Configuring Auxiliary Hydraulic Control on the Hitachi ZX200LC

[MikePhua]

The ZX200LC and Its Excavator Lineage
The Hitachi ZX200LC is part of Hitachi’s Zaxis series, a globally recognized lineup of hydraulic excavators known for their precision, reliability, and fuel efficiency. Introduced in the early 2000s, the ZX200LC was designed to meet the demands of mid-size excavation, offering a balance of reach, breakout force, and hydraulic versatility. With an operating weight around 45,000 pounds and a bucket breakout force exceeding 30,000 lbf, it became a staple in infrastructure, utility, and forestry projects.
Hitachi Construction Machinery, founded in 1970, has sold hundreds of thousands of Zaxis-series excavators worldwide. The ZX200LC, in particular, gained traction in North America and Asia due to its compatibility with a wide range of attachments—from hammers and thumbs to mulchers and compactors.
Understanding the Auxiliary Hydraulic Circuit
Auxiliary hydraulics on the ZX200LC allow operators to power external attachments beyond the standard boom, arm, and bucket functions. These circuits typically run along the boom and stick, terminating in quick couplers near the bucket linkage.
Terminology:

• Auxiliary Hydraulic Lines: Additional hoses and fittings that deliver pressurized fluid to attachments.
  
• MCV (Main Control Valve): The central hydraulic manifold that distributes flow to various actuators.
  
• One-Way Hammer Setup: A configuration where fluid flows in one direction to power impact tools, with return flow directed to tank.
  

In many cases, machines are shipped with auxiliary lines installed but lack in-cab controls to activate them. This leads to confusion when operators see the plumbing but cannot engage the circuit.
Control Options and Installation Pathways
There are multiple ways to activate auxiliary hydraulics on the ZX200LC, depending on whether the machine is a Dash-3 model or earlier. Control options include:

• Foot pedal: A mechanical or electronic pedal mounted in the cab, wired to solenoid valves
  
• Toggle switch or button: Mounted on the joystick or dashboard, controlling solenoids via electric-over-hydraulic signals
  
• Proportional thumb roller: Allows variable flow control, ideal for precision attachments like thumbs or grapples
  

If the auxiliary valve is present at the MCV, one line will typically connect to the valve block, while the other may route directly to tank. This setup is common for one-way tools like hydraulic breakers.
Installation steps:

• Trace auxiliary lines from the boom to the MCV to confirm valve presence
  
• Install solenoid valves if not already present
  
• Mount control interface (pedal, switch, or roller) in the cab
  
• Wire controls to the machine’s electrical system, ensuring proper fuse protection
  
• Test flow and pressure using a hydraulic gauge and flow meter
  

Aftermarket Solutions and Retrofit Kits
For machines lacking factory-installed controls, aftermarket kits are available. Companies like HKX and HCT offer modular solutions tailored to Hitachi excavators. These kits include:

• Solenoid valve blocks
  
• Wiring harnesses
  
• Control switches or joysticks
  
• Mounting brackets and hardware
  

While some kits are discontinued, components can be pieced together from suppliers or fabricated locally. Retrofit installations should match the machine’s hydraulic flow rate—typically 30–40 GPM for the ZX200LC—and pressure rating of 4,000 psi.
Field Anecdote from Georgia
An operator in northeast Georgia purchased a 2007 ZX200LC with auxiliary lines but no cab controls. After consulting with mechanics and tracing the lines, he confirmed the valve was present. He installed a foot pedal and solenoid block sourced from a salvage yard, wiring it to a fused switch on the dashboard. The system powered a hydraulic thumb flawlessly, and the machine was later used for storm debris cleanup after a tornado.
He noted that the dealer was unable to assist, but online communities and aftermarket suppliers provided the guidance needed. The total cost was under $1,500, and the installation took two days.
Performance Considerations and Safety Tips
When configuring auxiliary hydraulics:

• Verify flow rate and pressure compatibility with the intended attachment
  
• Use quick couplers rated for high-pressure applications
  
• Install pressure relief valves to protect hoses and actuators
  
• Label controls clearly to prevent operator confusion
  

Safety tips:

• Always depressurize the system before connecting or disconnecting attachments
  
• Inspect hoses for wear, abrasion, or leaks before each use
  
• Train operators on control layout and emergency shutoff procedures
  

Conclusion
Activating auxiliary hydraulic control on the Hitachi ZX200LC is a straightforward process when the valve is present. With the right combination of solenoids, wiring, and cab controls, operators can unlock the full potential of their machine for attachment work. Whether powering a hammer in Lincoln or a thumb in Georgia, the ZX200LC remains a versatile platform—ready to adapt to the demands of modern excavation.