valve group.)
ZAXIS225US:
(Up to serial No.104908)
Pilot Valve (Right)
Boom Electronic
Cushion Solenoid
Valve

T1GF-02-02-001
T2-2-4

ZAXIS200 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
10 11
9
8
7
2 1
1
4
3 3
5 6
14
13
Control Valve
Positioning Control Valve

Pilot (2-piece Boom Only)
Pump
T178-02-02-016
1- Boom Raise 5- Left Swing 9 - Left Travel Forward 12 - Right Travel Reverse
2- Boom Lower 6- Right Swing 10 - Left Travel Reverse 13 - Positioning Lower
3- Arm Roll-Out 7- Bucket Roll-In 11 - Right Travel Forward 14 - Positioning Raise
4- Arm Roll-In 8- Bucket Roll-Out
T2-2-5

Pump Control Circuit (Refer to the COMPOMENT
OPERATION / Pump Device group.)
Pump Flow Rate Control by Flow Rate Control

Pressure 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 ei-
ther 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 con-
trol 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

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

Valve Control Circuit (Refer to the COMPONENT
OPERATION / Control Valve and Travel Device
groups.)
The following valves are controlled by pressure oil
from the pilot valves, solenoid valve unit (SC, SE*,
and SG), the flow combiner valve control spool in
the signal control valve, the bucket flow rate control
valve control spool and the arm flow rate controll
valve control spool**.
Boom Lower Pilot Pressure: Boom Anti-Drift Auxiliary Flow Rate Control Solenoid Valve: Aux-
Valve, Holding Valve (Optional) iliary Flow Rate Control Valve (When the auxiliary
spool is used.)
Arm Roll-In Pilot Pressure: Arm Anti-Drift Valve,
Holding Valve (Optional) Auxiliary Flow Combining Solenoid Valve: Boom,
Arm, and Bucket Pilot Pressure
Auxiliary Pilot Pressure: Auxiliary Flow Combiner
Valve, Bypass Shut-Out Valve (When the auxil- Flow Combiner Valve Control Spool: Flow Com-
iary spool is used.) biner Valve
Positioning Lower Pilot Pressure (2-Piece boom Bucket Flow Rate Control Valve Control Spool:
only): Bypass Shut-Out Valve, Holding Valve (Op- Bucket Flow Rate Control Valve
tional)
Arm Flow Rate Control Valve Control Spool**:
Positioning Raise Pilot Pressure (2-Piece boom Arm Flow Rate Control Valve
only): Bypass Shut-Out Valve
NOTE: * Up to serial No.104678
Solenoid Valve SC: Arm Regenerative Valve (ZAXIS200 class and 225 class)
Solenoid Valve SE*: Arm Flow Rate Control Valve Up to serial No.020042 (ZAXIS270 class)
Solenoid Valve SG: Main Relief Valve (increasing

the set-pressure)
NOTE: **Serial No.104679 and up 104678
Serial No.010327 and up (ZAXIS230
class)
Serial No.020043 and up (ZAXIS270
class)
T2-2-8

Positioning
(2-piece Boom Only) Travel (Right) Arm Roll-In Boom Lower
**Arm Flow Con-

trol Valve Control
Spool
Auxiliary
13
Signal
4
Control Main Relief Valve Auxiliary Flow
Valve 2
Combining
Solenoid Valve
Auxiliary
Flow Combiner Valve
Flow
Control Spool
Rate
Control Bucket Flow Rate
4 Valve Control Valve Con-
trol Spool
Auxiliary Auxiliary Flow Com-
Holding Valve Flow Rate biner Valve
(Arm) (Optional) Control So- Flow Combiner Valve
lenoid Valve
Bucket Flow Rate
Control Valve
Boom Auti-Drift Valve
Arm Anti-Drift
Valve
2
Solenoid 2
Valve Unit
4
SG
2
SC
Holding Valve (Boom)
SE* (Optional)
Bypass Shutout Valve
Holding Valve 13
(Positioning)
Pilot Pump (Optional)
Arm Arm Flow Rate

Regenerative Control Valve
Valve
T178-02-02-015
T2-2-9

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 De-
vice group.)
The pilot oil pressure from solenoid valve SI
regulates 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
system 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
pilot pressure shifts the bypass shut-out valve
and positioning control valve spool.
T2-2-10

Positioning Boom Bucket

(2-piece Boom Only) Swing Arm
Orifice
Signal
Control
Valve Swing Parking Brake
Release Spool
Solenoid
Valve Unit
Control Valve Swing Motor
Travel Motor
SI
T178-02-02-017
Swash Angle Control Valve
T2-2-11

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

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

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

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

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

cylinders 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

Parallel Circuit
Boom 2 Boom 1 Boom Cylinder
Swing Motor
Swing
Parallel
Circuit
Pump 2 Pump 1
T178-02-02-002
T2-2-17

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
motors, ensuring that the machine can travel
straight.
NOTE: The right travel circuit is a tandem circuit

so that pressure oil from pump 1 does not
flow to the arm 2 spool.
T2-2-18

Pilot Pressure
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

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
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

4 Spool Side
Parallel Circuit
Pilot Pressure
from Position-
ing Pilot Valve
Positioning
Cylinder
Bypass Shut-Out
Valve
Pump 1
T178-03-03-065
Positioning
Control Valve
T2-2-21

Auxiliary Circuit
When a front attachment such as a hydraulic NOTE: During boom (raise or lower), arm (roll-in
breaker is operated, the pilot pressure oil from or rollout), bucket (roll-in or rollout),
the hydraulic breaker pilot valve shifts the auxil- and/or right travel operation, pilot pressure
iary flow combiner valve and bypass shut-out oil is routed to port SN from the signal pilot
valve. pressure control valve so that the aux. flow
combiner valve is not shifted. (Refer to the
Therefore, the neutral circuit in the 4-spool con- SYSTEM / Control System group.)
trol valve is blocked so that pressure oil from
pump1 is routed to the auxiliary spool via the
auxiliary flow combiner valve.
T2-2-22

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

(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

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. ÅKey Starts the engine. ÅKey Switch, Starter, Starter
Switch, Batteries, Fuses (Fuse Boxes, Fusible RelayÃ
Links), Battery RelayÃ
Charging Circuit
Indicator Light Check Circuit Charges the batteries. ÅAlternator, RegulatorÃ
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. Å Load
to the ACC position. Damp RelayÃ
Preheat Circuit Engine Stop Circuit

Assists the engine to start in cold weather. ÅKey Stops the engine using the EC motor. ÅMC, EC
Switch, QOS Controller, Coolant Switch, Glow MotorÃ
Plug Relay, Glow PlugsÃ
T2-3-2

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

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

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

PREHEAT CIRCUIT (KEY SWITCH: ON /
START)
When the key switch is turned ON or to the When preheating begins, QOS controller terminal
START position, terminal B is connected to #6 is connected to terminal #5 for 8 seconds,
terminal M in the key switch. Current from turning the preheat indicator ON. (When
terminal M is routed to QOS controller terminal preheating is not performed, the preheat indicator
#1 through fuse #19. comes ON for 2 seconds for indicator light
check.)
When the key switch is ON or in the START
position with the coolant switch OFF (when the
NOTE: After preheating has been performed,
coolant temperature is 10 pC (50 pF) or below),
QOS controller terminal #4 is connected to heating will continue for approx. 30
terminal #5 (ground). seconds after the engine starts.
Accordingly, the glow plug relay is turned ON,

routing current to the glow plugs so that
preheating begins.
T2-3-6

Monitor
Coolant Temperature Switch

Preheat Indicator
QOS
Key Switch
Controller
Fuse
Box
Glow
Plug
Relay
Glow Plug
T178-02-03-004
T2-3-7

STARTING CIRCUIT (KEY SWITCH:
START)
When the key switch is turned to the START Consequently, the relay in the starter is turned
position, terminal B is connected to terminals M ON so that the starter begins rotating.
and ST in the key switch.
On the other hand, current from key switch
As current from terminal M excites the battery terminal M flows to the MC via fuse #6 as a
relay, battery current is routed to starter terminal signal indicating that the key switch is in the ON
B and starter relay terminal B via the battery or START position.
relay.
As soon as the MC receives this signal, the MC
Key switch terminal ST is connected to starter drives the EC motor, moving the governor lever
relay terminal S so that current flows through the to the engine start position.
starter relay coil.
Then, the starter relay is turned ON, allowing

current to flow from starter relay terminal C to
starter terminal C.
T2-3-8

Key Switch
Battery
Battery
Relay
Starter Fuse
Box
Starter Relay
EC Motor
MC
T178-02-03-005
T2-3-9

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
To Alternator
Terminal L
Starter
Key Switch
Battery
T107-04-04-003
T2-3-10

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

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 ÅB R RF the rotor is further magnetized so that the
(R) (R1)Ã. 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
Regulator
Battery
T157-04-02-008
T2-3-12

Regulator Operation
When generating voltage increases more than When generating voltage decreases lower than
the set-voltage of Zener diode ZD, current is the set-voltage of Zener diode ZD, transistor T2
routed to base B of transistor T2, connecting is turned OFF, causing transistor T1 to turn ON
collector C to emitter E. again.
Then, current which was routed to base B of Then, current flows through field coil FC,
transistor disappears, turning transistor T1 OFF. increasing generating voltage at the stator coil.
The above operation is repeated so that the
Therefore, no current flows through filed coil FC, alternator generating voltage is kept constant.
reducing generating voltage at stator coil SC.
Battery
T157-04-02-009
T2-3-13

SERGE VOLTAGE PREVENTION CIRCUIT
When the engine is stopped (key switch: OFF), When the alternator is generating electricity,
current from key switch terminal M is generating current from alternator terminal L
disconnected, turning the battery relay OFF. flows to monitor controller terminal #A-2 so that
the monitor controller connects terminal #C-3 to
The engine continues to rotate due to inertia ground.
force just after the key switch is turned OFF so
that the alternator continues to generate Then, current flows through the load damp relay
electricity. exciting circuit, turning the load damp relay ON.
As the generating current cannot flow to the Accordingly, even if the key switch is turned OFF
battery, surge voltage arises in the circuit, while the engine is rotating, the battery current
possibly causing failures of the electronic continues to excite the battery relay via the load
components, such as the controller. To prevent damp relay until the alternator stops generating.
the occurrence of surge voltage, the surge Therefore, the battery relay is kept ON, allowing
voltage prevention circuit is provided. the generating current to flow to the batteries.
T2-3-14

Key Switch
Battery
Battery
Relay
Load
Damp
Relay
Alternator
Monitor Controller
T178-02-03-007
T2-3-15

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

MEMO

MEMO

SECTION 3
COMPONENT OPERATION
CONTENTS
Group 1 Pump Device Group 5 Travel Device
Outline ...................................................... T3-1-1 Outline ......................................................T3-5-1
Main Pump................................................ T3-1-2 Travel Reduction Gear ..............................T3-5-4
Regulator .................................................. T3-1-6 Travel Motor ..............................................T3-5-6
Solenoid Valve ........................................ T3-1-22 Parking Brake ......................................... T3-5-10
Pilot Pump .............................................. T3-1-24 Travel Mode Change ...............................T3-5-12
N Sensor (Engine Speed Sensor) ........... T3-1-24 Travel Brake Valve ..................................T3-5-22
Pump Delivery Pressure Sensor ............. T3-1-24
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 Control Spool,
Flow Combiner Valve Control Spool,
Group 3 Control Valve Swing Parking Brake Release Spool
Outline ...................................................... T3-3-1 Arm Flow Rate Control Valve
Hydraulic Circuit ..................................... T3-3-14 Control Spool.........................................T3-6-14
Flow Combiner Valve .............................. T3-3-20
Main Relief Valve .................................... T3-3-22 Group 7 Others (Upperstructure)
Overload Relief Valve ............................. T3-3-24 Pilot Shut-Off Valve ...................................T3-7-1
Regenerative Valve................................. T3-3-26 Solenoid Valve Unit ...................................T3-7-2
Arm Regenerative Valve ......................... T3-3-28 Holding Valve ............................................T3-7-6
Anti-Drift Valve ........................................ T3-3-30 Pilot Relief Valve .....................................T3-7-10
Flow Rate Control Valve ......................... T3-3-32 EC Motor ................................................. T3-7-10
Auxiliary Flow Combiner Valve and
Group 8 Others (Undercarriage)
Bypass Shut-Out Valve ......................... T3-3-34
Swing Bearing ...........................................T3-8-1
Group 4 Pilot Valve Center Joint...............................................T3-8-2
Outline ...................................................... T3-4-1 Track Adjuster ...........................................T3-8-3
Operation .................................................. T3-4-6

Shockless Function
(Only For Travel Pilot Valve) ................. T3-4-12
178T-3-1

(Blank)
178T-3-2

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

Sensor
2 - Pump 2 5 - Pump 2 Delivery Pressure 8 - Pump 1 Control Pressure Sensor 11 - Transmission
Sensor
3 - Pilot Pump 6 - Pump 1 Flow Rate Control 9 - Pump 2 Control Pressure Sensor 12 - Coupling
Solenoid Valve
T3-1-1

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

2 - Housing 4 - Plunger
T3-1-2

Operational Principle
Engine torque is transferred to the shaft and the
seven plungers, causing the cylinder block to rotate
while sliding along the valve plate surface. The
plungers oscillate in the cylinder block bores to al-
ternately draw and deliver hydraulic oil.
Plunger
Valve Plate
Shaft
Cylinder Block
T105-02-03-002
T3-1-3

Increasing and Decreasing Flow Rate
Changing inclination of cylinder block (3), causes
plunger (2) stroke to increase or decrease depend-
ing on the slant angle which in turn controls the main
pump flow rate. Up-down movement of servo piston
(6) changes inclination of cylinder block (3). Servo
piston (6) is interlocked with valve plate (4) via pin
(5). The one end of cylinder block (3) is kept in con-
tact with the surface of valve plate (4) and slides
along it.
Maximum Displacement Angle:

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

3 - Cylinder Block
T3-1-4

(Blank)
T3-1-5

REGULATOR
1 3 2 4
The regulator controls the main pump flow rate in re-
sponse to the various command signal pressures so Dr
that the pump driving power doesnt exceed the en-
gine power. Pump 1 and pump 2 are provided with
one regulator each. The major parts of the regulator
Pi
are spring (1), sleeve A (2), sleeve B (7), spool A (3),
spool B (6), piston (4), load piston (5), outer spring (8), Pd2 Air
and inner spring (9). According to the various com- Bleeding
Circuit
mand signal pressures, the regulator opens or closes Pps
Dr
the circuit to servo piston (10), causing the inclination
of cylinder block (11) to change, by which the pump Pd1
flow rate is controlled.
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 Pres- Pi - Pump Control Pressure

sure
Pd2 -Pump 2 Delivery Pres- Pps -Torque Control Pressure
sure
Dr - Returning to Hydraulic Pg - Primary Pilot Pressure
Oil Tank (From Pilot Pump)
T3-1-6

1 2 3 4
T178-03-01-006
5 6 7 8 9
12
11
10
T178-03-01-005
1 - Spring 4 - Piston 7 - Sleeve B 10 - Servo Piston

2 - Sleeve A 5 - Load Piston 8 - Outer Spring 11 - Cylinder Block
3 - Spool A 6 - Spool B 9 - Inner Spring 12 - Link
T3-1-7

Regulator Control Function
The regulator has the following four control func-
tions.
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 regu-
lates 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 pres-
sure Pi. When a control lever is operated, pump
control pressure Pi increases. Thereby, the regula-
tor increases the pump flow rate. When the control
lever is returned to neutral, pump control pressure 0 Pump Control Pressure (Pi)
Pi decreases, causing the regulator to reduce the
pump flow rate.
Control by Own or Opponent Pump Delivery Pres-

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

Control by Pilot Pressure from Torque Control So-
lenoid Valve
The main controller (MC) operates based on both
the engine target speed input data and actual Flow
Rate (Q)
speed information signals and outputs signals to the
torque control solenoid valve. In response to the
signals from the MC, the torque control solenoid
valve delivers torque control pilot pressure Pps to
the regulator. Upon receiving pilot pressure Pps, the
regulator reduces the pump flow rate. (Speed
Sensing Power Decrease Control: Slow Speed
Torque Increase Control)
(Refer to the CONTROL SYSTEM section.) 0 Pressure (P)
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 at-
tachment mode switch (optional), the MC send sig-
nals to the maximum pump flow rate control sole-
noid valve. Then, in response to the signals from
the MC, the maximum pump flow rate control sole-
noid valve reduces pump control pressure Pi, limit-
ing the maximum pump flow rate. (Pump Flow Rate
Limit Control) 0 Pressure (P)
(Refer to the CONTROL SYSTEM section.)
Dr
Pi
Pd2 Air
Bleeding
Circuit
Pps
Dr
Pd1
Pg
Increase Decrease
Cylinder Block Inclination T176-03-01-009

sure
Pd2 - Pump 2 Delivery Pres- Pps -Torque Control Pressure
sure
T3-1-9

Control by Pump Control Pressure
Increasing Flow Rate

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

sure
sure
T3-1-10

To Hydraulic Primary Pilot Oil

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

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

Decreasing Flow Rate

1. When a control lever is operated, the flow rate Flow
Rate (Q)
control valve in the signal control valve is re-
turned, 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 in- 1 3 2 4
clination direction, decreasing the pump flow
Dr
rate.
ted 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
Pd2 Air
as spool A (3), the pilot oil pressure circuit to Bleeding
servo piston (10) through sleeve A (2) and spool Circuit
A (3) is closed so that servo piston (10) is Pps
Dr
stopped, completing flow rate decrease opera-
tion. Pd1
Pg
10 12
Increase Decrease
2 - Sleeve A 10 - Servo Piston
3 - Spool A 12 - Link

sure
sure
T3-1-12

To Hydraulic Primary Pilot

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

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

Control by Own or Opponent Pump Delivery
Pressure

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

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

sure
sure
T3-1-14


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

Increasing Flow Rate

1. When the pump load is reduced, either pump 1
delivery pressure Pd1 or pump 2 delivery pres-
sure 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 di-
rection 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.
ted 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
servo piston (10) through sleeve B (7) and spool Circuit
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

8- Inner Spring

sure
sure
T3-1-16


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

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

Control by Pilot Pressure from Torque Control
Solenoid Valve

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

8- Inner Spring

sure
sure
T3-1-18


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

Pressure Pi
Torque
Control
Pressure
Pps
Pump 2
Delivery 8 9
Pressure
Pd2
Pump 1 12
Delivery
Pressure
Pd1
10
T178-03-01-017
T3-1-19

Control by Pilot Pressure from Flow Rate Control
Solenoid Valve Flow
Rate (Q)
Limiting Maximum Flow Rate (Pump 2 Only)
1. The maximum pump flow rate control solenoid
valve in the pump control pressure Pi circuit is
activated by the signals from the MC.
2. The maximum pump flow rate control solenoid
valve functions as a reducing valve, decreasing
pump control pressure Pi.
3. Piston (4) is moved toward the arrowed direction
0 Pressure (P)
by reduced pump control pressure Pi.
4. Then, piston (4) pushes spool A (3) and spring
(1) until force acting on piston (4) by pump con-
1 3 2 4
trol pressure Pi becomes balanced with spring
(1) force, causing spool A (3) to move toward the Dr
arrowed direction.
5. As pump control pressure has been reduced,
spool A (3) is moved in a shorter distance than
Pi
usual.
6. Due to the movement of spool A (3), the circuit Pd2 Air
from the large chamber of servo piston (10) is Bleeding
Circuit
opened to the hydraulic oil tank. Pps
Dr
7. Since the pilot oil pressure is constantly routed
into the small chamber of servo piston (10), servo Pd1
piston (10) is moved toward the direction of the
arrow so that the cylinder block is rotated in the
maximum inclination direction, increasing the
pump flow rate. Pg
8. The movement of the cylinder block is transmit- 10 12
ted to sleeve A (2) via link (12). Then, sleeve A Increase Decrease
(2) is moved in the same direction as spool A (3).
9. When sleeve A (2) is moved by the same stroke
as spool A (3), the pilot oil pressure circuit to the 2 - Sleeve A 10 - Servo Piston
large chamber of servo piston (10) is closed. 3 - Spool A 12 - Link
10. So that servo piston (10) is stopped, completing
flow rate increase operation. Pd1 - Pump 1 Delivery Pres- Pi - Pump Control Pressure
11. Accordingly, pump control pressure Pi increases sure
in proportion to the stroke of the control lever, al- Pd2 - Pump 2 Delivery Pres- Pps -Torque Control Pressure
lowing the pump delivery flow rate to increase. sure
However, as pump control pressure Pi is regu- Dr - Returning to Hydraulic Pg - Primary Pilot Pressure
lated, the strokes of spool A (3) and servo piston
(10) are reduced so that the maximum flow rate
becomes less than usual.
Fig:
Maximum Flow Rate
Limited Maximum Flow Rate
T3-1-20


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

Oil Tank Pressure 2 3 4 Pump Control
1 Pressure Pi Regu-
lated by Maximum
Pump Flow Rate
Control Solenoid
Valve
Torque
Control
Pressure
Pps
Pump 2
Delivery
Pressure
Pd2
Pump 1 12
Delivery
Pressure
Pd1
10
T178-03-01-019
T3-1-21

SOLENOID VALVE
The torque control solenoid valve and the pump 2 flow

rate limit solenoid valve are provided on the pump 1
regulator. The torque control solenoid valve supplies
the torque control pressure Pps to both the pump 1
and pump 2 regulators to reduce the pump flow rate.
The pump 2 flow rate limit solenoid valve reduces the
pump control pressure to the pump 2 regulator so that
the maximum pump flow rate is limited.
Operation
1. When neutral, port P is connected to the output
port through the notch on the spool.
2. When the current flows to the solenoid from the
MC, the solenoid is magnetized, pushing spring
1.
3. Then, spring 1 pushes the spool so that the out-
put port is connected to port T through the notch
on the spool.
4. Thereby, pressure at the output port begins to
decrease.
5. Left side spool diameter (A) at the notch is larger
than right side diameter (B).
6. Accordingly, until the oil pressure at the output
port disappears, the external force applied onto
the spool is expressed as P1 I B + S1 â P1 I A +
S2. Then, the spool is move toward the right side.
7. When the oil pressure at the output port disap-
pears so that when P1 I B + S1 becomes equal
to P1 I A + S2 (P1 I B + S1 = P1 I A + S2), the
spool stops moving.
P1 : Oil pressure at the output port

A and B: Pressure receiving area on the spool
S1 : Spring 1 force
(pushing the spool toward the right side)
S2 : Spring 2 force
(pushing the spool toward the left side)
T3-1-22

When Neutral:
Solenoid Spring 1 Spring 2 Sleeve Spool
T176-03-01-030
A Port P Port T B
Output Port
When in Operation:
T176-03-01-031
A Port P Port T B
Output Port
T3-1-23

PILOT PUMP
Inlet Port
1
Drive gear (1) is driven by the engine via the trans-
mission which in turn rotates driven gear (2) as they 2
are meshed together.
1 - Drive Gear 2 - Driven Gear
Outlet Port
N SENSOR (ENGINE SPEED SENSOR) T137-02-03-005
The N sensor detects the engine speed, which is used

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

which are used to control various operations. When oil
pressure is applied onto diaphragm (9), the dia-
phragm is deformed. The deformation of the dia-
phragm 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

PUMP CONTROL PRESSURE SENSOR
This sensor detects the pump control pressures,
which are used to control various operations. When oil
pressure is applied onto diaphragm (10), the dia-
phragm is deformed. The deformation of the dia-
phragm is detected as electrical signals.
10 - Pressure Receiving Area 12 - Output

T176-03-01-023
(Diaphragm)
10 11 12 13
11 - Ground 13 - Power Source (5V)
T3-1-25

(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.
ZAXIS200 class, 225 class, 230class ZAXIS270 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

SWING REDUCTION GEAR
The swing reduction gear is a two stage reduction The shaft meshes with the swing bearing internal gear
planetary gear type. The ring gear is formed on the secured to the undercarriage, causing the upper-
internal surface of the housing so that they are inte- structure to rotate.
grated. As the housing is bolted on the upperstructure,
the ring gear doesnt rotate. The swing motor shaft
rotates the first stage sun gear. Then, its torque is
transmitted to the second stage sun gear via the first
stage planetary gear and carrier. The second stage
sun gear rotates the shaft via the second stage plane-
tary gear and carrier.
ZAXIS200 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

ZAXIS270 class
First Stage Sun Gear Swing Motor Shaft
First Stage Carrier First Stage Planetary Gear
First Stage Ring Gear
Second Stage Planetary Gear

Second Stage Sun Gear
Second Stage Ring Gear
Second Stage Carrier
Shaft
T164-03-02-003
T3-2-3

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

ZAXIS270 class
Valve Plate
Rotor
Spring
Swing Parking
Brake Switch Valve
Brake Piston
Plate
Friction Plate
Plunger
Retainer
Shoe
Swash Plate
Housing
Shaft
T1HH-03-02-002
T3-2-5

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

ZAXIS270 (Serial No20745 and up)
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

ZAXIS270 class
(Up to serial No 20744)
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 ing the check valve.
to 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 orifice of the check valve.
pressure difference is developed between the 4. Consequently spring 1 force is applied to plates
front and the rear of the check valve caused by and friction plates which are meshed with the
the orifice, moving the check valve to the right outer diameter of the rotor and inner diameter of
when the pressure difference is increased more the housing respectively via the brake piston.
than the force of spring 2. Thereby, the drain cir- Then, the rotor outer diameter is held with friction
cuit to the 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
between the plates and friction plates so that the be automatically applied.
brake is released.
Spring 1
Check Valve Spring 2 Brake Piston
Rotor
Port PG
(Brake Release Plate
Pressure)
Friction Plate
Spool
Port SH
(Brake Release
Pressure) T1HG-03-02-004
Orifice Brake Piston Chamber
T3-2-7

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

ZAXIS270 class
Relief Valve
Poppet
Make-Up Valve
Make-Up Valve
T1HH-03-02-003
T3-2-9

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.

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, the spring is
oil chamber C through the poppet orifice. compressed so that the circuit pressure is in-
2. Pressure oil in oil chamber C is further routed creased to the set-pressure.
into oil chambers A and B via passages A and B 2. If pressure in port HP increases more than the
respectively. spring set-pressure, the poppet is unseated,
3. The pressure receiving area in oil chamber B is causing pressure oil to flow to port LP from port
larger than oil chamber A so that the piston HP.
moves to the left. 3. When pressure in port HP is reduced to the
4. As long as the piston keeps moving, a pressure specified level, the poppet is seated by spring
difference is developed between the front and the force.
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

ZAXIS270 class
Low Pressure Relief Operation (Shock Reducing
Function): High Pressure Relief Operation (Overload Preven-
1. Pressure at port HP (swing circuit) is routed into tion):
oil chamber through the poppet orifice. 1. After the piston is moved full stroke, so that the
2. When the pressure in the oil chamber is in- circuit pressure is increased to the set-pressure.
creased more than the force of spring 2, the pis- 2. If pressure in port HP increases more than the
ton moves to the left side. spring 1 set-pressure, the poppet is unseated,
3. As long as the piston keeps moving, a pressure causing pressure oil to flow to port C (Serial
difference is developed between the front and the No.020038 and up) (Up to serial No. 020037:
rear of the poppet. When this pressure difference port LP) from port HP.
is increased more than spring force, the poppet is 3. When pressure in port HP is reduced to the
unseated, allowing pressure oil to flow to port C specified level, the poppet is seated by spring 1
(Serial No.020038 and up) (Up to serial No. force.
020037: port LP).
4. When the piston is moved full stroke, the pres-
sure difference between the front and the rear of
the poppet disappears, causing the poppet to be
seated.
Serial No.020038 and up

Spring 2 Piston Oil Chamber Spring 1 Orifice
Return Circuit
(Port C)
Hp
Poppet
T107-02-04-020
Spring 1 Poppet Orifice
Spring 2 Piston
LP
HP
Oil Chamber
T157-02-04-006
T3-2-11

(Blank)
T3-2-12

COMPONENT OPERATION / Control Valve
OUTLINE
The control valve controls oil pressure, flow rate, and In the 4-spool section, the right travel, bucket, boom 1,
flow direction in the hydraulic circuit. The major parts and arm 2 spool sections are arranged in that order
of the control valve are the main relief valve, overload as viewed from the machine front (ZAXIS200 class,
relief valve, flow combiner valve, anti-drift valve, flow 230 class and 270 class) [as viewed from the machine
rate control valve, regenerative valve, auxiliary flow right on ZAXIS225 class]. In the 5-spool section, the
combiner valve, bypass shut-out valve, and spools. left travel, auxiliary, boom 2, arm 1, and swing spool
The spools are operated by pilot oil pressure. sections are arranged in that order as viewed from the
machine front (ZAXIS200 class, 230 class and 270
class) [as viewed from the machine right on
ZAXIS225 class].
Control Valve Front

ZAXIS200 class, ZAXIS230 class, Right Travel
ZAXIS270 class Bucket
Boom 1
Left Travel Arm 2
Main Relief Valve
4-Spool Section
Auxiliary
Boom 2
Arm 1
Swing
5-Spool Section
Front
ZAXIS225 class
T178-03-03-072
Positioning Control Valve (2-piece Boom only) ZAXIS230 class, ZAXIS270 class
ZAXIS200 class
T178-03-03-068
T178-03-03-070
T3-3-1

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

19 Front
12 ZAXIS225 class
29
18
22 3
35
2
20
14 4
9, 10
Front
36
ZAXIS200 class
ZAXIS230 class W178-02-05-017
ZAXIS270 class
1 - Load Check Valve 10 - Bucket Flow Rate Control 19 - Boom Anti-Drift Valve 28 - Overload Relief Valve
(Travel Parallel Circuit) Valve (Poppet Valve) (Switch Valve) (Arm: Bottom Side)
2 - Check Valve 11 - Bucket Regenerative Valve 20 - Load Check Valve 29 - Overload Relief Valve
(Main Relief Circuit) (Arm Tandem Circuit) (Arm: Rod Side)
3 - Main Relief Valve 12 - Overload Relief Valve 21 - Check Valve (Orifice) 30 - Arm Anti-Drift Valve
(Bucket: Rod Side) (4-Spool Side Parallel Cir- (Check Valve)
cuit)
4 - Check Valve 13 - Overload Relief Valve 22 - Bypass Shut-Out Valve 31 - Arm Anti-Drift Valve (Switch
(Main Relief Circuit) (Bucket: Bottom Side) Valve)
5 - Check Valve 14 - Load Check Valve (Boom 1 23 - Arm Flow Rate Control 32 - Load Check Valve
(Flow Combiner Valve Cir- Parallel Circuit) Valve (Poppet Valve) (Boom 2 Parallel Circuit)
cuit)
6 - Flow Combiner Valve 15 - Boom Regenerative Valve 24 - Arm Flow Rate Control 33 - Auxiliary Flow Rate Control
Valve (Switch Valve) Valve (Switch Valve)
7 - Auxiliary Flow Combiner 16 - Overload Relief Valve 25 - Load Check Valve 34 - Auxiliary Flow Rate Control
Valve (Boom: Bottom Side) (Swing Circuit) Valve (Poppet Valve)
8 - Check Valve 17 - Overload Relief Valve 26 - Check Valve 35 - Load Check Valve
(Aux. Flow Combiner (Boom: Rod Side) (Arm Regenerative Circuit) (Travel Tandem Circuit)
Valve Circuit)
9 - Bucket Flow Rate Control 18 - Boom Anti-Drift Valve 27 - Arm Regenerative Valve 36 - Load Check Valve (Orifice)
Valve (Switch Valve) (Check Valve) (Bucket)
T3-3-3

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

Front
ZAXIS225 class
25
31
16
30
23, 24
32
33, 34
26
Front
ZAXIS200 class
ZAXIS230 class 28
ZAXIS270 class 17
W178-02-05-018
13
6
cuit)
5 - Check Valve 14 - Load Check Valve (Boom 1 23 - Arm Flow Rate Control 32 - Load Check Valve
(Flow Combiner Valve Cir- Parallel Circuit) Valve (Poppet Valve) (Boom 2 Parallel Circuit)
cuit)
Valve Circuit)
T3-3-5

1 2 3 4 5 6 7 8 9 10
36
35
34
33
11
12
13
32 14
31 15
30
16
17
29
28
18
19
20
21
27 22
26
25 24 23
H A T178-03-03-016
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

Cross Section A Cross Section a
5
3
T178-03-03-047
1
Cross Section J
T178-03-03-044
7 6
T178-03-03-003
1- Load Check Valve 10 - Bucket Flow Rate Control 19 - Boom Anti-Drift Valve 28 - Overload Relief Valve
3 - Main Relief Valve 12 - Overload Relief Valve 21 - Check Valve (Orifice) 30 - Arm Anti-Drift Valve (Check
(Bucket: Rod Side) (4-Spool Side Parallel Cir- Valve)
cuit)
4- Check Valve 13 - Overload Relief Valve 22 - Bypass Shut-Out Valve 31 - Arm Anti-Drift Valve
(Main Relief Circuit) (Bucket: Bottom Side) (Switch Valve)
5 - Check Valve 14 - Load Check Valve 23 - Arm Flow Rate Control 32 - Load Check Valve
(Flow Combiner Valve Cir- (Boom 1 Parallel Circuit) Valve (Poppet Valve) (Boom 2 Parallel Circuit)
cuit)
7- Auxiliary Flow Combiner 16 - Overload Relief Valve 25 - Load Check Valve 34 - Auxiliary Flow Rate Control
Valve Circuit)
NOTE: There are only spools but no valves in

Cross Section B.
T3-3-7

1 2 3 4 5 6 7 8 9 10
36
35
34
33
11
12
13
32 14
31 15
30
16
17
29
28
18
19
20
21
27 22
26
25 24 23
T178-03-03-016
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

Cross Section E Cross Section G
22
31 16
30
23
20
T178-03-03-009
24
28
T178-03-03-007
1- Load Check Valve 10 - Bucket Flow Rate Control 19 - Boom Anti-Drift Valve 28 - Overload Relief Valve
3 - Main Relief Valve 12 - Overload Relief Valve 21 - Check Valve (Orifice) 30 - Arm Anti-Drift Valve (Check
(Bucket: Rod Side) (4-Spool Side Parallel Cir- Valve)
cuit)
4- Check Valve 13 - Overload Relief Valve 22 - Bypass Shut-Out Valve 31 - Arm Anti-Drift Valve
(Main Relief Circuit) (Bucket: Bottom Side) (Switch Valve)
cuit)
7- Auxiliary Flow Combiner 16 - Overload Relief Valve 25 - Load Check Valve 34 - Auxiliary Flow Rate Control
Valve Circuit)
T3-3-9

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

View K Cross Section L
36
T178-03-03-045
M Cross Section M
35
T178-03-03-046
T178-03-03-048
cuit)
cuit)
Valve Circuit)
T3-3-11

2-piece Boom (Optional)
4
T178-03-03-064
3
1 - Load Check Valve 2- Overload Relief Valve 3- Overload Relief Valve 4- Load Check Valve
(Positioning Circuit) (Positioning: Rod Side) (Positioning: Bottom Side) (Positioning Parallel Circuit)
T3-3-12

Positioning Control Valve

(2-Piece Boom Only)
ZAXIS200 class
X
2
X
3 Section X-X T198-03-03-003
T198-03-03-002
ZAXIS230 class, ZAXIS270 class

2
D
4
Section D-D
1 3
T178-03-03-067
T178-03-03-066
T3-3-13

HYDRAULIC CIRCUIT
Main Circuit
Pressure oil from pump 1 and from pump 2 is routed
to the 4-spool section and to the 5-spool section of
the control valve respectively. A parallel circuit is pro-
vided in both right and left main circuits, making
combined operations possible. An oil flow combiner
circuit is provided in both the boom and arm circuits
so that when a single operation is made, pressure
oil from both pumps 1 and 2 is supplied to the boom
or arm cylinders.
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) Åthe control lever (s)Ã is (are) operated. The over-
load 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) Åthe control lever
(s)Ã is (are) in neutral.
T3-3-14

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 Cyl-
inder Overload Re-
lief Valve
Swing Motor
Boom
Cylinder
Oil Flow
Combiner Circuit
5-Spool Section
Parallel Circuit
Pump 2 Pump 1
T178-02-02-001
T3-3-15

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.

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

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

4 Spool Side
Parallel Circuit
Pilot Pressure
from Position-
ing Pilot Valve
Positioning
Cylinder
Bypass Shut-Out
Valve
Pump 1
T178-03-03-065
Positioning
Control Valve
T3-3-17

Pilot Control Circuit External Pilot Pressure Oil Circuit
Pilot pressure oil (indicated with numbers) from the The main relief valve set-pressure is increased by
pilot valve exerts onto the spool ends in the control the pilot pressure oil delivered from solenoid valve
valve, shifting them. In the following operations, the unit (SG).
pilot pressure oil exerts on the switch valves while The arm regenerative valve is shifted by the pilot
shifting the spools. pressure oil delivered from solenoid valve unit
When the arm is rolled in, the pilot pressure oil (4) (SC).
shifts the switch valve in the arm anti-drift valve The arm flow rate control valve is shifted by the
while exerting onto the arm spool end. pilot pressure oil delivered from solenoid valve unit
When the boom is lowered, the pilot pressure oil (SE) (Serial No.104678 and earlier (ZAXIS200
(2) shifts the switch valve in the boom anti-drift class and 225 class),
valve while exerting onto the boom spool end. Serial No.010326 and earlier (ZAXIS230 class),
As the air bleed circuit is provided in the upper sec- Serial No.020042 and earlier (ZAXIS270 class))
tion of the control valve so that any air trapped in the The arm flow rate control valve is shifted by 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 (ZAXIS200
class and 225 class),
Serial No.010327 and later (ZAXIS230 class),
Serial No.020043 and later (ZAXIS270 class))
The flow combiner valve is shifted by the pilot
pressure oil delivered from the flow combiner
valve control spool in the signal control valve.
The bucket flow rate control valve is shifted by the
pilot pressure oil delivered from the bucket flow
rate control valve spool in the signal control valve.
The auxiliary flow 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

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

from Solenoid
Pilot Pressure from Bucket Flow Rate Control
Valve Unit (SG)
Valve Spool in Pilot pressure Signal Control Valve
Auxiliary Flow
Combiner
Valve
Main Relief
Valve
10
11
9
12
Bucket Flow
Flow Rate Control
Combiner Valve
Valve
Pilot Pressure 8
Oil from Aux-
iliary Flow 7
Rate Control
Solenoid
Valve
Auxiliary Flow
Rate Control 2
1
Solenoid 1
Valve
Arm Anti-Drift
Valve
Pilot Pres-
sure Oil from
Boom
Solenoid
Anti-Drift
Valve Unit 4 Valve
(SC)
3
3
Arm Regen-
erative Valve
Pilot Pressure Oil

from Pilot Pressure
Arm Flow Rate 6 Air Bleeding Oil from Aux.
Control Valve Circuit Pilot Valve
5
Control Spool in
the signal Control
Valve
(Up to serial
No.104678
(ZAXIS200 and Arm Flow Rate
225 class), Up to Control Valve
Bypass Shut-Out Valve
serial No.010326
(ZAXIS230 class),
Up to serial
No.020042
(ZAXIS270 class)) T178-03-03-040
Pilot Pressure Oil
from SE
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

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

biner 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
T3-3-20

(Blank)
T3-3-21

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 un-
seated 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

During Normal Operation:
Main Poppet Orifice A Orifice B Seat Passage Spring B
HP SG
LP
Sleeve Spring Spring 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

OVERLOAD RELIEF VALVE
(with Make-Up Function)
The overload relief valves are located in the boom,

arm, bucket, and positioning (2-piece boom only) cir-
cuits. The overload relief valve prevents each actuator
circuit pressure from rising excessively when the ac-
tuators 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 (posi- reduced more than port LP (hydraulic oil tank),
tioning: 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 the specified pressure, the sleeve is closed by
around the sleeve. spring C .
3. At this time a pressure difference arises between
port HP and the spring chamber due to the ori-
fice.
4. If this pressure difference increases more than
set-force of spring A, the main poppet is un- Positioning Circuit (2-piece boom only)
seated so that pressure oil at port HP flows to
port LP.
5. Thereby, the actuator circuit pressure decreases. Seat Spring C Sleeve Spring A Main Poppet
6. When the actuator circuit pressure decreases
Orifice A
more than the specified pressure, the main pop-
pet is seated by spring A. HP
Passage A
Pilot Pop- Valve
Spring B Spring
pet
Chamber LP T198-03-03-006
T3-3-24

Boom, Arm and Bucket
During Normal Operation:

Make-Up Valve Main Poppet Sleeve Spring A Passage A Spring B
HP
LP
Orifice Piston Spring Pilot Spring C T107-02-05-019
Chamber Poppet
During Relief Operation:
Main Poppet Sleeve Spring A Passage A Spring B
HP
LP
Orifice Piston Spring Pilot T178-03-03-049
Chamber Poppet
During Make-Up Operation:
Sleeve
HP
LP
Spring C T178-03-03-050
T3-3-25

REGENERATIVE VALVE
The regenerative valves are provided in the boom
lower, arm roll-in, and bucket roll-in circuits to in-
crease cylinder speeds and to prevent cylinder hesita-
tion, improving machine controllability.
Boom Regenerative Valve and Bucket Regener

-ative Valve
NOTE: Operational principle of the boom regen-

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

tom side circuit will increases more than the rode
side, causing the check valve to close and stop-
ping regenerative operation.
T3-3-26

Orifice
Return Oil from

Cylinder Rod
Hole A Side
Spool
Pressure Oil to
Cylinder Bottom
Check Valve Side
T178-03-03-052
T3-3-27

ARM REGENERATIVE VALVE
Operation
1. Normally, during arm rolled-in operation, the re-
turn oil from the cylinder rod side flows back to
the hydraulic oil tank through the hole (orifice) in
the arm regenerative valve spool.
2. When solenoid valve unit (SC) is activated by a
signal from the MC (main controller), pilot pres-
sure oil delivered from solenoid valve unit (SC)
shifts the arm regenerative valve spool, blocking
the return oil circuit from the cylinder rod side.
(Refer to the SYSTEM /Control System group.)
3. Thereby, the return oil from the cylinder rod side
flows to the bottom side together with oil deliv-
ered from the pump, increasing the cylinder
speed.
T3-3-28

Arm Regenerative
Valve
Arm 1 Arm 2
Return Oil from Arm

Cylinder Rod Side To Arm Regenera-
tive 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

ANTI-DRIFT VALVE
The anti-drift valves are provided in the boom cylinder
bottom side circuit and the arm cylinder rod side cir-
cuit, preventing the cylinders from drifting.
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, re-
ducing cylinder drift.
Releasing Operation
1. When the arm is rolled in or the boom is lowered,
pilot pressure oil from the pilot valve pushes the
piston in the anti-drift valve so that the switch Anti-Drift Valve Anti-Drift Valve
T176-03-03-028
valve is shifted. (Switch Valve) (Check Valve)

2. Then, oil in the check valve spring chamber flows To
back to the hydraulic oil tank through the switch Pressure Oil Hydraulic
from Pump 1 Oil Tank Boom Cylinder
valve.
3. Thereby, the check valve is opened, allowing the
return oil from the boom cylinder bottom side
(arm cylinder rod side) to flow to the spool.
From Pilot
Valve
To Hydrau-
lic Oil Tank
T176-03-03-029
Anti-Drift Valve Anti-Drift Valve

(Switch Valve) (Check Valve)
T3-3-30

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

FLOW RATE CONTROL VALVE
The flow rate control valves are provided in the arm,
bucket and auxiliary circuits to restrict oil flow rate in Arm Cyl-
the circuit when a combined operation is made, giving inder
priority to other actuators.
NOTE: Each flow rate control valve functions in
respective combined operation as shown To Hydraulic
Oil Tank
below. As an example, the arm flow rate
control valve operation is explained in this
section.
Flow Rate
Combined Operation
Control Valve
Arm Swing and Arm Roll-In
Switch
Bucket Boom Raise and Arm Roll-In Valve
Auxiliary Front Attachment and Auxiliary

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

inder
pressure oil from pump 2 flows to the main spool.
Flow Rate Control Operation

To Hydraulic
1. Pilot pressure oil from *arm flow rate control Oil Tank
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
rate to the main spool, allowing pressure oil to be
Switch
supplied to the swing motor which is loaded more Valve
than the arm.
NOTE: * SE (Up to serial No. (ZAXIS200 class Poppet
and 225 class), Up to serial No.010326 Valve
(ZAXIS230 class), Up to serial
No.020042 (ZAXIS 270 class)) *Arm Flow
Rate Control
Valve Control Pressure Oil
Spool from Pump 2
T178-03-03-031
T3-3-32

Spring A Check Valve Poppet
Spring B
To Main Spool
To Hydraulic Oil Tank
Switch Valve Pressure Oil from

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: * Flow Rate Control Operation

(VS Solenoid Valve Unit)
Serial No.104679 and Up (200 class and 225 class)
Serial No.010327 and Up (ZAXIS230 class)
Serial No.020043 and Up (ZAXIS270 class)
NOTE: ** Flow Rate Control Operation

(Arm Flow Rate Control Valve Control Spool)
Up to Serial No.104678
Up to Serial No.010326 (ZAXIS230 class)
Up to Serial No.020042 (ZAXIS270 class)
T3-3-33

AUXILIARY FLOW COMBINER VALVE
AND BYPASS SHUT-OUT VALVE
NOTE: As for 2-piece boom, when the positioning During Single Operation of Attachment:
pilot valve is operated, the positioning pilot When only the aux. pilot valve is operated, pressure
pressure is routed to port SJ, shifting the oil from both pumps 1 and 2 is combined and sup-
bypass shut-out valve spool. plied together to the attachment, increasing attach-
ment speed.
The auxiliary flow combiner valve and the bypass 1. When only the aux. pilot valve is operated, the
shut-out valve are provided in the front and the rear of aux. pilot valve pilot pressure is routed to port SM
the 4-spool control valve section respectively. These and port SJ, shifting the auxiliary flow combiner
valve functions differ depending on whether only the valve and the bypass shut-off valve spools.
aux. pilot valve is operated or a combined operation 2. When the bypass shut-out valve spool is shifted,
with other front attachments is made. the neutral passage in the 4-spool section is
blocked.
3. At the same time, as the auxiliary flow combiner
valve spool is shifted, pressure oil to be supplied
to the 4-spool section from pump 1 is routed to
the auxiliary spool via the auxiliary flow combiner
valve.
4. Therefore, pressure oil from both pumps 1 and 2
is supplied to the attachment, increasing attach-
ment operation speed.
T3-3-34

Pilot Pressure from
Signal Control Valve Aux. Pilot Valve
Auxiliary Flow Combiner
Auxiliary Flow Valve Control Solenoid
Combiner Valve Valve
Port SN Port SM
Attachment Neutral
Passage
Auxiliary
Port SJ
4-Spool Section
5-Spool Section
Pump 2 Pump 1
Positioning Pilot Valve
(2-Piece Boom Only)
Auxiliary Flow Combiner Valve
To Auxiliary Spool
T178-03-03-062
Port SM
Neutral Passage in
4-Spool Section
Spool Spring
Pressure Oil
from Pump 1
Spool
Check Valve
Spring
Port SJ T178-03-03-054
To Hydraulic
Port SN T178-03-03-053 Oil Tank
T3-3-35

During a Combined Operation of Attachment and Auxiliary Flow Combiner Valve
Front Attachment: To Auxiliary Spool
When the aux. pilot valve and the boom, arm, bucket
or travel functions are operated simultaneously, the
auxiliary flow combiner valve is kept closed so that Port SM
the boom, arm, or bucket travel operation speed is
maintained.
1. When the aux. pilot valve is operated, the at-
tachment pilot pressure is routed to port SM of
the auxiliary flow combiner valve.
2. Then when the boom, arm, bucket, or travel func- Pressure Oil
tion is operated at the same time, pilot pressure From Pump 1
from the signal pilot pressure control valve is
routed to port SN. Spool
3. The auxiliary flow combiner valve spool receives
pressure from port SM in the opening direction Check Valve
and pressure from port SN in the closing direc-
tion. In addition, spring force acts on the spool in Spring
the closing direction.
4. Therefore, spool closing direction force is larger
than opening direction force, holding the spool
closed.
Port SN T178-03-03-053
T3-3-36

COMPONENT OPERATION / Pilot Valve
OUTLINE
The pilot valve controls the pilot pressure to move the

control valve spools.
The 4-port pilot valve is used for front attachment,
swing, and travel operation. The 2-port pilot valve is
used for blade and offset operation.
ZAXIS200 class : Up to serial No.109561

ZAXIS225 class
(ZAXIS225USR) : Up to serial No.109555
(ZAXIS225US) : Up to serial No.109545
4 Oil Ports Pilot Valve

Front Attachment / Swing Pilot Valve
Port ISO Control
Hitachi Pattern
No. Pattern
1 Bucket Roll-Out
2 Boom Lower
Right
3 Bucket Roll-In
4 Boom Raise
1 Right Swing Arm Roll-In
2 Arm Roll-Out Right Swing
Left
3 Left Swing Arm Roll-Out
4 Arm Roll-In Left Swing
1
Hydraulic P T
Symbol T
2
1 3 2 4 P
T105-02-07-020 T178-03-04-001
T3-4-1

ZAXIS200 class : Up to serial No. 107148
ZAXIS225 class
(ZAXIS225USR) : Up to serial No. 107149
(ZAXIS225US) : Up to serial No. 107197
Travel Pilot Valve

1 Right Travel Reverse
2 Right Travel Forward
3 Left Travel Forward
4 Left Travel Reverse
Hydraulic P T
Symbol T
1 3 2 4
3 4
T105-02-07-020
2 1
T178-03-04-002
T3-4-2

ZAXIS200 class : Serial No. 109562 and up
ZAXIS225 class
(ZAXIS225USR) : Serial No. 109556 and up
(ZAXIS225US) : Serial No. 109546 and up
Front and Swing Pilot Valve

Port No. HITACHI ISO
Standard Standard
1 Bucket Roll-Out
2 Boom Lower
Right 3 Bucket Roll-In
4 Boom Raise
1 Arm Roll-In Swing Right
2 Swing Right Arm Roll-Out
Left
3 Arm Roll-Out Swing Left
4 Swing Left Arm Roll-In
P
Hydraulic Symbol
T1M9-03-05-001
A
View A 4
2 P T 4 1 3 2 PT 4 1 3
1
T1M7-03-04-001 3
T1M9-03-05-002
2
T3-4-3

ZAXIS225 class
(ZAXIS225US) : Serial No. 107198 and up
Travel Pilot Valve

Port No.
1 Right Travel Reverse
2 Right Travel Forward
3 Left Travel Forward
4 Left Travel Reverse T
P T P
T1M9-03-05-004
B
View B 3 4
1 2 4 3
T1M9-03-05-006
2
1
T1M9-03-05-005
T3-4-4

(Blank)
T3-4-5

OPERATION
Spool (6) head comes in contact with the upper face of
spring guide (3) which is kept raised by return spring
(5).
NOTE: Pilot valve changes by machine serial No.

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

downward while keeping the under face of the
spool head in contact with spring guide (3).
3. This status continues until hole (7) on spool (6) is
opened to port P.
T3-4-6

1 1
2 2
6
3 3 Port T
4 4 7
5 5 Port P
6 Output Port
6
Port T Port T
7 Port P 7 Port P
Output Port T178-03-04-005

Travel Pilot Valve

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

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

2 - Pusher 4 - Balance Spring 6 - Spool
T3-4-7

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

to push spool (6) upward increases. When, this
force overcomes balance spring (4) force, bal-
ance 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.
T3-4-8

1 1
2 2
3 3
4 4
5 5
6 6
Port T Port T
7 Port P 7 Port P
Output Port T178-03-04-008 Output Port T178-03-04-009
Travel Pilot Valve

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

T3-4-9

Full Stroke (Output Diagram: E to F)
1. When the control lever is fully stroked, pusher (2)
is moved downward until pusher (2) in the front E F
attachment / swing pilot valve comes in contact
with the casing shoulder, or cam (1) on the travel
D
pilot valve comes in contact with the casing. Pilot Pres-
2. At this moment, the bottom of pusher (2) directly sure
pushes spool (6). Therefore, even if oil pressure
in the output port increases further, hole (7) on
C
spool (6) is kept open.
3. Consequently, oil pressure in the output port is
equal to oil pressure in port P. A B
Lever Stroke
T522-02-05-001
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 deter-
mined by stroke dimension (E) of cam (1).
T3-4-10

2 2
4
5
6
Port T
7 Port P

T178-03-04-005
Travel Pilot Valve

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

T3-4-11

SHOCKLESS FUNCTION
(ONLY FOR TRAVEL PILOT VALVE) Damper Spring Pin Travel Pedal
ZAXIS200 class : Serial No.107149 and up A

ZAXIS225 class Travel Lever
(ZAXIS225US) : Serial No. 107198 and up Support
Bracket
The travel pilot valve has the damper enabling Pin

damping of the speed change shock by the lever.
The damper is composed of the support, gears 1
Gear 2
and 2, and others. Gear 1 is connected with the
A
support.
Gear 1
The support is secure to the bracket with the
spring pin. And the travel lever and the travel
pedal are secure to the bracket.
At this time, support sway transversely around the
pin in line with the movement of the travel lever.
Operation
1. If the travel lever is released from the hand during T1M7-03-04-002
traveling, return force of the return spring returns

the travel lever to the neutral position. Section A-A
2. At this time, gears 1 and 2 inside the damper re- Spring Pin
ceive opposing force due to friction.
3. Therefore, the travel lever gradually returns to the
neutral position, thus moderating the extent of
sudden stop at the time of abrupt release of the
travel lever.
Damper
Support
Pin
T1M7-03-04-003
T3-4-12

COMPONENT OPERATION / Travel Device
OUTLINE
ZAXIS200 class, 225 class, 225 class, 230 class
The travel device consists of the travel motor, travel The travel reduction gear is a three stage reduction
reduction gear, and travel brake valve. The travel mo- planetary gear type, converting rotary power transmit-
tor is a swash plate type variable displacement axial ted from the travel motor to slow large torque causing
plunger motor, equipped with parking brake (wet-type the sprocket and track to rotate. The travel brake valve
negative multi-disc brake). The travel motor is driven protects the travel circuit from being overloaded and
by pressure oil from the pump and transmits its rotary prevents the occurrence of cavitation.
power to the travel reduction gear.
NOTE: The structure and theory of operation of the
travel device for ZAXIS 200 class, ZAXIS
225 class and ZAXIS 230 class can be
thought as identical. Only some parts differs.
This section describes the operation of
ZAXIS 200 class and ZAXIS 270 class.
ZAXIS200 class : Up to serial No 108985 ZAXIS225 class

ZAXIS225 class (ZAXIS225USR) : Serial No 108987 and up
(ZAXIS225USR) : Up to serial No 108986 (ZAXIS225US) : Serial No 108986 and up
(ZAXIS225US) : Up to serial No 108985 ZAXIS230 class : Serial No 11129 and up
ZAXIS230 class : Up to serial No 11128
Travel Brake Valve Travel Reduction Gear Travel Brake Valve Travel Reduction Gear
Sprocket
Sprocket
T178-03-05-012
T178-03-05-001
Travel Motor Travel Motor
T3-5-1

ZAXIS270 class
(ZAXIS270) : Up to serial No 20226
(ZAXIS270LCN): Up to serial No 82518
ZX270 class
The travel device consists of the travel motor, travel
reduction gear, and travel brake valve. The travel mo- Travel Brake Valve Travel Reduction Gear
tor is a bent axis type plate type variable displacement
axial plunger motor, equipped with parking brake
(wet-type negative multi-disc brake). The travel motor
is driven by pressure oil from the pump and transmits
its rotary power to the travel reduction gear.
The travel reduction gear is a three stage reduction
planetary gear type, converting rotary power transmit-
ted from the travel motor to slow large torque causing
the sprocket and track to rotate. The travel brake valve
protects the travel circuit from being overloaded and
prevents the occurrence of cavitation.
T1HG-03-05-001
Travel Motor
T3-5-2

ZAXIS270 class
(ZAXIS270) : Serial No 20227 and up
(ZAXIS270LCN): Serial No 22519 and up
The travel device consists of the travel motor, travel Travel Brake Valve Travel Reduction Gear
reduction gear, and travel brake valve. The travel mo-
tor is a swash plate type variable displacement axial
Sprocket
plunger motor, equipped with parking brake (wet-type
negative multi-disc brake). The travel motor is driven
by pressure oil from the pump and transmits its rotary
power to the travel reduction gear.
The travel reduction gear is a three stage reduction
planetary gear type, converting rotary power transmit-
ted from the travel motor to slow large torque causing
the sprocket and track to rotate. The travel brake valve
protects the travel circuit from being overloaded and
prevents the occurrence of cavitation.
T1HG-03-05-001
Travel Motor
T3-5-3

TRAVEL REDUCTION GEAR
The travel reduction gear is a Three stage reduction Travel motor housing (14) is bolted to the track frame
planetary gear type. and is secured to third stage carrier (2) by hub (11).
The travel motor rotates propeller shaft (7). This rota- Ring gear (1) is bolted to drum (13). Drum (13) is
tion is transmitted to ring gear (1) via first stage plane- bolted to sprocket (12). Accordingly, when ring gear (1)
tary gear (8), first stage carrier (6), first stage sun gear is rotated, drum (13) and sprocket (12) are also ro-
(5), second stage planetary gear (9), second stage tated.
carrier (4), second stage sun gear (3), third stage
planetary gear (10), and third stage carrier (2).
ZAXIS200 class
ZAXIS225 class
(ZAXIS225USR) : Up to serial No 108986
(ZAXIS225US) : Up to serial No 108985
1 2 3 4 5 6
14 13 11 10 9 8
12
T178-03-05-001
1 - Ring Gear 5 - First Stage Sun Gear 9 - Second Stage Planetary 12 - Sprocket
Gear
2 - Third Stage Carrier 6 - First Stage Carrier 10 - Third Stage Planetary Gear 13 - Drum
3 - Second Stage Sun Gear 7 - Propel Shaft 11 - Hub 14 - Housing
4 - Second Stage Carrier 8 - First Stage Planetary Gear
T3-5-4

ZAXIS270 class
(ZAXIS270LCN) : Up to serial No 82518
NOTE: The travel motor is another type of
ZAXIS270 (Serial No 20227 and up),
ZAXIS270LCN (Serial No 82519 and up).
(Refer to T3-5-7)
1 2 3 4 5 6
Travel Motor
11 10 9
14 13
12 T1HG-03-05-001
T3-5-5

TRAVEL MOTOR
ZAXIS200 class
ZAXIS225 class
The travel motor is a variable-displacement swash Shoes on the tips of plungers slide along swash plate
plate axial plunger motor. The travel motor consists of surface due to the inclination of swash plate, causing
valve plate, swash plate, rotor, plungers, and shaft. rotor to rotate.
Shaft is splined to rotor, in which plungers are inserted.
When pressure oil is supplied from the pump, the
plungers are pushed.
Shaft Rotor Shoe Swash Plate
Valve Plate Plunger
T178-03-05-002
T3-5-6

ZAXIS225 class
(ZAXIS225USR) : Serial No 108987 and up
(ZAXIS225US) : Serial No 108986 and up
ZAXIS230 class : Serial No 11129 and up
Valve Plate Plunger

T178-03-05-014
T3-5-7

ZAXIS270 class
(ZAXIS270LCN) : Up to serial No 82518
The travel motor is a variable-displacement bent-axis Pressure oil supplied to port AM of valve plate (2)
axial plunger motor. flows into rotor (14) bores underneath port AM, push-
The travel motor consists of the motor are plate (1), ing plungers (13). Vertical component force (FV) of
valve plate (2), rotor (14), plungers (13), center shaft plunger pushing force (F) rotates drive disc (7). As
(5), drive disc (7), servo piston (16), parking brake drive disc (7) rotates, rotor (14) also rotates.
piston (12), friction plates (11), and plates (10). When plungers (13) moves to port BM side, oil is
routed to the hydraulic oil tank.
Whether pressure oil from the pump is supplied to port
AM or BM determines travel direction.
1 2 3 4 5 6
14
13
BM 7
8
AM
9
FR
FV F
16 15 14 13 12 11 10
T140-03-02-002
T107-03-04-014
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
T3-5-8

ZAXIS270 class
(ZAXIS270): Serial No 20227 and up
Valve Plate Plunger
W1HH-03-02-006
T3-5-9

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. ZAXIS200 class, 225 class, 230 class, 2. ZAXIS 200 class, 225 class, 230 class,
ZAXIS270 class ZAXIS270 class
(ZAXIS270) Serial No 20227 and up (ZAXIS270) Serial No 20227 and up),
(ZAXIS270LCN) Serial No 82519 and up (ZAXIS270LCN) Serial No 82519 and up:
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
ZAXIS270 class pushed back by the disc spring.
(ZAXIS270) Up to serial No 20226 ZAXIS270 class
(ZAXIS270LCN) Up to serial No 82518: (ZAXIS 270) Up to serial No 20226
This pressure oil shifts the counterbalance valve (ZAXIS270LCN) Up to serial No 82518:
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.
T3-5-10

When Applying Brake Friction Plate Plate When Releasing Brake Friction Plate Plate
Disk Spring Orifice Brake Piston Disk Spring Brake Piston
ZAXIS200 class, 225 class, 230 class,

ZAXIS270 class
(ZAXIS270) Serial No 20227 and up
(ZAXIS270LCN) Serial No 82519 and up
To Brake
Piston
BM AM
Counterbalance
Spool
ZAXIS270 class
(ZAXIS270) Up to serial No 20226
(ZAXIS270LCN) Up to serial No 82518
To Breke Piston T178-03-05-008
Reducing Valve
NOTE: The drawing shown in the above is from
ZAXIS200.
Drain
I
Counterbalance Spool
BM T137-03-02-009
AM
T3-5-11

TRAVEL MODE CHANGE
ZAXIS200 class
ZAXIS225 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) doesnt 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.
T3-5-12

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
T3-5-13

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.
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.
T3-5-14

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
T3-5-15

ZAXIS225 class
(ZAXIS225USR): Serial No 108987 and up
(ZAXIS225US): Serial No 108986 and up
(ZAXIS225US for EN): Serial No 10876 and up
ZAXIS230 class: Serial No 11129 and up
ZAXIS270 class
The tilt angle of swash plate (7) is changed by piston

(8) 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) doesnt 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. Accordingly, the pressure oil doesnt act on piston
(8), holding the swash plate angle to the maxi-
mum and increasing the stroke of plunger (6).
Then, the travel motor rotates at slow speed.
T3-5-16

1
Motor Port
(AM, BM)
4 5 7 8
T178-03-05-010
1 - Pilot Port 4 - Piston Operating Shuttle 6- Plunger 8- Piston

Valve
2 - Spool 5 - Orifice (Fast / Slow) 7- Swash Plate
3 - Spring
NOTE: The drawing shown in the above is from

ZAXIS225USR class (Up to serial No
108987) and ZAXIS225US class (Up to se-
rial No 108986) and ZAXIS230 class (Up to
serial No 11129).
T3-5-17

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.
BM) acts on piston (8) through piston operating
orifice (5).
3. Piston (8) moves swash plate (7) so that swash
plate (7) angle is reduced. Thereby, plunger (6)
stroke is reduced, causing the travel motor to ro-
tate at fast speed.
T3-5-18

1
Motor Port
(AM, BM)
4 5 6 7 8
T178-03-05-011
1 - Pilot Port 4- Piston Operating Shuttle 6- Plunger 8- Piston

Valve
2 - Spool 5 - Orifice (Fast / Slow) 7- Swash Plate
3 - Spring
T3-5-19

ZAXIS270 class
(ZAXIS270): Up to serial No 20226
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
T3-5-20

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
T3-5-21

TRAVEL BRAKE VALVE
The travel brake valve is located on the travel motor
head, consisting of the following valves.
Counterbalance Valve: ZAXIS200 class

Makes starting and stopping travel operations smooth, ZAXIS225 class
prevents the machine from running away while de- (ZAXIS225USR) : Up to serial No 108986
scending slopes, and routes the travel motor operating (ZAXIS225US) : Up to serial No 108985
pressure oil in high pressure port (AV or BV) to the ZAXIS230 class : Up to serial No 11128
parking brake. ZAXIS270 class
Check Valve: (ZAXIS270LCN) : Up to serial No 82518
Assists the counterbalance valve operation and pre-
vents cavitation in the motor circuit. Travel Motor Swash Plate Angle Control Valve:
Delivers pressure oil routed by the piston control shut-
Overload Relief Valve: tle valve to the slow or fast side piston.
Prevents the occurrence of overload and surge pres-
sure in the motor circuit and reduces shock loads de- Slow-Speed Orifice, Fast-Speed Orifice:
veloped when stopping travel operation. Makes the travel mode change (swash plate angle
control) smooth.
Shuttle Valve:
Routes the travel motor operating high pressure oil in ZAXIS225 class
high pressure port (AM or BM) to the slow or fast side (ZAXIS225USR) : Serial No 108987 and up
piston so that the piston is controlled. (ZAXIS225US) : Serial No 108986 and up
ZAXIS230 Class : Serial No 11129 and up
ZAXIS270 class
(ZAXIS270) : Serial No 20227 and up
(ZAXIS270LCN) : Serial No 82519 and up
Travel Motor Swash Plate Angle Control Valve:

Delivers pressure oil routed by the piston control shut-
tle valve to the orifice (Fast / slow side) piston.
Orifice (Fast / slow):

Makes the travel mode change (swash plate angle
control) smooth.
T3-5-22

NOTE: The drawing shown in the below is from

ZAXIS225USR (Up to serial No 108987),
and ZAXIS225US (Up to serial No 108986)
and ZAXIS230 (Up to serial No11129).
1 2 3
7 6 5 4
T178-03-05-003
1 - Counter Balance Valve 3- Slow-Speed Orifice 5- Travel Motor Swash Plate 7- Overload Relief Valve
Angle Control Valve
2 - Check Valve 4- Fast-Speed Orifice 6 - Shuttle Valve
T3-5-23

ZAXIS270 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.
T3-5-24

4 2
1 1
AM BM
AV BV
A
Section A-A
6 3
Section B Section C
T1HG-03-05-002
1 - Check Valve 3- Parking Brake Release 5- Counterbalance Valve 6- Servo Piston Operating
Shuttle Valve Shuttle Valve
2 - Reducing Valve 4 - Overload Relief Valve
T3-5-25

While Traveling: While descending:
1. When pressure oil from the control valve enters 1. While descending a slope, the travel motor is
port BV (8), pressure oil flows around the outer forcibly rotated by the machine weight so that the
diameter of spool (9), unseats check valve BC (7), motor operates like a pump, drawing oil.
and flows further to motor port BM (6). 2. If the travel motor draws oil, oil pressure in port
2. On the other hand, the return oil from the travel BV (8) and chamber B (10) will decrease, causing
motor is routed to motor port AM (4). However, its spool (9) to the left so that the return oil flow from
passage is blocked by check valve AC (3) and the travel motor is restricted.
spool (9). 3. Therefore, oil pressure in motor port AM (4) will
3. When oil pressure in port BV (8) increases, increase, braking the travel motor.
pressure oil is routed into chamber B (10) through 4. Once pressure oil flow is restricted, oil pressure in
orifice (f) in spool (9), moving spool (9) to the motor port AM (4) will increase again, moving
right. spool (9) to the right. As this operation (hydraulic
4. Consequently, the return oil from the travel motor braking operation) is repeated, the machine is
flows to port AV (1) through notch (h) on spool (9). prevented from running away.
Then, pressure oil is allowed to flow so that the
travel motor starts rotating. Circuit Protection Operation:
5. When the travel lever is returned to neutral, spool 1. When oil pressure in the circuit increases over the
(9) is returned to the original position by spring set-pressure of overload relief valve (5), the
force, blocking the oil passage so that the travel overload relief valve is opened, allowing the high
motor rotation is stopped. pressure oil to relieve to the low pressure side so
that the travel motor is protected from being over-
loaded.
2. In addition, the overload relief valve relieves the
shock loads developed due to inertia force when
stopping the travel motor.
3. If the travel motor draws oil like a pump, check
valve BC (7) is unseated (make-up operation) so
that cavitation is prevented.
T3-5-26

ZAXIS 200 class, 225 class, 230 class,
ZAXIS270 class
10 8 9 1 2
BV AV
6
4
7
3
T178-03-05-006
ZAXIS270 class
5
(ZAXIS270): Up to serial No 20226
4 6
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
T3-5-27

(Blank)
T3-5-28

COMPONENT OPERATION / Signal Control Valve
OUTLINE
The signal control valve is provided in the pilot circuit
between the pilot valve and the control valve and con-
trols pilot signal pressure used to regulate the pumps
and various kinds of valves.
The major components of the signal control valve are,
shuttle valves, shockless valve, pump 1 flow rate con-
trol valve, pump 2 flow rate control valve, flow com-
biner valve control spool, bucket flow rate control
valve control spool, swing parking brake release spool
and *arm flow rate control valve control spool.
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

PILOT PORT
Pilot Valve Side
Port Name Connecting to Note
Port A Right Pilot Valve Boom Raise Pilot Pressure
Boom Electronic Cushion Solenoid Valve
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

Pilot Valve Side

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

SM
3
1 5
13
2 4
SK
SE

8
14
Control Valve Side
7
9
6
10
SN
SL
11
Pressure Sensor (Travel) 12 SP T178-03-06-015
T3-6-3

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 (ZAXIS200 class and (Up to serial No.104678 (ZAXIS200 class and 225
225 class), Up to serial No.010326 (ZAXIS230 class), Up to serial No.010326 (ZAXIS230 class), Up
class), Up to serial No.020042 (ZAXIS270 to serial No.020042 (ZAXIS270 class))
class))
Control Valve
(Serial No.104679 and up (ZAXIS200 class Arm Flow Rate Control Valve Control Pressure
and 225 class), Serial No.010327 and up (Serial No.104679 and up (ZAXIS200 class and 225
(ZAXIS230 class) Serial No.020043 and up class), Serial No.010327 and up (ZAXIS230 class)
(ZAXIS270 class)) Serial No.020043 and up (ZAXIS270 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

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

SM
3
1 5
13
2 4
SK
SE

8
14
Control Valve Side
7
9
6
10
SN
SL
11
Pressure Sensor (Travel) 12 SP T178-03-06-015
T3-6-5

SHUTTLE VALVE
The shuttle valve selects the pilot pressure oil used to
perform each operation and routes it to the corre-
sponding flow rate control valves and/or switch valve
spools. The flow rate control valves and/or switch
valve spools corresponding to each operation are as
follows:
Pump 1 Flow Pump 2 Flow Flow Com- Bucket Flow Swing Park- *Arm Flow
Rate Control Rate Control biner Valve Rate Control ing Brake Rate Con-
Valve Valve Control Spool Valve Control Release trol Valve
Spool Spool Control
Spool
Boom Raise - - -
Boom Lower - - - -
Arm Roll-In - - -
Arm Roll-Out -
Bucket Roll-In - - - -
Bucket Roll-Out - - - -
Right Swing - - - -
Left Swing - - - -
Right Travel - - - -
Left Travel - - - - -
Auxiliary - - - -
NOTE: *Serial No.104679 and up (ZAXIS200 class and 225 class)

T3-6-6

5 6 7 8 9 10
Left Right
Swing Arm Boom Bucket
Travel Travel 11
1 2 3 4
12
13
14 15 16 17
Pump 1 Flow Pump 2 Flow Bucket Flow Flow Combiner Swing Parking *Arm Flow Rate
Rate Control Rate Control Rate Control Valve Control Brake Release Control Valve
Valve Valve Valve Control Spool Spool Control Spool
Spool
T178-03-06-018
T3-6-7

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 11 - Boom / Arm / Bucket 16 - Swing / Auxiliary
Travel
2 - Left Travel/Right Travel 7 - Boom/Arm 12 - Boom / Arm / Bucket / Swing / 17 - Auxiliary
Auxiliary
3 - Right Travel 8- Boom 13 - Arm / Boom Raise / Swing /
Auxiliary
4 - Boom / Arm / Bucket / Right 9- Arm / Boom Raise 14 - Bucket
Travel
5 - Arm 10 - Boom Raise / Arm / Bucket / 15 - Swing
Left Travel / Swing
T3-6-8

(Blank)
T3-6-9

SHOCKLESS VALVE
The shockless valve is provided in the boom raise cir-
cuit and functions during boom lowering operation.
During Boom Raising Operation:

1. Boom raise pilot pressure oil is routed into port A
and acts on the spool.
2. Immediately after operation is started, the low pi- Detail of C
lot pressure oil flows into the spring B chamber
via clearance between the spool and the housing.
At the same time, the pilot pressure oil flows to
port 1 through inner passage 2.
3. When the pilot oil pressure increases, the pres-
sure in the spring B chamber increases, causing
the spool to move to the left while pushing spring
A.
4. As the spool is moved to the left, port A is con-
nected to port 1, increasing pressure in port 1 so T183-03-06-002
that the spool in the control valve is moved.
During Boom Lowering Operation (Shock Re-

ducing Operation)
1. When the boom is lowered, the return oil from the
boom raise spool in the control valve is routed to
port 1.
2. Since the spool blocks the oil passage between
port 1 and port A, the return oil cannot flow di-
rectly to port A.
3. Port 1 is connected to spring A side via inner
passage 1 and to the oil chamber via inner pas-
sage 2.
4. Pressure oil in the oil chamber flows out from
clearance C between the spool and the housing,
reducing pressure in the oil chamber. Then, the
spool is moved to the right by pressure in the
spring A side. Thereby, clearance C between the
spool and the housing is closed, blocking pres-
sure oil flow.
5. When clearance C is closed, pressure in the oil
chamber increases, moving the spool to the left.
Therefore, clearance C is opened again, allowing
pressure oil to flow to port A.
6. As operations in steps (4 and 5) are repeated,
pressure oil is gradually returned to port A so that
the control spool returns slowly.
T3-6-10

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

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

Port SA, SB
Spring Spool
Primary Pilot Pressure
Pilot Pressure
Shuttle Valve
T178-03-06-017
T3-6-13

BUCKET FLOW RATE CONTROL VALVE
CONTROL SPOOL, FLOW COMBINER
VALVE CONTROL SPOOL, SWING PARK-
ING BRAKE RELEASE SPOOL, *ARM
FLOW RATE CONTROL VALVE CONTROL Bucket Flow Rate Control Valve Control Spool:
SPOOL To Hydraulic Boom Raise Control
Oil Tank Pilot Pressure
Spool Spring
NOTE: The three captioned spools are identical in
operational principle.
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:
control valve. To Hydraulic Primary Pilot
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 T178-03-06-014
rate control valve in the control valve. Right Travel To Flow Combiner
Control Pilot Valve
Pressure
NOTE: * Serial No.104679 and up
(ZAXIS200 class and 225 class) Swing Parking Brake Release Spool:
Serial No.010327 and up Oil Tank Pressure
(ZAXIS230 class) Spool Spring
Serial No.020043 and up
(ZAXIS270 class).
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 Pump
T178-03-07-013
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

SOLENOID VALVE UNIT
Two kinds of solenoid valve are provided: the solenoid Serial No.104679 and up (ZX200 class and 225 class)
valve unit to control pumps and valves, and the boom Serial No.010327 and up (ZX230 class)
electronic cushion solenoid valve (ZAXIS225US: Up to Serial No.020043 and up (ZX270 class)
serial No.104908) to control the boom electronic
cushion.
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.)
(Solenoid valve unit changes with machine serial No.)
SE*: Controls the arm flow rate control valve located in
the control valve
SC : Controls the arm regenerative valve located in the T178-03-07-005
SC SI SG
control valve.
SI : Controls the travel motor servo piston.
(Travel Speed Selection)
SG : Functions to increase the main relief valve
pressure setting. Up to serial No.104678 (ZX200 class and 225 class)
Up to serial No.010326 (ZX230 class)
NOTE:* Up to serial No.104678 (ZX200 class and Up to serial No.020042 (ZX270 class)
225 class)
SC SE SI SG T178-01-02-003
T3-7-2

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

Boom Electronic Cushion Solenoid Valve
(Up to Serial No.104908 (ZAXIS225US))
Output Port
The boom electronic cushion solenoid valve reduces
the boom raise pilot pressure by the signal from MC
(Main Controller).
By reducing the pressure, the spool in the control
valve is controlled to reduce the shock which may
occur when the boom reaches to its full stroke position.
(Refer to SYSTEM / Control System group.)
Operation:
1. Port P and output port are connected by the spool
notch when neutral.
2. When the power flows to the solenoid from MC
(Main Controller), the solenoid is energized and
T1GF-03-07-001
pushes spring 1.
3. As spring 1 pushes the spool, the output port and Port P Port T
port T are connected by the spool notch.
Therefore, the pressure in the output port begins
to decrease.
4. The right side of spool diameter (B) is larger than
the left side of spool diameter (A).
5. Therefore, until the pressure at the output port
disappears, the external force applied onto the
spool is expressed as P1 I B + S1 â P1 I A + S2.
Then, the spool is move toward the right side.
6. When the oil pressure at the output port disap-
pears so that when P1 I B + S1 becomes equal to
P1 I A + S2 (P1 I B + S1 = P1 I A + S2), the
spool stops moving.
P1 : Oil pressure at the output port

A and B: Pressure receiving area on the spool
S1 : Spring 1 force
(pushing the spool toward the right side)
S2 : Spring 2 force
(pushing the spool toward the left side)
T3-7-4

When Neutral:
T176-03-01-030
A Port P Port T B
Output Port
When in Operation:
T176-03-01-031
A Port P Port T B
Output Port
NOTE: The theory of operation of this solenoid

valve is similar to that of the solenoid valve
to control the pump. Refer to T3-1-23 also
for the illustration.
T3-7-5

HOLDING VALVE
(Only on the machines equipped with the corre-
sponding optional parts.)
The holding valves function to hold the front attach-

ment in position if any hose for the front attachment is
punctured accidentally. The holding valves are at-
tached to the bottom side of the boom cylinder, the rod Chamber a Passage c Passage b
side of the arm cylinder, and the rod side of the posi-
tioning cylinder.
NOTE: The following explanation will be made
about the holding valve for the boom cyl-
inder as an instance.
Holding valve operation when the control lever is in

neutral. Pilot
1. Because the pilot pressure Pi does not act on the Pressure
spool, the spool remains in neutral. Pi
2. The cylinder-holding pressure at the cylinder port Port B Spool
B is applied to the poppet and to the spool
Port A Poppet Passage a
through passage c. To the Spool
3. The cylinder-holding pressure, after passing in the Control T178-03-07-006
Valve
through passage c, is blocked by the spool. The
pressure in the chamber a is applied to the spool
through passage c, but not transmitted to pas-
sage a by blocking with the spool.
4. As a result, the cylinder pressure at cylinder port
B is maintained unchanged. Therefore, even if
any hose at the front attachment is punctured, the
front attachment is held in position to avoid unin-
tended lowering.
T3-7-6

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

Holding valve operation when the boom lower con-
trol lever is operated The Boom Lower Control Lever: Half Stroke or less
1. When moving the boom lower control lever at half
stroke or less, the pilot pressure Pi acts on the Chamber a Passage c Passage b Relief
spool, and makes the spool move to the orifice B Valve
position.
2. At this time, the spool blocks passage B, so that
the poppet is pushed against the seat.
3. As a result, the pressurized oil from the port B Orifice A
flows through passages c and a in order to lower
Poppet
the boom.
4. When moving the boom lower control lever at half
stroke or more, the pilot pressure Pi acts on the
Pressure
spool, and makes the spool shift to the orifice C Pi
position.
5. Then, passages b and a are connected through Port B
Spool
orifice C. At this time, an oil passage, from port B Port A
to orifice A to chamber a to passage b to orifice C To the Spool
to passage a to port A, is opened. in the Control Seat Passage a Orifice B
6. The oil from passage c is blocked by the spool, so Valve T178-03-07-009
that the oil does not flow into passage a.

7. 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

Section X-X
X Relief Valve
Passage a
Orifice B Spool
Pressure Pi
Orifice C Passage b
Passage c Chamber a
Spring
Orifice A
From Port B
Poppet
Port A Port B
X
T178-03-07-008
T3-7-9

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

CENTER JOINT
The center joint is a 360p 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 Right Travel
To Left 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

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

(Blank)
T3-8-4

MEMO

MEMO

Hitachi Construction Machinery Co. Ltd Hitachi Ref. No.
Attn: Publications, Marketing & Product Support
Fax: 81-29-831-1162
SERVICE MANUAL REVISION REQUEST FORM
NAME OF COMPANY: MODEL:

PUBLICATION NO.:
YOUR NAME: (Located at the right top corner in the cover page)
DATE: PAGE NO.:

(Located at the bottom center in the page. If two or more revi-
FAX: sions are requested, use the comment column)
YOUR COMMENTS / SUGGESTIONS:

Attach photo or sketch if required.
If your need more space, please use another sheet.
REPLY:
(Copy this form for usage)


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What is the purpose of this manual?

What is the purpose of this manual?

What are the three portions that make up this manual?

What are the three portions that make up this manual?

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Consecutive Page Number for Each Group

SAFETY ALERT SYMBOL AND HEADLINE

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

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Group 2 Component Layout

Group 3 Component Specifications

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ZX200 Hydraulic ZX200LC Hydraulic ZX210H Hydraulic ZX210LCH Hydraulic

NOTE: H/P mode

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ZAXIS210, ZAXIS210LC, ZAXIS210N

Model ZAXIS210 ZAXIS210LC ZAXIS210N

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Model ZAXIS225USR ZAXIS225USRLC

NOTE: H/P mode

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Model ZAXIS225US ZAXIS225USLC

NOTE: H/P mode

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ZAXIS230, 230LC, 240H, 240LCH

ZX230 Hydraulic ZX230LC Hydraulic ZX240H Hydraulic ZX240LCH Hydraulic

NOTE: H/P mode

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ZAXIS250, 250LC, 250LCN

Model ZAXIS250 ZAXIS250LC ZAXIS250LCN

NOTE: H/P mode

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Model ZAXIS270 ZAXIS270LC

NOTE: H/P mode

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Model ZAXIS280LC ZAXIS280LCN

NOTE: H/P mode

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ZAXIS210, ZAXIS210LC, ZAXIS210N (2-piece Boom)

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ZAXIS240 (2-piece Boom)

Model ZAXIS240 2-piece Boom

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ZAXIS250, 250LC, 250LCN (2-piece Boom)

ZAXIS250 ZAXIS250LC ZAXIS250LCN

NOTE: H/P mode

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ZAXIS280LC, 280LCN (2-piece Boom)

Model ZAXIS280LC 2-piece Boom ZAXIS280LCN 2-piece Boom

NOTE: H/P mode

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

Std 8985 29 6 8985 29 6 8865 29 1 8865 29 1

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