t02 - 1 Hitachi

SECTION 2
SYSTEM
CONTENTS
Group 1 Control System
Outline .....................................................T2-1-1
Engine Control .........................................T2-1-2
Pump Control .........................................T2-1-23
Valve Control..........................................T2-1-32
Other Controls........................................T2-1-46
Group 2 Hydraulic System

Outline .....................................................T2-2-1
Pilot Circuit...............................................T2-2-2
Main Circuit ............................................T2-2-12
Group 3 Electrical System

Outline .....................................................T2-3-1
Main Circuit ..............................................T2-3-2
Electric Power Circuit ...............................T2-3-3
Indicator Light Check Circuit.....................T2-3-4
Accessory Circuit .....................................T2-3-5
Preheat Circuit .........................................T2-3-6
Starting Circuit .........................................T2-3-8
Charging Circuit .....................................T2-3-10
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
operations. Electronic signals from the engine control
dial, various sensors and switches are sent to the MC.
After processing the received signals in the logic circuit,

the MC sends out control signals to the EC motor,
solenoid valve units, torque control solenoid valve, and
other control circuits to regulate the engine, pumps,
motors and valves.
Input Signals
EC Sensor
Engine Control Dial
Pump 1 Control Pressure Sensor
Pump 2 Control Pressure Sensor
Pump 1 Delivery Pressure Sensor
(Oprtional)
N sensor
Output Signals
Engine Control (EC Motor)

Engine Control Dial
HP Mode Control
E mode Control
Auto-Idle Control
Auto-Acceleration Control
Auto-Warming Up Control
Idle Speed-Up Control
Engine Speed Automatic Increase Control
Travel(Oniy ZAXIS270)
Attachment Operation Speed Increase Control
Attachment Operation Speed Limit Control

Engine Learning Control
Pressure Switch (Travel)
Pressure Switch (Front Attachment)

Pressure Switch (Swing)
Pressure Switch (Boom Raise)
Pressure Switch (Arm Roll-In)
Pressure Switch (Auxiliary)
Pressure Switch (Arm Roll-Out)

(Optional)
Hydraulic Oil Temperature Sensor

Auto-Idle/Acceleration Selector
Power Digging Switch
Power Mode Switch (HP/E/P)
Travel Mode Switch (Fast/Slow)
Work Mode Switch

(Digging/Attachment)
Learning Switch
Key Switch
Boom Angle Sensor (Only ZAXIS225US)

Auxiliary Mode Switch (Optional)
MC
at
Pump Control (Torque Control Solenoid Valve)

Speed Sensing Control
Slow Speed Torque Increase Control
Pump 1 Flow Rate Limit Control
Pump 3 Torque Decrease Control

Valve Control (Solenoid Valve Unit)
Power Digging Control
Arm Flow Rate Control
Arm Regenerative Control
Travel Motor Swash Angle Control
Auto-Power Lift Control
Auxiliary Flow Rate Control

Other Controls
Boom
Electronic
Cushion
ZAXIS225US)
Work Mode Control
Travel Alarm Control
NOTE: Only on the machines equipped with the

corresponding optional parts.
T2-1-1
Control
(Only

ENGINE CONTROL
The engine control system is grouped as follows:

Engine Speed Automatic Increase Control at
Travel (Only ZAXIS270)
Attachment Operation Speed Limit Control

Engine Control Dial Control

HP Mode Control
E Mode Control
Auto-Idle Control
NOTE: Only on the machines

with
the
Engine Control System Layout
Learning Switch
Pressure Sensor
Travel
Front Attachment
Swing
Boom Raise
Arm Roll-In
Key Switch
Pump 2
Delivery
Pressure
Sensor
Pump 1
Delivery
Pressure
Sensor
Auxiliary (Optional)
Engine
Control Dial
EC Sensor
Auto-Idle /
Acceleration
Selector
Auto-Idle
EC Motor
Auto-Acceleration
Power Mode Switch

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

(Blank)
T2-1-3

Engine Control Dial Control
Function: Controls the engine speed in response to
the rotation angle of the engine control dial
-1
and reduces the engine speed by 100 min
to reduce fuel consumption and noise level
when all control levers are in neutral.
Operation: The MC drives the governor lever in
response to the rotation angle of the engine
control dial to regulate the engine speed.
Engine
Speed
Engine speed is
reduced by 100
min-1 when the
control levers are
in neutral.
Control Range
NOTE: Even if the control dial is rotated to the full

speed position, the governor lever doesnt
come in contact with the full speed stopper.
(Refer to the HP mode control.)
Approx. 1 second after all control levers are in neutral
(the travel and front attachment sensors are OFF), the
MC drives the EC motor so that the engine speed is
-1
reduced from the maximum speed by 100 min .
NOTE: The engine speed is reduced from the
-1
maximum speed by 100 min . Therefore,
when the engine speed set by the engine
control dial is already slower than the
-1
maximum speed by 100 min , the engine
speed remains unchanged. This engine
speed reduction control is activated
regardless of whether the auto-idle and/or
auto-acceleration control is activated or not.
T2-1-4
Minimum
Speed
Maximum
Speed
Engine
Control Dial
Position
ANIMATION
Pressure Sensor
Travel
Front Attachment
Engine
Control 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
deeply.
Engine
Speed
Operation: The MC drives the EC motor to slightly

increase the engine speed set by the
engine control dial when all the following
conditions exist with the power mode
switch is in the HP position.
Maximum speed
increases by
200 min-1 except
ZAXIS230 and
270 (by 100
min1 ).
1650 min-1
1500 min-1
-1
Engine Control Dial: Set at 1500 min or faster.

Boom Raise and/or Arm Roll-In Control: In
Operation
Average Delivery Pressure of Pumps 1 and 2:
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
Minimum
Speed
Maximum
Speed
Engine
Control Dial
Position
ANIMATION
Pressure Sensor
Boom Raise
Arm Roll-In
Pump 2
Delivery
Pressure
Sensor
Pump 1
Delivery
Pressure
Sensor
Engine
Control Dial
EC Motor
Power Mode Switch

HP Mode
T178-02-01-005
T2-1-7
ANIMATION

E Mode Control
Function: Reduce the engine speed by the constant
specified ratio.
Engine
Speed
Engine speed is
reduced at the
constant
specified ratio.
Operation: The MC drives the EC motor to reduce the

engine speed set by the engine control dial
when the power mode switch is in the E
mode position. The engine speed is
reduced in proportion to the rotation angle
of the engine control dial.
Minimum Speed
Maximum Speed
Engine
Control Dial
Position
Engine
Control 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 control
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
motor so that the engine speed is reduced
to the auto-idle speed. As soon as a control
lever is operated (the travel and/or front
attachment pressure sensor is turned ON),
the MC drives the EC motor so that the
engine speed is increased to the original
engine speed (set by the engine control
dial).
Auto-Idle System Deactivation Requirements:
Control Levers: Being operated (either travel or
front attachment control levers with pilot sensor
ON)
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
Engine
Speed
Engine speed is
reduced to the
auto-idle speed
3.5 seconds later.
Minimum
Speed
Auto-Idle
Speed
Maximum
Speed
Engine
Control Dial
Position
ANIMATION
Pressure Sensor
Travel
Front Attachment
Engine
Control Dial
Auto-Idle/
Acceleration
Selector
Auto-Idle
EC Motor
Power Mode Switch
E Mode
T178-02-01-007
T2-1-11

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

Engine
Speed
Engine speed is
automatically
controlled in
response to the
control lever
operations.
Engine speed is reduced

to the auto-idle speed 3.5
seconds later.
Engine speed is reduced
from the maximum speed by
400 min-1 .
Minimum
Speed
Auto-Idle
Speed
Maximum
Speed
Engine
Control Dial
Position
Operating Time Progress VS. Engine Speed Change

Control Lever Stroke
Full Stroke
NOTE: When all control levers are returned to

neutral, the engine speed is reduced by
-1
400 min from the maximum speed. In
case the engine speed is set by the engine
control dial and is running at a speed
slower than the maximum speed by 100
-1
min , the engine speed will be reduced by
-1
300 min .
Neutral
Position
Time
Engine Speed
Max. Engine
Speed (P Mode)
In response to the control

lever stroke and the pump
delivery pressure, the
optimum engine speed is
selected.
Auto
Acceleration
Control
Auto-Idle
Engine Speed
Time
T2-1-12
ANIMATION
Pressure Sensor
Travel
Swing
Boom Raise
Arm Roll-In
Pump 2
Delivery
Pressure
Sensor
Pump 1
Delivery
Pressure
Sensor
Engine
Control Dial
Auto-Idle/
Acceleration
Selector
AutoAcceleration
EC Motor
Pump 2 Control
Pressure
Sensor
Pump 1 Control
Pressure
Sensor
T178-02-01-008
T2-1-13
ANIMATION

Engine
Speed
Function: Automatically warms up the hydraulic

system (similar to the auto choke on
automobiles).
Operation: When the hydraulic oil temperature is

below 0 C (32 F), the MC drives the EC
motor in response to signals from the key
switch and the hydraulic oil temperature
sensor to run the engine at the auto warm
up speed for 15 minutes after starting the
engine.
IMPORTANT: When adjusting the auto-idle speed
deactivate the auto warming up
control function using Dr. EX, or wait
to adjust until 15 minutes after
starting the engine.
Increasing
Speed
Minimum
Maximum
Speed
Speed
Auto
Warm Up
Speed
Engine
Control Dial
Position
Key Switch
Engine
Control Dial
EC Motor
Hydraulic Oil
Temperature
Sensor
T178-02-01-009
T2-1-14
ANIMATION

Function: Prevents the engine from hunting when
running the engine at slow speed.
Operation: When the travel or front attachment
function is operated while the engine is
running at a speed between the minimum
speed and the Idle Speed-Up Speed, the
MC drives the EC motor so that the engine
speed is increased to the Idle Speed-Up
Speed.
Engine
Speed
Increasing
Speed
Minimum
Speed
Maximum
Speed
Idle Speed-Up
Speed
Engine
Control Dial
Position
Pressure Sensor
Travel
Front Attachment
Engine
Control Dial
EC Motor
T178-02-01-010
T2-1-15
ANIMATION

Engine Speed Automatic Increase Control at
Travel (Only ZAXIS270)
Function: Increases the engine speed at travel single
operation to increase the travel speed.
Operation: MC drives EC motor to increase the engine
speed by 100 min1 (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
increases.
Condition: Engine Control Dial: The speed is set to
maximum.
Travel Operation: Operated
Front Attachment Operation: Not operated
Pressure Sensor
Travel
Front
Attachment
Engine
Control Dial
EC Motor
T1HG-02-01-001
T2-1-16

(Blank)
T2-1-17

(Only on the machines equipped with the
auxiliary mode switch (Optional).)
When all
conditions exist,
the maximum
engine speed is
increased to the
speed set by Dr.
EX.
Engine
Speed
Function: Increases the maximum engine speed to

the
attachment
(hydraulic
breaker,
secondary crusher, primary crusher or
vibrating hammer) operating engine speed
set by Dr. EX when the attachment is
operated.
Operation: When the following conditions exist, the MC
drives the EC motor so that the engine
maximum speed is increased to the
attachment operating speed set by Dr. EX
when the attachment is operated.
Operating Conditions:
Dr. EX: 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
Power Mode Switch: HP Mode
Auxiliary: In Operation
Work Mode Switch: Attachment Mode
Auxiliary Mode Switch (Optional): Attachment position
(hydraulic breaker, secondary crusher, primary crusher,
or vibrating hammer) reset by Dr. EX.
NOTE: When the P mode engine speed is preset to
a slower speed in the Dr. EX service mode,
the maximum engine speed wont be
increased when operating the attachment.
T2-1-18
Minimum
Speed
Maximum
Speed
Engine
Control Dial
Position
ANIMATION
Pressure Sensor
Auxiliary(Optional)
Engine
Control Dial
EC Motor
Power Mode Switch

HP Mode
Work Mode
Switch
Auxiliary Mode
Switch
(Optional)
Attachment
Mode
T2-1-19
T178-02-01-011
ANIMATION

Attachment Operation Speed Limit Control (Only
on the machines equipped with the auxiliary
mode switch (Optional).)
Function: Decreases the maximum engine speed to
the
attachment
(hydraulic
breaker,
secondary crusher, primary crusher or
vibrating hammer) operating engine speed
set by Dr. EX when the attachment mode is
selected.
Engine
Speed
When all
conditions exist,
the maximum
engine speed is
reduced to the
speed set by Dr.
EX.
Operation: When the following conditions exists, the

MC drives the EC motor so that the engine
maximum speed is reduced to the
attachment operating speed set by Dr. EX
when the attachment mode is selected.
Minimum
Speed
Maximum
Speed
Engine
Control Dial
Position
Dr. EX: 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. EX.
EC Motor
Work Mode
Switch
Auxiliary Mode
Switch
(Optional)
Attachment
Mode
T2-1-20
T178-02-01-012

Function: Inputs the governor lever stopper positions
on both the STOP and FULL sides as the
standard data to control the engine.
Operation:When the learning switch in the rear
console is turned to the engine learning
position, the EC motor is driven by the
signals from the MC. The EC motor moves
the governor lever from the IDLE to FULL
and to STOP positions in this order. The EC
sensor detects the stopper positions of the
governor lever on both the FULL and STOP
sides and sends each stopper position
signal to the MC. The MC stores these
signals in its memory.
IMPORTANT: Be sure to perform the engine

learning if the following repair work
is
done.
(Refer
to
the
Troubleshooting Section in T/M.)
After performing the engine learning,
check that the engine learning has
been performed correctly using Dr.
EX.
After the engine, engine control
cable, or EC motor has been
removed or replaced.
After the MC has been replaced.
NOTE: The engine learning is not required when
the batteries are replaced.
Learning Switch
Key Switch
EC Sensor
EC Motor
T178-02-01-014
T2-1-21

(Blank)
T2-1-22

PUMP CONTROL
The pump control system has the following functions:

Pump 3 Flow Torque Decrease Control

Pump Control System Layout

Pressure Sensor
Travel
N Sensor
Pump 2
Delivery
Pressure
Sensor
Engine
Control Dial
Pump 1
Delivery
Pressure
Sensor
Pump 3
Delivery
Pressure
Sensor
(Optional)
Auxiliary(Optional)
Torque Control Solenoid Valve

Max. Pump 2 Flow Rate
Limit Solenoid Valve
Max. Pump 1 Flow Rate Limit

Solenoid Valve (Optional)
T178-02-01-002
T2-1-23

Function: Controls the pump flow rate in response to
engine speed changes due to variations in
load so that the engine output can be utilized
more efficiently. (Engine stall is prevented
when the machine operates under adverse
conditions such as operating at high
altitude.)
Q
Operation:
1. The target engine operating speed is set by
controlling the engine control dial.
2. The MC calculates the difference in speed
between the target operating speed and the actual
operating speed monitored by the N sensor. Then,
the MC sends signals to the torque control
solenoid 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 engine
operating speed becomes slower than the 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.
Flow Rate
T2-1-24
Pump P-Q Curve
Pressure
ANIMATION
N Sensor
Engine
Control Dial
T178-02-01-015
T2-1-25

Function: Allows the machine to travel at the maximum

pump flow rate when the engine is running at
slow speed. When travel operation is made
with the engine running at slow 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
between pump 1 and pump 2 flow rate, the
machine
will
mistrack.
To
prevent
mistracking, 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 point B (maximum flow
rate).
Flow Rate
Increased Torque
P-Q Curve
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 delivery
pressure sensors and sends control signals to the
torque control solenoid valve.
2. The torque control solenoid valve delivers the pilot
pressure oil corresponding to the signals received
from the MC to the regulator, increasing the pump
flow rate.
NOTE: If the MC stops the slow speed torque
increase 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
increase control even if the front
attachment is simultaneously operated
while traveling.
T2-1-26
Normal P-Q Curve
Pressure
ANIMATION

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

Pump 1 Flow Rate Limit Control (Only on the
machines with the auxiliary sensor (Optional).)
Pump 2 Flow Rate Limit Control (Only on the

machines with the auxiliary sensor (Optional).)
Function: Limits the maximum pump 1 flow rate when

a front attachment (mainly a vibrating
hammer) is used.
Function: Limits the maximum pump 2 flow rate when

a front attachment (mainly a hydraulic
breaker) is used.
Operation:
1. When a front attachment is used, the MC receives
signals from the pressure sensor (auxiliary).
2. In response to the signals arriving from the
pressure sensor, the MC drives the maximum
pump 1 flow rate limit solenoid valve (optional) to
reduce the maximum pump flow rate.
Operation:
1. When a front attachment is used, the MC receives
signals from the pressure sensor (auxiliary).
2. In response to the signals arriving from the
pressure sensor, the MC drives the maximum
pump 2 flow rate limit solenoid valve (optional) to
reduce the maximum pump flow rate.
NOTE: In proportion to the attachment control

pedal stroke, the maximum pump flow rated
is reduced. The minimum pump swash setangle for a front attachment (hydraulic
breaker, secondary crusher, primary
crusher or vibrating hammer) can be set in
the service mode of Dr. EX.
NOTE: In proportion to the attachment control pedal

stroke, the maximum pump flow rated is
reduced. The minimum pump swash setangle for a front attachment (hydraulic
breaker, secondary crusher, primary
crusher or vibrating hammer) can be set in
the service mode of Dr. EX.
Q
Flow Rate
Maximum flow rate is reduced.
Pump P-Q Curve
Pressure
T2-1-28
ANIMATION

Pressure Sensor
Auxiliary(Optional)
Maximum Pump 2 Flow

Rate Limit Solenoid
Valve(Optional)
Maximum Pump 1 Flow Rate
Limit Solenoid Valve
T178-02-01-017
T2-1-29
ANIMATION

Pump 3 Torque Decrease Control (Only on the
machines equipped with pump 3 (Optional).)
Function: Reduces pump 1 and pump 2 driving
torque to prevent the engine from stalling,
utilizing the engine output efficiently when
the pump 3 driving torque increases.
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.
Flow
Rate
P-Q curve is controlled in

proportion to pump 3 delivery
pressure.
Normal P-Q Curve
Pressure
Pump 3
Delivery
Pressure
Sensor
T178-02-01-018
T2-1-30

(Blank)
T2-1-31

VALVE CONTROL
The valve control system functions as follows:


T2-1-32
ANIMATION

Valve Control System Layout
Pressure Sensor
Learning
Switch
Swing
Boom Raise
Arm Roll-In
Auxiliary(Optional)
Key Switch
Pump 2
Delivery
Pressure
Sensor
Pump 1
Delivery
Pressure
Sensor
Engine
Control Dial
Power
Digging
Switch
Hydraulic Oil
Temperature Sensor
Fast
Pump 2 Control
Pressure Sensor
Slow
Travel Mode Switch
Pump 1 Control
Pressure Sensor
Solenoid Valve Unit
SG
SC
SE
SI
Main Relief Valve
Auxiliary Flow
Rate Control
Solenoid Valve
(Optional)
Auxiliary Flow Rate

Control Valve
Travel Motor
Swash Angle
Control Valve
Arm Regenerative
Valve
T2-1-33

Valve
T178-02-01-003

Function: Increases digging force by temporarily
increasing relief pressure.
Operation: For maximum 8 seconds after the power
digging switch is turned ON, the MC
continuously activates solenoid valve
unit(SG). Solenoid valve unit (SG) delivers
the pilot oil pressure to the relief valve,
increasing the relief set-pressure. (Refer to
the COMPONENT OPERATION / Control
Valve group.)
T2-1-34
ANIMATION
Power
Digging
Switch
Main Relief Valve
Solenoid Valve Unit

SG
T178-02-01-019
T2-1-35

Function: Increases oil pressure when raising the
boom.
Operation: The MC activates solenoid valve unit (SG)
when signals from pressure sensor (boom
raise) and pump 1 delivery pressure sensor
meet the following conditions. Solenoid
valve (SG) delivers the pilot pressure oil to
the relief valve, increasing the relief setpressure. (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
control lever is in neutral.)
NOTE: This control system is activated during
combined operations (except for the arm
roll-in combined operation).
T2-1-36
ANIMATION

Pressure Sensor
Boom Raise
Arm Roll-In
Pump 1 Delivery
Pressure Sensor
Main Relief Valve

Solenoid Valve Unit
SG
T178-02-01-020
T2-1-37

Function: Gives pressure oil from pump 2 priority to
flow to the swing motor spool over the arm
1 spool to ensure swing power.
Operation: The MC activates solenoid valve unit (SE)
when signals from the pump 2 delivery
pressure sensor and pressure sensors
(swing and arm roll-in) meet the following
conditions. Solenoid valve unit (SE)
delivers the pilot pressure oil to the arm
flow rate control so that the parallel oil
passage to the arm 1 spool is restricted.
Thereby, the swing spool has priority,
ensuring swing motor power, preventing the
upperstructure from being rotated by the
arm reaction force when the arm is rolled in.
(Refer
to
the
COMPONENT
OPERATION/Control Valve group.)
Pump 2 Delivery Pressure Sensor: High pressure.
Swing Pressure Sensor: Must have some output. (The
swing control lever is stroked to a certain extent.)
Arm Pressure Sensor: Outputting signals.
T2-1-38
ANIMATION

Pressure Sensor
Swing
Arm Roll-In
Pump 2
Delivery
Pressure
Sensor
Solenoid Valve Unit
SE
Arm Flow Rate Control Valve
T2-1-39
T178-02-01-021

Function: Accelerates the arm roll-in speed to prevent
arm hesitation during arm roll-in operation.
Operation: The MC activates the solenoid valve unit
(SC) so that solenoid valve delivers the
pilot pressure oil to shift the arm
regenerative valve when signals from the
pump 2 delivery pressure sensor, swing
pressure sensor, arm roll-in pressure
sensor, and boom raise pressure sensor
meet the following conditions. When the
arm regenerative valve is shifted, the return
circuit from the arm cylinder rod side to the
hydraulic oil tank is closed. Then, the return
oil from the cylinder rod side is combined
with the pressure oil from the pump and is
routed to the cylinder bottom, accelerating
the arm roll-in speed and preventing arm
hesitation. (Refer to the COMPONENT
OPERATION / Control Valve group.)
Pump 2 Delivery Pressure Sensor: Low pressure. (The
arm doesnt need much power.)
Arm Roll-In Pressure Sensor: High output. (The arm
control lever stroke is large.)
Swing or Boom raise Sensor: Outputting signal.
NOTE: To improve arm leveling performance, the
MC gradually activates solenoid valve unit
(SC) when the hydraulic oil temperature is
at 0 to 10 C (32 to 50 F).
T2-1-40
ANIMATION

Pressure Sensor
Swing
Boom Raise
Arm Roll-In
Pump 2
Delivery
Pressure
Sensor
Hydraulic Oil
Temperature Sensor
Solenoid Valve Unit

SC
Arm Regenerative Valve
T2-1-41
T178-02-01-022

Function: Controls the travel mode.
Operation: When the travel mode switch is in the
SLOW position, the travel motor swash
angle is kept in the maximum angle so that
the travel speed is slow.
When the MC receives the signals from the
travel pressure sensor, pump 1 and 2
delivery pressure sensors, pump 1 and 2
control pressure sensors under the
following conditions with the travel mode
switch in the FAST position, the MC
activates the solenoid valve unit (SI). Then,
the solenoid valve (SI) delivers the pilot
pressure oil to the travel motor swash angle
control valve, reducing the swash angle to
the minimum so that the travel speed
increases.
ZAXIS200,225USR,225US,230
Travel Pressure Sensor: ON
Front Attachment Pressure Sensor: OFF
Pump 1 and 2 Delivery Pressure Sensor: Either pump
delivery pressures are low.
Pump 1 and 2 Control Pressure Sensor: Either pump
control pressures are high.
NOTE: When one side track is raise off the ground
using the front attachment and is rotated,
the one side pump control pressure
increases, allowing the raised track to
rotate at fast speed.
When the machine is traveling in the fast
mode, even if the front attachment is
operated (the front attachment pressure
sensor is turned ON), the travel mode is
kept unchanged in the fast mode.
ZAXIS270
Travel Pressure Sensor: ON
Front Attachment Pressure Sensor: OFF
Pump 1 and 2 Delivery Pressure sensor: Both of pump
1 and 2 delivery pressure are low.
Pump 1 and 2 Control Pressure Sensor: Both of pump
1 and 2 control pressures are high.
NOTE: When one side track is raise off the ground
using the front attachment and is rotated,
the one side pump displacement target
angle remains small so that the travel motor
speed does not increase.
T2-1-42
ANIMATION

Pressure Sensor
Travel
Pump 2
Delivery
Pressure
Sensor
Pump 1
Delivery
Pressure
Sensor
Travel Mode Switch

Fast
Mode
Pump 2 Control
Pressure Sensor
Pump 1 Control
Pressure Sensor
Solenoid Valve Unit
SI
Travel Motor
Swash Angle Control Valve

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

Auxiliary Flow Rate Control (Only on the
machines equipped with the auxiliary pressure
sensor and auxiliary flow rate control solenoid
valve)
Function: Restricts the oil flow to the auxiliary spool
when the combined operation of the swing,
boom raise, and arm roll-in is made while
operating a front attachment using the
auxiliary spool to maintain controllability of
the combined operation.
Operation: The MC activates the auxiliary flow rate
control solenoid valve (optional) so that the
oil flow to the auxiliary spool is restricted
under the following conditions.
Auxiliary Pressure Sensor: ON
Swing, Boom Raise, Arm Roll-In Pressure Sensors:
ON
T2-1-44
ANIMATION

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

OTHER CONTROLS
Boom Electronic Cushion Control (ZAXIS225US)
Function: Reduces the shock which may occur when
the boom reaches to its full stroke position
at boom raise operation by functioning the
electronic cushion in the speed reduction
area.
Operation:The signal from the boom angle sensor
comes into MC at boom raise operation.
MC calculates the boom angle by this
signal. When the boom angle reaches to
the speed reduction area, MC controls the
boom electronic cushion solenoid valve to
decrease the boom raise pilot pressure.
Speed Reduction Area
Position where speed

reduction begins
Boom Full Stroke Position
T1GF-02-01-001
T2-1-46
ANIMATION
Boom Angle Sensor
Boom Raise
Boom Electronic
Cushion Solenoid
Valve
Signal Control Valve
1
Control Valve
Boom 2
1
Boom 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
optional kit is operated. The engine speed (see
T2-1-18 and 20) and pump flow rate (see T2-128) are controlled so as to match the installed
front attachment operation in response to the
movement of the auxiliary valve spool. The engine
speed and pump flow rate control settings are
made by using Dr. EX.
T2-1-48
ANIMATION

Travel Alarm Control (Only on the machines
equipped with the travel alarm device)
Function: Sounds the buzzer while traveling.
Operation: As long as the MC receives signals from
the travel pressure sensor when travel
operation is made, the MC sends out
signals to the travel alarm device to sound
the buzzer.
NOTE: After traveling continuously for more than
13 seconds, the buzzer can be stopped
with the buzzer deactivation switch.
Pressure Switch
Travel
Travel Alarm
Device (Optional)
Buzzer Deactivation
Switch (Optional)
Buzzer
(Optional)
T178-02-01-025
T2-1-49

(Blank)
T2-1-50
SYSTEM / Hydraulic System

OUTLINE
The hydraulic system is broadly divided into two circuits, the main circuit and the pilot circuit.
Main Circuit:
Power Source
Main Pumps
Controller
Actuator
Control Valves
Motors
Cylinders
Front Attachmens (Optional)
Pilot Circuit:
Power Source
Pilot Pumps
Controller
Pilot Circuit
Pilot Valves
Operation Control Circuit
Pump Regulator
Pump Control Circuit
Solenoid Valve Unit
Valve Control Circuit
Swing Parking Brake Release Circuit
Boom Electronic Cushion
Travel Motor Swash Angle Control Circuit
Solenoid Valve
Hydraulic Oil Heat Circuit
(Only ZAXIS225US)
T2-2-1

PILOT CIRCUIT
Outline:
Pressure oil from the pilot pump is used to operate the operation control circuit, pump control circuit, valve control circuit, swing parking brake release circuit, travel motor swash angle control circuit, and hydraulic oil heat circuit.
T2-2-2
ANIMATION

Travel Pilot
Valve
Left Pilot
Valve
Swing Parking Brake

Release Circuit
Right Pilot
Valve
Auxiliary Pilot
Valve
Boom Electronic Cushion

Solenoid Valve
Swing Motor
Pump
Control Circuit
Maximum Pump 2
Flow Rate Control
Solenoid Valve
Pilot ShutOff Valve
Hydraulic Oil
Heat Circuit
Torque
Control Solenoid Valve
Maximum Pump 1 Flow

Rate Control Solenoid
Valve (Optional)
To Control Valve
Spools
Auxiliary Flow Combining
Solenoid Valve (When the
auxiliary spool is used.)
Flow
Combiner
Valve
Bucket Flow
Rate Control
Valve
Regulator
Boom Anti-Drift Valve

Solenoid Valve (When the
auxiliary spool is used.)
Arm Anti-Drift Valve

Auxiliary Flow Combiner Valve
Bypass Cut Valve
Auxiliary Flow Control Valve
Valve
Control
Circuit
Main Relief Valve
Arm Regenerative Valve
Arm Flow Rate Control Valve
VC Solenoid
Valve Unit
Travel Motor
Hydraulic
Oil Tank
Control Valve
Suction
Filter
Travel Motor Swash

Angle Control Circuit
Travel Motor
NOTE: *Boom Electronic Cushion Solenoid Valve

is ZAXIS225US Only.
T2-2-3
Relief Valve
Pilot Filter
Pilot Pump

The pilot valves control the pressure oil from the
pilot pump to operate the control valve spools.
The signal control valve is provided between the
pilot valves and the control valve. The shockless
valve (in the boom lower circuit) built in the signal
control valve dampens quick spool movement in
the control valve. (Refer to the COMPONENT
OPERATION / Signal Control Valve group.)
ZAXIS225US:
The boom electronic cushion solenoid valve is

provided between the pilot valve (right) and the
signal control valve on ZAXIS225US.
This valve reduces the shock which may occur
when the boom reaches to its full stroke position.
(Refer to SYSTEM / Control System group.)
Pilot Valve (Right)
Boom Electronic
Cushion Solenoid
Valve
T2-2-4
T1GF-02-02-001

ZAXIS200,225USR,230,270
Travel Pilot Valve
Pilot Valve (Left)
Pilot Valve (Right)
Shockless Valve
9 10 11 12
4
3
10
12
7 6
11
Control Valve
Pilot
Pump
T178-02-02-005
1 - Boom Raise
2 - Boom Lower
3 - Arm Roll-Out
4 - Arm Roll-In
5 - Left Swing
6 - Right Swing
7 - Bucket Roll-In
8 - Bucket Roll-Out
9 - Left Travel Forward
T2-2-5
10 - Left Travel Reverse

11 - Right Travel Forward
12 - Right Travel Reverse

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 either the
pump 1 flow rate control valve or the pump 2 flow
rate control valve in the same signal control valve,
shifting either of the flow rate control valves.
When either the pump 1 flow rate control valve or
the pump 2 flow rate control valve is shifted, the
pilot pressure oil from the pilot pump is routed to
either main pump 1 or main pump 2 as flow rate
control pressure Pi.
NOTE: When the boom (raise/lower), arm (rollin/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 (rollin/out), swing (right/left), and/or travel (left)
function is operated, flow rate control pressure Pi is routed to main pump 2.
Torque Control (Speed Sensing) by Torque Control

Solenoid Valve
After the pilot oil pressure from the pilot pump is
regulated by the torque control solenoid valve, the
regulated pilot oil pressure is routed to main pump
1 and 2 as speed sensing pressure Ppc.
T2-2-6
ANIMATION
Travel (Left)
Swing
Travel (Right)
Arm
Boom
Bucket
Signal
control
Valve
Pump 1 Flow Rate

Control Valve
Pump 2 Flow Rate
Control Valve
Control Valve
Torque
Control
Solenoid
Valve
Pilot Pump
Pump 2
Pump 1
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, and the bucket flow rate control
valve control spool.
Boom Lower Pilot Pressure: Boom Anti-Drift Valve
Arm Roll-In Pilot Pressure: Arm Anti-Drift Valve
Auxiliary Pilot Pressure: Auxiliary Flow Combiner

Valve, Bypass Shut-Out Valve (When the auxiliary
spool is used.)
Solenoid Valve SC: Arm Regenerative Valve
Solenoid Valve SE: Arm Flow Rate Control Valve
Solenoid Valve SG: Main Relief Valve (increasing

the set-pressure)
Auxiliary Flow Rate Control Solenoid Valve: Auxiliary Flow Rate Control Valve (When the auxiliary
spool is used.)
Auxiliary Flow Combining Solenoid Valve: Boom,

Arm, and Bucket Pilot Pressure
Flow Combiner Valve Control Spool: Flow Combiner Valve
Bucket Flow Rate Control Valve Control Spool:

Bucket Flow Rate Control Valve
T2-2-8
Travel (Right)
Arm Roll-In
Boom Lower
Auxiliary
Signal
Control
Valve
4
2
Main Relief Valve
Auxiliary Flow
Rate Control
Valve
Auxiliary Flow
Combining
Solenoid Valve
Flow Combiner Valve

Control Spool
Bucket Flow Rate
Control Valve Control
Spool
Auxiliary Flow Combiner
Valve
Flow Combiner Valve
Auxiliary Flow
Rate Control
Solenoid Valve
Bucket Flow Rate

Control Valve
Arm Anti-Drift
Valve
Solenoid
Valve Unit
Boom Anti-Drift Valve
4
SG
SC
SE
Bypass Shut-Out
Valve
Pilot Pump
Arm
Regenerative
Valve
Arm Flow Rate

Control Valve
T178-02-02-007
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 Device
group.)
The pilot oil pressure from solenoid valve SI regulates the travel motor swash angle control valve.
Hydraulic Oil Heat Circuit (Refer to the COMPONENTS 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.
T2-2-10
Swing
Arm
Boom
Bucket
Orifice
Signal
Control
Valve
Swing Parking Brake

Release Spool
Solenoid
Valve Unit
Swing Motor
Control Valve
SI
Travel Motor
T178-02-02-008
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
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
ANIMATION
Travel Motor (Left)
Travel Motor (Right)

Bucket Cylinder
Front Attachment (s)
Control Valve
Boom Cylinder
4-Spool
Side
Arm Cylinder
Travel (Left)
Travel (Right)
Auxiliary
Bucket
Boom 2
Boom 1
Arm 1
Arm 2
Swing
5-Spool Side
Bypass Check
Valve
Swing Motor
Oil
Cooler
Main
Pump 2
Main
Pump 1
Suction
Filter
T2-2-13
Hydraulic
Oil Tank

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 4spool 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 5spool control valve and is further routed to each
spool of the swing, arm 1, boom 2, and travel
(left).
The boom and arm are actuated by pressure oil
from two main pumps. Pressure oil from each
main pump is combined and supplied together.
T2-2-14
ANIMATION
Travel Motor (Left)
Control Valve
Travel
(Left)
Front Attachment
Travel
(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 combined with pressure oil from pump 1, flows into the
boom cylinders, raising the boom together with
pressure oil from pump 1.
T2-2-16
ANIMATION
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 spoolis 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 cylinder 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.
T2-2-18
ANIMATION
Pilot Pressure
Oil from Flow
Combiner Valve
Control Spool in
Signal Control
Valve
Travel Motor (Left)
Left
Travel
Right
Travel
Arm Cylinder
Arm 1
5-Spool Side
Pump 2
4-Spool Side
Pump 1
T178-02-02-003
T2-2-19

Auxiliary Circuit
When a front attachment such as a hydraulic
breaker is operated, the pilot pressure oil from the
hydraulic breaker pilot valve shifts the auxiliary
flow combiner valve and bypass shut-out valve.
Therefore, the neutral circuit in the 4-spool control
valve is blocked so that pressure oil from pump1
is routed to the auxiliary spool via the auxiliary
flow combiner valve.
T2-2-20
NOTE: During boom (raise or lower), arm (roll-in or

rollout), bucket (roll-in or rollout), and/or
right travel operation, pilot pressure oil is
routed to port SN from the signal pilot pressure control valve so that the aux. flow
combiner valve is not shifted. (Refer to the
SYSTEM / Control System group.)
ANIMATION

Pilot Oil Pressure
from Hydraulic
Breaker Pilot Valve
Auxiliary Flow Combining Solenoid Valve
Auxiliary Flow
Combiner Valve
Pilot Pressure from

SN
SM
Front
Attachment
Neutral
Circuit
Auxiliary
Bypass
Cut Valve
Pump 2
Pump 1
T178-02-02-004
T2-2-21

(Blank)
T2-2-22
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
to all electrical systems on this machine. [Key
Switch, Batteries, Fuses (Fuse Boxes, Fusible
Links), Battery Relay]
Indicator Light Check Circuit
Checks all indicator bulbs for burning.
Accessory Circuit
Becomes operative when the key switch is turned
to the ACC position.
Preheat Circuit
Assists the engine to start in cold weather. [Key
Switch, QOS Controller, Coolant Switch, Glow
Plug Relay, Glow Plugs]
Starting Circuit
Starts the engine. [Key Switch, Starter, Starter
Relay]
Charging Circuit
Charges the batteries. [Alternator, Regulator]
Serge Voltage Prevention Circuit
Prevents the occurrence of serge voltage
developed when stopping the engine. [Load
Damp Relay]
Engine Stop Circuit
Stops the engine using the EC motor. [MC, EC
Motor]
T2-3-2
ANIMATION

ELECTRIC
POWER
SWITCH: OFF)
CIRCUIT
(KEY
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
Fusible Link
Glow Plug Relay

Power
Terminal #1: Radio (Backup Power)

Monitor (Backup Power)
Key Switch (B)

Load Damp Relay
Fuse Box
ICX Controller (Backup Power)

Terminal #2: MC (Power)
Terminal #3: MC (EC Motor Power)
Terminal #10: Optional
Key Switch
Battery
Load
Damp
Relay
Glow
Plug
Relay
Radio, Monitor,
ICX Controller
Optional
MC
MC
T178-02-03-001
T2-3-3
ANIMATION

INDICATOR LIGHT CHECK CIRCUIT (KEY
SWITCH: ON)
When the key switch is turned ON, terminal B is
connected to terminals ACC and M in the key
switch.
Current from key switch terminal M excites the
battery relay.
Therefore, the battery current enters the monitor
controller via the battery relay and fuse #6 and
checks the indicator bulbs.
Key Switch
Battery
Battery
Relay
Fuse
Box
Monitor
Controller
T178-02-03-002
T2-3-4
ANIMATION

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
START position, terminal B is connected to
terminal M in the key switch. Current from
terminal M is routed to QOS controller terminal #1
through fuse #19.
When the key switch is ON or in the START
position with the coolant switch OFF (when the
coolant temperature is 10 C (50 F) or below),
QOS controller terminal #4 is connected to
terminal #5 (ground).
Accordingly, the glow plug relay is turned ON,
routing current to the glow plugs so that
preheating begins.
When preheating begins, QOS controller terminal
#6 is connected to terminal #5 for 8 seconds,
turning the preheat indicator ON. (When
preheating is not performed, the preheat indicator
comes ON for 2 seconds for indicator light check.)
T2-3-6
NOTE: After preheating has been performed,

heating will continue for approx. 30
seconds after the engine starts.
ANIMATION
Monitor
Coolant Temperature Switch
Preheat Indicator
QOS
Controller
Key Switch
Fuse
Box
Glow
Plug
Relay
Glow Plug
T178-02-03-004
T2-3-7
ANIMATION

STARTING
START)
CIRCUIT
(KEY
SWITCH:
When the key switch is turned to the START

position, terminal B is connected to terminals M
and ST in the key switch.
Starter Relay Operation

When the key switch is turned to the START
position, key switch terminal B is connected to
terminal ST so that current is routed to the base in
transistor (Q2) through resistance R4 in the
starter relay. Then, transistor (Q2) is turned ON,
allowing current to flow to coil (L) in the starter
relay. Therefore, starter terminal B is connected to
terminal C, rotating the starter.
As current from terminal M excites the battery

relay, battery current is routed to starter terminal B
and starter relay terminal B via the battery relay.
Key switch terminal ST is connected to starter
relay terminal S so that current flows through the
starter relay coil.
After the engine starts, the alternator starts

generating electricity, increasing voltage at starter
relay terminal R.
Then, the starter relay is turned ON, allowing

current to flow from starter relay terminal C to
starter terminal C.
When this voltage increases up to 21 to 22 V,

Zener diode (Z) is turned ON so that transistor
(Q1) is turned ON. Then, current to the base of
transistor (Q2) is not routed, turning transistor
(Q2) OFF. At this moment, starter terminal B is
disconnected from terminal C, stopping the
starter.
Consequently, the relay in the starter is turned ON

so that the starter begins rotating.
On the other hand, current from key switch
terminal M flows to the MC via fuse #6 as a signal
indicating that the key switch is in the ON or
START position.
Condenser C1 is used to stabilize the operating

voltage and diode D4 protects the circuit in case the
battery terminals are reversely connected.
As soon as the MC receives this signal, the MC

drives the EC motor, moving the governor lever to
the engine start position.
Starter Relay
To Alternator
Terminal L
Starter
Key Switch
Battery
T107-04-04-003
T2-3-8
ANIMATION
Key Switch
Battery
Battery
Relay
Fuse
Box
Starter
C
C
Starter Relay
EC Motor
MC
T178-02-03-005
T2-3-9
ANIMATION

CHARGING CIRCUIT (KEY SWITCH: ON)
After the engine starts and the key switch is
released, the key switch moves to the ON
position.
Then, key switch terminal B is connected to
terminals ACC and M in the key switch.
When the alternator starts generating electricity,
current flows from alternator terminal B to the
batteries via the battery relay, charging the
batteries.
Current from alternator terminal L flows to the
monitor controller and the ICX controller, turning
the alternator indicator OFF.
Key Switch
Battery
Monitor
Controller
ICX
Controller
Battery
Relay
Alternator
T178-02-03-006
T2-3-10

(Blank)
T2-3-11
ANIMATION

Alternator Operation
The alternator consists of field coil FC, stator coil
SC, and diodes D. The regulator consists of
transistors (T1 and T2), Zener diode ZD, and
resistances (R1 and R2).
At the beginning, no current is flowing through

field coil FC. When the rotor starts turning,
alternate current is generated in stator coil SC by
the rotor remanent magnetism.
When current starts to flow through field coil FC,
the rotor is further magnetized so that the
generating voltage increases. Thereby, current
flowing through field coil FC increases and
generating voltage is increased further, to charge
the batteries.
Alternator terminal B is connected to base B of

transistor T1 through the circuit [B R RF
( R ) (R1)].
When battery relay BS is ON, the battery voltage
is applied to base B of transistor T1 so that
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
ANIMATION

Regulator Operation
When generating voltage increases more than the
set-voltage of Zener diode ZD, current is routed to
base B of transistor T2, connecting collector C to
emitter E.
When generating voltage decreases lower than

the set-voltage of Zener diode ZD, transistor T2 is
turned OFF, causing transistor T1 to turn ON
again.
Then, current flows through field coil FC,
increasing generating voltage at the stator coil.
The above operation is repeated so that the
alternator generating voltage is kept constant.
Then, current which was routed to base B of

transistor disappears, turning transistor T1 OFF.
Therefore, no current flows through filed coil FC,
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),
current from key switch terminal M is
disconnected, turning the battery relay OFF.
The engine continues to rotate due to inertia force
just after the key switch is turned OFF so that the
alternator continues to generate electricity.
As the generating current cannot flow to the
battery, surge voltage arises in the circuit, possibly
causing failures of the electronic components,
such as the controller. To prevent the occurrence
of surge voltage, the surge voltage prevention
circuit is provided.
T2-3-14
When the alternator is generating electricity,

generating current from alternator terminal L flows
to monitor controller terminal #A-2 so that the
monitor controller connects terminal #C-3 to
ground.
Then, current flows through the load damp relay
exciting circuit, turning the load damp relay ON.
Accordingly, even if the key switch is turned OFF
while the engine is rotating, the battery current
continues to excite the battery relay via the load
damp relay until the alternator stops generating.
Therefore, the battery relay is kept ON, allowing
the generating current to flow to the batteries.
ANIMATION
Key Switch
Battery
Battery
Relay
Load
Damp
Relay
Alternator
Monitor Controller
T178-02-03-007
T2-3-15
ANIMATION

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

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SECTION 2

Group 2 Hydraulic System

Group 3 Electrical System

SYSTEM / Control System

After processing the received signals in the logic circuit,

Engine Control (EC Motor)

Attachment Operation Speed Increase Control

Attachment Operation Speed Limit Control

Pressure Switch (Travel)

Pressure Switch (Front Attachment)

Pressure Switch (Boom Raise)

Pressure Switch (Arm Roll-In)

Pressure Switch (Auxiliary)

Pressure Switch (Arm Roll-Out)

Hydraulic Oil Temperature Sensor

Power Digging Switch

Power Mode Switch (HP/E/P)

Travel Mode Switch (Fast/Slow)

Work Mode Switch

Boom Angle Sensor (Only ZAXIS225US)

Pump Control (Torque Control Solenoid Valve)

Pump 1 Flow Rate Limit Control

Pump 2 Flow Rate Limit Control

Pump 3 Torque Decrease Control

Auxiliary Flow Rate Control

Travel Alarm Control

NOTE: Only on the machines equipped with the

SYSTEM / Control System

Idle Speed-Up Control

Attachment Operation Speed Increase Control

Attachment Operation Speed Limit Control

Engine Control Dial Control

NOTE: Only on the machines

Engine Control System Layout

Power Mode Switch

SYSTEM / Control System

SYSTEM / Control System

NOTE: Even if the control dial is rotated to the full

SYSTEM / Control System

SYSTEM / Control System

Operation: The MC drives the EC motor to slightly

Engine Control Dial: Set at 1500 min or faster.

SYSTEM / Control System

Power Mode Switch

SYSTEM / Control System

Operation: The MC drives the EC motor to reduce the

Power Mode Switch

SYSTEM / Control System

SYSTEM / Control System

SYSTEM / Control System

Power Mode Switch

SYSTEM / Control System

Lever Stroke VS. Engine Speed Change

Engine speed is reduced

Operating Time Progress VS. Engine Speed Change

NOTE: When all control levers are returned to

In response to the control

SYSTEM / Control System

SYSTEM / Control System

Function: Automatically warms up the hydraulic

Operation: When the hydraulic oil temperature is

SYSTEM / Control System

SYSTEM / Control System