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ZAXIS200-3225US-3225USR-3240-3270-3 class
Technical Manual
Operational Principle
HYDRAULIC EXCAVATOR
200-3 class
200-3200LC-3210H-3210LCH-3210K-3210LCK-3210-3210LC-3
210LCN-3240N-3
225US-3 class
TECHNICAL MANUAL
225US-3225USLC-3
OPERATIONAL PRINCIPLE
URL:http://www.hitachi-c-m.com
270-3 class
225USR-3 class
225USR-3225USRLC-3225USRK-3225USRLCK-3
240-3 class
240-3240LC-3250H-3250LC-3250LCN-3250LCH-3250K-3250LCK-3
270-3270LC-3280LC-3280LCN-3
Hydraulic Excavator
Service Manual consists of the following separate Part No;
Technical Manual (Operational Principle)
: Vol. No. TO1V1-E
Technical Manual (Troubleshooting)
: Vol. No. TT1V1-E
Workshop Manual
: Vol. No. W1V1-E
TO1V1-E-01 Zaxis.p65
TO1V1-E-01
1/8/06, 15:25
INTRODUCTION
TO THE READER
This manual is written for an experienced technician
ADDITIONAL REFERENCES
Please refer to the materials listed below in addition
to this manual.
MANUAL COMPOSITION
This manual consists of three portions: the Techni-
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
W: Workshop Manual
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
In this manual, the following safety alert symbol and
signal words are used to alert the reader to the
potential for personal injury of machine damage.
IMPORTANT:
CAUTION:
Indicated potentially hazardous situation which could,
if not avoided, result in personal injury or death.
Indicates a situation which, if not conformed to the
instructions, could result in damage to the machine.
NOTE:
Indicates supplementary technical information or
know-how.
UNITS USED
2
this manual.
MKSA system units and English units are also
indicated in parenthheses just behind SI units.
Quantity
Length
Volume
Weight
Force
Torque
To Convert
From
mm
mm
L
L
3
m
kg
N
N
Nm
Nm
Into
in
ft
US gal
US qt
3
yd
lb
kgf
lbf
kgfm
lbfft
Quantity
Multiply By
0.03937
0.003281
0.2642
1.057
1.308
2.205
0.10197
0.2248
1.0197
0.7375
Pressure
Power
Temperature
Velocity
Flow rate
IN-02
To Convert
From
MPa
MPa
kW
kW
C
km/h
-1
min
L/min
mL/rev
Into
Multiply By
2
kgf/cm
psi
PS
HP
F
mph
rpm
US gpm
cc/rev
10.197
145.0
1.360
1.341
C1.8+32
0.6214
1.0
0.2642
1.0
SECTION 1 GENERAL
Group 1 Specification
Group 2 Component Layout
Group 3 Component Specifications
SECTION 2 SYSTEM
TECHNICAL MANUAL
(Operational Principle)
Group
Group
Group
Group
Group
1
2
3
4
5
Controller
Control System
ECM System
Hydraulic System
Electrical System
1 Pump Device
2 Swing Device
3 Control Valve
4 Pilot Valve
5 Travel Device
6 Signal Control Valve
7 Others (Upperstructure)
8 Others (Undercarriage)
COPYRIGHT(C)2006
Hitachi Construction Machinery Co., Ltd.
Tokyo, Japan
All rights reserved
SECTION 5 TROUBLESHOOTING
Group 1 Diagnosing Procedure
Group 2 Monitor Unit
Group 3 Dr. ZX
Group 4 e-Shovel
Group 5 Component Layout
Group 6 Troubleshooting A
Group 7 Troubleshooting B
Group 8 Electrical System Inspection
WORKSHOP MANUAL
SECTION 1 GENERAL INFORMA- SECTION 3 UNDERCARRIAGE
TION
Group 1 Swing Bearing
Group 1 Precautions for Disassem- Group 2 Travel Device
Group 3 Center Joint
bling and Assembling
Group 4 Track Adjuster
Group 2 Tightening Torque
Group 5 Front Idler
Group 3 Painting
Group 4 Bleeding Air from Hydraulic Group 6 Upper and Lower Roller
Group 7 Track
Oil Tank
SECTION 4 FRONT ATTACHMENT
SECTION 2 UPPERSTRUCTURE
Group 1 Cab
Group 1 Front Attachment
Group 2 Counterweight
Group 2 Cylinder
Group 3 Main Frame
Group 3 Control Valve
Group 4 Pump Device
Group 5 Control Valve
Group 6 Swing Device
Group 7 Pilot Valve
Group 8 Pilot Shut-Off Solenoid
Valve
Group 9 Signal Control Valve
Group 10 4-Spool Solenoid Valve
Unit
Group 11 Engine
SECTION 1
GENERAL
CONTENTS
Group 1 Specifications
Specifications ...........................................T1-1-1
Working Ranges.......................................T1-1-8
1V1T-1-1
(Blank)
1V1T-1-2
GENERAL / Specifications
SPECIFICATIONS
ZAXIS200-3, ZAXIS200LC-3, ZAXIS210H-3, ZAXIS210LCH-3
T1V1-01-01-006
Model
Type of Front-End Attachment
Bucket Capacity (Heaped)
Operating Weight
Basic Machine Weight
Engine
A: Overall Width
(Excluding back mirrors)
B: Cab Height
C: Rear End Swing Radius
D: Minimum Ground Clearance
E: Counterweight Clearance
F: Engine Cover Height
G: Overall Width of Upperstructure
H: Undercarriage Length
I: Undercarriage Width
J: Sprocket Center to Idler Center
K: Track Shoe Width
Ground Pressure
Swing Speed
Travel Speed (fast/slow)
Gradeability
ZAXIS200-3
ZAXIS200LC-3
ZAXIS210H-3
ZAXIS210LCH-3
2.91 m (9 ft 7 in) Arm
2.91 m (9 ft 7 in) H Arm
3
3
3
PCSA 0.8 m (1.05 yd ), CECE 0.7 m
19800 kg
20400 kg
21000 kg
21500 kg
(43700 lb)
(44974 lb)
(46297 lb)
(47399 lb)
15400 kg
16000 kg
16400 kg
16800 kg
(34000 lb)
(35274 lb)
(36155 lb)
(37037 lb)
-1
ISUZU AI-4HK1XYSA-02 122 kW/2000 min (166 PS/2000 rpm)
2860 mm
2990
2860
2990
(9 ft 5 in)
(9 ft 10 in)
(9 ft 5 in)
(9 ft 10 in)
2950 mm (9 ft 8 in)
2750 mm (9 ft 0 in)
* 450 mm (18 in)
* 1030 mm (3 ft 5 in)
* 2270 mm (7 ft 5 in)
2710 mm (8 ft 11 in)
4170 mm
4470 mm
4170 mm
4470 mm
(13 ft 8 in)
(14 ft 8 in)
(13 ft 8 in)
(14 ft 8 in)
2800 mm
2990 mm
2800 mm
2990 mm
(9 ft 2 in)
(9 ft 10 in)
(9 ft 2 in)
(9 ft 10 in)
3370 mm
3660 mm
3370 mm
3660 mm
(11 ft 1 in)
(12 ft 0 in)
(11 ft 1 in)
(12 ft 0 in)
600 mm (24 in)
600 mm (24 in)
(Grouser shoe)
(Enhanced grouser shoe)
44 kPa (0.45
42 kPa (0.43
47 kPa (0.48
44 kPa (0.45
2
2
2
2
kgf/cm , 6.4 psi) kgf/cm , 6.1 psi) kgf/cm , 6.8 psi) kgf/cm , 6.4 psi)
1
13.3 min (rpm)
5.5/3.5 km/h (3.4/2.2 mph)
35 (tan = 0.70)
T1-1-1
GENERAL / Specifications
ZAXIS210K-3, 210LCK-3
T1V1-01-01-006
Model
Type of Front-End Attachment
Bucket Capacity (Heaped)
Operating Weight
Basic Machine Weight
Engine
A: Overall Width
(Excluding back mirrors)
ZAXIS210K-3
ZAXIS210LCK-3
Standard
High-Grade
Standard
High-Grade
2.91 m (9 ft 7 in) K Arm
3
3
3
PCSA 0.8 m (1.05 yd ), CECE 0.7 m
21100 kg
21900 kg
21600 kg
22300 kg
(46517 lb)
(48218 lb)
(47619 lb)
(19163 lb)
16400 kg
17100 kg
16800 kg
17500 kg
(36155 lb)
(37699 lb)
(37037 lb)
(38581 lb)
-1
ISUZU AI-4HK1XYSA-02 122 kW/2000 min (166 PS/2000 rpm)
2860 mm (9 ft 5 in)
3080 mm
2950 mm
3080 mm
(10 ft 1 in)
(9 ft 8 in)
(10 ft 1 in)
C: Rear End Swing Radius
2750 mm (9 ft 0 in)
D: Minimum Ground Clearance
* 450 mm (18 in)
E: Counterweight Clearance
* 1030 mm (3 ft 5 in)
F: Engine Cover Height
* 2270 mm (7 ft 5 in)
G: Overall Width of Upperstructure
2710 mm (8 ft 11 in)
H: Undercarriage Length
4170 mm (13 ft 8 in)
4470 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 0 in)
K: Track Shoe Width
600 mm (24 in) (Enhanced grouser shoe)
47 kPa (0.48 49 kPa (0.50 45 kPa (0.46, 46 kPa (0.47
Ground Pressure
2
2
2
2
kgf/cm , 6.8 psi) kgf/cm , 7.1 psi) kgf/cm , 6.5 psi) kgf/cm , 6.7 psi)
1
Swing Speed
13.3 min (rpm)
Travel Speed (fast/slow)
5.5/3.5 km/h (3.4/2.2 mph)
Gradeability
35 (tan = 0.70)
B: Cab Height
2950 mm
(9 ft 8 in)
2990 mm (9 ft 10 in)
T1-1-2
GENERAL / Specifications
ZAXIS225US-3, 225USLC-3
A
G
B
F
E
D
K
J
I
H
M1U4-12-001
Model
Type of Front-End Attachment
Bucket Capacity (Heaped)
Operating Weight
Basic Machine Weight
Engine
A: Overall Width
(Excluding back mirrors)
B: Cab Height
C: Rear End Swing Radius
D: Minimum Ground Clearance
E: Counterweight Clearance
F: Engine Cover Height
G: Overall Width of Upperstructure
H: Undercarriage Length
I: Undercarriage Width
J: Sprocket Center to Idler Center
K: Track Shoe Width
Ground Pressure
Swing Speed
Travel Speed (fast/slow)
Gradeability
ZAXIS225US-3
ZAXIS225USLC-3
2.91 m (9 ft 7 in) Arm
3
3
3
PCSA 0.8 m (1.05 yd ), CECE 0.7 m
23200 kg (51147 lb)
23600 kg (52029 lb)
19000 kg (41887 lb)
19400 kg (42769 lb)
-1
ISUZU AI-4HK1XYSA-02 122 kW/2000 min (166 PS/2000 rpm)
2940 mm (9 ft 8 in)
2990 mm (9 ft 10 in)
2950 mm (9 ft 8 in)
1680 mm (5 ft 6 in)
* 450 mm (18 in)
* 975 mm (3 ft 2 in)
* 2300 mm (7 ft 7 in)
2870 mm (9 ft 5 in)
4170 mm (13 ft 8 in)
4460 mm (14 ft 8 in)
2800 mm (9 ft 2 in)
2990 mm (9 ft 10 in)
3370 mm (11 ft 1 in)
3660 mm (12 ft 0 in)
600 mm (24 in) (Grouser shoe)
2
2
52 kPa (0.53 kgf/cm , 7.6 psi)
49 kPa (0.50 kgf/cm , 7.1 psi))
1
13.3 min (rpm)
5.5/3.5 km/h (3.4/2.2 mph)
35 (tan = 0.70)
T1-1-3
GENERAL / Specifications
ZAXIS225USR-3, 225USRLC-3, 225USRK-3, 225USRLCK-3
A
G
B
F
E
D
K
J
H
M1U4-12-003
Model
Type of Front-End Attachment
Bucket Capacity (Heaped)
Operating Weight
Basic Machine Weight
Engine
A: Overall Width
(Excluding back mirrors)
B: Cab Height
C: Rear End Swing Radius
D: Minimum Ground Clearance
E: Counterweight Clearance
F: Engine Cover Height
G: Overall Width of Upperstructure
H: Undercarriage Length
I: Undercarriage Width
J: Sprocket Center to Idler Center
K: Track Shoe Width
Ground Pressure
Swing Speed
Travel Speed (fast/slow)
Gradeability
ZAXIS225USR-3
T1-1-4
GENERAL / Specifications
ZAXIS240-3, ZAXIS240LC-3, ZAXIS250H-3, ZAXIS250LCH-3
T1V1-01-01-001
Model
Type of Front-End Attachment
Bucket Capacity (Heaped)
Operating Weight
Basic Machine Weight
Engine
A: Overall Width
(Excluding back mirrors)
B: Cab Height
C: Rear End Swing Radius
D: Minimum Ground Clearance
E: Counterweight Clearance
F: Engine Cover Height
G: Overall Width of Upperstructure
H: Undercarriage Length
I: Undercarriage Width
J: Sprocket Center to Idler Center
K: Track Shoe Width
Ground Pressure
Swing Speed
Travel Speed (fast/slow)
Gradeability
ZAXIS240-3
ZAXIS240LC-3
ZAXIS250H-3
ZAXIS250LCH-3
T1-1-5
GENERAL / Specifications
ZAXIS250K-3, 250LCK-3
T1V1-01-01-001
Model
Type of Front-End Attachment
Bucket Capacity (Heaped)
Operating Weight
Basic Machine Weight
Engine
A: Overall Width
(Excluding back mirrors)
B: Cab Height
C: Rear End Swing Radius
D: Minimum Ground Clearance
E: Counterweight Clearance
F: Engine Cover Height
G: Overall Width of Upperstructure
H: Undercarriage Length
I: Undercarriage Width
J: Sprocket Center to Idler Center
K: Track Shoe Width
Ground Pressure
Swing Speed
Travel Speed (fast/slow)
Gradeability
ZAXIS250K-3
ZAXIS250LCK-3
2.96 m (9 ft 9 in) K Arm
3
3
3
PCSA 1.0 m (1.3 yd ), CECE 0.9 m
25400 kg (55997 lb)
26000 kg (57320 lb)
19500 kg (42990 lb)
20100 kg (44312 lb)
-1
ISUZU AH-4HK1XYSA-01 132 kW/2000 min (180 PS/2000 rpm)
2990 mm (9 ft 10 in)
3190 mm (
ft
in)
T1-1-6
GENERAL / Specifications
ZAXIS270-3, ZAXIS270LC-3
T1V1-01-01-001
Model
Type of Front-End Attachment
Bucket Capacity (Heaped)
Operating Weight
Basic Machine Weight
Engine
A: Overall Width
(Excluding back mirrors)
B: Cab Height
C: Rear End Swing Radius
D: Minimum Ground Clearance
E: Counterweight Clearance
F: Engine Cover Height
G: Overall Width of Upperstructure
H: Undercarriage Length
I: Undercarriage Width
J: Sprocket Center to Idler Center
K: Track Shoe Width
Ground Pressure
Swing Speed
Travel Speed (fast/slow)
Gradeability
ZAXIS270-3
ZAXIS270LC-3
3.11 m (10 ft 2 in) Arm
3
3
3
PCSA 1.1 m (1.44 yd ), CECE 1.0 m
27300 kg (60200 lb)
27800 kg (61288 lb)
21300 kg (47000 lb)
21800 kg (48060 lb)
-1
ISUZU AH-4HK1XSA-03 140 kW/2100 min (190 PS/2100 rpm)
3190 mm (10 ft 6 in)
3100 mm (10 ft 2 in)
2940 mm (9 ft 8 in)
* 510 mm (20 in)
* 1180 mm (3 ft 11 in)
* 2515 mm (8 ft 3 in)
2890 mm (9 ft 6 in)
4670 mm (15 ft 4 in)
4940 mm (16 ft 2 in)
3190 mm (10 ft 6 in)
3720 mm (12 ft 3 in)
4052 mm (13 ft 4 in)
600 mm (24 in) (Grouser shoe)
2
2
55 kPa (0.56 kgf/cm , 8.0 psi)
52 kPa (0.53 kgf/cm , 7.6 psi))
1
12.6 min (rpm)
5.5/3.3 km/h (3.4/2.1 mph)
35 (tan = 0.70)
T1-1-7
GENERAL / Specifications
WORKING RANGES
ZAXIS200-3, ZAXIS200LC-3, ZAXIS210H-3, ZAXIS210LCH-3
(Grouser Shoe)
T1V1-01-01-002
ZAXIS200-3, 200LC-3
Model
Category
Item
ZAXIS210H-3, 210LCH-3
Backhoe
Backhoe
mm
ftxin
mm
Backhoe
ftxin
mm
ftxin
9430
3011
9920
327
9920
327
6180
203
6670
2111
6670
2111
9670
319
10040
3211
10040
3211
6830
225
7180
237
7180
237
E: Transport Height
3180
105
3010
911
3010
911
9605
316
9520
313
9520
313
3280
109
3180
105
3180
105
NOTE: The dimensions do not include height of the shoe lug (except Item E).
T1-1-8
GENERAL / Specifications
ZAXIS210K-3, 210LCK-3
(Grouser Shoe)
T1V1-01-01-002
Model
Category
Item
ZAXIS210H-3, 210LCH-3
2.91 m (9 ft 7 in) K Arm
Backhoe
mm
ftxin
9920
327
6670
2111
10040
3211
7180
237
3010 (Standard)
3080 (High-grade)
911
101
9520
313
3180
105
NOTE: The dimensions do not include height of the shoe lug (except Item E).
T1-1-9
GENERAL / Specifications
ZAXIS225US-3, 225USLC-3
(Grouser Shoe)
C
D
F
A
B
M1U4-12-002
Model
Category
Item
ZAXIS225US-3, 225USLC-3
2.42 m (7 ft 11in) Arm
2.91 m (9 ft 7 in) Arm
Backhoe
Backhoe
mm
ftxin
mm
ftxin
9520
313
10010
3210
6210
204
6700
2112
10560
348
10980
360
7640
251
8050
265
E: Transport Height
3200
106
2980
99
9040
298
8920
293
2740
812
2370
79
NOTE: The dimensions do not include height of the shoe lug (except Item E).
T1-1-10
GENERAL / Specifications
ZAXIS225USR-3, 225USRLC-3, 225USRK-3, 225USRLCK-3
(Grouser Shoe)
G
C
D
F
A
B
M1U4-12-004
Model
Category
Item
ZAXIS225USR-3, 225USRLC-3
ZAXIS225USRK-3, 225USRLCK-3
Backhoe
Backhoe
mm
ftxin
mm
Backhoe
ftxin
mm
ftxin
9430
3011
9920
327
9920
327
6180
203
6670
2111
6670
2111
9670
319
10040
3211
10040
3211
6830
225
7180
237
7180
237
E: Transport Height
3180
105
3010
911
2950
98
8940
294
9520
313
8850
290
3280
109
3180
105
3180
105
NOTE: The dimensions do not include height of the shoe lug (except Item E).
T1-1-11
GENERAL / Specifications
ZAXIS240-3 (Machine with 2-Piece Boom)
T1V1-01-01-005
Model
Category
Item
ZAXIS240-3
2.19 m ( 7 ft 3 in) Arm
mm
ftxin
mm
ftxin
mm
ftxin
ftxin
A:
9770
321
10010
3210
10430
343
11070
364
B:
5810
191
6080
1911
6530
215
7190
237
C:
11300
371
11470
378
11840
3810
12420
409
D:
8210
271
8350
275
8720
287
9300
306
E:
Transport Height
3150
104
3200
106
3090
102
3340
1012
F:
10230
337
10250
338
10220
336
10190
335
2500
82
2560
85
2310
77
2610
87
NOTE: The dimensions do not include height of the shoe lug (except Item E).
T1-1-12
GENERAL / Specifications
ZAXIS270-3 (Machine with 2-Piece Boom)
T1V1-01-01-005
Model
Category
Item
ZAXIS270-3
2.42 m (7 ft11 in) Arm
mm
mm
mm
ftxin
ftxin
ftxin
10070
364
10740
353
11330
372
6020
199
6690
2111
7330
241
11500
379
12080
398
12550
412
8390
276
8960
295
9430
3011
E: Transport Height
3220
107
3150
104
3380
111
10330
3310
10300
3310
10310
339
2820
93
2580
86
2740
812
NOTE: The dimensions do not include height of the shoe lug (except Item E).
T1-1-13
GENERAL / Specifications
ZAXIS240-3, ZAXIS240LC-3
(Grouser Shoe)
T1V1-01-01-002
Model
Category
Item
ZAXIS240-3, 240LC-3
2.5 m (8 ft 2 in) Arm
Backhoe
Backhoe
mm
ftxin
mm
ftxin
mm
ftxin
9880
325
10290
339
10910
3510
6500
214
6960
2210
7610
2412
9950
328
10160
334
10560
348
6990
2211
7200
238
7580
2410
E: Transport Height
3370
111
3070
101
3320
1011
10270
338
10150
334
10200
336
3480
115
3440
113
3430
113
NOTE: The dimensions do not include height of the shoe lug (except Item E).
T1-1-14
GENERAL / Specifications
ZAXIS250H-3, ZAXIS250LCH-3, ZAXIS250K-3, ZAXIS250LCK-3
(Grouser Shoe)
T1V1-01-01-002
Model
Category
Item
ZAXIS250H-3, 250LCH-3
ZAXIS250K-3, 250LCK-3
Backhoe
mm
Backhoe
ftxin
mm
ftxin
10290
339
10290
339
6960
2210
6960
2210
10160
334
10160
334
7200
238
7200
238
E: Transport Height
3070
101
3070
101
10150
334
10150
334
3440
113
3440
113
NOTE: The dimensions do not include height of the shoe lug (except Item E).
T1-1-15
GENERAL / Specifications
ZAXIS270-3, ZAXIS270LC-3
(Grouser Shoe)
T1V1-01-01-002
Model
Category
Item
ZAXIS270-3, 270LC-3
2.42 m (7 ft 11 in) Arm
Backhoe
Backhoe
mm
ftxin
mm
ftxin
mm
ftxin
10060
330
10710
352
10270
338
6540
215
7230
239
7880
2510
9890
325
10260
338
10460
344
6970
2210
7310
2312
7520
248
E: Transport Height
3410
112
3170
105
3310
1010
10440
343
10340
3311
10390
341
4070
134
3910
1210
3900
1210
NOTE: The dimensions do not include height of the shoe lug (except Item E).
T1-1-16
2
3
24
6
7
8
9
23
10
22
11
21
12
20
19
14
18
12-
Bucket Cylinder
Arm Cylinder
34-
Boom Cylinder
Center Joint
56-
Swing Bearing
Swing Device
7 - Fuel Tank
8 - Hydraulic
Oil Tank
9 - Control Valve
10 - Pilot Filter/ Pilot Relief
Valve
11 - Pump Device
12 - Engine
17
16
13
15
T1V1-01-02-013
13 - Intercooler
14 - Air Conditioner Condenser
19 - Fuel Cooler
20 - Air Cleaner
15 - Radiator
16 - Battery
17 - Travel Device
18 - Oil Cooler
T1-2-1
1
2
3
4
5
6
7
8
9
10
11
22
12
21
13
20
14
19
15
18
17
16
1V1-01-02-031
12-
Bucket Cylinder
Arm Cylinder
3-
Boom Cylinder
7 - Fuel Tank
8 - Hydraulic
Oil Tank
9 - Swing Device
456-
10 - Pump Device
11 - Engine
12 - Center Joint
13 - Radiator
14 - Intercooler
18 - Fuel Cooler
19 - Oil Cooler
15 - Air Conditioner
Condenser
16 - Battery
17 - Air Cleaner
T1-2-2
3
4
2
7
8
1
11
T1V1-01-02-006
10
1-
Bucket
23-
Bucket Cylinder
Arm
7-
T1-2-3
Engine
Cam Angle Sensor
Crank Speed Sensor
Engine Oil Pressure Sensor
Coolant Temperature Sensor
Fuel Temperature Sensor
Boost Temperature Sensor
Boost Pressure Sensor
Common Rail Pressure
Sensor
Overheat Switch
Supply Pump Actuator
EGR Valve
Injector
Glow Plug
Refer toT1-2-8.
Pump Device
Pump 1,2 Delivery Pressure
Sensors
Pumps 1, 2 Control Pressure
Sensors
Torque Control Solenoid Valve
Maximum Pump 2 Flow Rate
Limit Control Solenoid Valve
Refer to T1-2-9.
14
13
Electrical System
(Relays)
Fresh Air
Temperature
Sensor
Starter Relay 2
Battery Relay
Glow Relay
Fusible Link
Refer to T1-2-7.
Control Valve.
Pressure Sensor
(Arm Roll-In)
Pressure Sensor
(Boom Raise)
Refer to T1-2-10.
12
11
2
3
Swing Device
Pressure Sensor
(Front Attachment)
Refer to T1-2-9.
10
4
9
7
6
1-
5-
234-
Battery
Communication Aerial
Air Filter Restriction
Switch
678-
Wiper Motor
Monitor Unit
Horn
9-
T1-2-4
Electrical System
(Around Air Cleaner)
ECM
Atmospheric Pressure
Sensor
Intake-Air Temperature
Sensor
Refer to T1-2-7.
T1V1-01-02-022
Pump Device
Pump 1,2 Delivery Pressure
Sensors
Pumps 1, 2 Control Pressure
Sensors
Torque Control Solenoid Valve
Maximum Pump 2 Flow Rate
Limit Control Solenoid Valve
(Refer to T1-2-14.)
Engine
Cam Angle Sensor
Overheat Switch
Crank Speed Sensor
Supply Pump Actuator
Engine Oil Pressure Sensor
EGR Valve
Coolant temperature sensor Injector
Fuel Temperature Sensor Glow Plug
Boost Temperature Sensor
Boost Pressure Sensor
Common Rail Pressure
Electrical System
Sensor
(Relays)
(Refer to T1-2-13.)
Fresh Air
Temperature
Sensor
Starter Relay 2
Battery Relay
Glow Relay
Fusible Link
(Refer to T1-2-12.)
14
Swing Device
Pressure Sensor
(Front Attachment)
(Refer to T1-2-15.)
13
Electrical System
(Around Air Cleaner)
Atmospheric Pressure
Sensor
Intake-Air Temperature
Sensor
(Refer to T1-2-11.)
12
11
4
Signal Control Valve
Pressure Sensor (Travel)
Pressure Sensor (Swing)
(Refer to T1-2-16.)
10
6
7
Control Valve
Pressure Sensor (Arm Roll-In)
Pressure Sensor (Boom Raise)
(Refer to T1-2-16.)
1-
8
T1V1-01-02-033
5 - Battery
9 - Monitor Unit
10 - Horn
11 - Working Light
13 - Fuel Sensor
14 - Hydraulic Oil Temperature
Sensor
4-
8 - Wiper Motor
T1-2-5
Rear Tray
Refer to T1-2-8.
Switch Panel
Refer to T1-2-10.
1-
2-
Radio
T1-2-6
T1V1-01-02-011
Rear Tray
(Refer to T1-2-9.)
Switch Panel
(Refer to T1-2-10.)
2-
Radio
T1-2-7
T1V1-01-02-034
T1V1-01-02-007
10
11
12
13
14
T1V1-01-02-009
19
123-
MC (Main Controller)
Fuse Box
Dr. ZX Connector
(Download Connector
Using Combinedly)
4 - ICF (Information
Controller)
5 - Satellite Communication
Terminal (Optional)
18
17
16
15
67-
8-
9-
T1-2-8
2
3
4
T1V1-01-02-035
18
17
16
15
14
13
10
12
11
T1V1-01-02-036
1-
Satellite Communication
Terminal (Optional)
2 - Dr. ZX Connector (Download
Connector Using Combinedly)
3 - Fuse Box
4 - ICF (Information Controller)
5-
T1-2-9
2
1
4 - Auto-Idle Switch
6-
7-
Key Switch
T1-2-10
T1V1-01-02-037
8-
Air Cleaner
Air Cleaner
T1V1-01-02-023
T1V1-01-02-012
2
Air Cleaner
T1V1-01-02-038
1-
2-
Atmospheric Pressure
Sensor
T1-2-11
3-
Intake-Air Temperature
Sensor
T1V1-01-02-018
1-
3 - Battery Relay
4-
T1-2-12
Glow Relay
5-
Fusible Link
T1V1-01-02-017
T1V1-01-02-016
10
11
12
T1V1-01-02-015
13
1-
5-
Overheat Switch
Coolant temperature
sensor
4 - Common Rail Pressure
Sensor
67-
23-
8-
T1-2-13
7
6
9
T1V1-01-02-032
T1V1-04-05-002
11
T1V1-01-02-039
1-
Pilot Pump
2-
Pump 2
3-
Pump 1
T1-2-14
10 - Solenoid Pump
ZX270-3 class
Machine Front
2
T1V1-01-02-005
2-
T1-2-15
T1V1-01-02-004
2
T1V1-03-03-073
T1V1-01-02-014
1-
2-
3-
T1-2-16
4-
T1V1-03-07-007
ZX270-3 class
TRAVEL DEVICE
ZX200-3 class, ZX225US-3 class,
ZX225USR-3 class, ZX240-3 class
5
5
T1HD-01-02-001
T178-01-02-014
6
5
12-
34-
5-
T1-2-17
Counterbalance Valve
Utility Space
Selector Valve Control
Solenoid Valve
Secondary Pilot Relief
Pressure Control Solenoid
Valve
Accumulator Control
Solenoid Valve
Pressure Sensor (Auxiliary)
Auxiliary Flow Combining
Solenoid Valve
Auxiliary Flow Rate Control
Solenoid Valve
Pressure reducing valve:
Accumulator (pilot Circuit)
Check Valve
(Refer to T1-2-22.)
T1V1-01-02-024
T1-2-18
T1V1-01-02-026
Swing Device
Control Valve
Secondary Pilot Relief
Pressure Valve
Boom
T1V1-01-02-025
Center Joint
T1-2-19
T1V1-01-02-027
T1V1-01-02-028
T1V1-01-02-029
1-
4 - Pressure Sensor
(Auxiliary)
5 - Auxiliary Flow
Combining Solenoid
Valve
6-
T1-2-20
8-
9-
Check Valve
Accumulator
(Low Pressure)
Accumulator
(High Pressure)
Accumulator
Control Valve
T1V1-01-02-030
T1-2-21
Selector Valve
(Refer to T1-2-25.)
Secondary Pilot
Relief Pressure
Control Valve
(Refer to T1-2-25.)
T1-2-22
T1V1-01-02-046
Fuel Tank
Solenoid Valve
Unit
T1V1-01-02-040
Secondary Pilot
Relief Pressure
Control Valve
Swing
Device
Machine Front
T1V1-01-02-042
Center Joint
Machine Front
T1V1-01-02-041
T1-2-23
4
5
6
7
Swing
Device
T1V1-01-02-043
8
Swing
Device
T1V1-01-02-044
1-
4 - Pressure Sensor
(Auxiliary)
5 - Auxiliary Flow
Combining Solenoid
Valve
6-
T1-2-24
8-
Check Valve
9-
Accumulator
(Low Pressure)
Accumulator
(High Pressure)
Accumulator
Control Valve
T1V1-01-02-045
T1-2-25
T1-2-26
T1-3-1
T1-3-2
T1-3-3
700
Torque (Nm)
600
500
400
Output
(kW)
120
100
80
60
40
20
0
260 Fuel Consumption
Ratio (g/PSh)
240
220
200
Engine Speed min-1 (rpm)
T1-3-4
T1GR-01-02-002
Torque (Nm)
600
500
400
Output (kW) 160
140
120
100
80
60
40
20
0
Fuel Consumption
260 Ratio (g/PSh)
240
220
0
500
1000
1500
Engine Speed min
T1-3-5
2000
-1
(rpm)
2500
T1V1-01-03-002
Torque (Nm)
600
500
400
Output (kW)
140
120
100
80
60
40
20
0
260
Fuel Consumption
Ratio (g/PSh)
240
220
800
1000
1200
1400
1600
T1-3-6
1800
2000
200
2200
T1V1-01-03-003
Oil Cooler
10 L (2.6 US gal)
2
1470 kPa (15 kgf/cm , 213 psi)
Intercooler
Capacity ......................................................... 8.0 L (2.1 US gal)
2
Air-Tight Test Pressure................................... 245 kPa (2.5 kgf/cm , 36 psi)
Cap Opening Pressure...................................
T1-3-7
Oil Cooler
10.5 L (2.8 US gal)
2
1470 kPa (15 kgf/cm , 213 psi)
T1-3-8
T1-3-9
T1-3-10
T1-3-11
T1-3-12
Arm
95 mm (3.74)
135 mm (5.31)
1475 mm (410)
2007 mm (67)
30 m (1.18 m)
Bucket
Rod Diameter ......................................... 80 mm (3.15)
Cylinder Bore.......................................... 115 mm (4.53)
Stroke ..................................................... 1060 mm (36)
Fully Retracted Length ........................... 1590 mm (53)
Plating Thickness ................................... 30 m (1.18 m)
ZX225US-3 class:
Boom
Rod Diameter ......................................... 85 mm (3.35)
Cylinder Bore.......................................... 120 mm (4.72)
Stroke ..................................................... 1325 mm (44)
Fully Retracted Length ........................... 1843 mm (60)
Plating Thickness ................................... 30 m (1.18 m)
Arm
95 mm (3.74)
135 mm (5.31)
1475 mm (410)
2007 mm (67)
30 m (1.18 m)
Bucket
Rod Diameter ......................................... 80 mm (3.15)
Cylinder Bore.......................................... 115 mm (4.53)
Stroke ..................................................... 1060 mm (36)
Fully Retracted Length ........................... 1590 mm (53)
Plating Thickness ................................... 30 m (1.18 m)
ZAXIS240-3:
Boom
Rod Diameter ......................................... 90 mm (3.54)
Cylinder Bore.......................................... 125 mm (4.92)
Stroke ..................................................... 1390 mm (46)
Fully Retracted Length ........................... 1990 mm (66)
Plating Thickness ................................... 30 m (1.18 m)
Bucket
Rod Diameter ......................................... 90 mm (3.54)
Cylinder Bore.......................................... 130 mm (5.12)
Stroke ..................................................... 1075 mm (36)
Fully Retracted Length ........................... 1632 mm (5!4)
Plating Thickness ................................... 30 m (1.18 m)
T1-3-13
Arm
100 mm (3.94)
140 mm (5.51)
1610 mm (53)
2177 mm (71)
30 m (1.18 m)
T1-3-14
Arm
105 mm (41)
150 mm (59)
1615 mm (56 )
2259 mm (74)
30 m (1.18 m)
Arm
100 mm (3.94)
140 mm (5.51)
1610 mm (53)
2177 mm (71)
30 m (1.18 m)
Bucket
Rod Diameter ......................................... 90 mm (3.5)
Cylinder Bore.......................................... 130 mm (5.12)
Stroke ..................................................... 1075 mm (36)
Fully Retracted Length ........................... 1632 mm (54)
Plating Thickness ................................... 30 m (1.18 m)
Positioning
100 mm (3.94)
150 mm (5.91)
1327 mm (44)
1910 mm (63)
30 m (1.18 m)
ZAXIS270-3:
Boom
Rod Diameter ......................................... 95 mm (3.7)
Cylinder Bore.......................................... 135 mm (5.3)
Stroke ..................................................... 1360 mm (46)
Fully Retracted Length ........................... 1940 mm (64)
Plating Thickness ................................... 30 m (1.18 m)
Arm
105 mm (4.1)
150 mm (5.9)
1659 mm (55)
2259 mm (75)
30 m (1.18 m)
Bucket
Rod Diameter ......................................... 90 mm (3.5)
Cylinder Bore.......................................... 135 mm (5.32)
Stroke ..................................................... 1070 mm (36)
Fully Retracted Length ........................... 1660 mm (55)
Plating Thickness ................................... 30 m (1.18 m)
Positioning
100 mm (3.94)
150 mm (5.91)
1327 mm (44)
1910 mm (63)
30 m (1.18 m)
T1-3-15
T1-3-16
ZX225US-3
HORN
Voltage / Current ............................................ 24 V2.50.5 A
Sound Pressure ............................................. 1135 dB (A) @2 m
ILLUMINATION
Specifications ................................................. Working Light: Halogen 24V, 70 W / 60 W
Cab Light:
24 V, 10 W
T1-3-17
class,
T1-3-18
MEMO
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SECTION 2
SYSTEM
CONTENTS
Group 5 Electrical System
Group 1 Controller
Outline .....................................................T2-1-1
Outline .....................................................T2-5-1
Accessory Circuit......................................T2-5-6
Outline ...................................................T2-1-25
Valve Control..........................................T2-2-42
Other Controls........................................T2-2-64
1V1T-2-1
(Blank)
1V1T-2-2
SYSTEM / Controller
OUTLINE
The controllers are provided for each control
respectively.
Each controller is connected by using CAN (network
provided for machine) in order to display on the
monitor unit in cab or the monitoring of machine
overall condition including the engine.
MCMain Controller
ECMEngine Control Module
ICFInformation Controller
Monitor Unit
Dr.ZX
Satellite Terminal
(Optional)
ICF
Monitor Unit
MC
ECM
T2-1-1
SYSTEM / Controller
CAN
(NETWORK
MACHINE)
PROVIDED
FOR
Dr.ZX
Satellite Terminal
(Optional)
ICF
Monitor Unit
CAN High
MC
CAN Low
ECM
T1V1-02-01-050
T2-1-2
SYSTEM / Controller
(Blank)
T2-1-3
SYSTEM / Controller
MC: MAIN CONTROLLER
Function Outline
Engine Control
Engine Control Dial Control
MC sends the signal to ECM according to the idle
position of engine control dial and controls the engine
speed.
When all control levers are in neutral with the engine
control dial at fast idle position, MC sends the signal
1
to ECM and reduces engine speed by 100 min
from the fast idle speed.
HP Mode Control
Average Delivery Pressure of Pumps 1 and 2: High
-1
Engine Control Dial: Engine Speed 1500 min or
faster
Power Mode Switch: HP Mode Position
When operating boom raise and arm roll-in on
conditions above, MC sends the signal to ECM and
increases engine speed beyond the set speed by
engine control dial in order to increase engine power.
Travel HP Mode Control
E Mode Control
Condition:
Pump Control Pressure and Pump Average
Delivery Pressure: Both Low Pressure
Pump Control Pressure and Pump Average
Delivery Pressure: Both High Pressure
Pump Control Pressure: Low Pressure and Pump
Average Delivery Pressure: High Pressure
-1
Engine Control Dial: Engine Speed 1800 min or
faster
Power Mode Switch: E Mode Position
On conditions above, MC sends the signal to ECM and
decreases engine speed below the set speed by
engine control dial.
Pump Control Pressure: High Pressure and Pump
Average Delivery Pressure: Low Pressure
On conditions above, MC sends the signal to ECM and
-1
increases engine speed 200 min beyond the set
speed by engine control dial.
T2-1-4
SYSTEM / Controller
MC
Engine Control Dial
Power Mode
Switch
CAN Bus Line
HP Mode
E Mode
ECM
Pump 2 Delivery
Pressure Sensor
Pump 1 Delivery
Pressure Sensor
Pressure Sensor
Travel
Front Attachment
Boom Raise
Pump 2 Control
Pressure Sensor
Arm Roll-In
Pump 1 Control
Pressure Sensor
T1V1-02-01-039
T2-1-5
SYSTEM / Controller
Auto-Idle Control
All Control Levers: Neutral Position
Auto-Idle Switch: ON
On conditions above, MC sends the signal to ECM and
set engine speed to auto-idle speed.
When operating the engine control dial, shifting the
power mode switch (E mode to P mode or P mode to E
mode) or operating front attachment/travel, auto-idle
control is released.
Auto-Warming Up Control
When hydraulic oil temperature is below 0 C (32 F)
for 15 minutes after starting the engine, MC sends the
signal to ECM in response to the signal from key
switch and hydraulic oil temperature sensor, and
increases engine speed to auto warm-up speed.
Idle Speed-Up Control
Engine Speed: Between Slow Idle and Idle Speed-Up
Speed
When operating front attachment or travel on condition
above, MC sends the signal to ECM and increases
engine speed to idle speed-up speed.
Heater Control
Coolant Temperature: Less than 5 C (41 F)
Pump Control Pressure of Pumps 1 and 2: 0.5 Mpa
2
(5.1 kgf/cm , 37 psi) or less
Engine Control Dial: Fast Idle Position
When the engine starts on conditions above, MC
sends the signal to ECM and increases engine speed
beyond fast idle speed.
Attachment Operation Speed Increase Control
(Optional)
Set attachment operation speed to increase (+) in the
service mode of Dr. ZX.
Engine Control Dial: Fast Idle Position
Power Mode Switch: HP Mode Position
When operating attachment on conditions above, MC
sends the signal to ECM and increases engine speed
to attachment operating speed set by Dr. ZX beyond
fast idle.
T2-1-6
SYSTEM / Controller
Key Switch
MC
Engine Control Dial
Oil Temperature
Sensor
Auto-Idle Switch
E Mode
To ICF
Set by Dr. ZX (via ICF)
P Mode
Pressure Sensor
Travel
Front Attachment
Auxiliary (Optional)
Coolant
Temperature Pump 2 Control
Pressure Sensor
Signal
Pump 1 Control
Pressure Sensor
T1V5-02-01-008
T2-1-7
SYSTEM / Controller
Pump Control
Speed Sensing Control
MC calculates difference between engine speed set by
the engine control dial and actual engine speed
detected by ECM. MC sends the signal to the torque
control solenoid valve in order to control pilot pressure
oil to the pump regulator. The pump delivery flow rate
is changed due to engine speed so that engine power
can be used effectively.
T2-1-8
SYSTEM / Controller
MC
CAN Bus Line
Pressure Sensor
Auxiliary
Travel
ECM
Pump 1 Delivery
Pressure Sensor
Pump 2 Delivery
Pump 3 Delivery
Pressure Sensor
Pressure Sensor
Actual Engine
Speed
Torque Control
Solenoid Valve
Maximum Pump 2
Flow Rate Limit Control
Solenoid Valve
Maximum Pump 1
Flow Rate Limit Control
Solenoid Valve
T1V1-02-01-041
T2-1-9
SYSTEM / Controller
Valve Control
Power Digging Control
While the power digging switch is turned ON, MC
drives solenoid valve unit (SG) and increases relief
pressure of the main relief valve in control valve.
T2-1-10
SYSTEM / Controller
CAN Bus Line
MC
Pressure Sensor
Swing
Boom Raise
To Arm Regenerative
Valve (Control Valve)
Arm Roll-In
Pump 2 Delivery
Pressure Sensor
Pump 1 Delivery
Pressure Sensor
T1V1-02-01-042
T2-1-11
SYSTEM / Controller
Travel Motor Displacement Angle Selection
Control
ZX200-3 class, ZX225US-3 class, ZX225USR-3
class, ZX240-3 class
Condition:
Pump 1, 2 Delivery Pressure: Either Low
Pump 1, 2 Control Pressure: Either High
Travel Mode Switch: Fast
When operating travel on conditions above, MC drives
solenoid valve unit (SI) according to the signals from
pressure sensor (travel), pump 1, 2 delivery pressure
sensors and pump 1, 2 control pressure sensors.
When pilot pressure from solenoid valve unit (SI) acts
on the travel motor displacement angle selection valve,
reduces displacement angle of the travel motor, and
increases travel speed.
ZX270-3 class
Condition:
Pump 1,2 Delivery Pressure: Low
Pump 1, 2 Control Pressure: High
Travel Mode Switch: Fast
When operating travel on conditions above, MC drives
solenoid valve unit (SI) according to the signals from
pressure sensor (travel), pump 1, 2 delivery pressure
sensors and pump 1, 2 control pressure sensors.
When pilot pressure from solenoid valve unit (SI) acts
on the travel motor displacement angle selection valve,
reduces displacement angle of the travel motor, and
increases travel speed.
T2-1-12
SYSTEM / Controller
MC
Fast
Pressure Sensor
Travel
To ICF
CAN Bus Line
Travel Device
Solenoid
Valve Unit
From Pilot
Pump
SI
Pump 2 Delivery
Pressure Sensor
Displacement Angle
Selection Valve
Pump 1 Delivery
Pressure Sensor
Pump 2 Control
Pressure Sensor
Pump 1 Control
Pressure Sensor
T1V5-02-01-009
T2-1-13
SYSTEM / Controller
HSB Breaker Control (Optional)
As for the machine equipped with HSB breaker, when
breaker 1 is selected on the monitor unit or is set by Dr.
ZX, MC drives the selector valve control solenoid valve
and the secondary pilot relief pressure control solenoid
valve.
Pilot pressure from the selector valve control solenoid
valve shifts the selector valve and connects the return
circuit in breaker to hydraulic oil tank.
Pilot pressure from the secondary pilot relief pressure
control solenoid valve shifts the secondary pilot relief
pressure control valve and reduces relief set pressure
in the breaker circuit.
NPK Breaker Control (Optional)
As for the machine equipped with NPK breaker, when
breaker 2 is selected on the monitor unit or is set by Dr.
ZX, MC drives the selector valve control solenoid valve
and the accumulator control solenoid valve.
Pilot pressure from the selector valve control solenoid
valve shifts the selector valve and connects the return
circuit in breaker to hydraulic oil tank.
Pilot pressure from the accumulator control solenoid
valve shifts the accumulator control valve, connects
the accumulator to the circuits in breaker cylinder
bottom side and rod side, reduces shock of oil
pressure, and buffers vibration when the breaker is
used.
T2-1-14
SYSTEM / Controller
Accumulator
Control Valve
Breaker
Monitor Unit
Accumulator
MC
Selector Valve
Secondary Pilot
Relief Pressure
Valve
Attachment
From Control
Valve
Selection Signal
ICF
Dr.ZX
CAN
Bus
Line
Accumulator Control
Solenoid Valve
Maximum Pump 2
Flow Rate Limit
Solenoid Valve
T2-1-15
T1V5-02-01-003
SYSTEM / Controller
Secondary Crusher Control (Optional)
As for the machine equipped with the secondary
crusher, when secondary crusher 1 is selected on the
monitor unit or is set by Dr. ZX, MC drives the auxiliary
flow combining solenoid valve.
When operating the secondary crusher, pilot pressure
from the attachment pilot valve shifts the bypass
shut-out valve and the auxiliary flow combining valve
through the auxiliary flow combining solenoid valve.
When pressure oil from pump 1 is combined with
pressure oil from pump 2 through the auxiliary flow
combining valve. Therefore, combined pressure oil
flows to the auxiliary spool and speed operating the
secondary crusher increases.
When operating combined operation of arm roll-out,
arm roll-out + boom raise, swing or travel and
secondary crusher, MC drives the auxiliary flow rate
control solenoid valve according to the signals from
pressure sensors (auxiliary, arm roll-out, boom raise,
swing or travel) so that pressure oil to the secondary
crusher is restricted.
Primary Crusher Control (Optional)
As for the machine equipped with the primary crusher,
when primary crusher 1 is selected on the monitor unit
or is set by Dr. ZX, MC drives the auxiliary flow
combining solenoid valve.
When operating the primary crusher, pilot pressure
from the attachment pilot valve shifts the bypass
shut-out valve and the auxiliary flow combining valve
through the auxiliary flow combining solenoid valve.
When pressure oil from pump 1 is combined with
pressure oil from pump 2 through the auxiliary flow
combining valve. Therefore, combined pressure oil
flows to the auxiliary spool and speed operating the
primary crusher increases.
When operating combined operation of arm roll-out,
arm roll-out + boom raise, swing or travel and primary
crusher, MC drives the auxiliary flow rate control
solenoid valve according to the signals from pressure
sensors (auxiliary, arm roll-out, boom raise, swing or
travel) so that pressure oil to the primary crusher is
restricted.
As the primary crusher is heavier than the secondary
crusher, when operating combined operation of arm
roll-out or arm roll-out + boom raise and primary
crusher, MC restricts flow rate of the auxiliary flow rate
control solenoid valve further, and gives priority to
operation of arm roll-out or arm roll-out + boom raise.
T2-1-16
SYSTEM / Controller
Secondary
Crusher Cylinder
Monitor Unit
MC
Selector Valve
From Pump 1
Auxiliary Flow
Combiner Valve
Attachment
Control Valve
Fine
Selection
Signal
ICF
CAN
Bus
Line
Dr.ZX
Auxiliary Flow
Rate Control
Solenoid Valve
Pressure Sensor
Travel
From Pilot
Pump
Swing
Boom Raise
Auxiliary Flow
Rate Control Valve
Arm Roll-Out
Auxiliary
From
Attachment
Pilot Valve
Auxiliary Flow
Combining
Solenoid Valve
Bypass
Shut-Out Valve
From
Pump 2
T1V5-02-01-004
the
circuit
of
T2-1-17
SYSTEM / Controller
Other Controls
Rear Monitoring Display Selection Control
MC shifts the monitor unit into the back-screen display
according to the signal from pressure sensor (travel) or
rear monitoring switch (optional).
T2-1-18
SYSTEM / Controller
Monitor Unit
MC
Rear Monitoring
Switch (Optional)
To ICF
Back-Screen
CAN Bus Line
Buzzer
(Optional)
Swing Alarm
Relay (Optional)
Buzzer
(Optional)
Beacon Light
(Optional)
T1V1-02-01-046
T2-1-19
SYSTEM / Controller
ECM: ENGINE CONTROL MODULE
Function Outline
Fuel Injection Control
ECM detects the engine operating condition according
to the signals from each sensor and MC and controls
the fuel injection.
T2-1-20
SYSTEM / Controller
ECM
Emergency
Stop Switch
From Terminal #5
in Key Switch
Fuse Box
From Battery
MC
Common Rail
Pressure Sensor
Common Rail
Supply Pump
Glow Plug
Fuel Tank
Injector
T1V1-02-01-047
T2-1-21
SYSTEM / Controller
ICF: INFORMATION CONTROLLER
Function Outline
Operating Hours Management
The built-in clock is provided for ICF.
ICF sends data of built-in clock to the monitor unit by
using CAN bus line.
T2-1-22
SYSTEM / Controller
ICF
MC
Communication
Built-In Clock
ECM
Satellite Terminal
(Optional)
GPS
Monitor Unit
Center Server
Dr.ZX
T1V1-02-01-049
T2-1-23
SYSTEM / Controller
(Blank)
T2-1-24
SYSTEM / Controller
OUTLINE
Function Outline
Primary Screen
Machine with Overload Alarm
(Optional) Attached
9
22
10
11
12
13
14
15
21
20
19
18
17
16
T1V1-05-01-094
15 - Back-Screen Selection
10 - Fuel Gauge
11 - Mail Display (Optional)
16 - Menu
17 - Auxiliary Selection
6 - Glow Display
12 - Auxiliary
NOTE: *ML crane display and ML crane selection is only available in Japanese domestic marked.
T2-1-25
SYSTEM / Controller
Display of Meters
Data to be displayed on each meter from are
displayed on the monitor unit according to the input
signal from sensor, the signal received by using
CAN and the internal data of monitor unit.
Items to be displayed
1. Coolant Temperature Gauge (Input signal from
the coolant temperature sensor)
2. Hour Meter (Internal data of the monitor unit)
3. Fuel Consumption Gauge (Input signal from the
fuel sensor)
4. Clock (Signal received from ICF by using CAN)
T1V1-05-01-108
Attachment Mode
Breaker
T1V1-05-01-104
Pulverizer
T1V1-05-01-105
Crusher
T1V1-05-01-106
Vibrating Hammer
T1V1-05-01-107
Others
T1V1-05-02-003
T2-1-26
Work Mode
T1V1-05-01-008
SYSTEM / Controller
Fuel Sensor
Attachment
ICF
Cloc
k
CAN Bus Line
T1V1-02-01-053
T2-1-27
SYSTEM / Controller
T1V1-05-01-008
T2-1-28
T1V1-05-01-128
SYSTEM / Controller
Auto-Idle Switch
OFF
ON
Fuel Consumption
Glow Plug:
Continuity
MC
Fuel
Consumption
CAN Bus
Line
CAN Bus
Line
From Terminal #5 in
Key Switch
ECM
From Battery
Glow Plug Relay
Glow Plug
T1V1-02-01-054
T2-1-29
SYSTEM / Controller
Fuel Sensor Error Display
Coolant Temperature
Sensor Error Display
T2-1-30
T1V1-05-02-005
Alarm Display
T1V1-05-01-096
T1V5-05-01-013
SYSTEM / Controller
Pilot Shut-off
Lever
Fuel Sensor
Coolant
Temperature
Sensor
Overheat
Switch
Hydraulic Oil
Hydraulic Oil Filter Alarm Display
Filter Alarm
Switch (Optional)
Air Cleaner
Restriction
Switch
Alternator
Alarm
Display
From
Terminal M in
Key Switch
To Terminal
B in Key
Switch
CAN Bus
Line
Battery
MC
Battery Relay
To Terminal B in Starter
To Terminal R in Starter Relay 2
Alternator
T1V1-02-01-060
T2-1-31
SYSTEM / Controller
Troubleshooting
T1V5-05-01-097
T1V5-05-01-122
Monitoring Screen
T1V5-05-01-087
T1V5-05-01-025
Controller Version
Monitoring
Operating Conditions
T2-1-32
SYSTEM / Controller
ECM
T1V1-02-01-061
T2-1-33
SYSTEM / Controller
Pump 2 Flow Rate Adjustment
key 1
key 2
T1V5-05-01-111
key 1
key 2
Type of
Attachments
2-Speed
Valve Selector
Selector Circuit
Circuit
Breaker 1
OFF
Breaker 2
OFF
Pulverizer 1
Crusher 1
ON
ON
Accumulator
Circuit
to Hydraulic
Oil Tank
to Hydraulic
Oil Tank
to Control Valve
to Control Valve
OFF
T1V5-05-01-024
ON
OFF
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
ON
T2-1-34
SYSTEM / Controller
MC
Pump 2
T1V5-02-01-011
Control Valve
Auxiliary Flow
Rate Control
Solenoid Valve
MC
T2-1-35
From
Pump 2
T1V5-02-01-010
SYSTEM / Controller
Attachment Selection
T1V5-05-01-109
Secondary Pilot
Relief Pressure Valve
MC
CAN Bus
Line
Selector Valve
From Control
Valve
Selector Valve
Control
Solenoid Valve
Secondary Pilot
Relief Pressure
Control Solenoid
Valve
From Pilot
Pump
T1V1-02-01-063
T2-1-36
SYSTEM / Controller
When breaker 2 (NPK breaker) is selected:
Breaker
Accumulator
Control Valve
Accumulator
(High Pressure)
MC
CAN Bus
Line
Selector
Valve
Accumulator
(Low Pressure)
From Control
Valve
Selector Valve
Control
Solenoid Valve
Accumulator
Control Solenoid
Valve
From Pilot
Pump
T1V1-02-01-064
From Pump 1
Auxiliary Flow
Combining Valve
Control Valve
Selector Valve
MC
From
Attachment
Pilot Valve
T2-1-37
From
Pump 2
Bypass Shut-out
Valve
T1V1-02-01-065
SYSTEM / Controller
When crusher 1 is selected:
From Pump 1
Auxiliary Flow
Combining Valve
Pulverizer Cylinder
Control Valve
Selector Valve
MC
Auxiliary Flow
Rate Control
Valve
Auxiliary Flow
Rate Control
Solenoid Valve
From Pilot
Pump
Auxiliary Flow
Combining
Solenoid Valve
From
Attachment
Pilot Valve
T2-1-38
From
Pump 2
T1V1-02-01-066
SYSTEM / Controller
(Blank)
T2-1-39
SYSTEM / Controller
Back Monitor Settings
T1V5-05-01-173
Back Monitor
Pressure Sensor
Travel
Image
MC
T1V1-02-01-056
T2-1-40
SYSTEM / Controller
(Blank)
T2-1-41
SYSTEM / Controller
Maintenance Settings
T1V5-05-01-049
T1V5-05-01-052
Language Settings
(Optional Function)
Send requests such as general, fuel replenishment,
service maintenance and forwarding requests in the
mail switch screen.
Contents of mails are registered in ICF, and are sent
to the central server by a satellite terminal.
(Refer to ICF: Information Controller.)
T2-1-42
T1V1-05-01-137
T1V5-05-01-037
SYSTEM / Controller
ICF
Hours
T1V1-02-01-062
T2-1-43
SYSTEM / Controller
Overload Alarm
Alarm
Primary Screen
T1V1-05-01-128
T2-1-44
T1V1-05-02-004
SYSTEM / Controller
Boom Bottom
Pressure Sensor
MC
Buzzer
From Battery
T1V1-02-01-057
T2-1-45
SYSTEM / Controller
(Blank)
T2-1-46
Input Signal
Output Signal
Engine Control (ECM)
Engine Control Dial Control
HP Mode Control
Travel HP Mode Control
E Mode Control
Auto-Idle Control
Auto-Warming Up Control
Sensor
(Arm
(Optional)
Oil Temperature Sensor
Auto-Idle Switch
Roll-Out)
MC
T2-2-1
Input Signal
Key Switch
MC
*
*
*
*
Other Control
Rear Monitoring Display Selection Control
Work Mode Control
* Travel Alarm Control
* Swing Alarm Control
CAN Communication
Actual Engine Speed (From ECM)
Work Mode (Digging / Attachment)
(From Monitor Unit)
T2-2-2
T2-2-3
T2-2-4
Key Switch
Engine
Control Dial
Monitor Unit
Auto-Idle
Switch
MC
Digging
Mode
Power Mode Switch
Attachment
Mode 1 to 5
ICF
Mode
Mode
Mode
ECM
T1V1-02-01-002
Pump 2 Control
Pressure Sensor
T2-2-5
Pump 1 Control
Pressure Sensor
T2-2-6
Engine
Speed
Slow Idle
Engine speed is
reduced by 100
min-1 when the
control levers are in
neutral.
Fast Idle
Engine
Control Dial
Position
Pressure Sensor
Travel
Front Attachment
Engine
Control Dial
CAN Communication
MC
Dr. ZX
ICF
ECM
T1V1-02-01-005
T2-2-7
T2-2-8
Engine
Speed
1650 min-1
Increasing
Range of Fast
Idle
1500 min-1
Slow Idle
Model
ZX200-3 class
ZX225US-3 class
ZX225USR-3 class
ZX240-3 class
ZX270-3 class
Fast Idle
Engine
Control Dial
Position
Pressure Sensor
Boom Raise
Arm Roll-In
Engine
Control Dial
CAN Communication
MC
Dr. ZX
Power Mode Switch
ICF
HP Mode
Pump 2 Delivery
Pressure Sensor
Pump 1 Delivery
Pressure Sensor
ECM
T1V1-02-01-006
T2-2-9
Engine
Speed
1800 min-1
1750 min-1
Slow Idle
Condition:
1. Engine Control Dial: Set the engine speed in the
fast idle speed position.
2. Travel Operation: Operated
3. Front Attachment Operation: Not Operated (When
starting traveling)
4. Delivery Pressure of Pumps 1 and 2: Delivery
pressure of either pump is high.
(Reference: ZX200-3 class, ZX225US-3 class,
ZX225USR-3 class, ZX240-3 class:
2
19 MPa, (195 kgf/cm , 2760 psi)
2
ZX240-3 class: 15 MPa (153 kgf/cm ,
2180 psi))
T2-2-10
Increasing
Range of Fast
Idle
Model
ZX200-3 class
ZX225US-3 class
ZX225USR-3 class
ZX240-3 class
Fast Idle
Engine
Control Dial
Position
Pressure Sensor
Travel
Engine
Control Dial
CAN Communication
MC
Pump 2 Delivery
Pressure Sensor
Pump 1 Delivery
Pressure Sensor
T1V1-02-01-014
T2-2-11
T2-2-12
Engine
Speed
Engine Speed
increases from
the fast idle
speed by 100
min-1.
1800 min-1
1750 min-1
Slow Idle
Fast Idle
Engine
Control Dial
Position
Pressure Sensor
Travel
Engine
Control Dial
CAN Communication
MC
T1V1-02-01-015
T2-2-13
Engine
Speed
Engine Speed
Set by E
Mode Control
Operation
Steps 1, 2
Engine speed
increase by 150
min-1.
Operation Steps 3, 4
P Mode
Speed
Slow Idle
Model
ZX200-3 class
ZX225US-3 class
ZX225USR-3 class
ZX240-3 class
ZX270-3 class
T2-2-14
Fast Idle
Engine
Control Dial
Position
Engine Speed
Set by E Mode
Control
P Mode
Speed
1650 min1
1800 min1
1750 min1
1850 min1
1900 min1
2000 min1
Engine
Control Dial
CAN Communication
MC
E Mode
Pump 2 Delivery Pump 1 Delivery
Pressure Sensor Pressure Sensor
ECM
T1V1-02-01-007
Pump 2 Control
Pressure Sensor
T2-2-15
Pump 1 Control
Pressure Sensor
Engine
Speed
Engine speed is
reduced to the
auto-idle speed
after 3.5 seconds.
Fast Idle
Auto-Idle
Speed
T2-2-16
1200 min-1
Slow Idle
Fast Idle
Engine
Control Dial
Position
Pressure Sensor
Travel
Front Attachment
Engine
Control Dial
Auto-Idle
Switch
CAN Communication
MC
Dr. ZX
Power Mode Switch
E Mode
ECM
T1V1-02-01-008
T2-2-17
Engine
Speed
Fast Idle
1400 min-1
Auto-Warming
Up Speed
Increasing
Speed
Slow Idle
T2-2-18
Slow Idle
Fast Idle
Engine
Control Dial
Position
Oil Temperature
Sensor
Key Switch
Engine
Control Dial
CAN Communication
MC
Dr.ZX
ICF
ECM
T1V1-02-01-009
T2-2-19
900 min-1
Idle Speed-Up
Control
Increasing
Speed
Slow Idle
T2-2-20
Fast Idle
Engine
Control Dial
Position
Pressure Sensor
Travel
Front Attachment
Engine
Control Dial
CAN Communication
MC
ECM
T1V1-02-01-010
T2-2-21
Engine
Speed
Increasing
Range of Fast
Idle
Slow Idle
Model
ZX200-3 class
ZX225US-3 class
ZX225USR-3 class
ZX240-3 class
ZX270-3 class
T2-2-22
Fast Idle
Engine
Control Dial
Position
Pressure Sensor
Travel
Front Attachment
Key Switch
Engine
Control Dial
MC
CAN Communication
ECM
Coolant
Temperature
Sensor
Pump 2 Control
Pressure Sensor
Pump 1 Control
Pressure Sensor
T1V1-02-01-035
T2-2-23
T2-2-24
When all
conditions exist,
the maximum
engine speed is
increased to the
speed set by Dr.
ZX.
Engine
Speed
Slow
Idle
Fast
Idle
Engine
Control Dial
Position
Pressure Sensor
Auxiliary (Optional)
Engine
Control Dial
CAN Communication
Monitor Unit
MC
Attachment Mode
1 to 5
Dr.ZX
Power Mode Switch
ICF
HP Mode
ECM
T1V1-02-01-011
T2-2-25
Engine
Speed
Operation:
1. When the following conditions exist and the
attachment is operated, MC sends the signals
equivalent to the target engine speed set by Dr.
ZX to ECM by using CAN communication.
2. ECM increases engine speed to the attachment
operating speed set by Dr. ZX.
Conditions:
Dr. ZX: Resets the maximum engine speed to a
slower () attachment (hydraulic breaker,
secondary crusher, primary crusher or vibrating
hammer) operating speed in the service mode.
Work Mode: Attachment Mode
Auxiliary Mode: Attachment mode Attachment
selected by using the monitor unit is set () by Dr.
ZX
T2-2-26
When all
conditions exist,
the maximum
engine speed is
reduced to the
speed set by Dr.
ZX.
Slow Idle
Fast Idle
Engine
Control Dial
Position
CAN Communication
Monitor Unit
MC
Dr.ZX
Attachment Mode
1 to 5
ICF
ECM
T1V1-02-01-012
T2-2-27
T2-2-28
Pressure Sensor
Travel
Front Attachment
Engine
Control Dial
Auxiliary (Optional)
Monitor Unit
ICF
ECM
Pump 1 Delivery
Pressure Sensor
Pump 3 Delivery
Pump 2 Delivery
Pressure Sensor
Pressure Sensor
(Optional)
T1V1-02-01-003
T2-2-29
Operation:
1. The target engine operating speed is set by
controlling the engine control dial.
2. MC calculates the difference in speed between
the target engine speed and the actual engine
speed monitored by CAN communication from
ECM. Then, MC sends the signals to the torque
control solenoid valve.
3. The torque control solenoid valve delivers pilot
pressure in response to the received signals to
the pump regulator and controls the pump
delivery flow rate.
4. If the engine load increases and the actual engine
speed becomes slower than the target engine
speed, the pump swash angle is reduced so that
pump flow rate will be reduced. Therefore, the
engine load is reduced and engine stall is
prevented.
5. If the actual engine speed becomes faster than
the target engine speed, the pump swash angle is
increased so that pump delivery flow rate will
increase. Therefore, the engine output power can
be utilized more efficiently.
Flow Rate
T2-2-30
Pressure
Engine
Control Dial
CAN Communication
MC
ECM
Pump 2 Delivery
Pressure Sensor
Pump 1 Delivery
Pressure Sensor
T1V1-02-01-016
T2-2-31
Flow Rate
Operation:
1. When the engine speed set by the engine control
dial is slow, MC processes signals from the travel
pressure sensor, and pump 1 and 2 delivery
pressure sensors, and sends the signals to torque
control solenoid valve.
2. The torque control solenoid valve delivers pilot
pressure corresponding to the received signals to
the regulator and increases pump delivery flow
rate.
T2-2-32
Increased Torque
P-Q Curve
Pressure
Pressure Sensor
Travel
Front Attachment
Engine
Control Dial
MC
T1V1-02-01-018
T2-2-33
T2-2-34
Engine
Control Dial
Attachment Mode
Select secondary crusher or primary
crusher.
CAN Communication
Monitor Unit
MC
Dr.ZX
ICF
Pump 2 Delivery
Pressure Sensor
Pump 1 Delivery
Pressure Sensor
T1V1-02-01-017
T2-2-35
T2-2-36
Pressure Sensor
Travel
Auxiliary (Optional)
Work Mode Attachment
(Mainly Vibrating Hammer)
Monitor Unit
Dr.ZX
ICF
T1V1-02-01-019
T2-2-37
Q
Flow Rate
Operation:
1. When attachment is used, MC receives the
signals from pressure sensor (auxiliary)
(optional).
2. In response to attachment control operation, MC
drives the maximum pump 2 flow rate limit control
solenoid valve and reduces maximum pump flow
rate.
3. When the auxiliary flow combining solenoid valve
stops, pump 2 flow rate can be adjusted finely by
the monitor unit.
NOTE: In proportion to the attachment control
operation, maximum pump flow rated is
reduced. The minimum pump swash
set-angle on monitor unit for a attachment
(hydraulic breaker 1 to 5, secondary
crusher 1 to 5, primary crusher 1 to 5 or
vibrating hammer 1 to 5) can be set in the
service mode of Dr. ZX.
T2-2-38
Pressure
Pressure Sensor
Travel
Auxiliary (Optional)
Work Mode Attachment
(Mainly Hydraulic Breaker)
Monitor Unit
Dr.ZX
ICF
T2-2-39
T1V1-02-01-020
Q
Flow Rate
Operation:
1. When MC receives the signals from pump 3
delivery pressure sensor (optional), MC drives the
torque control solenoid valve.
2. The torque control solenoid valve reduces pumps
1, 2 flow rates.
3. Thereby, the total pump 1, 2 and 3 driving torque
(pump torque) is maintained not to exceed the
engine output power and the engine output power
is utilized efficiently.
T2-2-40
Pressure
MC
Pump 3 Delivery
Pressure Sensor
T1V1-02-01-021
T2-2-41
T2-2-42
Monitor Unit
Travel
Front Attachment
Key Switch
Swing
Boom Raise
Arm Roll-In
Auxiliary
(Optional)
Pump 2 Delivery
Pressure Sensor
Pump 1 Delivery
Pressure Sensor
Dr.ZX
Power Digging
Switch
Oil
ICF
Slow
Digging
Regenerative Spool
Auxiliary Flow
Rate Control Valve
Travel Motor
Swash Angle
Control Valve
T1V1-02-01-004
Arm Regenerative
Valve
T2-2-43
by
temporarily
Operation:
1. For maximum 8 seconds after the power digging
switch is turned ON, MC continuously activates
solenoid valve unit (SG).
2. Solenoid valve unit (SG) delivers pilot pressure to
the main relief valve in control valve and
increases relief pressure. (Refer to Control Valve /
COMPONENT OPERATION.)
T2-2-44
Power Digging
Switch
ICF
MC
SG
T1V1-02-01-024
T2-2-45
T2-2-46
Pressure Sensor
Boom Raise
Arm Roll-In
Pump 1 Delivery
Pressure Sensor
MC
SG
T1V1-02-01-025
T2-2-47
T2-2-48
Swing
Boom Raise
Arm Roll-In
Pump 2 Delivery
Pressure Sensor
Pump 1 Delivery
Pressure Sensor
MC
Boom Cylinder
From Pump 1
SC
Boom 1
Boom 2
Arm Cylinder
Arm 1
Swing Device
Arm 2
From Pump 2
Arm 2 Parallel
Circuit
T2-2-49
T2-2-50
Boom Raise
Arm Roll-In
MC
Boom Cylinder
Digging
Regenerative Valve
From Pump 1
Arm Cylinder
Boom 2
Boom 1
Arm 1
Arm 2
From Pump 2
T2-2-51
T1V1-02-01-023
T2-2-52
MC
Travel Mode Switch
Fast
Pump 2 Control
Pressure Sensor
Pump 1 Control
Pressure Sensor
SI
Swash Angle
Control Valve
T1V1-02-01-027
T2-2-53
T2-2-54
Pump 2 Delivery
Pressure Sensor
Pump 1 Delivery
Pressure Sensor
MC
Travel Mode Switch
Fast
Pump 2 Control
Pressure Sensor
Pump 1 Control
Pressure Sensor
SI
Swash Angle
Control Valve
T1V1-02-01-027
T2-2-55
T1V5-05-01-111
T2-2-56
Monitor Unit
Dr.ZX
ICF
Secondary Pilot Relief
Pressure Control
Solenoid Valve
MC
Secondary Pilot
Relief Pressure
Control Valve
Selector Valve
Secondary Pilot
Pressure Relief
Valve
Selector Valve
Control Solenoid
Valve
Attachment
Pilot Valve
From Pilot
Pump
13
Maximum Pump
2 Flow Rate Limit
Control Solenoid
Valve
From Pump 2
Flow Rate
Control Valve
in Signal
Control Valve
Pump 2
13
T1V1-02-01-033
T2-2-57
T1V5-05-01-112
T2-2-58
Accumulator
Control Valve
Accumulator
(High Pressure)
Monitor Unit
ICF
Dr.ZX
MC
Selector Valve Control
Solenoid Valve
Accumulator
(Low Pressure)
Selector Valve
Accumulator Control
Solenoid Valve
Attachment
Pilot Valve
From Pilot
Pump
13
Maximum Pump
2 Flow Rate
Limit Control
Solenoid Valve
From Pump 2
Flow Rate
Control Valve in
Signal Control
Valve
Pump 2
13
T1V1-02-01-032
T2-2-59
T1V5-05-01-024
T2-2-60
Pressure Sensor
Secondary
Crusher Cylinder
Travel
Swing
Boom Raise
Arm Roll-Out
Auxiliary
Monitor Unit
Dr. ZX
ICF
MC
Auxiliary Flow
Combiner Valve
13
From Pump 1
14
Attachment
Pilot Valve
From Pilot
Pump
From
Pump 2
14
Bypass
Shut-Out Valve
13
Auxiliary Flow
Combining
Solenoid Valve
T1V1-02-01-030
T2-2-61
T1V5-05-01-113
T2-2-62
Pressure
S
Travel
Swing
Boom Raise
Arm Roll-Out
Auxiliary
Monitor Unit
Primary Crusher
Cylinder
Dr.ZX
ICF
MC
Auxiliary Flow
Combiner Valve
Auxiliary Flow
Rate Control
Solenoid Valve
13
Attachment
Pilot Valve
From Pump 1
14
From Pilot
Pump
From
Pump 2
14
13
Auxiliary Flow
Combining Solenoid
Valve
Bypass
Shut-Out Valve
T1V1-02-01-030
T2-2-63
T2-2-64
Rear view
Monitor
Image
Pressure Sensor
Travel
CAN
communication
Monitor Unit
MC
T1V1-02-01-100
Setup Menu
T2-2-65
Back-Screen
Selection Switch
Digging Mode:
Normal control is performed.
T2-2-66
Travel Alarm
Device (Optional)
Buzzer
Deactivation
Switch (Optional)
Buzzer (Optional)
T2-2-67
T178-02-01-025
Pressure Sensor
Swing
Swing Alarm
Relay (Optional)
Buzzer
Deactivation
Switch (Optional)
Buzzer
(Optional)
Beacon Light
(Optional)
T178-02-01-026
T2-2-68
MC
Two-Way Valve
Common Rail
Pressure
Sensor
Suction Control
Valve
Common Rail
Supply Pump
Injector
Fuel Tank
T1GR-02-02-001
T2-3-1
MC
Common Rail
Pressure
Two-Way Valve
Suction Control
Valve
Common Rail
Supply Pump
Injector
Fuel Tank
T1GR-02-02-001
T2-3-2
T2-3-3
T2-3-4
Front Attachment
Swing
Boom Raise
Arm Roll-In
Auxiliary (Optional)
Auto-Idle
Switch
Power Mode
Switch
ECM
HP Mode
E Mode
CAN
Common Rail
Pressure Sensor
Two-Way Valve
P Mode
Monitor Unit
Digging
Mode
Common Rail
Attachment
Mode
Pump 2 Delivery
Pressure Sensor
Fuel Tank
Supply Pump
Injector
Pump 1 Delivery
Pressure Sensor
Pump 1 Control
Pressure Sensor
Oil Temperature
Sensor
T1V1-02-02-001
Pump 2 Control
Pressure Sensor
T2-3-5
T2-3-6
Front
Swing
Boom Raise
Arm Roll-In
Auxiliary (Optional)
Engine
Control Dial
Auto-Idle
Switch
MC
Power Mode
Switch
ECM
HP Mode
E Mode
Two-Way Valve
P Mode
Monitor Unit
Digging
Mode
Common Rail
Suction Control
Valve
Attachment
Mode
Pump 2 Delivery
Pressure Sensor
Fuel Tank
Supply Pump
Injector
Pump 1 Delivery
Pressure Sensor
Pump 1 Control
Pressure Sensor
Oil Temperature
Sensor
T1V1-02-02-012
Pump 2 Control
Pressure Sensor
T2-3-7
T2-3-8
2. Injection Start
From ECM
Electromagnetic Coil
From ECM
Two-Way Valve
Two-Way Valve
Valve
Returning to Fuel Tank
From Common
Rail
Orifice 1
Control
Chamber
Hydraulic
Pressure Piston
Spring
Nozzle
Nozzle
4. Injection Stop
From ECM
Electromagnetic Coil
Two-Way Valve
Two-Way Valve
Valve
From Common
Rail
From Common
Rail
Control
Chamber
Orifice 2
Hydraulic
Pressure Piston
Hydraulic
Pressure Piston
Nozzle
Nozzle
T1GR-02-02-012
T2-3-9
Coolant
Temperature Sensor
From Terminal
#5 in Key Switch
Fuse Box
ECM
From Battery
Glow Plug
T2-3-10
T1V1-02-02-003
T2-3-11
T2-3-12
To Intercooler
Exhaust
From Air Cleaner
Outlet of Coolant
Cooling System
Engine
Inlet of Coolant
EGR Valve
Intake Manifold
From Suction
Intercooler
EGR Motor
Position
Sensor
EGR Motor
Lead Valve
ECM
T2-3-13
Atmospheric
Pressure Sensor
ECM
Two-Way
Valve
T1GR-02-02-002
T2-3-14
T2-3-15
T2-3-16
Key Switch
Fuse #8
ECM Main
Relay
OFF
ECM
#1-47
Emergency
Stop Switch
T1V1-02-05-010
T2-3-17
T2-3-18
Controller
Actuator
Control Valves
Motors
Cylinders
Front Attachmens (Optional)
Pilot Circuit:
Power Source
Pilot Pumps
Controller
Pilot Circuit
Pilot Valves
Pump Regulator
T2-4-1
T2-4-2
*Positioning
Pilot Valve
Left Pilot
Valve
Travel Pilot
Valve
Right Pilot
Valve
Auxiliary Pilot
Valve
Swing Motor
*To Positioning
Control Valve
Pump Control
Circuit
Maximum Pump 2
Flow Rate Control
Solenoid Valve
Pilot Shut-Off
Valve
Torque Control
Solenoid Valve
SB
ST
SA
Arm
To Control
Valve Spool
Boom
Position
ing
Auxiliary Flow
Combining Solenoid
Valve (When auxiliary
spool is used.)
Hose
Rupture
Valve
Auxiliary Flow Control
Solenoid Valve (When
auxiliary spool is used.)
Flow
Combiner
Valve
Bucket Flow
Control
Valve
Regulator
Valve
Control
Circuit
SG
SI
SF
SC
Solenoid
Valve Unit
Suction Filter
Control Valve
Relief Valve
Travel Motor
Hydraulic
Oil Tank
Travel Motor
Pilot Pump
Pilot Filter
T1V1-02-03-104
T2-4-3
T2-4-4
Shockless Valve
13 14
Pilot Shut-Off
Valve
9 10 11 12
4
3
Signal
Control Valve
10
11
12
2
1
4
3
3
Pilot Pump
5
Control Valve
14
13
Positioning Control
Valve (2-Piece
Boom only)
T1V1-02-03-011
1
2
3
4
Boom Raise
Boom Lower
Arm Roll-Out
Arm Roll-In
5678-
Left Swing
Right Swing
Bucket Roll-In
Bucket Roll-Out
T2-4-5
Control Pressure Pi
The pilot pressure from control valve is selected
by the shuttle valve in signal control valve so that
the pump 1 flow control valve or pump 2 flow
control valve in the signal control valve is shifted.
Pilot pressure from the pilot pump is supplied to
the regulator in pump 1 or pump 2 as flow rate
control pressure Pi by shifting the pump 1 flow
control valve or pump 2 flow control valve.
NOTE: When operating boom raise/ lower, arm
roll-out/in, bucket roll-in/out, auxiliary and
travel (right), flow rate control pressure Pi
is supplied to main pump1.
When operating boom raise/ lower, arm
roll-out/in, swing right/left and travel (left),
flow rate control pressure Pi is supplied to
main pump 2.
Solenoid Valve
Pilot pressure from the pilot pump is controlled by
the torque control solenoid valve and supplied to
the regulator in pumps 1 and 2 as speed sensing
pressure Ppc.
T2-4-6
Travel (Left)
Travel (Right)
Swing
Boom
Arm
Bucket
Pilot
Shut-Off
Valve
Pump 1 Flow
Control Valve
Signal
Control Valve
Pump 2 Flow
Control Valve
Control Valve
Maximum Pump 2
Flow Rate Control Torque Control
Solenoid Valve
Solenoid Valve
Pilot Pump
Pump 1
Pump 2
Pi
Ppc
T2-4-7
Ppc
Pi
T1V1-02-03-100
T2-4-8
Arm Roll-In
Boom Lower
Positioning
(2-Piece Boom only)
Auxiliary
Signal
Control
Valve
1
2
Arm Roll-In
Pilot
Pressure
Auxiliary Flow
Combining
Solenoid Valve
19
20
4
18
17
Arm Roll-In
Pilot Pressure
Auxiliary Flow
Control Solenoid
Valve
6
7
16
Solenoid
Valve Unit
SG
SF
10
SC
Pilot
Pump
Positioning Lower
Pilot Pressure
11
15
Arm Roll-In
Pilot
Pressure
14
13
12
T1V1-02-03-012
T2-4-9
T2-4-10
Swing
Arm
Boom
Signal
Control Valve
Solenoid
Valve Unit
Bucket
Control Valve
Swing Motor
SI
Bypass
Shut-Out
Valve
Travel Motor
Swash Angle
Control Valve
Positioning Control
Valve
T2-4-11
T1V1-02-03-013
T2-4-12
Bucket Cylinder
Front Attachments
Control Valve
Boom Cylinder
4-Spool
Side
Arm Cylinder
Travel (Left)
Travel (Right)
Auxiliary
Bucket
Boom 2
Boom 1
Arm 1
Arm 2
Swing
Positioning Cylinder
(2-Piece Boom Only)
5-Spool
Side
Bypass Check
Valve
Swing Motor
Oil
Cooler
Pump 2
Pump 1
Main
Pump
Positioning Control
Valve (2-Piece Boom
Only)
Suction
Filter
Hydraulic
Oil Tank
T1V1-02-03-103
T2-4-13
T2-4-14
Travel (Left)
Travel (Right)
Front
Attachment
Bucket Cylinder
Auxiliary
Bucket
Boom 1
Boom 2
Arm Cylinder
Boom Cylinder
Arm 1
Swing Motor
Arm 2
Swing
5-Spool Side
Pump 2
4-Spool Side
Pump 1
T1V1-02-03-001
T2-4-15
T2-4-16
Parallel
Circuit
Boom 2
Boom 1
Boom Cylinder
Swing Motor
Swing
Parallel
Circuit
Pump 2
Pump 1
T1V1-02-03-002
T2-4-17
T2-4-18
Flow Combiner
Valve
Travel (Left)
Travel (Right)
Arm Cylinder
Arm 1
Arm 2
5-Spool Side
Pump 2
4-Spool Side
Pump 1
T1V1-02-03-003
T2-4-19
T2-4-20
T178-02-02-014
Bypass Shut-Out
Valve
Positioning Cylinder
Pump 1
Positioning Control
Pressure
Positioning Control
Valve
Positioning
Control
Pressure
T1V1-02-03-014
T2-4-21
T2-4-22
Auxiliary Flow
Combining Valve
Auxiliary Flow
Combining Solenoid
Valve
SN
Front
Attachment
Neutral
Circuit
Auxiliary
Bypass
Shut-Out Valve
Pump 2
Pump 1
T1V1-02-03-004
T2-4-23
T2-4-24
Boom Lower
Meter-In Cut Valve
Boom 2
Arm
Cylinder
Boom 1
Boom Cylinder
Arm 1
Arm 2
Pump 2
Pump 1
T1V1-02-03-005
T2-4-25
T2-4-26
Boom Flow
Control Valve
(Poppet Valve)
Boom Flow
Control Valve
(Switch Valve)
Boom Lower
Meter-In Cut
Valve
Boom 2
Boom 1
Boom Cylinder
Pump 2
Pump 1
T1V1-02-03-006
T2-4-27
T2-4-28
Main Circuit
Monitor Circuit
T2-5-1
Accessory Circuit
Becomes operative when the key switch is turned
to the ACC position.
Starting Circuit
Starts the engine. [ Key Switch, Starter, Starter
Relay 2]
Charging Circuit
Charges the batteries. [Alternator, (Regulator)]
Wiper Circuit
Operate the intermittent operation of wiper and
the washer.
T2-5-2
T2-5-3
CIRCUIT
(KEY
Battery
Fusible Link
T2-5-4
Key Switch
Fusible Link
Battery
Load Damp
Relay
Fuse Box
Horn Relay
Glow Relay
ECM Main Relay
Optional
Monitor Unit
T1V1-02-05-001
T2-5-5
T2-5-6
Key Switch
Battery
Fuse Box
Auxiliary
T1V1-02-05-002
T2-5-7
CIRCUIT
(KEY
SWITCH:
6. Consequently, the relay in starter is turned ON so
that the starter begins rotating.
T2-5-8
Battery
Battery
Relay
Starter
C
C
Starter
Relay 2
ICF
ECM Main
Relay
EMC
MC
Monitor
Unit
T1V1-02-05-007
T2-5-9
Starter Relay 2
S
B
D3
(1)
R4
R3
From Alternator
Terminal L
R2
(2)
D2
Q1
C
(1)
M
Q2
C
B
(2)
E
D4
C1
Starter
12V
ST
Key Switch
12V
Battery
T107-04-04-003
T2-5-10
T2-5-11
Monitor Unit
T2-5-12
Alternator
Alarm
Key Switch
Battery
To
Monitor
Unit,
ICF
Battery
Relay
Alternator
T1V1-02-05-003
T2-5-13
Alternator
B
Battery
Relay
R
RF
Regulator
L
(R)
R3
R5
R4
R6
D
ZD
Battery
R2
B
SC
R1
FC
D1
C
B
C
T2
E
T1
(F)
(E)
T157-04-02-008
T2-5-14
Battery Relay
RF
R3
R4
R5
R6
Battery
ZD
R2
B
SC
A
C
FC
R1
B
C
T2
E
T1
(F)
D1
(E)
T157-04-02-009
T2-5-15
T2-5-16
Key Switch
Battery
Battery
Relay
Load
Damp
Relay
Alternator
Monitor Unit
#A-12
#C-7
T1V1-02-05-004
T2-5-17
T2-5-18
Starter
Relay 2
Security
Relay
Pilot Shut-Off
Lever
Pilot Shut-Off
Relay
Pilot Shut-Off
Solenoid Valve
Monitor
Unit
T1V1-02-05-008
T2-5-19
T2-5-20
Key Switch
Starter Cut
Relay
Battery
Battery
Relay
Starter
Starter
Relay 2
Security
Relay
Pilot Shut-Off
Lever
ICF
Pilot Shut-Off
Relay
Pilot Shut-Off
Solenoid Valve
Monitor
Unit
T1V1-02-05-009
T2-5-21
T2-5-22
Key Switch
Battery
ICF
ECM Main
Relay
ECM
MC
Monitor Unit
1-24
T1V1-02-05-011
T2-5-23
From Battery
Fuse #9
Signal from
ICF
Monitor Unit
Security Horn
Security Horn
Relay
T1V1-02-05-006
T2-5-24
T2-5-25
T2-5-26
#A-6
Working
Light Input
From
Battery
Fuse #1
Light
Relay 1
Light
Relay 2
Cab Light
Working
Light
Boom Light
T1V1-02-05-012
T2-5-27
Fast
Speed
Middle
Speed
Slow
Speed
M178-01-016
Position ITN.
Slow
Middle
Fast
Washer Operation
Purpose: Operates the washer.
Operation:
1. While pushing the wiper/washer switch, the
monitor unit receives the electrical signal from the
wiper/washer switch.
2. The monitor unit connects the ground circuit of
washer relay and the washer relay is turned ON.
3. When the washer relay is turned ON, current
from fuse #2 operates the washer motor and
washer liquid jets.
T2-5-28
Set Time
8 seconds
6 seconds
3 seconds
From
Battery
Wiper / Washer Switch
Wiper
Fuse #2
Monitor Unit
Washer
Washer Relay
Wiper Motor
Washer Motor
Wiper Relay
T1V1-02-05-005
T2-5-29
T2-5-30
MEMO
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SECTION 3
COMPONENT OPERATION
Group 1 Pump Device
CONTENTS
Group 4 Pilot Valve
Outline .....................................................T3-1-1
Outline .....................................................T3-4-1
Operation .................................................T3-4-4
Regulator .................................................T3-1-6
Shockless Function
Solenoid Valve........................................T3-1-22
Pilot Pump..............................................T3-1-24
Pump Delivery Pressure Sensor .............T3-1-24
Pump Control Pressure Sensor ..............T3-1-24
Outline .....................................................T3-2-1
Parking Brake...........................................T3-5-6
Outline .....................................................T3-3-1
Flow
1V1T-3-1
Combiner
1V1T-3-2
9
6
7
8
3
1
10
11
4
T1V1-03-01-006
1-
Pump 1
2-
Pump 2
3-
Pilot Pump
4-
78-
T3-1-1
10 - Transmission
11 - Coupling
4
T1V1-03-01-007
1 - Regulator
2 - Housing
3 - Shaft
4 - Plunger
5 - Valve Plate
T3-1-2
6 - Cylinder Block
Plunger
Valve Plate
Shaft
Cylinder Block
T105-02-03-002
T3-1-3
3
T105-02-03-021
T105-02-03-022
2 - Plunger
3 - Cylinder Block
4 - Valve Plate
5 - Pin
T3-1-4
6 - Servo Piston
T1V1-03-01-008
T3-1-5
Dr
5
Pi
Air
Bleeding
Circuit
Dr
Pd1
Pps
Pd2
Dr
9, 10
Pg
11
13
Increase
Decrease
T1V1-03-01-005
T3-1-6
Spring
Sleeve A
Spool A
Piston
Load Piston 1
Load Piston 2
Spool B
Sleeve B
Inner Spring
Outer Spring
Servo Piston
Cylinder Block
Link
10
T1V1-03-01-009
13
12
11
T1V1-03-01-007
1234-
Spring
Sleeve A
Spool A
Piston
567-
Load Piston 1
Load Piston 2
Spool B
8 - Sleeve B
9 - Inner Spring
10 - Outer Spring
T3-1-7
11 - Servo Piston
12 - Cylinder Block
13 - Link
Flow
Rate (Q)
Solenoid Valve
The main controller (MC) operates based on both
the engine target speed input data and actual speed
information signals and outputs the signals to the
torque control solenoid valve. In response to the
signals from MC, the torque control solenoid valve
delivers torque control pilot pressure Pps to the
regulator. When receiving pilot pressure Pps, the
regulator reduces the pump delivery flow rate.
(Speed Sensing Power Decrease Control: Slow
Speed Torque Increase Control)
(Refer to the Control System group.)
T3-1-8
Flow
Rate (Q)
Pressure Increase
Flow Rate Decrease
Pressure (P)
Flow
Rate (Q)
Pressure (P)
Flow Rate
(Q)
Pressure (P)
Flow Rate
(Q)
Pressure (P)
Dr
Pi
Air
Bleeding
Circuit
Pd2
Pps
Dr
Pd1
Pg
Increase
Decrease
T1V1-03-01-005
T3-1-9
Flow
Rate (Q)
Dr
Pi
Air
Bleeding
Circuit
Pd1
Pps
Dr
Pd2
Dr
Pg
11
Increase
13
T1V1-03-01-005
Decrease
1 - Spring
2 - Sleeve A
3 - Spool A
4 - Piston
11 - Servo Piston
13 - Link
T3-1-10
Primary Pilot
Pressure
Pump Control
Pressure Pi
Torque
Control
Pressure
Pps
Pump 1 Delivery
Pressure Pd1
Pump 2 Delivery
Pressure Pd2
13
11
To Hydraulic
Oil Tank
Primary Pilot
Pressure
T1V1-03-01-010
Pump Control
Pressure Pi
Torque
Control
Pressure
Pps
Pump 1 Delivery
Pressure Pd1
Pump 2 Delivery
Pressure Pd2
13
11
12-
Spring
Sleeve A
3 - Spool A
4 - Piston
11 - Servo Piston
T3-1-11
T1V1-03-01-011
13 - Link
Flow
Rate (Q)
Dr
Pi
Air
Bleeding
Circuit
Pd2
Pps
Dr
Pd1
Pg
11
13
T1V1-03-01-005
Increase
Decrease
Cylinder Block Inclination
1 - Spring
2 - Sleeve A
3 - Spool A
4 - Piston
10 - Servo Piston
12 - Link
T3-1-12
Primary Pilot
Pressure
Pump Control
Pressure Pi
Torque
Control
Pressure
Pps
Pump 1 Delivery
Pressure Pd1
Pump 2 Delivery
Pressure Pd2
13
11
1
To Hydraulic
Oil Tank
Primary Pilot
Pressure
T1V1-03-01-012
Pump Control
Pressure Pi
Torque
Control
Pressure
Pps
Pump 1 Delivery
Pressure Pd1
Pump 2 Delivery
Pressure Pd2
13
11
12-
Spring
Sleeve A
34-
Spool A
Piston
11 - Servo Piston
T3-1-13
T1V1-03-01-013
13 - Link
Flow
Rate (Q)
Pressure (P)
Dr
5
Pi
Air
Bleeding
Circuit
Dr
Pd1
Pps
Pd2
Dr
9, 10
Pg
11
13
Increase
Decrease
Cylinder Block Inclination
5678-
Load Piston 1
Load Piston 2
Spool B
Sleeve B
T3-1-14
910 11 13 -
T1V1-03-01-005
Inner Spring
Outer Spring
Servo Piston
Link
To Hydraulic
Oil Tank
Primary Pilot
Pressure
Pump Control
Pressure Pi
Torque
Control
Pressure
Pps
Pump 1 Delivery
Pressure Pd1
Pump 2 Delivery
Pressure Pd2
10
13
11
T1V1-03-01-014
To Hydraulic
Oil Tank
Primary Pilot
Pressure
Pump Control
Pressure Pi
Torque
Control
Pressure
Pps
Pump 1 Delivery
Pressure Pd1
Pump 2 Delivery
Pressure Pd2
10
13
11
T1V1-03-01-015
56-
Load Piston
Spool B
78-
Sleeve B
Inner Spring
9 - Outer Spring
10 - Servo Piston
T3-1-15
12 - Link
Flow
Rate (Q)
Pressure (P)
Dr
5
Pi
Air
Bleeding
Circuit
Dr
Pd1
Pps
Pd2
Dr
9, 10
Pg
11
13
Increase
Decrease
Cylinder Block Inclination
23567-
Sleeve A
Spool A
Load Piston 1
Load Piston 2
Spool B
T3-1-16
910 11 13 -
T1V1-03-01-005
Inner Spring
Outer Spring
Servo Piston
Link
To Hydraulic
Oil Tank
Primary Pilot
Pressure
Pump Control
Pressure Pi
Torque
Control
Pressure
Pps
Pump 1 Delivery
Pressure Pd1
Pump 2 Delivery
Pressure Pd2
10
13
11
5
To Hydraulic
Oil Tank
Primary Pilot
Pressure
T1V1-03-01-016
Pump Control
Pressure Pi
Torque
Control
Pressure
Pps
Pump 1 Delivery
Pressure Pd1
Pump 2 Delivery
Pressure Pd2
10
13
11
T1V1-03-01-017
23-
Sleeve A
Spool A
67-
Load Piston 2
Spool B
9 - Inner Spring
10 - Outer Spring
T3-1-17
11 - Servo Piston
13 - Link
Flow
Rate (Q)
Pressure (P)
Dr
5
Pi
Air
Bleeding
Circuit
Pd1
Pps
Dr
Pd2
Dr
7
11
9, 10
Pg
13
Increase
Decrease
Cylinder Block Inclination
56789-
Load Piston 1
Load Piston 2
Spool B
Sleeve B
Inner Spring
T3-1-18
T1V1-03-01-005
10 - Outer Spring
11 - Servo Piston
13 - Link
To Hydraulic
Oil Tank
Primary Pilot
Pressure
Pump Control
Pressure Pi
Torque
Control
Pressure
Pps
Pump 1 Delivery
Pressure Pd1
Pump 2 Delivery
Pressure Pd2
10
13
11
5
To Hydraulic
Oil Tank
Primary Pilot
Pressure
T1V1-03-01-018
Pump Control
Pressure Pi
Torque
Control
Pressure
Pps
Pump 1 Delivery
Pressure Pd1
Pump 2 Delivery
Pressure Pd2
10
13
11
56-
Load Piston 1
Load Piston 2
78-
Spool B
Sleeve B
9 - Inner Spring
10 - Outer Spring
T3-1-19
T1V1-03-01-019
11 - Servo Piston
13 - Link
Pressure (P)
Dr
5
Pi
Air
Bleeding
Circuit
Dr
Pd1
Pps
Pd2
Dr
Pg
11
13
T1V1-03-01-005
Increase
Decrease
Cylinder Block Inclination
1 - Spring
2 - Sleeve A
3 - Spool A
4 - Piston
11 - Servo Piston
13 - Link
T3-1-20
To Hydraulic
Oil Tank
Primary Pilot
Pressure
Pump Control
Pressure Pi
Regulated by
Maximum Pump
Flow Rate Control
Solenoid Valve
Torque
Control
Pressure
Pps
Pump 1 Delivery
Pressure Pd1
Pump 2 Delivery
Pressure Pd2
13
11
1
To Hydraulic
Oil Tank
Primary Pilot
Pressure
T1V1-03-01-020
Pump Control
Pressure Pi
Regulated by
Maximum Pump
Flow Rate Control
Solenoid Valve
Torque
Control
Pressure
Pps
Pump 1 Delivery
Pressure Pd1
Pump 2 Delivery
Pressure Pd2
13
11
T1V1-03-01-021
1 - Spring
2 - Sleeve A
3 - Spool A
4 - Piston
11 - Servo Piston
T3-1-21
13 - Link
T3-1-22
Solenoid
Spring 2
Piston
Port P
Spool
Output
Port
T1V1-03-01-002
Operating state:
Spring 2
Spring 1
Solenoid
Piston
Fsol
T3-1-23
Output
Port
Port T
Spool
T1V1-03-01-003
Inlet Port
2 - Driven Gear
Outlet Port
T137-02-03-005
Ground
Output
56-
T157-02-03-010
9-
Output
10
T176-03-01-023
T3-1-24
Swing Motor
T1V1-03-02-003
T3-2-1
ZX240-3 class
1
1
9
2
9
2
8
3
8
3
7
4
7
4
6
6
5
T1V1-03-02-018
5
T1V1-03-02-006
1-
23-
T3-2-2
7-
89-
7
6
T1V1-03-02-007
1-
23-
T3-2-3
7-
89-
1
13
2
12
3
4
11
5
10
8
T1V1-03-02-008
1234-
Spring
Brake Piston
Plate
Swing Parking Brake Selection
Valve
5 - Friction Plate
6 - Plunger
7 - Retainer
8 - Shaft
9 - Swash Plate
10 - Shoe
T3-2-4
11 - Housing
12 - Rotor
13 - Valve Plate
13
12
1
2
3
5
4
6
7
11
10
1234-
Spring
Brake Piston
Plate
Swing Parking Brake Selection
Valve
5 - Friction Plate
6 - Plunger
7 - Retainer
8 - Shaft
9 - Swash Plate
10 - Shoe
T3-2-5
T1V7-03-02-001
11 - Housing
12 - Rotor
13 - Valve Plate
T3-2-6
4
Port SH (Brake Release Pressure)
T178-03-02-003
ZX270-3 class
1
5
4
8
12-
Spring
Brake Piston
3 - Orifice
4 - Check Valve
56-
T3-2-7
T1V7-03-02-002
7 - Plate
8 - Rotor
Relief valve
Make-Up Valve
Port M
Control Valve
T107-02-04-013
Poppet
Make-Up Valve
Make-Up Valve
Port M
T1V1-03-02-011
Relief Valve
T3-2-8
Control Valve
Poppet
Make-Up
Valve
Make-Up
Valve
Port M
Relief
Valve
T3-2-9
T1V7-03-02-003
Poppet
Orifice
Spring
tion):
1. After the piston is moved to full stroke, the spring
is compressed so that the circuit pressure becomes the set-pressure.
2. If pressure at port HP increases more than the
spring set-pressure, the poppet is unseated and
pressure oil flows to port LP.
3. When pressure at port HP is reduced to the
specified level, the poppet is seated by the spring
force.
Passage A
Passage B
Piston
HP
LP
Oil Chamber C
Oil Chamber B
Oil Chamber A
T3-2-10
T178-03-02-005
Spring 2
Piston
Oil Chamber
tion):
1. After the piston is moved to full stroke, the circuit
pressure becomes the relief set-pressure.
2. If pressure at port HP increases more than the
spring 1 set-pressure, the poppet is unseated
pressure oil flows to port LP.
3. When pressure at port HP is reduced to the
specified level, the poppet is seated by the spring
1 force.
Spring 1
Orifice
Return Circuit
(Port LP)
HP
Plungert
Poppet
T107-02-04-020
NOTE: Although the structure of relief valve is different, the operational principle is same.
T3-2-11
T3-2-12
Combination
Valve
Swing Dampener
Valve
T1V1-03-02-003
T3-2-13
Pressure at Port AM
Pressure (P)
B CD E
Time (T)
T1V1-03-02-001
Pressure at Port BM
Pressure (P)
C
D
T3-2-14
Time (T)
Without Combination Valve
T1V1-03-02-002
Swing Motor
AM
Plug
BM
Chamber N
Chamber M
2 Chamber M
5
Combination Valve (B)
Chamber N
Control Valve
T1V1-03-02-013
1 - Poppet
2 - Ball
3 - Plunger
4 - Spring
5 - Piston
6 - Orifice
T3-2-15
7 - Spring
to decrease)
When the swing motor rotation due to the inertia force
of machine is reduced, pressure at port BM decreases.
At this time, combination valve (A) functions as the
following.
Pressure at Port AM
Pressure (P)
B CD E
Time (T)
T1V1-03-02-001
Pressure at Port BM
Pressure (P)
T3-2-16
B
C
D
Time (T)
Without Combination Valve
T1V1-03-02-002
Swing Motor
AM
BM
Chamber N
Combination Valve A
2 Chamber M 1
5
Combination Valve B
Chamber N
Control Valve
T1V1-03-02-014
12-
Poppet
Ball
34-
Plunger
Spring
56-
T3-2-17
Piston
Orifice
7-
Spring
BM decreases)
When the swing motor rotation is reduced more,
pressure at port BM decreases more. At this time,
combination valve (B) functions as the following.
Pressure at Port AM
Pressure (P)
B CD E
Time (T)
T1V1-03-02-001
Pressure at Port BM
Pressure (P)
T3-2-18
With
Combination
Valve
B
C
D
Time (T)
Without
Combination
Valve
T1V1-03-02-002
Swing Motor
AM
BM
Chamber N
Chamber M
2 Chamber M 1
5
Combination ValveB
Chamber N
Control Valve
T1V1-03-02-015
12-
Poppet
Ball
3 - Plunger
4 - Spring
5 - Piston
6 - Orifice
T3-2-19
7 - Spring
Pressure at Port AM
Pressure (P)
B CD E
Time (T)
T1V1-03-02-001
Pressure at Port BM
Pressure (P)
6. Combination valves (A, B) repeat these procedures and prevent aftershock of the machine.
When pressures at ports AM and BM decrease
completely, the combination valve stops functioning.
T3-2-20
With
Combination
Valve
B
C
D
Time (T)
Without
Combination
Valve
T1V1-03-02-002
Swing Motor
AM
BM
Combination Valve A
2
Combination Valve (B)
B
Control Valve
T1V1-03-02-016
1-
Poppet
2-
Ball
T3-2-21
T3-2-22
Travel
(Right)
Bucket
Boom 1
4-Spool
Section
Arm 2
Machine
Front
Travel
(Left)
Auxiliary
Boom 2
Arm 1
Swing
5-Spool
Section
T1V1-03-03-072
Machine Front
T178-03-03-370
T3-3-1
Machine Upper
Machine Lower
Machine Upper
4
5 6
10
11
12
42
13
14
41
15
40
16
39
17
38
18
19
20
37
36
35
21
34
22
23
33
24
32
31
30
29
28
27
26
25
T1V1-03-03-021
T3-3-2
18
19, 22
13
10, 11
23
15, 17
16
7
Boom Raise
Pressure Sensor
1-
20
14
T3-3-3
T1V1-03-03-073
Machine Lower
1
Machine Upper
Machine Lower
Machine Upper
5 6
10
11
12
42
13
14
41
15
40
16
39
17
38
18
19
20
37
36
35
21
34
22
23
33
24
32
31
30
29
28
27
26
25
T1V1-03-03-021
T3-3-4
37
34, 36
1
30, 32
40, 41
1-
T1V1-03-03-072
28
35
23 - Arm 2 Flow Rate Control
Valve (Switch Valve)
24 - Load Check Valve (Arm 2
Tandem Circuit)
25 - Bypass Shut-Out Valve
26 - Arm 2 Flow Rate Control
Valve (Poppet Valve)
27 - Arm Regenerative Valve
28 - Digging Regenerative
Valve
29 - Load Check Valve (Digging
Regenerative Circuit)
30 - Arm 1 Flow Rate Control
Valve (Poppet Valve)
31 - Load Check Valve (Swing
Circuit)
32 - Arm 1 Flow Rate Control
Valve (Switch Valve)
33 - Load Check Valve (Arm
Regenerative Circuit)
T3-3-5
Machine Lower
1
Machine Upper
Machine Lower
Machine Upper
5 6
10
11
12
42
13
14
41
15
40
16
39
17
38
18
19
20
37
36
35
21
34
22
23
33
24
32
31
30
29
28
27
26
25
T1V1-03-03-021
T3-3-6
5
7
T1V1-03-03-003
T1V1-03-03-026
2
12
28
21
27
29
T1V1-03-03-002
T1V1-03-03-001
1-
T3-3-7
Machine Lower
1
Machine Upper
Machine Lower
Machine Upper
5 6
10
11
12
42
13
14
41
15
40
16
39
17
38
18
19
20
37
36
35
21
34
22
23
33
24
32
31
30
29
28
27
26
25
T1V1-03-03-021
T3-3-8
Auxiliary
Bucket
13
10
41
11
14
40
12
T1V1-03-03-004
1-
T3-3-9
T1V1-03-03-005
Machine Upper
Machine Lower
1
Machine Lower
Machine Upper
5 6
10
11
12
42
13
14
41
15
40
16
39
17
38
18
19
20
37
36
35
21
34
22
23
33
24
32
31
30
29
28
27
26
25
T1V1-03-03-021
T3-3-10
Boom 2
Boom 1
22
37
19
39
16
17
15
38
21
28
20
T1V1-03-03-007
T1V1-03-03-006
1-
26
T3-3-11
Machine Upper
Machine Lower
1
Machine Lower
Machine Upper
5 6
10
11
12
42
13
14
41
15
40
16
39
17
38
18
19
20
37
36
35
21
34
22
23
33
24
32
31
30
29
28
27
26
25
T1V1-03-03-021
T3-3-12
34
Arm 2
Swing
18
27
36
32
30
35
1-
24
31
23
T1V1-03-03-009
T1V1-03-03-008
T3-3-13
Machine Upper
Machine Lower
1
Machine Lower
Machine Upper
5 6
10
11
12
42
13
14
41
15
40
16
39
17
38
18
19
20
37
36
35
21
34
22
23
33
24
32
31
30
29
28
27
26
25
T1V1-03-03-021
T3-3-14
25
K
L
T1V1-03-03-010
T1V1-03-03-027
6
N
T1V1-03-03-028
T1V1-03-03-022
1-
T3-3-15
4
3
T1V1-03-03-019
T3-3-16
3
T178-03-03-070
1-
T198-03-03-003
2-
3-
T3-3-17
4-
T3-3-18
Main Relief
Valve
5-Spool
Section
4-Spool Section
Parallel Circuit
Travel Motor
(Right)
4-Spool Section
Front
Attachment
Bucket
Cylinder
Overload
Relief Valve
Arm Cylinder
Overload
Relief Valve
Swing Motor
Boom
Cylinder
5-Spool Section
Parallel Circuit
Pump 2
Flow Combining
Circuit
Pump 1
T1V1-03-03-018
T3-3-19
T3-3-20
Neutral
Circuit
Bypass
Shut-Out Valve
Positioning
Cylinder
Shuttle
Valve
Parallel
Circuit
Pump 1
Positioning
Pilot Pressure
Boom
Lower Pilot
Pressure
Positioning Control
Valve
Overload Relief
Valve
T1V1-03-03-020
T3-3-21
T3-3-22
Main Relief
Valve
Auxiliary Flow
Combiner Valve
Pilot Pressure
from Auxiliary
(Only machine
equipped with
optional
auxiliary flow
combining
system)
Pilot Pressure
from Solenoid
Valve Unit
(SG)
Flow Combiner
Valve
Auxiliary Flow
Rate Control
Valve
Pilot Pressure from
Auxiliary Flow Rate
Control
Solenoid
Valve (Only machine
equipped
with
optional
auxiliary
flow
combining
system)
Digging
Regenerative
Valve
9
10
14
11
12
13
Pilot Pressure
from Flow
Combiner
Valve Spool in
Signal Control
Valve
Pilot Pressure
from Bucket
Flow Rate
Control Valve
Spool in
Signal Control
Valve
Boom Lower
Meter-In Cut
Valve
1
1
Arm Anti-Drift
Valve
Pilot Pressure
from Solenoid
Valve Unit
(SF)
3
Pilot Pressure
from Arm 1
Flow Rate
Control Valve
Spool in Signal
Control Valve
Boom Anti-Drift
Valve
Arm 2 Flow
Rate Control
Valve
Bypass Shut-Out
Valve
5
Pilot Pressure
from Solenoid
Valve Unit
(SC)
Arm
Regenerative
Valve
T1V1-03-03-023
1234-
Boom Raise
Boom Lower
Arm Roll-Out
Arm Roll-In
5678-
Left Swing
Right Swing
Bucket Roll-In
Bucket Roll-Out
910 11 12 -
T3-3-23
13 - Auxiliary (Open)
14 - Auxiliary (Close)
T3-3-24
Pilot Pressure
from Auxiliary
(Only machine
equipped with
optional auxiliary
flow combining
system)
Pilot Pressure
from Solenoid
Valve Unit
(SG)
Flow Combiner
Valve
Bucket Flow Rate
Control Valve
Pilot Pressure
from Flow
Combiner Valve
Spool in Signal
Control Valve
13
11
12
10
14
Pilot Pressure
from Bucket
Flow Rate
Control Valve
Spool in Signal
Control Valve
Digging
Regenerative
Valve
1
Pilot Pressure
from Hose
Rupture Valve
(Arm)
Boom
Anti-Drift
Valve
Pilot Pressure
from Solenoid
Valve Unit (SF)
3
4
Pilot Pressure
from Arm 1 Flow
Rate Control
Valve Spool in
Signal Control
Valve
Pilot Pressure
from
Hose
Rupture Valve
(Arm)
Pilot Pressure
from Solenoid
Valve Unit
(SC)
Shuttle Valve
Pilot Pressure from
Positioning
Arm 1 Flow Rate
Control Valve
1234-
Boom Raise
Boom Lower
Arm Roll-Out
Arm Rool-In
5678-
Arm Regenerative
Valve
Left Swing
Right Swing
Bucket Roll-In
Bucket Roll-Out
910 11 12 -
T3-3-25
13 - Auxiliary (Open)
14 - Auxiliary (Close)
Pressure Oil
from Pump 1
Pilot Pressure
from Flow
Combiner Valve
Control Spool
Spool
Hydraulic
Oil Tank
To Left Travel
Spool
T3-3-26
T1V1-03-03-056
Pilot Pressure
from Flow
Combiner Valve
Control Spool in
Signal Control
Valve
Travel Motor
(Right)
Bucket
Cylinder
Pump 1
T1V1-03-03-046
T3-3-27
T3-3-28
Orifice A
Orifice B
Seat
Passage Spring B
HP
SG
LP
Spring
Chamber
Sleeve
Spring A
Pilot Poppet
Piston
T157-02-05-003
Orifice A
Orifice B
Seat
Passage Spring B
HP
LP
Sleeve
Spring
Chamber
Spring A
Pilot Poppet
T157-02-05-003
HP
SG
LP
Pilot Poppet
T3-3-29
Piston
T157-02-05-004
Make-Up Operation
1. When pressure in port HP (actuator circuit)
decreases lower than port LP (hydraulic oil tank),
the sleeve moves to the right.
2. Hydraulic oil flows in port HP from port LP and
cavitation is prevented.
3. When pressure in port HP increases more than
the specified pressure, the sleeve is closed by the
force of spring C .
Sleeve
Spring A
Main Poppet
Orifice A
HP
Spring B
T3-3-30
Pilot
Poppet
Passage A
Spring
Chamber
Valve
LP
T198-03-03-006
Main Poppet
Sleeve
Spring A
Passage A
Spring B
HP
LP
Piston
Orifice
Spring
Chamber
Pilot
Poppet
Spring C
T107-02-05-019
Sleeve
Spring A
Passage A
Spring B
HP
LP
Orifice
Piston
Spring
Chamber
T178-03-03-049
Pilot
Poppet
HP
LP
Spring C
T3-3-31
T178-03-03-050
T3-3-32
Bucket
Cylinder
Check Valve
T176-03-03-027
Spool
Pressure Oil to
Cylinder Bottom
Side
Check
Valve
T1V1-03-03-057
T3-3-33
Arm Regenerative
Valve
A
Chamber B
Hole
Spool
Pilot Pressure
from Solenoid
Valve Unit (SC)
Spool
To Arm Cylinder
Bottom Side
T3-3-34
Check Valve
T1V1-03-03-075
Arm Cylinder
Boom
Cylinder
Swing Motor
Pilot Pressure
from Solenoid
Valve Unit (SC)
Pump 2
Pump 1
Arm
Regenerative
Valve
T1V1-03-03-052
T3-3-35
Boom Cylinder
Releasing Operation
1. When the arm is rolled in or the boom is lowered,
pressure oil from the pilot valve pushes the piston
in anti-drift valve and shifts the switch valve.
Anti-Drift Valve
2. Oil in the spring chamber of check valve flows
(Switch Valve)
back to the hydraulic oil tank through the passage
in switch valve.
3. When pressure in the spring chamber decreases
Pressure Oil
and pressure oil from the cylinder bottom side is
from Pump 1
larger than pressure in the spring chamber and
spring force, the check valve moves to the right
due to a area difference.
4. Consequently, return oil from the boom cylinder
bottom side (arm cylinder rod side) flows to the
spool.
From Pilot
As pressure decrease in the spring chamber is Valve
reduced by the orifice in switch valve, the check
valve is prevented from rapidly moving and the
shock is reduced during boom lower operation.
Anti-Drift Valve
(Switch Valve)
T3-3-36
Anti-Drift Valve
(Check Valve)
To Hydraulic
Oil Tank
Anti-Drift Valve
(Check Valve)
T1V1-03-03-047
Boom Cylinder
T1V1-03-03-048
Switch Valve
Hydraulic Oil
Tank
To Main Spool
Check Valve
From Cylinder
Bottom Circuit
T1V1-03-03-060
Releasing Operation:
Pressure Oil
from Pilot Valve
Piston
Hydraulic
Oil Tank
Switch Valve
To Main Spool
Spring
Check Valve
From Cylinder
Bottom Circuit
T3-3-37
T1V1-03-03-061
Arm
Cylinder
Poppet
Valve
Check
Valve
Hydraulic
Oil Tank
Pressure Oil
from Pump 2
T1V1-03-03-049
Arm
Cylinder
Switch
Valve
Normal Operation
1. Pressure oil from pump 2 acts to the check valve
in poppet valve.
2. As the switch valve is usually kept opened,
pressure oil from pump 2 opens the check valve
flows to the arm 1 spool.
3. If load at the actuator side is high, the poppet
valve is open and pressure oil from pump 2 flows
to the arm 1 spool.
4. Therefore, flow rate through the arm 1 spool
increases and speed of arm increases.
Flow Rate Control Operation
1. The switch valve in arm 1 flow rate control valve
is shifted by pilot pressure from the arm 1 flow
rate control valve spool in signal control valve.
2. Therefore, back pressure in the poppet valve
increases and the force to close the poppet valve
appears.
3. Consequently, the poppet valve restricts flow rate
to the arm 1 spool and pressure oil is supplied to
the swing side which load pressure is higher at.
Switch
Valve
Poppet
Valve
Pressure Oil
from Pump 2
T1V1-03-03-050
From Boom 2
Spool
Switch
Valve
Boom Cylinder
T1V1-03-03-076
T3-3-38
Poppet
To Arm 1 Spool
To Hydraulic
Oil Tank
Pressure Oil
from Pump 2
Switch Valve
To Hydraulic
Oil Tank
To Arm 1 Spool
T1V1-03-03-062
Poppet
To Arm 1 Spool
To Hydraulic
Oil Tank
Pressure Oil
from Pump 2
Switch Valve
To Hydraulic
Oil Tank
To Arm 1 Spool
T1V1-03-03-063
Poppet
To Arm 1 Spool
Switch Valve
To Hydraulic
Oil Tank
To Arm 1 Spool
T3-3-39
T1V1-03-03-064
To Arm 1 Spool
Inner
Passage
Check Valve
SF
Spool
Pilot Pressure
from Solenoid
Valve Unit (SF)
Return Oil
from Boom
Cylinder Rod
Side
Spring
Digging
Regenerative
Valve
T3-3-40
T1V1-03-03-069
Boom 2
Spool
Boom Cylinder
Arm Cylinder
Pilot Pressure
from Solenoid
Valve Unit (SF)
Arm 1
Spool
Check
Valve
Pump 2
T1V1-03-03-053
T3-3-41
Operation (Jack-Up)
1. During jack-up operation, as pressure at the
boom cylinder bottom side decreases, pressure in
the spring chamber decreases.
2. When pressure in spring chamber becomes
lower than the spring force, the boom lower
meter-in cut valve moves to the right due to the
spring force.
3. Therefore, as pressure oil which acts to the
switch valve in boom flow rate control valve from
port P17 flows to the hydraulic oil tank through
the boom lower meter-in cut valve, the switch
valve is returned to the original position.
4. Pressure oil from port P17 flows to the boom 2
spool from port P 19 through the boom lower
meter-in cut valve.
5. Therefore, during jack-up operation, the boom
lower meter-in cut control is not operated.
(Refer to Hydraulic System/ SYSTEM.)
T3-3-42
Boom 1 Spool
Boom 2 Spool
Port P17
Arm Cylinder
Port P19
Boom Cylinder
Pump 2
Pump 1
T1V1-03-03-051
Orifice
To
Hydraulic
Oil Tank
Spring
PI7
To Switch
Valve
PI9
To Boom 2 Spool
Boom Lower
Pilot Pressure
T3-3-43
T1V1-03-03-074
To Auxiliary Spool
SM
Front
Attachment
Pilot
Pressure
Pressure Oil
from Pump 1
Check Valve
Spool
To Hydraulic Oil
Tank
T1V1-03-03-066
Front
Attachment
Pilot
Pressure
SJ
T1V1-03-03-068
To Hydraulic
Oil Tank
T3-3-44
Spool
Auxiliary Flow
Combiner Valve
Auxiliary Flow
Combining
Solenoid Valve
SM
SN
Front
Attachment
Auxiliary
Neutral
Circuit
Bypass
Shut-Out Valve
SJ
Pump 1
Pump 2
T1V1-03-03-054
T3-3-45
SM
Front
Attachment
Pilot
Pressure
Pressure Oil
from Pump 1
Check Valve
Spool
SN
Front Attachment
or Travel Pilot
Pressure
T3-3-46
T1V1-03-03-065
Pilot Pressure
from Signal
Control Valve
Auxiliary Flow
Combiner Valve
Auxiliary Flow
Combining
Solenoid Valve
SM
SN
Front
Attachment
Bucket Cylinder
Auxiliary
Bucket
Bypass
Shut-Out Valve
SJ
Pump 2
Pump 1
T1V1-03-03-055
T3-3-47
T3-3-48
NOTE: As for the pilot valves for front attachment/swing and for travel, the structure of
cam to push in the pusher is different and
that of pressure-reducing valve is same.
Right
Left
1
2
3
4
1
2
3
4
ISO Control
Hitachi
Pattern
Pattern
Bucket Roll-Out
Boom Lower
Bucket Roll-In
Boom Raise
Right Swing
Arm Roll-Out
Left Swing
Arm Roll-In
Hydraulic
Symbol
Arm Roll-In
Right Swing
Arm Roll-Out
Left Swing
T105-02-07-020
T3-4-1
T1V1-03-04-001
T
P
Hydraulic
Symbol
B
View B
P T
T1M9-03-05-004
T178-03-04-017
1
T1M9-03-05-005
Open
Close
Lower
Raise
T
P
P T
T1CF-03-04-002
T1CF-03-04-001
T3-4-2
T3-4-3
T3-4-4
D
Pilot
Pressure
C
Lever Stroke
T523-02-05-001
7
Port P
Output Port
Port T
Port T
Port P
Output Port
Port T
Port P
Output Port
T1V1-03-04-007
T1V1-03-04-008
Port T
7
3
Output Port
Port P
Port T
Port T
6
Port P
Output Port
1 - Cam
2 - Pusher
3 - Spring Guide
4 - Balance Spring
Port P
Output Port
T1V1-03-04-002
5 - Return Spring
6 - Spool
T3-4-5
T1V1-03-04-003
7 - Hole
T3-4-6
D
Pilot
Pressure
C
Lever Stroke
T523-02-05-001
6
Port T
Port T
Port P
Output Port
Port P
Output Port
T1V1-03-04-009
T1V1-03-04-010
6
Port T
Port P
Output Port
1 - Cam
2 - Pusher
Port T
3 - Spring Guide
4 - Balance Spring
Port P
Output Port
T1V1-03-04-004
5 - Return Spring
6 - Spool
T3-4-7
7 - Hole
T1V1-03-04-005
D
Pilot
Pressure
Lever Stroke
T523-02-05-001
T3-4-8
1
2
3
4
5
E
6
Port T
Port P
Output Port
T1V1-03-04-011
T1V1-03-04-007
3
4
5
6
Port T
Port P
Output Port
1 - Cam
2 - Pusher
3 - Spring Guide
4 - Balance Spring
T1V1-03-04-006
T1V1-03-04-002
5 - Return Spring
6 - Spool
T3-4-9
7 - Hole
Pilot
Pressure
D
Pedal Stroke
T1F3-03-09-004
T3-4-10
1
2
4
3
5
Port T
Port T
6
(A)
Port P
Port P
Hole
Hole
Passage
Output Port
Output Port
T1M7-03-04-008
Port T
(A)
Port P
Output Port
12-
Cam
Pusher
34-
Plate
Spring Guide
T1M7-03-04-021
5 - Balance Spring
6 - Return Spring
T3-4-11
7 - Spool
T1M7-03-04-022
The travel pilot valve has the damper enabling damping of the speed change shock by the travel lever.
The damper is composed of support, gears 1 and 2
and others. Gear 1 is connected with the support.
The support is secure to the bracket by using a spring
pin. The travel lever and travel pedal are secure to the
bracket.
Therefore, the support swings transversely around the
pin in line with movement of the travel lever.
Travel Pedal
A
Travel Lever
Support
Bracket
Pin
Gear 2
Operation
1. If the travel lever is released from the hand during
traveling, spring force of the return spring returns
the travel lever to the neutral position.
2. At this time, gears 1 and 2 inside the damper receive opposing force due to friction.
3. Therefore, as the travel lever gradually returns to
the neutral position, the extent of sudden stop at
the time of abrupt release of the travel lever is
damped down.
A
Gear 1
T1M7-03-04-002
Section A-A
Spring Pin
Damper
Support
Pin
T1M7-03-04-003
T3-4-12
ZX270-3 class
Sprocket
Sprocket
Travel Motor
T1V1-03-05-001
T3-5-1
Travel Motor
W1HH-03-02-003
15
14
13
11
10
12
T178-03-05-001
1 - Ring Gear
T3-5-2
13 - Drum
14 - Housing
15 - Bearing
15
Travel Motor
14
13
11
10
W1HH-03-02-003
12
1-
Ring Gear
2-
34-
7 - Propeller Shaft
8 - First Stage Planetary Gear
9-
T3-5-3
13 - Drum
14 - Housing
15 - Bearing
Shaft
Rotor
Valve Plate
Shoe
Plunger
T3-5-4
Swash
Plate
T1V1-03-05-002
Shaft
Rotor
Valve Plate
Shoe
Swash Plate
Plunger
W1HH-03-02-006
T3-5-5
Applying Brake
1. When the travel lever is returned to neutral, the
counterbalance valve spool in the travel brake
valve is returned to neutral.
2. As pressure oil acting on the brake piston is returned to the drain circuit from the orifice of brake
piston, the brake piston is slowly pushed back by
the disc spring.
3. Consequently, spring force is applied to the plates
engaging on the outer diameter of rotor and the
friction plates engaging on the inner diameter of
motor housing via the brake piston, and the rotor
outer diameter is secured by friction force.
T3-5-6
Friction Plate
Disc Spring
BM
Orifice
To Brake
Piston
Plate
Brake Piston
When Brake is
Released
Disc Spring
Friction Plate
Plate
Brake Piston
AM
Counterbalance
Valve Spool
T1V1-03-05-004
T3-5-7
1. When the travel mode switch is in the SLOW position, MC (main controller) does not send the signals to solenoid valve unit (SI) so that pilot pressure is not routed to pilot port (1). Spool (2) is
kept raised by spring (3).
2. Therefore, piston (8) is not acted by pressure oil
and secured at the maximum swash angle.
3. Thereby, the plunger (6) stroke is increased and
the travel motor rotates at slow speed.
T3-5-8
Motor Port
(AM, BM)
3
To
Drain
T178-03-05-010
1-
Pilot Port
3-
Spring
5-
2-
Spool
4-
T3-5-9
7-
Swash Plate
8-
Piston
1. When the travel mode switch is in the FAST position, MC sends the signals to solenoid valve unit
(SI) in response to travel loads. (Refer to Travel
Motor Swash Angle Control / SYSTEM / Control
System.)
2. Pilot pressure is routed from pilot port (1) and
moves spool (2) downward.
3. Pressure oil in high-pressure motor port (AM or
BM) acts on piston (8) through orifice (5).
4. Piston (8) pushes swash plate (7) so that the
swash angle of swash plate (7) is reduced.
Thereby, as the plunger (6) stroke is reduced, the
travel motor rotates at fast speed.
T3-5-10
Motor Port
(AM, BM)
T178-03-05-011
1-
Pilot Port
3-
Spring
5-
2-
Spool
4-
T3-5-11
7-
Swash Plate
8-
Piston
Counterbalance Valve:
Check Valve:
Assists the counterbalance valve operation and prevents cavitation in the motor circuit.
Shuttle Valve:
Orifice:
T3-5-12
Shuttle
Valve
Counterbalance Check
Valve
Valve
Section A-A
T1V1-03-05-003
A
Overload Relief
Valve
T3-5-13
Travel Motor
Swash Angle Control Valve
Orifice
While Descending:
1. While descending a slope, the travel motor is
forcibly rotated by the machine weight so that the
motor operates like a pump.
2. If the travel motor draws oil, oil pressure in port
BV (8) and chamber B (10) decrease, spool (9)
moves to the left so that return oil from the travel
motor is restricted.
3. Therefore, pressure in motor port AM (4) increases and brakes the travel motor.
4. Once pressure oil is restricted, pressure in motor
port BV (8) increases again and moves spool (9)
to the right. As this operation (hydraulic braking
operation) is repeated, the machine is prevented
from running away.
Circuit Protection Operation:
1. When pressure in the circuit increases over the
set-pressure of overload relief valve (5), overload
relief valve (5) is opened and high-pressure oil relieves to the low pressure side so that the travel
motor is protected from being overloaded.
2. In addition, overload relief valve (5) 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.
T3-5-14
10
AV
BV
f
6
4
7
T178-03-05-006
1 - Port AV
4 - Motor Port AM
7 - Check Valve BC
2 - Chamber A
3 - Check Valve AC
8 - Port BV
T3-5-15
9 - Spool (Counterbalance
Valve)
10 - Chamber B
T3-5-16
T178-03-06-016
Shockless Valve
T178-03-06-002
T3-6-1
Connecting to
Right Pilot Valve
Right Pilot Valve
Left Pilot Valve
Left Pilot Valve
Left Pilot Valve
Left Pilot Valve
Right Pilot Valve
Right Pilot Valve
Travel Pilot Valve
Travel Pilot Valve
Travel Pilot Valve
Travel Pilot Valve
Auxiliary Pilot Valve
Auxiliary Pilot Valve
Pump 1 Regulator
Pump 2 Regulator
Pilot Shut-Off Valve
Swing Parking Brake
Hydraulic Oil Tank
Remark
Boom Raise Pilot Pressure
Boom Lower Pilot Pressure
Arm Roll-Out Pilot Pressure
Arm Roll-In Pilot Pressure
Left Swing Pilot Pressure
Right Swing Pilot Pressure
Bucket Roll-In Pilot Pressure
Bucket Roll-Out Pilot Pressure
Left Travel Forward Pilot Pressure
Left Travel Reverse Pilot Pressure
Right Travel Forward Pilot Pressure
Right Travel Reverse Pilot Pressure
Auxiliary Open Pilot Pressure
Auxiliary Close Pilot Pressure
Pump 1 Control Pressure
Pump 2 Control Pressure
Primary Pilot Pressure
Plug
Brake Release Pressure
Returning to Hydraulic Oil Tank
T3-6-2
PH
E
M
D
H
B
SB
G
PI
I
SH
J
DF
SA
L
T178-03-06-016
3
5
1
13
2
SK
SE
8
14
Control Valve Side
7
9
6
10
SN
SL
11
12
T3-6-3
SP
T178-03-06-015
Connecting to
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Control Valve
Hydraulic Oil Tank
Hydraulic Oil Tank
Control Valve
Control Valve
Remark
Boom Raise Pilot Pressure
Boom Lower Pilot Pressure
Arm Roll-Out Pilot Pressure
Arm Roll-In Pilot Pressure
Left Swing Pilot Pressure
Right Swing Pilot Pressure
Bucket Roll-In Pilot Pressure
Bucket Roll-Out Pilot Pressure
Left Travel Forward Pilot Pressure
Left Travel Reverse Pilot Pressure
Right Travel Forward Pilot Pressure
Right Travel Reverse Pilot Pressure
Auxiliary Open Pilot Pressure
Auxiliary Close Pilot Pressure
Arm 1 Flow Rate Control Valve Control Pressure
Returning to Hydraulic Oil Tank
Plug
Returning to Hydraulic Oil Tank
Flow Combiner Valve Control Pressure
Bucket Flow Rate Control Valve Control Pressure
Machine with Front Attachment (Secondary Crushers 1 to 5 and Hydraulic Crushers 1 to 5) attached.
Port SM
Port SN
Port SP
T3-6-4
Valve
Control
Valve
Control
PH
E
M
D
H
B
SB
G
PI
I
SH
J
DF
SA
L
T178-03-06-016
3
5
1
13
2
SK
SE
8
14
Control Valve Side
7
9
6
10
SN
SL
11
12
T3-6-5
SP
T178-03-06-015
Boom Raise
Boom Lower
Arm Roll- Out
Arm Roll- In
Bucket Roll-In
Bucket Roll-Out
Right Swing
Left Swing
Right Travel
Left Travel
Auxiliary
Positioning
(2-Piece Boom
Only)
Pump 1 Flow
Rate Control
Valve
Pump 2 Flow
Rate Control
Valve
Flow
Combiner
Valve Control
Spool
Bucket Flow
Rate Control
Valve Control
Spool
{
{
{
{
{
{
{
*{
{
{
{
{
{
{
{
{
-
{
-
{
{
{
{
{
{
{
{
{
Arm Flow
Rate
Control
Valve
Control
Spool
{
-
T3-6-6
Swing
Parking
Brake
Release
Spool
Swing
Arm
9
Boom
Bucket
10
11
12
13
14 15 16 17
Arm 1 Flow
Rate Control
Valve Spool
Pump 1 Flow
Rate Control
Valve
Flow
Combiner
Valve Spool
Swing Parking
Brake Release
Spool
T1V1-03-06-001
1-
Left Travel
234-
6-
16 - Swing / Auxiliary
17 - Auxiliary
Right Travel
8-
Boom
9-
15 - Swing
T3-6-7
Auxiliary
Auxiliary Flow
Rate Combiner
Solenoid Valve
Pump 1 Flow Rate
Control Valve
T1V1-03-06-007
Auxiliary
Shuttle
Valve
Shuttle Valve
Auxiliary Flow
Rate Combiner
Solenoid Valve
T3-6-8
T178-03-06-016
7
16
17
15
13
11
14
10
12
4
2
T178-03-06-009
1 - Left Travel
6-
16 - Swing / Auxiliary
17 - Auxiliary
3 - Right Travel
8-
Boom
9-
T3-6-9
15 - Swing
Spool
Port A
Spring B
Port 1
T1V1-03-06-003
Port A
Spring A Spool
Spring B
Port 1
T3-6-10
T1V1-03-06-002
Spring A
Port A
Spool
Inner Passage 2
Spring B
Port 1
T183-03-06-003
Port A
Spool
Port 1
T183-03-06-004
Housing
Detail of
Clearance C
Spool
T1V1-03-06-008
T3-6-11
Spring A
Port A
Spool
Port 1
Spring A
Spool
T1V1-03-06-004
Port A
Port 1
T3-6-12
Spring B
Spring B
T1V1-03-06-002
Lowering
Spring A
Operation
(Shockless
Inner Passage 1
Spool
Port A
C
T183-03-06-005
Port 1
Spool
Inner Passage 2
Oil Chamber
Port A
T183-03-06-004
Port 1
Inner Passage 2
Detail of Clearance C
Oil Chamber
Housing
Spool
T1V1-03-06-008
T3-6-13
T3-6-14
Ports SA, SB
Spool
Spring
To Hydraulic
Oil Tank
Chamber A
Shuttle Valve
Primary Pilot
Pressure
Pilot Pressure
T1V1-03-06-005
T3-6-15
are
identical
in
T178-03-06-014
Arm Roll-In
Control Pilot
Pressure
Spring
Right Travel
Control Pilot
Pressure
T178-03-06-014
To Flow Combiner
Valve
Primary Pilot
Pressure
Spool
Spring
T178-03-06-014
Boom, Arm,
Bucket or
Auxiliary Pilot
Pressure
To Swing
Motor
Swing Pilot
Pressure
Spool
Spring
T178-03-06-014
Arm Roll-in
Control Pilot
Pressure
T3-6-16
Arm 1 Flow
Rate Control
Valve
To Ports T1
to T4
From Pilot
Pump
To Ports A1
to A4
Spool
T1V1-03-07-012
A1
P
T1
T2
A2
A3
Z
T4
T3
A4
T1V1-03-07-011
T3-7-1
To Ports T1
to T4
From Pilot
Pump
To Ports A1
to A4
Spool
T1V1-03-07-012
T3-7-2
SC
SF
SI
SG
T1V1-03-07-007
Auxiliary Flow
Combiner
Solenoid Valve
Auxiliary Flow
Rate Control
Solenoid Valve
T1GL-03-10-002
T3-7-3
When energized:
1. Solenoid (3) pushes spool (1) to the left due to
force in proportional to the electric current flowing
through solenoid (3).
2. Pilot oil pressure from port P flows into output
port S and pressure at output port S increases.
3. Pressure at output port S acts on step part a on
spool (1).
Because of difference in the pressure receiving
area between step part a, spool (1) is pushed to
the right.
4. When pressure at port S increases and the force
to push spool (1) to the right overcomes the force
to push spool (1) to the left by solenoid (3), spool
(1) moves back to the right side and the passage
between output port S and port P is closed. As a
result, pressure increase at port S stops.
a
T107-02-07-005
1-
Spool
2-
Spring
3-
T3-7-4
Solenoid
In Neutral State
Spool (1) is pushed to the right by spring (2).
Output port (S) is connected to tank port (T).
In Operation
As solenoid (3) is activated, spool (1) moves to the left.
Pilot port (P) is connected to output port (S) and tank
port (T) is blocked.
3
P
1 - Spool
2 - Spring
T105-02-11-010
3 - Solenoid
T3-7-5
External
Force
Port B
10
Port A
To Spool in Control
Valve (To Hose of
Front Attachment)
2456-
T3-7-6
Spool
Passage A
Spring
Poppet
8 - Passage B
9 - Passage C
10 - Spring
T1V1-03-07-018
10
11
Port Pi
4
5
6
7
Port B
Port A
T1V1-03-07-017
123-
Relief Valve
Spool
Piston
456-
Passage A
Spring
Poppet
789-
T3-7-7
Orifice
Passage B
Passage C
10 - Spring
11 - Orifice
Pressure
Pi
Port B
10
Port A
To Spool in Control
Valve
23456-
T3-7-8
Spool
Piston
Passage A
Spring
Poppet
78910 -
T1V1-03-07-019
Orifice
Passage B
Passage C
Spring
10
11
Pressure Pi
4
5
6
7
Port B
Port A
T1V1-03-07-015
123-
Relief valve:
Spool
Piston
456-
Passage A
Spring
Poppet
789-
T3-7-9
Orifice
Passage B
Passage C
10 - Spring
11 - Orifice
Pressure
Pi
Port B
Port A
10
To Spool in Control
Valve
23456-
T3-7-10
Spool
Piston
Passage A
Spring
Poppet
78910 -
T1V1-03-07-020
Orifice
Passage B
Passage C
Spring
10
11
Pressure Pi
4
5
6
7
Port B
Port A
T1V1-03-07-016
123-
Relief valve:
Spool
Piston
456-
Passage A
Spring
Poppet
789-
T3-7-11
Orifice
Passage B
Passage C
10 - Spring
11 - Orifice
Pilot Relief
Valve
Port P
Pilot Filter
T178-03-07-001
T3-7-12
4
6
T135-03-02-001
1 - Outer Race
2 - Seal
34-
Inner Race
Seal
5 - Support
T3-8-1
6-
Ball
To Left Travel
Motor (Reverse)
To Right Travel
Motor (Forward)
To Left Travel
Motor (Forward)
To Right Travel
Motor (Reverse)
To Left Travel
Motor (Forward)
To Right Travel
Motor (Forward)
To Left Travel
Motor (Reverse)
To Right Travel
Motor (Reverse)
1
Pilot Pressure
for Travel Speed Selection
Pilot Pressure
for Travel Speed
Selection
Drain
2
Drain
Drain
Drain
: Forward
: Reverse
: Pilot Pressure
for Travel Speed Selection
T157-03-02-004
1 - Spindle
2 - Body
T3-8-2
3 - Seal
Grease Fitting
12
Grease Discharge
Hole
W8HY-04-03-001
11
12
10
W1V7-03-04-002
1 - Holder
2 - Piston Rod
3 - Dust Seal
456-
U-Ring
Adjuster Cylinder
Rod
789-
T3-8-3
Spring
Spacer
Washer
10 - Plug
11 - Nut
12 - Valve
T3-8-4
MEMO
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